Lennox International Inc. Water Heater AIR HANDLERS User's Manual
Contents
1. 505047 09 06 Page 14 Table 7 CBWMV 36C 090 Blower Performance 0 through 0 80 in w g 0 Through 200 Pa External Static Pressure Range Factory Settings Heating Speed 4 Cooling Speed 3 Speed Adjust NORM Applications with single sided inlets will reduce CFM by approximately 5 BDC3 Jumper Speed Positions ADJUST 1st Stage COOL Speed Jumper 1 2 3 4 Setting cfm L s cfm L s cfm L s cfm L s 620 290 770 365 930 440 1010 475 NORM 570 270 700 330 830 390 910 430 520 245 630 295 760 360 810 380 ADJUST HEAT Speed 2nd Stage COOL Speed Jumper 1 2 3 4 1 2 3 4 Setting cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s 820 385 1000 470 1180 555 1340 630 890 420 1130 535 1340 630 1450 685 NORM 760 360 900 425 1070 505 1220 575 800 380 1020 480 1220 575 1310 620 675 320 810 380 950 450 1100 520 720 340 900 425 1100 520 1180 555 The effect of static pressure and filter resistance is included in air volumes shown 1st stage COOL is approximately 7096 of the same 2nd stage COOL speed position Continuous Fan Only speed is approximately 38 of the same 2nd stage COOL speed position Lennox Harmony zone control applications Minimum blower speed is 4002. With the thermostat set for Continuous Fan and without call for heating or cooling the CBWMV will provide 3896 of the COOL CFM selected HEAT Pins The HEAT jumper is used to determine CFM heating These jumper selections are activated only when W1 is energized There is a fixed 45 seconds and 30 seconds OFF delay on a W call DELAY Pins The DELAY jumper is used to set the spe cific motor fan operation during cooling mode Depending on the application one of four options may be chosen by moving the jumper to the appropriate set of pins 1 Pins Jumpered A Motor runs at 10096 until demand is satisfied A B OFF OFF B Once demand is met motor ramps down to stop 2 Pins Jumpered A Motor runs at 10096 until demand is satisfied A B OFF OFF B Once demand is met motor runs at 100 for 45 seconds Then C ramps down to stop NOTE Blower OFF DELAY also applies during heat pump operation Pins Jumpered A Motor runs at 82 for approximately 7 1 2 min utes If demand has not been satisfied after 7 1 2 minutes B motor runs at 10096 until demand is satisfied A B OFF OFF C Once demand is met motor ramps down to stop 4 Pins Jumpered Motor runs at 50 for 30 seconds B Motor then runs at 82 for approximately 7 1 2 minutes If demand has not been satisfied after 7 1 2 minutes C Motor runs at 100 until demand is satisfied D Once demand is met motor runs at 50
3. for 30 seconds Then B D OFF OFF E ramps down to stop Page 13 CBWMV SERIES Table 5 CBWMV 24B 040 Blower Performance 0 through 0 80 in w g 0 Through 200 Pa External Static Pressure Range Factory Settings Heating Speed 2 Cooling Speed 1 Speed Adjust NORM Applications with single sided inlets will reduce CFM by approximately 4 BDC3 Jumper Speed Positions ADJUST 1st Stage COOL Speed Jumper 2 3 4 Setting L s cfm L s cfm L s cfm L s 610 290 770 365 930 440 1010 475 NORM 560 265 700 330 830 390 910 430 510 240 630 295 750 355 810 380 ADJUST HEAT Speed 2nd Stage COOL Speed Jumper 2 3 2 3 4 Setting cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s 820 385 990 465 1180 555 1340 630 880 415 1120 530 1340 630 1440 680 NORM 750 355 900 425 1070 505 1230 580 800 375 1000 470 1200 565 1300 615 970 315 810 380 940 445 1080 510 720 340 900 425 1080 510 1170 550 The effect of static pressure and filter resistance is included in air volumes shown 1st stage COOL is approximately 70 of the same 2nd stage COOL speed position Continuous Fan Only speed is approximately 38 of the same 2nd stage COOL speed position Lennox Harm
4. AIR BLOWER JACK MOTOR VARIABLE SPEED RELAY FIELD HOOKUP ICHOKE POWER IPLUG OUTPUT PLUG MOTOR FRESH AIR BLOWER PLUG MOTOR VARIABLE SPEED ISWITCH DOOR INTERLOCK ITHERMOSTAT ANT I FREEZE ITRANSFORMER CONTROL TERMINAL STRIP ERMINAL STRIP UNIT TERMINAL STRIP ERMINAL STRIP TERMINAL STRIP FIELD HOOKUP TB67 RMINA RIP D HOOKUP REFER TO FACTORY BLOWER SPEED TAP SELECTION CHART FOR BLOWER SPEED INFORMATION REMOVE JUMPER BETWEEN DS AND YI WHEN SIGNATURE STAT OR HARMONY ZONING 15 USED JUMPER YI TO Y2 IS FOR SINGLE STAGE COOLING REMOVE JUMPER FOR TWO STAGE COOLING 13 USED ON IHP ONLY FIELD SUPPLIED ACCESSORY WIRE REMOVE 0 TO TB7 24 JUMPER FOR HEAT PUMP APPLICATIONS FOR HARMONY APPLICATIONS REMOVE PIN 2 JP49 ON B3 BLOWER MOTOR TAPE WITH ELECTRICAL TAPE TO PREVENT ELECTRICAL PATH TWO TERMINAL BLOCKS AND A RELAY ARE FACTORY PROVIDED FOR FIELD HOOKUPS BLOWER SPEED TAP SELECTION BLOWER 248 040 PIN I PIN 2 368 070 PIN 3 PIN 4 36C 090 PIN 3 PIN 4 60C 100 PIN 4 PIN 4 60 120 PIN 4 W D NE VOLTAGE FIELD INSTALLED CLASS 11 VOLTAGE FIELD WIRING CBWMV SERIES Freezestat Operation A IMPORTANT Use of the freezestat feature is required in all instal lations using CBWMV units The CBWMV unit is equipped with a field wired freezestat The freezestat protects the CBWMV system from freezing temperatures when the unit is installed
5. ANSI Z223 Available from the American Gas Association 8501 E Pleasant Valley Road Cleveland OH 44134 Reference should also be made to local gas utility regulations and other codes in effect in the same area in which the installation is to be made When installed in Canada The latest revision of the CAN1 CSA B149 1 and or B149 2 Installation Codes for Gas Burning Equip ment and or local codes Determine the CBWMV unit installation location and posi tion units so that door panels are accessible Keep in mind routing of the water and plumbing lines and electrical con nections The CBWMV unit is multi positional No adjustment is nec essary to apply unit for upflow or horizontal discharge A downflow base is available and provides clearance for routing the inlet outlet water lines when the CBWMV unit is applied without an add on cooling coil Downflow applica Page 4 505047 09 06 tions with add on cooling coils require field fabricated tran sitions that provide at least 6 inches of clearance for the CBWMV unit s inlet outlet water lines See figure 2 for ex amples CBWMV Multi Positional Unit UPFLOW DOWNFLOW BASE LEFT HAND DISCHARGE DOWNFLOW CBWMV units must not be installed horizontally on the front or back of the unit Figure 2 Units may be horizontally installed in either attic or crawl space CAUTION CBWMV series units are shipped with an antifreeze thermostat to prevent the water coil from
6. Canadian Electric Code Part I CSA Standard C22 1 CAUTION USE COPPER CONDUCTORS ONLY A WARNING Electric shock hazard Can cause inju ry or death Before attempting to per form any service or maintenance turn the electrical power to unit OFF at dis connect switch es Unit may have multiple power supplies Refer to figure 12 for schematic wiring diagram and trouble shooting Line Voltage 120V Line voltage field supply conductors are terminated at the CBWMV unit The unit is shipped with the line voltage con nections secured to the lower left coil manifold for left side make up box installations For right side make up box installations remove the wire tie that holds the line voltage connections and pull excess wires into blower deck control box area as shown in figure 8 Install make up box provided for line voltage wiring in the unit s bag assembly as shown in figure 9 Make up Box Wiring WIRES SHOWN AS SHIPPED ROUTED FOR LEFT SIDE MAKE UP BOX INSTALLATION st 2 FOR RIGHT SIDE MAKE UP BOX INSTALLATION y Ww REMOVE WIRE TIE PULL EXCESS WIRE INTO BLOWER DECK CONTROL WA BOX AREA Figure 8 Interior Make Up Box Installation MAKE UP BOX MAKE UP BOX Wet RIGHT SI
7. cfm Max cfm is the same as 2nd stage cool position Initial Air Purging Air Bleed Valve Location After all plumbing connections have been made leak tested and flushed the water heating device is ready to be filled with water and purged of air Air bleeder valves are provided as a convenience for installations that are not equipped with purge manifolds 1 Make sure electrical power and gas supply to system are OFF 2 Remove CBWMV coil section access panel 3 Remove cap from highest air bleed valve and depress valve stem until water is released This may be done with a refrigerant style hose See figure 15 SHOWN WITH CAP ON 4 Replace cap on valve and access panel 5 Apply electrical power and gas supply to the system 6 Follow the System Start Up section to operate the sys tem Complete purging of air after unit has gone through initial start up Figure 15 Page 16 505047 09 06 System Adjustments Timed ON and Timed OFF Delays The 45 second timed ON delay and the 30 second timed OFF delay for heating time that the blower operates after the heat demand has been satisfied is not adjustable Blower Speeds Select the blower speed by moving the pins on the variable speed control board See figure 14 Refer to the speed selection chart on unit wiring diagram NOTE To check for proper CFM take the reading exter nal
8. cfm is the same as 2nd stage cool position Page 15 CBWMV SERIES Table 9 CBWMV 60C 120 Blower Performance 0 through 0 80 in w g 0 Through 200 Pa External Static Pressure Range Factory Settings Heating Speed 4 Cooling Speed 4 Speed Adjust NORM Applications with single sided inlets will reduce CFM by approximately 5 BDC3 Jumper Speed Positions ADJUST 1st Stage COOL Speed Jumper 1 2 3 4 Setting cfm Lis cfm Lis cfm Lis cfm Lis 1100 520 1250 590 1400 660 1560 735 NORM 990 465 1130 535 1260 595 1400 660 930 440 1020 480 1130 535 1260 595 ADJUST HEAT Speed 2nd Stage COOL Speed Jumper 1 2 3 4 1 2 3 4 Setting cfm L s cfm L s cfm L s cfm L s Lis cfm L s cfm L s cfm L s 1510 715 1720 810 1900 895 2120 1000 1570 740 1800 850 2000 945 2200 1040 NORM 1380 650 1560 135 1740 820 1920 905 1410 665 1620 765 1820 860 2020 955 1240 585 1380 650 1540 725 1720 810 1260 595 1440 680 1620 765 1810 855 The effect of static pressure and filter resistance is included in air volumes shown 1st stage COOL is approximately 70 of the same 2nd stage COOL speed position Continuous Fan Only speed is approximately 38 of the same 2nd stage COOL speed position Lennox Harmony zone control applications Minimum blower speed is 600
9. freezing The freezestat is installed at the factory but must be field wired see figures 12 and 13 Do not bypass this feature when you install or run the unit CAUTION Use a drain pan for installations over finished living areas Either suspend the unit from the roof rafters or floor joists or mount on a platform The CBWMV unit must be level and well supported NOTE 1 2 hp and 1 hp blower motors are equipped with three flexible legs and one rigid leg The rigid leg is equipped with a shipping bolt and a flat white plastic wash er rather than the rubber mounting grommet used with a flexible mounting leg The bolt and washer must be re moved before the air handler is placed into operation After the bolt and washer have been removed the rigid leg will not touch the blower housing Duct System Use industry approved standards such as those pub lished by Air Conditioning Contractors of America or Amer ican Society of Heating Refrigerating and Air Conditioning Engineers to size and install the supply and return air duct system This will result in a quiet and low static system that has uniform air distribution NOTE Do not operate the air handler with an external static pressure that exceeds 0 8 inches w c Higher exter nal static pressures may cause erratic operation Return Air Plenum A IMPORTANT Return air must not be drawn from a room where any fossil fuel appliance ie a water heater is installe
10. in unconditioned areas The factory provided freezestat must energize the circula tor when water temperatures fall below 45 F Freezestat wiring is shown in figure 13 Freezestat Field Wiring 1B 13 120 NEUTRAL 819 INTERLOCK PUMP ANTI FREEZE THERMOS FIELD FURNISHED FACTORY FURNISHED AND INSTALLED FIELD INSTALLED 1 TB67 I TB2 120V HOT Figure 13 BDC3 Variable Blower Control Board CBWMV units are equipped with a variable speed motor that is capable of maintaining a specified CFM throughout the external static range A particular CFM can be obtained by positioning jumpers COOL HEAT and ADJUST on the BDC3 control board The COOL and HEAT jumpers are labeled 1 2 3 and 4 Each of the numbers corre sponds with an air volume CFM setting The ADJUST jumper is labeled TEST and NORM The and pin settings are used to add or subtract a percentage of the CFM selected The TEST jumper is used to operate the motor in the test mode The DELAY jumper controls ramp ing profiles Figure 14 shows the BDC3 control board Use tables 5 through 9 to determine the correct air volume for heat and cool speed taps Diagnostic LEDs located on the BDC3 control board are provided to aid in identifying the unit s mode of operation Certain scenarios will arise depending on the jumper posi tions Read through the jumper settings sections before adjusting blower speed Refer to figure 14 for identificati
11. Cooling TB1 and C on A15 Terminal Strip YES YES Blower Shuts Off According to the DELAY Jumper Blower Operates at the 2nd Check for 24 Volts Between Pins 14 Position on the BDC3 Control A52 Sage Hoop and 3 on J49 YES ADJUST Jumper Positions Demand for Cooling Satisfied Go he Bosne tss CFM Light on 52 Indi cates Blower CFM Selec tion with 100CFM Blink NO NO 2nd Stage Thermostat 51 Demand Satisfied Blower Returns to 1st Stage Cooling Speed Page 19 CBWMV SERIES 4 WARNING WARNING TO SERVICE PERSONS Electric shock hazard When electrical power to the internal control box components must be available for troubleshooting a common practice is to construct a by pass of the door interlock switch When such a by pass is in place a potential shock hazard is present which can cause injury or death Make sure any door interlock switch by pass has been removed after troubleshooting is complete and BEFORE attempting any pairs to the control box components Troubleshooting Heating Sequence of Operation CONDITIONS Power On Normal Operation LED Steady Flash Thermostat 51 Calls for Heat Check for 24 Volts Between W and C at A52 Terminal Strip Fixed blower ON delay 45 second complete Blower Operates at the Heating Speed Selected by HEAT Jumper and ADJUST Jumper Positions on Check for 24 Volts Between Pins 3 and 2 on J49 the BDC3 Control A52 YES CFM Light on A52 Indicates Blower Speed
12. DE LEFT SIDE Figure 9 Page 8 505047 09 06 Electrostatic Discharge ESD Precautions And Procedures CAUTION Electrostatic discharge can affect electronic com ponents Take precautions during air handler instal lation and service to protect the air handler s elec tronic controls Precautions will help to avoid con trol exposure to electrostatic discharge by putting the air handler the control and the technician at the samedectrostatic potential Neutralizedectrostatic charge by touching hand and all tools on an un painted unit surface such as the blower deck be fore performing any service procedure Refer to table 3 for field wiring 1 Refer to the CBWMV units nameplate for minimum circuit ampacity and maximum overcurrent protection size 2 Install a separate disconnect switch protected by ei ther fuse or circuit breaker near the air handler so that power can be turned off for servicing 3 Complete the wiring connections to the equipment Use the provided unit wiring diagram and the field wir ing diagrams shown in table 3 Use 18 gauge wire or larger that is suitable for Class II rating for thermostat connections 4 Electrically ground the unit according to local codes or in the absence of local codes according to the current National Electric Code ANSI NFPA No 70 for the USA and current Canadian Electric Code part 1 CSA standard C22 1 for Canada A green ground wire is provided in
13. ING STRAIN RELIEF BUSHING VARIABLE SPEED CONTROL ACCESSORY FIELD TB66 WIRING of TERMINAL 1867 W 2 A gt TERMINAL BLOCKS 1 9 BLOCK 24 212 TERMINAL amp E RELAY BLOCK TB1 SS ACCESSORY RELAY 24 125 1 4 QUICK CONNECT TERMINALS RELAY CONTACTS RATING 8 AMPS 120V MAX 24V COIL Figure 11 Figure 10 Page 10 505047 09 06 I20y ACC OR KA ECON Typical CBWMV Wiring Diagram DESCRIPTION S105 COMPONENT 551 DOOR INTERLOCK A2 SignatureStat THERMOSTAT WARNING ANTI FREEZE THERMOSTAT BIg PUMP CIRCULATOR CBWMV CONTROL BOX Pe INDOOR X BLOWER B5 MOTOR SUR ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES NOTE A2 SignatureSta IF ANY WIRE THIS APPLIANCE IS REPLACED IT MUST REPLACED THERMOSTAT WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION 551 DOOR INTERLOCK TB7 TB2 120V HOT YELLOW A rm s BLACK 24 S105 ANTI FREEZE THERMOSTAT FACTORY FURNISHED FIELD INSTALLED 19 PUMP CIRCULATOR FIELD FURNISHED AND INSTALLED TB 13 120V NEUTRAL 1 EQUIPMENT GROUND BLUE 2 BLUE TB7 YELLOW PURPLE n GREEN GREEN YELLOW _ GROUND 2345 67 891011 12131415 16 Figure 12 Page 11 THERMOSTAT ICONTROL BDC3 MOTOR BLOWER RETO PUMP CIRCUIT BREAKER JACK OUTPUT JACK MOTOR FRESH
14. LENNOX J 2006 Lennox Industries Inc Dallas Texas USA RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE 4 WARNING Due to higher operating pressures CBWMV units must not be applied to steam boiler systems CAUTION Unit is designed to be used with non potable boiler systems only CAUTION Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury Be aware of and use caution when working near these areas during installation or while servicing this equipment Introduction The multi positional Dave Lennox Signature Collection CBWMV air handler hot water coil unit is designed to be used with non potable boiler systems for warm air heating A variety of Lennox air conditioning systems may be ap plied to the CBWMV unit for optional cooling 09 06 Page 1 INSTALLATION INSTRUCTIONS CBWMV Series Units AIR HANDLER Technical 505 047M 5 09 06 Litho U S A Supersedes 02 06 Table of Contents Introduction 1 Shipping amp Packing 1 CBWMV Unit Dimensions 2 General eese Hale a tae esas dae Gane 3 CBWMV Unit Parts Arrangement 3 CBWMNV Unit Parts Description 3 CBWMV Unit Optional Accessories 3 Requirements 4 Application 4 Inst
15. Motor e Blower Housing Electrical Parts e BDC3 Board e Transformer e Circuit Breaker 24VAC e 3PDT Relay Page 17 CBWMV SERIES 4 WARNING WARNING TO SERVICE PERSONS Electric shock hazard When electrical power to the internal control box components must be available for troubleshooting a common practice is to construct a by pass of the door interlock switch When such a by pass is in place a potential shock hazard is present which can cause injury or death Make sure any door interlock switch by pass has been removed after troubleshooting is complete and BEFORE attempting any pairs to the control box components Troubleshooting Continuous Fan Sequence of Operation CONDITIONS Power On Normal Operation LED Steady Flash Thermostat S1 Calls for Continuous Fan G Only Check for 24 Volts Between G and C at A15 Terminal Strip YES Blower Operates at the Continuous Fan Speed Selected by COOL Jumper and ADJUST Jumper Check for 24 Volts Between Pins 3 and 15 on J49 Positions on the BDC3 Control A52 RUN Light on BDC3 Control A52 illuminates to Indi cate a Continuous Fan Call CFM Light on A52 Indicates Blower CFM Selection with 100CFM Blink Thermostat S1 Continuous Fan Demand Satisfied Blower Off 505047 09 06 Page 18 4 WARNING WARNING TO SERVICE PERSONS Electric shock hazard When electrical power to the internal control box components must be available for troubleshooting a common pra
16. Selection with 100CFM Blink YES Thermostat S1 Demand Satisfied YES 30 Second Blower Off Delay Fixed Complete YES Demand for Heat Satisfied Page 20 505047 09 06
17. Y OPERATIONAL SELECTOR PINS AFFECTS BOTH HEATING AND COOLING MODES HEATING SPEED COOLING SPEED FAN DELAY DIAGNOSTIC SELECTOR PINS SELECTOR PINS SELECTOR PINS LEDS Figure 14 Page 12 505047 09 06 Jumper Settings A IMPORTANT Before changing jumper setting make sure the mo tor has completely stopped Any jumper setting change will not take place while the motor is run ning Table 4 shows the factory blower speed tap settings for CBWMV series units These settings are for nominal ton nage match ups with the CBWMV When matched with other sizes it is recommended that the CFM be adjusted approximately to 400 CFM per ton Table 4 Factory Blower Speed Tap Settings CBWMV Blower Coil Cool Pin 24B 040 36B 070 36 090 60 100 60 120 Speed Selection Heat Pin Adjust Delay To change jumper positions gently pull the jumper off the pins and place it on the desired set of pins The following section outlines the different jumper selections available and conditions associated with each one Refer to figure 14 After the CFM for each application has been determined the jumper settings must be adjusted to reflect those given in tables 5 through 9 From the tables determine which row of CFM volumes most closely matches the desired CFM Once a specific row has been chosen NORMAL or CFM volumes from other rows cannot
18. air handler may be installed in either an attic or a crawlspace Either suspend the air handler from roof raf ters or floor joists as shown in figure 7 The unit must be supported at both ends and beneath the blower deck to prevent sagging Unit Suspended in Attic or Crawlspace ALLOW SUFFICIENT CLEARANCE BETWEEN ROD AND UNIT TO REMOVE ACCESS PANEL ANGLE IRON U CHANNELS Figure 7 NOTE Heavy gauge perforated sheet metal straps plumbers straps may be used to suspend the unit from roof rafters or ceiling joists When suspending the unit in this manner support must be provided for both the ends and the middle of the airhandlerto prevent sagging Straps must not interfere with plenum or water piping Securing screws should be 1 2 inch from the top edge and 1 1 2 inch from the side edge in all cases Cooling coils and supply and returnair plenums mustbe supported separately NOTE When the air handler is installed on a platform in a crawlspace it must be elevated enough to avoid water damage and to allow the optional evaporator coil to drain Horizontal and Downflow Applications Return air can be brought in through the end of an air han dler installed in the horizontal or downflow application The air handler is equipped with a removable bottom panel to facilitate installation see figure 5 Page 7 CBWMV SERIES Filter Assembly amp Filters This unit is not equipped with a filter or rack A fie
19. allation Setting Equipment 4 Duci System css ben pir RE EE CERTES 5 Return Air Opening Guidelines 6 Filter Assembly amp Filters 8 RR eb RN ns 8 Electrical essei dea cerne me er dea 8 Freezestat Operation 12 BDC3 Variable Blower Control Board 12 Blower Speed Adjustments 12 Initial Air System 0 16 System Adjustments 17 Annual Service 17 Service Filters 17 Winterizing the CBWMV 17 Repair Parts List 17 Troubleshooting Continuous Fan Sequence of Operation 18 Cooling Sequence of Operation 19 Heating Sequence of Operation 20 Shipping amp Packing List 1 CBWMV Air Handler NOTE Includes freezestat mounted to the manifold 1 Bag assembly containing 1 Electrical make up box 1 Copper fitting 1 Snap bushing 2 Water line grommets 3 Wire nuts 2 7 8 cabinet plugs Check equipment for shipping damage If you find any damage immediately contact the last carrier 505 047M Unit Dimensions inches mm NOTE Single side inlet applications result in approximately 4 percent reduction of CFM on B size units and approximately 5 pe
20. be used Below are descriptions of the jumper selections ADJUST Pins The ADJUST pins allow the motor to run at normal speed approximately 10 higher or approxi mately 10 lower than normal speed Tables 5 through 9 gives three rows NORMAL and with their respective CFM volumes Notice that the normal adjustment setting for heat speed position 3 is 1070 CFM The adjustment setting for that position is 1180 CFM and for the adjust ment setting is 940 CFM After the adjustment setting has been determined chose the remainder speed jumper set tings from those offered in the table in that row The TEST pin is available to bypass the BDC3 control and run the motor at approximately 70 to test that the motor is operational This is beneficial primarily in troubleshooting G must be energized for motor to run COOL Pins The COOL jumper is used to determine the CFM during either 1 cooling or 2 heat pump operation without a W1 call for electric heat These jumper selections are activated for cooling when Y1 and or 2 and DS termi nals in the CBWMV unit are energized and for heating when Y1 and or Y2 is energized For applications with the Harmony Zoning System the blower CFM volume is determined by the Harmony control center The minimum blower speed is predetermined at 400 CFM for CBWMV 24B 040 and 36B 070 series units and 600 CFM for CBWMV 36C 090 60C 100 and 60C 120 series units This speed is not adjustable
21. cfm Max cfm is the same as 2nd stage cool position Table 8 CBWMV 60C 100 Blower Performance 0 through 0 80 in w g 0 Through 200 Pa External Static Pressure Range Factory Settings Heating Speed 4 Cooling Speed 3 Speed Adjust NORM Applications with single sided inlets will reduce CFM by approximately 5 BDC3 Jumper Speed Positions ADJUST 1st Stage COOL Speed Jumper 1 2 3 4 Setting L s cfm L s cfm L s cfm L s 1110 525 1250 590 1380 650 1530 720 NORM 1000 470 1130 535 1250 590 1380 650 930 440 1040 490 1130 535 1260 595 ADJUST HEAT Speed 2nd Stage COOL Speed Jumper 1 2 3 4 1 2 3 4 Setting cfm Lis cfm Lis cfm Lis cfm Lis cfm Lis cfm Lis cfm Lis cfm Lis 1500 710 1700 800 1880 885 2100 990 1540 725 1760 830 1970 930 2200 1040 NORM 1370 645 1540 725 1720 810 1920 905 1400 660 1600 755 1800 850 1980 935 1250 590 1380 650 1540 725 1720 810 1270 600 1420 670 1600 755 1780 840 The effect of static pressure and filter resistance is included in air volumes shown 1st stage COOL is approximately 70 of the same 2nd stage COOL speed position Continuous Fan Only speed is approximately 38 of the same 2nd stage COOL speed position Lennox Harmony zone control applications Minimum blower speed is 600 cfm Max
22. ctice is to construct a by pass of the door interlock switch When such a by pass is in place a potential shock hazard is present which can cause injury or death Make sure any door interlock switch by pass has been removed after troubleshooting is complete and BEFORE attempting any re pairs to the control box components Troubleshooting Cooling Sequence of Operation CONDITIONS Power On Normal Operation LED Steady Flash Thermostat S1 Provides 24 Volt Cooling Call to In door Blower B3 NO Check for 24 Volts Between Y and C at A15 Terminal Strip Blower B3 Operates at the 2nd Stage Check for 24 Volts 2 Stage Condensing Unit Cooling Speed Determined by COOL Between Pins 14 and DELAY and ADJUST Jumper Positions on 3 on J49 YES the BDC3 Control A52 YES Blower B3 Operates at tee pode Dooling Spoed CFM Light on A52 Indicates Blower CFM Determined by COOL DELAY and ADJUST Jumper NO Selecti ith 100CFM Blink Positions on BDC3 Control 52 election wi in CFM Light on A52 Indicates Blower CFM Selection with YES Blink Thermostat S1 Demand Satisfied YES Check for 24 Volts Between Y Blower Shuts Off According to the DELAY and C on A15 Terminal Strip Jumper Position on the BDC3 Control Check for 24 Volts Between A52 Pins 6 and 3 on J49 YES Demand for Cooling Satisfied First Stage Demand for Cooling Satisfied NO Thermostat S1 Calls for Check for 24 Volts Between Y2 on 2nd Stage
23. d When return air is drawn from a room a negative pres sure is created in the room If a fossil fuel appliance is op erating in a room with negative pressure the flue prod ucts can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in in complete combustion and the formation of carbon mon oxide gas This toxic gas might then be distributed throughout the house by the air handler duct system Page 5 CBWMV SERIES Return Air Opening Guidelines NOTE Do not bring in air from the back of the unit Return air can be brought in from the sides or bottom only Bottom Return If the air handler is installed on a platform with bottom re turn make an airtight seal between the bottom of the air handler and the platform to ensure that the air handler op erates properly and safely Use aluminum tape or mastic between the plenum and the air handler cabinet to ensure a tight seal The air handler is equipped with a removable bottom panel to facilitate installation Side Return For side return air applications cut the air handler cabinet at the maximum return air dimensions shown on page 2 See figure 3 for a typical side inlet arrangement with a tran sition and filter NOTE Single side inlet applications result in approxi mately a 4 percent reduction of CFM on B size units and approximately a 5 percent reduction of CFM on C size units Side Return Air With Transition An
24. d Filter 20 X 25 X 1 508MM X 635MM X 25MM CLEANABLE FILTER RETURN AIR PLENUM TRANSITION Figure 3 Return Air Base For return air with the optional return air base RAB see figure 4 and refer to installation instructions provided with Return Air Base kit NOTE Both unit and return air base openings must be connected to and entirely covered by a single plenum or IAQ accessory opening Optional side return air filter kits cannot be used with RAB Return Air Base Optional Return Air Base and Unit Dimensions Inches mm NOTE IN SIDE RETURN APPLICATIONS THE RAB IS REQUIRED FOR 100 i CFM CAPACITY AIR FLOW RETURN AIR BASE 17 432 RAB B 98M60 21 533 RAB C 98M58 FRONT VIEW Side Return 7 8 22 Air Openings Either Side Bm 4 102 Mt 23 584 Overall Max O Minimum 11 279 Maximum Height varies 14 356 with plenum or Unit IAQ accessory Opening height Base Opening 23 584 27 58 702 SIDE VIEW Figure 4 Page 6 505047 09 06 Removing the Bottom Panel bottom return or return air base configurations Remove the two screws that secure the bottom cap to the air handler Pivot the bottom cap down to release the bottom panel Once the bottom panel has been removed reinstall the bottom cap See fig ure 5 Removing the Bottom Panel BOTTOM CAP BOTTOM PANEL Figu
25. ermostat Single Stage Heat Pump 2 Heat 2 Cool with SignatureStat Thermostat O terminal used only with heat pumps Yes No No SignatureStat CBWMV Remove Remove TERMINALS UNIT PAO ore o of o No No No SignatureStat CBWMV OUTDOOR Remove Remove Remove TERMINALS UNIT Two Stage Heat Pump Refer 0 69 to FM21 Instructions 4 6n N pb aL po N REMOVED ost o_o OUTDOOR Page 9 CBWMV SERIES Indoor Blower Speeds Accessory Field Wiring TB66 amp TB67 1 When the thermostat is set to FAN ON the indoor blower will run continuously at approximately 38 of the second stage cooling speed when there is no cool Connect wires from accessories e g powered air clean ing or heating demand ers humidifiers to terminal blocks TB66 and TB67 see 2 When the CBWMV is in the heating mode the indoor detail in figure 11 blower will run on the heating speed designated by the position of the HEAT pin 3 When there is a cooling demand the indoor blower will run on the cooling speed designated by the position of CBWMYV Control Box the COOL pin TERMINAL BLOCKS TB2 TB13 HOT NEUTRAL Accessory Field Wiring K212 TRANSTORMER Connect field wiring to 3PDT relay K212 Lennox part 67K66 as shown in figure 10 T CIRCUIT INTERLOCK SWITCH ay Accessory Relay Field Wiring K212 91 919 WIR
26. ld pro vided high velocity filter is required for the unit to operate properly Table 2 lists recommended filter sizes A filter must be in place any time the unit is operating Table 2 Recommended Filter Sizes Air Handler Filter Size Cabinet Size Bottom Return 17 112 16 X 25 X 1 1 20 X 25 X 1 1 Pipe and Fitting Specifications Refer to local building and plumbing codes for approved copper pipe and fittings Side Return 16 X 25 X 1 1 21 16 X 25 X 1 1 Plumbing Procedures Refer to the installation instructions of the water heating device to be used with the CBWMV unit Follow the recom mendations outlined in that instruction as well as govern ing plumbing codes and practices Plumbing Checklist e Flush water lines between the CBWMV unit and the water heating device before start up Normal flushing procedures should be used to rid the system of con taminants and foreign debris e CBWMNV units are installed non potable systems Wiring and grounding must conform to the current National Electric Code ANSI NFPA No 70 or Canadian Electric Code Part 1 CSA Standard C22 1 and local building codes Refer to following wiring diagrams See unit name plate for minimum circuit ampacity and maximum overcur rent protection size Select the proper supply circuit conductors in accor dance with tables 310 16 and 310 17 in the National Electric Code ANSI NFPA No 70 or tables 1 through 4 in the
27. on Continuous Low Blower Option Refer to the blower speed chart located on the CBWMV unit wiring diagram for factory set cooling heating and low continuous blower speeds Systems using a cooling ther mostat subbase may operate continuous blower factory set to operate at 3896 of second stage cooling speed through the FAN ON switch of the thermostat For continu ous low blower with a system without a cooling subbase a fan switching subbase may be used Heating or cooling demand will cause blower to go to heat or cool speed Blower Speed Adjustments Diagnostic LEDs RUN LED Indicates a demand for blower operation in either the heating mode or continuous fan only mode RUN LED will not illuminate during a cooling demand CFM LED Indicates the CFM at which the unit is operat ing The light flashes once for approximately every 100 CFM For example if the unit is operating at 1000 CFM CFM LED will flash 10 times If the CFM is 1150 CFM LED will flash 11 full times plus one fast or half flash At times the light may appear to flicker or glow This takes place when the control is communicating with the motor between cycles This is normal operation The appropriate speed according to application and CFM need is selected by moving jumper pins BDC3 Variable Speed Control Board JP1 15 PIN PLUG koron LENNOX ACCESSORY S RELAY CON TACTS ACC DRIVES OP TIONAL 24V 1A ACCESSORY RELA
28. ony zone control applications Minimum blower speed is 400 cfm Max cfm is the same as 2nd stage cool position Table 6 CBWMV 36B 070 Blower Performance 0 through 0 80 in w g 0 Through 200 Pa External Static Pressure Range Factory Settings Heating Speed 4 Cooling Speed 3 Speed Adjust NORM Applications with single sided inlets will reduce CFM by approximately 4 BDC3 Jumper Speed Positions ADJUST 1st Stage COOL Speed Jumper 2 3 4 Setting cfm L s cfm L s cfm L s cfm L s 590 280 745 350 895 420 975 460 NORM 545 255 680 320 805 380 890 420 490 230 600 280 725 340 780 370 ADJUST HEAT Speed 2nd Stage COOL Speed Jumper 2 3 2 3 4 Setting cfm Lis cfm Lis cfm Lis cfm Lis cfm Lis cfm Lis cfm Lis cfm Lis 790 370 980 465 1140 540 1310 620 850 400 1090 515 1300 620 1430 675 NORM 730 345 870 410 1040 490 1190 560 775 365 990 465 1190 560 1280 605 640 300 770 360 920 435 1070 505 700 330 870 410 1065 500 1150 540 The effect of static pressure and filter resistance is included in air volumes shown 1st stage COOL is approximately 7096 of the same 2nd stage COOL speed position Continuous Fan Only speed is approximately 38 of the same 2nd stage COOL speed position Lennox Harmony zone control applications Minimum blower speed is 400 cfm Max cfm is the same as 2nd stage cool position
29. parate cooling and heating CFM selections and low continuous fan speeds Hot Water Coil The copper tube coil is equipped with aluminum fins which provide excellent heat transfer Manual air bleed ports are located in the copper tubing to release trapped air in the water circuit in all unit configurations Blower Control The control provides a fixed blower delay of 45 seconds ON 30 seconds OFF W call Thermostat and accessory connections are made to the terminal strips in the control box CBWMV Unit Optional Accessories Accessory Circulators 53J76 99K69 An accessory circulator should be used in long line ap plications Two circulators are available with either 9 gal lons per minute 99K69 or 14 53J76 flow rate Both units have 7 8 soldering joints inlet and outlet See pip ing section for more information Downflow Base 68M03 A downflow base kit is available for downflow applications without add on cooling coils The base provides clearance for routing the CBWMV unit s inlet and outlet water lines NOTE Downflow applications with an add on cooling coil require field fabricated transitions to provide adequate clearance for servicing removing the cooling coil without cutting the water lines Page 3 CBWMV SERIES 4 WARNING Improper installation adjustment alteration ser vice or maintenance can cause personal injury loss of life or damage to property Installation and service m
30. rcent reduction of CFM on C size units OPTIONAL EXTERNAL SIDE RETURN AIR FILTER KIT Either Side Not for use with optional Return Air Base WATER INLET SUPPLY AIR OPENING WATER OUTLET 25 635 TOP VIEW OPTIONAL EXTERNAL SIDE RETURN AIR FILTER KIT Either Side T AIR FLOW C Bottom Return Air Opening 3 4 19 we FRONT VIEW 3 4 19 CBWMV Model No 24B 040 36B 070 17 1 2 445 16 3 8 416 28 1 2 724 19 7 16 ALTERNATE WATER INLET far side 1 1 4 32 1 3 4 44 ALTERNATE WATER OUTLET ELECTRICAL INLET Either Side OPTIONAL RETURN CUTOUT Either Side 356 Bottom Return Air Opening 109 SIDE VIEW 16 406 1 1 2 38 1 3 4 44 8 203 2 51 36C 090 60C 100 60C 120 21 533 19 7 8 454 505047 09 06 19 1 2 495 2 51 2 1 2 64 9 1 2 241 1 1 2 38 2 These instructions are intended as general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation Only qualified ser vice technicians or installers may install and service this unit CBWMV Unit Parts Arrangement CBWMV Unit HOT WATER INSULATED COPPER STEEL TUBE COIL CABINET SUPPLY AIR BLOWER CONTROL BOX Figure 1 CBWMV Unit Parts Description Blower CBWMV is equipped with a variable speed motor that provides se
31. re 5 Leveling an Upflow Unit When the side return air inlets are used in an upflow application it may be necessary to install leveling bolts on the bottom of the air handler Use field supplied corrosion resistant 5 16 inch machine bolts 4 and nuts 8 See figure 6 NOTE Maximum leveling bolt length is 1 1 2 inches Leveling Bolt Installation 3 8 10 inches mm AIR HANDLER FRONT 1 3 4 44 LEVELING BOLT LOCATIONS HANDLER LEVELING BOLT BOTTOM LOCATIONS 3 8 10 1 8 4 44 Figure 6 1 Lay the air handler on its back and drill a 5 16 inch di ameter hole in each corner of the air handler s bottom See figure 6 for the correct location of the holes Drill through the bottom panel and the bottom flange of the cabinet 2 Install one bolt and two nuts into each hole Screw the first nut onto a bolt and then insert the bolt into a hole A flat washer may be added between the nut and the bottom of the unit 3 Screw another nut onto the bolt on the inside of the air handler base A flat washer may be added between the nut and the bottom of the unit 4 Adjust the outside nut to the appropriate height and tighten the inside nut to secure the arrangement Horizontal Applications CBWMV air handler be installed in horizontal ap plications Refer to Engineering Handbook for additional in formation Allow for clearances to combustible materials as indicated on the unit nameplate This
32. the field make up box 5 Install the room thermostat according to the instruc tions provided with the thermostat See table 3 for field wiring connections in varying applications If the air handler is beng matched with a heat pump refer to the FuelMaster21 installation instruction Removeable Jumpers Removeable Jumper DS to 1 factory installed wire jumper that connects terminals DS and Y1 on the TB1 terminal strip in the control box must be removed when the air handler is installed in a system supporting dehumidifi cation using a SignatureStat thermostat e g Humidi trol Enhanced Dehumidification Accessory or Harmony zone controls Removeable Jumper R to O The factory installed wire jumper that connects TB7 24V terminal R to TB1 termi nal O must be removed when the air handler is installed in applications which include a heat pump unit and the Fuel Master219 control board If the jumper is left intact termi nal O will remain energized eliminating the heat mode in the heat pump Removeable Jumper Y1 to Y2 The factory installed wire jumper that connects Y1 and Y2 on the TB1 terminal strip must be removed if two stage cooling is used If the jumper is not removed the outdoor unit will only operate in second stage cooling Table 3 Field Wiring Application Jumper Settings See figure 12 Thermostat Application TB1 Y1 to Y2 TB1 DS to Y1 TB1RtoO Wiring Connections 1 Heat 1 Cool with SignatureStat Th
33. ting or the cooling unit unless it is in the full HEAT or COOL setting NOTE CBWMV series units must not be used in or for the following applications e construction heater during any phase of construction e unit heater e mobile home heater e potable water applications Application CBWMV unit is designed for use in non potable water boiler systems The water heating device must be ade quate to provide enough heat according to the Engineering Handbook specifications The water heating device must provide a minimum of 6 gallons minute for small units CBWMV 040 070 and 9 gallons minute for large units CBWMV 090 100 120 Installation Setting Equipment 4 WARNING This product contains fiberglass wool Disturbing the insulation during installation main tenance or repair will expose you to fiberglass wool dust Breathing this may cause lung cancer Fiber glass wool is known to the State of California to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 The boiler installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the latest revision of the National Fuel Gas Code
34. to the unit The coil must be dry when you take the reading Annual Service AWARNING Electric shock hazard Can cause inju ry or death Before attempting to per form any service or maintenance turn W the electrical power to unit OFF at dis v connect switch es Unit may have multiple power supplies At the beginning of each heating season system should be checked as follows by a qualified service technician Electrical 1 Check all wiring for loose connections 2 Check for correct voltage at CBWMV unit unit operat ing 3 Check to see that blower is operating Blower 1 Check and clean blower wheel 2 Motors are pre lubricated for extended life no further lubrication is required Freezestat Verify that the freezestat functions Service Filters Filters must be cleaned or replaced when dirty to assure proper unit operation Winterizing CBWMV Water Coil If unit is installed in an unconditioned space the piping be tween the CBWMV unit and the water heating device should be insulated If power is removed from the unit wa ter must be drained from the system to prevent freezing Repair Parts List The following repair parts are available When ordering parts include the complete unit model number listed on the unit rating plate of each piece of equipment Cabinet Parts e Blower Access Panel e Coil Access Panel Hot Water Coil Parts Coil Replacement Kit Blower Part e Blower Wheel e Blower
35. ust be performed by a qualified installer or service agency Installation of Lennox CBWMV unit must conform with lo cal building codes Refer to the electrical section Page 8 for US and Canadian electrical regulations When paired with a water heating device refer to local building codes for special considerations Refer to water heating device for agency and service clearances Clear ances to combustibles for the CBWMV unit only is zero inches on all sides Table 1 lists recommended service clearances Table 1 CBWMV Unit Service Clearances Clearances Location Inches mm Recommended Front Access Service Access Panel 30 762 NOTE Service access clearance must be maintained Accessibility and service clearances must take prece dence over fire protection clearances For installation in a residential garage unit must be lo cated or protected to avoid physical damage by vehicles The CBWMV unit must be installed so that its electrical components are protected from water When the CBWMV unit is used with an air conditioner the air handler shall be installed on the upstream side of the cooling evaporator coil to avoid freeze up of water system and condensation With a parallel flow arrangement a damper or other means to control the flow of air must ad equately prevent chilled air from entering the air handler If the damper is manually operated it must be equipped to prevent operation of either the hea
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