Lennox International Inc. Lennox Air Handler Air Conditioner User Manual
Contents
1. HEAT PUMP APPLICATION WITH AIR CONDITIONER ELECTRIC HEAT UNIT COOLING APPLICATION WITH ELECTRIC HEAT 3k NOTE Connect common wire only if required Refer to the appropriate thermostat installation instructions Figure 12 Low Voltage Connections 3 Speed PSC Motor Field Wiring Airflow Cooling Blower Speed CHANGE BLOWER SPEED 1 Disconnect all power supplies The cooling blower speed is factory configured to provide correct airflow for an outdoor unit that matches the cooling 2 Remove the air handler access panel Capacity rating Ch he dir andien 3 Locate pin number 2 on the blower relay Two black If the outdoor unit is smaller than the maximum cooling wires are connected to this terminal pin One connects capacity rating for the air handler the cooling blower speed to pin number 5 on the blower relay one connects to may need to be changed Refer to blower performance an in line splice connecting to a red wire hart table 2 11 bp df 4 Remove the wire going to the 4 pin blower motor WARNING connector from the splice 5 Connect the blower lead Red LO Black HI onto Electric shock hazard Disconnect all the splice from the 4 pin blower motor connector power supplies before servicing Replace all parts and2. Drain Line Duct Static Temperature Electric Heat Amps Blower motor Amps DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated if necessary Registers Open and Unobstructed RETURN AIR DUCT Sealed Filter Installed and Clean Registers Open and Unobstructed INTEGRATED CONTROL Jumpers Configured Correctly if applicable Appropriate Links in Place if applicable VOLTAGE CHECK Supply Voltage Low Voltage Electrial Connections Tight DRAIN LINE Leak Free C Explained Operation of System to Homeowner Technician s Name TOTAL EXTERNAL STATIC dry coil dry coil wet coil Supply External Static Return External Static e Total External Static ELECTRIC HEAT AMPS INDOOR BLOWER AMPS INDOOR BLOWER CFM TEMPERATURE DROP Cooling Mode Return Duct Temperature Supply Duct Temperature Temperature Drop TEMPERATURE RISE Heating Mode Return Duct Temperature Supply Duct Temperature Temperature Rise THERMOSTAT Adjusted and Programmed Operation Explained to Owner Date Start Up amp Performance Check Completed Figure 17 Start Up and Performance Checklist Horizontal Configuration Page 15 CBX25UH SERIES
3. 8 Sealing the Unit 0 ee eee eee 8 Electrical Connections uss 9 Airflow Cooling Blower Speed 10 Check Out Procedures 00 eee eee 12 Operation i chee eds dewee ceed 3a X eee 12 Maintenance 2 0 cece eee 13 Cabinet Insulation 0 00 0c cece eee 13 Shipping and Packing List Package 1 of 1 contains the following 1 Assembled air handler unit for upflow or horizontal air discharge application includes upflow and horizontal drain pans and pre installed air filter Check equipment for shipping damage If found immediately report damage to the last carrier Check the unit rating plate to confirm that delivered unit matches order The CBX25UH air handler is designed for indoor installation only As shipped the unit is ready for installation in either upflow horizontal left hand and right hand air discharge applications Electric heat down flow air discharge application kits air filters and other various accessories are available and listed in the CBX25UH Product Specification bulletin for ordering All units come with a factory installed check expansion valve 506757 01 065937 1 80 CBX25UH Unit Dimensions inches mm AIR FLOW SUCTION LINE LIQUID 3 4 1 E Ok 965 381 22 559 279 92 254 470 22 559 6 152 14 357 13 1 2 343 9 LINE VOLTAGE ZT Right Le
4. Y Filter o Drain Line DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated if necessary Registers Open and Unobstructed RETURN AIR DUCT Sealed Filter Installed and Clean Registers Open and Unobstructed INTEGRATED CONTROL Jumpers Configured Correctly if applicable Appropriate Links in Place if applicable VOLTAGE CHECK Supply Voltage Low Voltage Electrial Connections Tight DRAIN LINE Leak Free C Explained Operation of System to Homeowner Technician s Name TOTAL EXTERNAL STATIC dry coil dry coil Supply External Static wet coil Return External Static as Total External Static ELECTRIC HEAT AMPS INDOOR BLOWER AMPS INDOOR BLOWER CFM TEMPERATURE DROP Cooling Mode Return Duct Temperature Supply Duct Temperature Temperature Drop TEMPERATURE RISE Heating Mode Return Duct Temperature Supply Duct Temperature Temperature Rise THERMOSTAT Adjusted and Programmed Operation Explained to Owner Date Start Up amp Performance Check Completed Figure 16 Start Up and Performance Checklist Upflow Configuration Page 14 Installing Contractors Name Installing Contractor s Phone Job Address O Duct System O m O o O o O O E m O o O Integrated Control Installing Date Air Handler Model Thermostat Disconnect RETURN AIR NX Line Voltage Duct System
5. Red 1325 1315 1300 1275 1225 42 Med Blue 1490 1465 1440 1395 1315 High Black 1820 1770 1690 1600 1500 Low Red 1775 1710 1645 1565 1470 48 Med Blue 1995 1895 1800 1685 1560 High Black 2070 1970 1850 1719 1595 Low Red 1675 1630 1580 1520 1450 60 Med Blue 1965 1925 1875 1800 1695 High Black 2140 2085 2000 1895 1795 e Blower Performance CFM vs ESP inches H20 e Cooling speeds should not be reduced below factory setting e Units with electric heat approved at 0 5 maximum and medium blower speed minimum Page 11 CBX25UH SERIES Check out Procedures NOTE Refer to outdoor unit installation instructions for system start up instructions and refrigerant charging instructions PRE START UP CHECKS e Is the air handler properly and securely installed e f horizontally configured is the unit sloped up to 5 8 inch toward drain lines e Will the unit be accessible for servicing e Has an auxiliary pan been provided under the unit with separate drain for units installed above a finished ceiling or in any installation where condensate overflow could cause damage e Have ALL unused drain pan ports been properly plugged e Has the condensate line been properly sized run trapped pitched and tested e Is the duct system correctly sized run sealed and insulated e Have all cabinet openings and wiring been sealed e Is the indoor coil factory installed TXV properly sized for the outdoor unit being used e H
6. 4 Use UL listed wire nuts to connect the field supply power supplies before servicing conductors to the unit black and yellow leads and the Replace all parts and panels before op ground wire to ground terminal marked GND erating 5 Replace the air handler access panel Failure to do so can result in death or elec trical shock AWARNING Electric Shock Hazard Can cause injury or death Foil faced insulation has conductive characteristics sim ilar to metal Be sure there are no electrical connections within a 72 of the insulation If the foil faced insulation comes in contact with electrical voltage the foil could provide a path for current to pass through to the outer metal cabinet While the current produced may not be enough to trip existing electrical safety devices e g fuses or circuit breakers the current can be enough to cause an electric shock hazard that could cause person al injury or death CONNECT BLACK AND YELLOW WIRES TO FIELD PROVIDED CONDUCTORS e All field wiring must be done in accordance with ET E ND National Electrical Code applicable requirements of TERMINAL MARKED GND UL and local codes where applicable e Electrical wiring disconnect means and over current protection are to be supplied by the installer Refer to the air handler rating plate for maximum over current protection minimum circuit ampacity as well as 208 VOLT CONVERSION Figure 11 Making Electrical Connectio
7. BRACKET SECURING MAIN DRAIN PAN TO UNIT Figure 6 Install Main Drain Pan Mounting Bracket 018 through 036 REMOVE BRACKETS SECURING BOTH DRAIN PANS TO UNIT Figure 7 Install both Horizontal and Main Drain Pan Brackets 042 through 060 6 Remove two screws securing the blow off prevention bracket Rotate the brackets 180 and reinstall using the same screws See figure 8 CBX25UH SERIES HORIZONTAL RIGHT HORIZONTAL LEFT REMOVE 2 SCREWS B ced FACTORY DEFAULT SECURING BLOW OFF PREVENTION BRACKET ROTATE BRACKET TO THIS POSITION AND REINSTALL 240 240 1 EE Figure 8 Blow Off Prevention Plate Condensate Drain A IMPORTANT On units of this type where the blower draws rather than blows air through the coil traps must be installed in the con densate drain lines primary and auxiliary if used Traps prevent the blower from drawing air through the drain lines into the air supply OVERFLOW DRAIN LINE ALWAYS RUN AN OVERFLOW DRAIN LINE IF NOT POSSIBLE TO SPACE ROUTE OVERFLOW DRAIN LINE INSTALL LOW VOLTAGE OVERFLOW SWITCH KIT WIRE KIT TO SHUT DOWN VENT MUST EXTEND COMPRESSOR PER INSTRUCTIONS ABOVE HEIGHT OF COIL DRAIN PAN BY m TWO INCHES 51MM LENNOX Se DN X3169 ml CBW CLEAN OU
8. any area that may be damaged by overflow from the main drain pan In some localities local codes may require a secondary drain pan for any horizontal installation The air handler is provided with NPT condensate drain connections SLOPING THE DRAIN Make sure the unit is sloped similar to the slope shown in figure 10 horizontal or upflow so that the drain pan will empty completely without water standing in the pan THIS CORNER SHOULD BE 5 8 1 8 HIGHER THAN DRAIN CORNER THIS CORNER SHOULD BE 5 8 1 8 HIGHER THAN DRAIN CORNER Figure 10 Sloping the Drain INSTALL CONDENSATE DRAIN 1 Remove the appropriate drain knockouts f necessary remove the indoor coil assembly from the cabinet 2 Connect primary drain line connection to the primary drain pan connection The primary drain connection is flush with the bottom of the inside of the pan Secondary connection is raised above the bottom of the inside of the pan NOTE When making drain fitting connections to the drain pan hand tighten the fitting and use a thread sealant Over tightening the fittings can split connections on the drain pan 3 If the auxiliary drain line is to be used remove the plug and route the drain line so that water draining from the outlet will be easily noticed by the homeowner The auxiliary drain line does not require venting or a trap Refer to local codes 4 After removal of drain pan plugs check the d
9. panels before op NOTE Reuse the factory installed plastic cap on whichever wire is not used erating Failure to do so can result in death or elec 6 Replace all panels trical shock 7 Reconnect power Page 10 BLOWER RELAY CHANGING BLOWER SPEED PLASTIC CAPS BLOWER RELAY HARNESS BLUE MED RED L0 BLACK HI RN WHT MTR BRN YELLOW COM 4 PIN BLOWER CONNECTOR Figure 13 Changing Blower Speed NOTE Refer to wiring diagram located on the unit access panel or figure 13 above and blower performance table 2 e All air data measured external to unit with 1 inch non pleated air filter in place e All factory settings are medium speed except the 48 which is set to low speed from the factory e All data given while air handler is operating with a dry DX coil Table 2 CBX25UH Blower Performance 3 Speed PSC 240V CFM ESP in W C ee Blower Speed 10 WC 20 WC 30 WC 40 WC 50 WC Low Red 510 495 475 420 325 18 Med Blue 670 650 630 595 505 High Black 905 865 820 770 705 Low Red 630 625 615 610 580 24 Med Blue 885 875 850 820 780 High Black 1130 1100 1070 1010 950 Low Red 900 865 830 780 740 30 Med Blue 1075 1060 1030 985 940 High Black 1240 1210 1170 1135 1085 Low Red 1160 1140 1115 1085 990 36 Med Blue 1500 1445 1385 1300 1200 High Black 1660 1575 1495 1405 1390 Low
10. FLOW DRAIN PAN UPFLOW DRAIN CON NECTIONS BOTH SIDES USE ONE SIDE OR OTHER Figure 1 Upflow Configuration HORIZONTAL APPLICATIONS A IMPORTANT When removing the coil there is possible danger of equipment damage and personal injury Be careful when removing the coil assembly from a unit installed in right or left hand applications The coil may tip into the drain pan once it is clear of the cabinet Support the coil when removing it ANGLE IRON OR SHEET MAXIMUM 1 2 LONG SCREW ELECTRICAL INLET CLEAR ANCE 4 IN 102 MM T FRONT VIEW END VIEW Figure 2 Suspending Horizontal Unit NOTE When the unit is installed in horizontal applications a secondary drain pan is recommended Refer to local codes NOTE This unit may be installed in left hand or right hand air discharge horizontal applications Adequate support must be provided to ensure cabinet integrity Ensure that there is adequate room to remove service and access panels if installing in the horizontal position LEFT HAND DISCHARGE 1 Determine knockouts required for drain line connections 2 With access door removed knock out drain line opening for installing drain lines 3 Set unit so that it is sloped toward the drain pan end of the unit see figure 10 4 The horizontal configuration is shown in figure 3 AIRFLOW as LEFT HAND DRAINS KNOCKOUT Figure 3 Left Hand Disc
11. LENNOX 2012 Lennox Industries no Dallas Texas USA THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE 4 WARNING Improper installation adjustment alteration service or maintenance can cause personal injury loss of life or damage to property Installation and service must be performed by a licensed professional installer or equivalent or a service agency A IMPORTANT The Clean Air Act of 1990 bans the intentional venting of refrigerant CFCs HCFCs and HFCs as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration may be levied for noncompliance AWARNING The State of California has determined that this product may contain or produce a chemical or chemicals in very low doses which may cause serious illness or death It may also cause cancer birth defects or reproductive harm 10 2012 Page 1 INSTALLATION INSTRUCTIONS Merit CBX25UH Series Units Technical AIR HANDLERS Publications 506757 01 0659371 80 Litho U S A 10 2012 Table of Contents Shipping and Packing List 0 1 CBX25UH Series Units 000 0a 1 Requirements 2 00 0 cece eee ee eees 3 Installation Clearances 0 00 ee nnn 3 instalation serere eee 4 Condensate Drain 0 00 annann nrnna 6 Duct System and Filters 2 005 7 Connecting Refrigerant Lines
12. PA 90B Standard for the Installation of Warm Air Heating and Air Conditioning Systems latest edition The air handler is shipped from the factory completely assembled The unit is provided with flanges for the connection of the duct system Do not remove the cabinet knockouts until it has been determined which knockouts will need to be removed for the installation Select the final air discharge position which best suits the site conditions Consider required clearances space routing requirements for refrigerant line condensate disposal filters duct system wiring and accessibility for service Refer to the air handler rating plate on the air handler for specific information AWARNING Danger of explosion Keep flammable ma terials and vapors such as gasoline away from air handler Place air handler so that heating elements are at least 18 inches 46 cm above the floor for a garage installa tion Failure to follow these instructions can result in death explosion or fire NOTES During cooling operation excessive sweating may occur if the air handler is installed in a warm and humid space If installed in an unconditioned space sealant should be applied around the electrical wires refrigerant tubing and condensate lines where they enter the cabinet Electrical wires should be sealed on the inside where they exit the conduit opening Sealant is required to prevent air leakage into and condensate from
13. T COMPACT OVERFLOW SWITCH WITH 3 4 FEMALE SLIP INLET PRESS IN AND MALE ADAPTER TWO PART DESIGN FOR USE WHERE DO NOT GLUE OBSTRUCTIONS PREVENT DIRECT THREADING VENT 1 X 3 4 X 3 4 REDUCING TEE WITH NOTE WHEN A AIR HANDLER IS LOCATED ABOVE A FINISHED SPACE THE SECONDARY DRAIN PAN MUST HAVE A LARGER FOOTPRINT THAN THE AIR HANDLER WHEN A COIL IS LOCATED ABOVE A FINISHED SPACE A 3 4 19 1MM SECONDARY DRAIN LINE MUST BE CONNECTED TO SECONDARY DRAIN PAN LENNOX P TRAP 49P66 J TRAP 91P90 OR ANY PVC SCH 40 P OR J TRAP 3 4 SECONDARY DRAIN PAN OR CONNECTED TO THE OVERFLOW DRAIN OUTLET OF THE AIR HANDLER DRAIN PAN TRAPS MUST BE DEEP ENOUGH TO OFFSET MAXIMUM STATIC DIFFERENCES GENERALLY TWO INCHES 51MM TRAP DEPTH TO APPROVED 1 LENNOX P TRAP 49P66 REQUIRES A LARGER INSTALLATION SPACE THAN THE J TRAP 91P90 DRAIN FOR NEGATIVE PRESSURE COILS BLOWER 2 PIPE NIPPLE PROVIDED IN BAG ASSEMBLY SCH 80 3 4 I D X 5 34K7401 1 CUT THE PIPE AFTER COIL TRAPS ARE REQUIRED ON ALL DRAIN LINE SHOULD IN HALF AND USE IT TO ROUTE THE MAIN DRAIN DRAIN LINES CONNECTED TO COIL SLOPE A MINIMUM OF ONE INCH PER 10 FEET 25MM PER 3 METERS Figure 9 Typical Main and Overflow Drain Page 6 A IMPORTANT A field fabricated secondary drain pan with a drain pipe to the outside of the building is required in all installa tions over a finished living space or in
14. ating 24 volts is put on the blower time delay relay coil Then normally open contacts close causing the indoor blower motor to operate The circuit between R and Y is completed closing the circuit to the contactor in the outdoor unit starting the compressor and outdoor fan motor If the room temperature should continue to fall the circuit between R and W1 is completed by the second stage heat room thermostat Circuit R W1 energizes a heat sequencer The completed circuit will energize supplemental electric heat if applicable Units with a Page 12 second heat sequencer can be connected with the first sequencer to W1 on the thermostat They may also be connected to a second heating stage W2 on the thermostat subbase EMERGENCY HEAT HEATING HEAT PUMP If the selector switch on the thermostat is set to the emergency heat position the heat pump will be locked out of the heating circuit and all heating will be electric heat if applicable A jumper should be placed between W2 and E on the thermostat subbase so that the electric heat control will transfer to the first stage heat on the thermostat This will allow the indoor blower to cycle on and off with the electric heat when the fan switch is in the AUTO position Maintenance A IMPORTANT Do not operate system without a filter A filter is required to protect the coil blower and internal parts from exces sive dirt and dust The filter is placed in the return duc
15. ave all unused parts and packaging been disposed of e Is the filter clean in place and of adequate size e sthe wiring neat correct and in accordance with the wiring diagram e Is the unit properly grounded and protected fused e Is the thermostat correctly wired and in a good location e Are all access panels in place and secure CHECK BLOWER OPERATION e Set thermostat to FAN ON e The indoor blower should come on CHECK COOLING OPERATION e Set thermostat to force a call for cooling approximately 5 F lower than the indoor ambient temperature e The outdoor and indoor units should come on immediately e Check the airflow from a register to confirm that the system is moving cooled air e Set the thermostat 5 F higher than the indoor temperature The indoor blower and outdoor unit should cycle off Air handler should cycle off 45 seconds after the outdoor unit shuts off CHECK ELECTRIC HEATER IF USED e Set thermostat to call for auxiliary heat approximately 5 F above ambient temperature The indoor blower and auxiliary heat should come on together Allow a minimum of 3 minutes for all sequencers to cycle on e Set the thermostat so that it does not call for heat Allow up to 5 minutes for all sequencers to cycle off TIME DELAY RELAY Blower time delay operation 1 When cooling demand is initiated there is a 1 second motor on delay 2 After the motor on delay expires motor ramps up to 100 an
16. cause water damage TEST CONDENSATE DRAIN Test the drain pan and drain line after installation 1 Pour several quarts of water into drain pan enough to fill drain trap and line 2 Check to make sure the drain pan is draining completely no leaks are found in drain line fittings and water is draining from the end of the primary drain line 3 Correct any leaks found Duct System and Filters DUCT SYSTEM The air handler is provided with flanges for the connection of the plenum and ducts The air handler is equipped with flanges that can form a filter rack for the installation of the air filter or the filter may be installed as part of the return air duct system Supply and return duct system must be adequately sized to meet the system s air requirements and static pressure capabilities The duct system should be insulated with a minimum of 1 thick insulation with a vapor barrier in conditioned areas or 2 minimum in unconditioned areas Table 1 Unit Air Filter Size Chart Actual Minimum Filter Size 018 11 50 x 19 50 x 75 024 and 030 14 50 x 19 50 x 75 036 17 50 x 19 50 x 75 042 048 and 060 17 50 x 23 50 x 75 Filter Size Page 7 CBX25UH SERIES A IMPORTANT If a high efficiency filter is being installed as part of this system to ensure better indoor air quality the filter must be properly sized High efficiency filters have a higher static pressure drop t
17. d runs at 100 until cooling demand is satisfied 3 Once demand is met motor runs at 100 for 45 seconds 4 Motor ramps down to stop q 100 1 2 CFM NS SECOND COOLING DELAY DEMAND Figure 14 Blower Time Delay COOLING COOLING ONLY OR HEAT PUMP When the thermostat calls for cooling 24 volts is put on the blower time delay relay coil and then the indoor blower relay energizes The normally open contacts close causing the indoor blower motor to operate The circuit between R and Y is completed closing the circuit to the contactor in the outdoor unit starting the compressor and outdoor fan motor On heat pumps circuit R and O energizes the reversing valve switching the valve to the cooling position The reversing valve remains energized as long as the thermostat selector switch is in the COOL position At the completion of the cooling demand the indoor blower and outdoor unit should cycle off Air handler should cycle off 45 seconds after the outdoor unit shuts off HEATING ELECTRIC HEAT ONLY When the thermostat calls for heat the circuit between R and W is completed and the heat sequencer is energized A time delay follows before the heating elements and the indoor blower motor come on Units with a second heat sequencer can be connected with the first sequencer to W on the thermostat subbase or they may also be connected to a second stage on the subbase HEATING HEAT PUMP When the thermostat calls for he
18. esults in water blow off problems This is especially important when the unit is installed in an unconditioned area If installed in an unconditioned space sealant should be applied around the electrical wires refrigerant tubing and condensate lines where they enter the cabinet 4 WARNING There must be an airtight seal between the bottom of the air handler and the return air plenum Use fiberglass sealing strips caulking or equivalent sealing method between the plenum and the air handler cabinet to ensure a tight seal Return air must not be drawn from a room where this air handler or any gas fueled appliance i e water heater or carbon monoxide producing device i e wood fireplace is installed A IMPORTANT When sealing the cabinet be sure to seal closed any space around the holes where the drain lines exit the cabinet using duct tape and or Permagum Warm air must not be allowed to enter through any gaps or holes in the cabinet Make sure the liquid line and suction line entry points are sealed with either ARMAFLEX material or with Permagum Permagum may also be used to seal around the main and auxiliary drains and around open areas of electrical inlets Page 8 Electrical Connections 1 Disconnect all power supplies 2 Remove the air handler access panel 3 Route the field ly wires to the air handler electrical AWARNING e ani Mes o the air handler electrica Electric shock hazard Disconnect all
19. forming inside of the air handler the control box and on the electrical controls This unit is approved for installation clearance to combustible material as stated on the unit rating plate Accessibility and service clearances must take precedence over combustible material clearances The air handler must be installed so that free access is allowed to the coil filter compartment and blower control compartment Installation Clearances NON DUCTED RETURN CLOSET INSTALLATION The air handler can be installed in a closet with a false bottom to form a return air plenum It may also be installed with a return air plenum under the air handler Louvers or return air grilles are field supplied Local codes may limit application of systems without a ducted return to single story buildings When a CBX25UH unit is installed in a closet with a louvered return opening the minimum open area for the louvers will be e 320 square inches for 018 and 024 models e 360 square inches for 030 and 036 models e 450 square inches for 042 thru 060 models If the free area is not known assume a 25 free area for wood or a 75 free area for metal louvers or grilles Using the louver dimensions and the 25 or 75 assumption determine if the open area meets the minimum open area listed above Page 3 CBX25UH SERIES If a return air plenum is used the return air grille should be immediately in front of the opening in the plenum to allow for t
20. ft and Top LOW VOLTAGE o Right Side Only NI CONDENSATE DRAIN PIPING PLATE 4 2 1 4 x 3 3 4 FILTER ACCESS 16 13 1 2 o SR aes 470 406 18 7 8 343 16 7 8 556 22 soo 22 ss 22 559 22 sso 6 152 479 5 1 2 140 5 1 2 140 5 3 4 429 Opening SIDE VIEW 1219 556 660 26 660 6 3 8 162 17 7 8 454 15 1 4 387 3 14 83 3 14 83 16 7 8 429 16 7 8 429 Supply Air Opening 330 19 7 8 505 505 19 7 8 Return Air Opening 527 318 16 1 2 419 16 1 2 419 20 3 4 527 20 3 4 527 16 406 16 20 3 4 19 3 8 406 Page 2 527 492 24 3 4 19 3 8 629 492 24 3 4 19 3 8 AWARNING Excessive Weight Hazard Use two or more people when moving and installing the unit Failure to do so can result in back or other type of injury A IMPORTANT The CBX25UH units are designed to match and must be used with outdoor units as rated The indoor sections are manufactured with a check expansion valve TXV to provide optimum refrigerant control and system performance with a variety of different capacities of out door units 4 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 These instructions are intended as a ge
21. han standard efficiency glass foam filters If the pressure drop is too great system capacity and performance may be reduced The pressure drop may also cause the limit to trip more frequently during the winter and the indoor coil to freeze in the summer result ing in an increase in the number of service calls Before using any filter with this system check the spe cifications provided by the filter manufacturer against the data given in the appropriate Lennox Product Specifica tions bulletin Additional information is provided in Ser vice and Application Note ACC 00 2 August 2000 Supply plenum should be the same size as the flanged opening provided around the blower outlet and should extend at least 3 ft from the air handler before turning or branching off plenum into duct runs The plenum forms an extension of the blower housing and minimizes air expansion losses from the blower INSTALLING DUCT SYSTEM Connect supply air duct to the flange on top of the air handler If an isolation connector is used it must be nonflammable A return air duct system is recommended If the unit is installed in a confined space or closet a return connection must be run full size to a location outside the closet Connecting Refrigerant Lines Refrigerant lines must be connected by a qualified technician in accordance with established procedures A IMPORTANT Refrigerant lines must be clean dehydrated refrig erant grade copper li
22. harge Configuration Page 4 5 If the unit is suspended the entire length of the cabinet must be supported If you use a chain or strap use a piece of angle iron or sheet metal attached to the unit either above or below to support the length of the cabinet Use securing screws no longer than 1 2 inch to avoid damaging the coil or filter See figure 2 Use sheet metal screws to connect the return and supply air plenums as required RIGHT HAND AIR DISCHARGE For horizontal right hand air discharge the following field modifications are required 1 Remove and set aside blower and coil access covers 2 Remove bracket s securing pan s to unit as illustrated in figures 4 and 5 REMOVE BRACKET SECURING MAIN DRAIN PAN TO UNIT Figure 4 Remove Main Drain Pan Mounting Bracket 018 through 036 REMOVE BRACKETS SECURING BOTH DRAIN PANS TO UNIT Figure 5 Remove Horizontal and Main Drain Pan Mounting Brackets 042 through 060 Page 5 3 Remove coil assembly bottom drain pan and horizontal drain pan as one assembly from the air handler Move the horizontal drain pan to the opposite side of the coil Be sure drain holes toward the back of the unit are plugged Remove the plugs from the front drain pan ports Re install modified coil drain pan assembly in air handler in the same orientation as before figures 6 and 7 INSTALL
23. he free flow of return air When not installed in front of the opening there must be adequate clearance around the air handler to allow for the free flow of return air Installation Each unit consists of a blower assembly refrigerant coil and controls in an insulated galvanized steel factory finished enclosure Knockouts are provided for electrical wiring entrance For ease in installation it is best to make any necessary coil configuration changes before setting air handler in place REFRIGERANT METERING DEVICE CB25UH units are equipped with a factory installed check expansion valve UPFLOW APPLICATION 1 The air handler must be supported on the bottom only and set on solid floor or field supplied support frame Securely attach the air handler to the floor or support frame 2 If installing a unit in an upflow application remove the horizontal drain pan IMPORTANT The horizontal drain pan is not required in upflow air discharge installations its removal provides the best efficiency and air flow 3 Place the unit in the desired location and slope unit as previously mentioned Connect return and supply air plenums as required using sheet metal screws 4 Install units that have no return air plenum on a stand that is at least 14 from the floor This will allow proper air return HORIZONTAL DRAIN PAN IMPORTANT REMOVE PAN FOR BEST EFFICIENCY AND AIR FLOW HORIZONTAL DRAIN CONNECTIONS BOTH SIDES NOT USED UP
24. neral guide and do not supersede local or national codes in any way Consult authorities having jurisdiction before installation Compliance with all local state or national codes pertaining to this type of equipment should be determined prior to installation Read this instruction manual as well as the instructions supplied in separate equipment before starting the installation In addition to conforming to manufacturer s installation instructions and local municipal building codes installation of Lennox air handler units with or without optional electric heat MUST conform with National Fire Protection Association NFPA standards Standard for Installation of Air Conditioning and Ventilation Systems NFPA No 90A and Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems NFPA No 90B All models are designed for indoor installation only The installation of the air handler field wiring duct system etc must conform to the requirements of the National Electrical Code ANSI NFPA No 70 latest edition in the United States and any state laws and local ordinances including plumbing or wastewater codes Local authorities having jurisdiction should be consulted before installation is made Such applicable regulations or requirements take precedence over the general instructions in this manual Install the conditioned air plenum ducts and air filters provided in accordance with NF
25. nes Air handler coils should be installed only with specified line sizes for approved sys tem combinations Handle the refrigerant lines gently during the installation process Sharp bends or possible kinking in the lines will cause a restriction Do not remove the caps from the lines or system connec tion points until connections are ready to be completed 1 Route the suction and liquid lines from the fittings on the indoor coil to the fittings on the outdoor unit Run the lines in as direct a path as possible avoiding unnecessary turns and bends 2 Make sure that the suction line is insulated over the entire exposed length and that neither suction nor liquid lines are in direct contact with floors walls duct system floor joists or other piping 3 Connect the suction and liquid lines to the evaporator Coil 4 To avoid damaging the rubber grommets in the cabinet while brazing slide the rubber grommets over the refrigerant lines until they are away from the heat source 5 Braze using an alloy of silver or copper and phosphorus with a melting point above 1 100 F 593 C NOTE Do not use soft solder 6 Reinstall the rubber grommets after brazing is finished 7 Make sure outdoor unit has been put in place according to the Installation Instructions and is connected to the refrigerant lines Sealing the Unit Seal the unit so that warm air is not allowed into the cabinet Warm air introduces moisture which r
26. ns operating voltage 1 Disconnect all power supplies e The power supply must be sized and protected 2 Remove the air handler access panel according to the specifications supplied on the 3 Using the wiring diagram located on the unit access product panel as a reference move the 2 connected black e This air handler is factory configured for 240 volt transformer leads from the 240 volt terminal on the single phase 60 cycles For 208 volt applications see transformer to the 208 volt terminal on the transformer 208 Volt Conversion later in this section e For optional field installed electric heat applications AWARNING refer to the instructions provided with the accessory n f for proper installation Electrically ground air handler Connect ground wire to ground terminal marked 4 WARNING ak Failure to do so can result in death or elec USE COPPER CONDUCTORS ONLY trical shock Page 9 CBX25UH SERIES THERMOSTAT AIR HANDLER THERMOSTAT AIR HANDLER HEAT ONLY APPLICATION AIR CONDITIONER THERMOSTAT HEAT PUMP UNIT AIR HANDLER UNIT COOLING ONLY APPLICATION THERMOSTAT AIR HANDLER CONNECT COMMON WIRE ONLY IF REQUIRED REFER TO THE APPROPRIATE THERMOSTAT INSTALLATION INSTRUCTIONS
27. rain port to see if holes have been drilled If not drilled use a 19 32 bit to drill out the primary drain hole use a 3 8 drill bit for the secondary drain hole Remove all drill shavings 5 Make sure drain ports and drain pan are free of all debris 6 Plug and check any unused drain pan openings for tightness Torque plugs to 30 in Ib to prevent water leaks or seepage from the drain pan 7 Install a 2 trap in the primary drain lines as close to the unit as practical see figure 9 Make sure the top of the trap is below the connection to the drain pan to allow complete drainage of the pan NOTE Horizontal runs must have an anti siphon air vent standpipe installed ahead of the horizontal run See figure 9 An extremely long horizontal run may require an oversized drain line to eliminate air trapping NOTE Do not operate air handler without a drain trap The condensate drain is on the negative pressure side of the blower therefore air being pulled through the condensate line will prevent positive drainage without a proper trap 8 Route the drain line to the outside or to an appropriate drain Drain lines must be installed so they do not block service access to the front of the air handler A 24 clearance is required for filter coil or blower removal and service access NOTE Check local codes before connecting the drain line to an existing drainage system Insulate the drain lines where sweating could
28. rrosion and subsequently component failure REPAIRING DAMAGED INSULATION Areas of condensation on the cabinet surface are an indication that the insulation is in need of repair If the insulation in need of repair is otherwise in good condition the insulation should be cut in an X pattern peeled open glued with an appropriate all purpose glue and placed back against the cabinet surface being careful to not overly compress the insulation so the insulation can retain its original thickness If such repair is not possible replace the insulation If using foil faced insulation any cut tear or separations in the insulation surface must be taped with a similar foil faced tape GLUE make sure there is full coverage of glue on the metal or insulation so there are no areas where air pockets may form which can lead to sweating 1 CUT INSULATION IN X PATTERN 2 APPLY GLUE 3 PRESS GLUED TABS AGAINST CABINET Figure 15 Repairing Insulation Page 13 CBX25UH SERIES Installing Contractors Name Installing Contractor s Phone Job Address Installing Date Air Handler Model gt Temperature Duct Static ON SUPPLY AIR Thermostat Line Voltage Disconnect Switch Integrated Control Blower Motor Amps Electric Heat Amps RETURN AIR O O o O o O m m o O o O
29. t by the installer e Inspect air filters at least once a month and replace or clean as required Dirty filters are the most common cause of inadequate heating or cooling performance e Replace disposable filters Cleanable filters can be cleaned by soaking in mild detergent and rinsing with cold water e Install new clean filters with the arrows on the side pointing in the direction of airflow Do not replace a cleanable high velocity filter with a disposable low velocity filter unless return air system is properly sized for it e f water should start coming from the secondary drain line a problem exists which should be investigated and corrected Contact a qualified service technician A IMPORTANT DAMAGED INSULATION MUST BE REPAIRED OR REPLACED before the unit is put back into operation In sulation loses its insulating value when wet damaged separated or torn Matt or foil faced insulation is installed in indoor equipment to provide a barrier between outside air conditions surrounding ambient temperature and humidity and the varying conditions inside the unit If the insulation barrier is damaged wet ripped torn or separated from the cabinet walls the surrounding ambient air will affect the inside surface temperature of the cabinet The temperature humidity difference between the inside and outside of the cabinet can cause condensation on the inside or outside of the cabinet which leads to sheet metal co
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