ICP Evaporator Coils Manual L0604332
User Manual: ICP ICP Evaporator Coils Manual ICP Evaporator Coils Owner's Manual, ICP Evaporator Coils installation guides
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These instructions must be read and understood completely before attempting installation. It is important that the Blower and Duct System be properly sized to allow the system to operate at full capacity. Poorly designed systems will not give satisfactory cooling or economy, They may even shorten the service life of the compressor in the outdoor unit, Safety Labeling and Signal Words DANGER, NOTE WARNING, CAUTION, and Signal Words in Manuals The signal word WARNING is used throughout this manual in the following manner: The signal words DANGER, WARNING, CAUTION, and NOTE are used to identify levels of hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manuals that may apply to the product. The signal word CAUTION is used throughout this manual in the following manner: DANGER - Immediate hazards which will result in severe personal injury or death. Signal Words on Product Labeling WARNING - Hazards or unsafe practices which could result in severe personal injury or death. Signal words are used in combination with colors and/or pictures on product labels, CAUTION - Hazards or unsafe practices which may result in minor personal injury or product or property damage. NOTE - Used to highlight suggestions which will result in enhanced installation, reliability, or operation. TABLE OF CONTENTS Installation .................................. 2 - 3 Condensate Drain .............................. 3 Waste Line Connection .......................... 4 Refrigerant Line Connections ................. Refrigerant Metering Device ..................... Check and Adjust Airflow ..................... Start-Up Procedure ............................ 4 - 5 5 5 - 6 6 ELECTRICAL SHOCK HAZARD Failure to turn off electric power could result in personal injury or death. Before installing or servicing system, turn off main power to the system. There may be more than one disconnect switch, including accessory heater(s). 484 01 3000 00 September 2005 INSTALLATION EBA and EBD Coils are designed for Upflow application only (refer to Figures 3 & 4). Using these coils in other configurations may result is excessive water blow-off. EBA Loose Coils are shipped with a metal collar plate approximately the same size as the drain pan. The collar plate must be installed between the drain pan and the furnace or air handler cabinet to prevent condensation inside the cabinet. Position the collar plate as shown in Figure 1, with the flanges pointing down, towards the furnace or air handler cabinet. Size the plenum or fabricate spacers to seal against the outside of the collar and prevent air bypass. Figure 1 | EBA Collar Plate .L EBD Cased Coils are designed to fit furnaces and air handlers of the same width with no modifications. When an EBD Cased Coil is applied to a narrower or wider furnace or air handler, a field fabricated adapter is required. Refer to Figure 2 for examples of field fabricated adapters. PRODUCT DAMAGE HAZARD Failure to follow this caution may result in product damage. When a narrower coil is installed on a wider gas furnace (upflow, downflow, or horizontal), a field fabricated adapter must create 3" minimum space between furnace and coil to allow airflow to distribute evenly. When a loose coil is installed on any GAS furnace, the drain pan must be at least 2"away from the furnace heat exchanger to avoid drain pan damage. When a loose coil is installed on any OIL furnace, the drain pan must be at least 5" away from the furnace heat exchanger to avoid drain pan damage. PROPERTY DAMAGEHAZARD Collar Plate under drain pan Failure to follow this caution may result in property damage A field fabricated auxiliary drain pan, with a separate drain is REQUIRED for all installations over a finished living space or in any area that may be damaged by overflow from a restricted main drain pan. In some localities, local codes require an auxiliary drain pan for ANY horizontal installation. Flanges down Figure 2 1 Adapters for Coils Wider or Narrower than Furnace or Air Handler ADAPTER (FIELD SUPPLIED) 3" MIN. f ADAPTER (2) (FIELD SUPPLIED) WIDER FURNACE 2 NARROWER FURNACE 484 01 3000 00 NOTE: When coil is used in a heat pump application with electric heat, coil must be installed upstream of the electric heater (refer to Figure 3). This prevents electric heat from driving up refrigeration system pressure during heating cycle. Figure 3 NOTE: When coil is installed to a gas or oil furnace, coil must be installed downstream of the furnace heat exchanger (refer to Figure 4). This reduces condensate formation in the furnace heat exchanger during the cooling cycle. Heat Pump Coil Position Relative to Electric Heat ELECTRIC Figure 4 Coil Position Relative to Gas or Oil Furnace Heat Exchanger HEATER BLOWER HEAT FURNACE EXCHANGER BLOWER NOTE: When coil is installed with a Heat Pump in conjunction with a fossil fuel heating system, a Fossil Fuel Kit must be used. Refer to Product Specification literature for kit part number. CONDENSATE DRAIN Coil is provided with two 3_,,NPT condensate drain connections. The connection with the larger internal opening is the primary drain, and the connection with the smaller internal opening is the secondary (overflow) drain. Condensate drain lines should be installed in a manner that does not obstruct access to the filter. Use PVC fittings on the plastic condensate pan. Finger tighten plus 11/2turns. Do not over-tighten. Use pipe dope. If coil is located in or above a living space where damage may result from condensate overflow, a separate 3_,,drain must be provided from secondary (overflow) drain connection. Run this drain to a place in compliance with local installation codes where it will be noticed when unit is operational. Condensate flowing from secondary (overflow) drain indicates a plugged primary drain - unit requires service or water damage will occur. 1. 2. Connect drain lines to the appropriate drain connections. Drain lines should not be smaller than the drain connections (3_"), NOTE: Traps must be used when the coil is installed on the return air side of the system. When coil is installed on the supply side (outlet air) it is not necessary to install traps and better drainage is usually achieved without traps. Install properly sized condensate traps in the drain lines as close to the coil as possible. Install drain lines below the bottom of the drain pan and pitch the 484 01 3000 00 NOTE: On furnace installations where the coil is located in an unconditioned space, nuisance sweating may occur in the area around the cabinet to supply duct joint. Wrap the joint between the cabinet and the supply duct with a 6" wide piece of insulation with vapor barrier. 3, 4. 5. drain lines down from the coil at least ¼ inch per foot of run. Horizontal runs over 15 feet long must also have an anti-siphon air vent (stand pipe), installed ahead of the horizontal run. An extremely long horizontal run may require an oversized drain line to eliminate air trapping. Refer to Figure 5 for minimum trap dimensions. Route to the outside or to a floor drain. Check local codes before connecting to a waste (sewer) line. Prime all traps, test for leaks, and insulate drain lines where sweating could cause water damage. If a gravity drain cannot be used, install a condensate pump. Install the pump as close to the indoor section as possible. Figure 5 J Recommended Condensate Trap 2" MIN 3 WASTE LINE CONNECTION If the condensate line is to be connected to a waste (sewer) line, an open trap must be installed ahead of the waste line to prevent escape of sewer gases (refer to Figure 6). EXPLOSION HAZARD Failure to provide trap could result in personal injury, death, or property damage. Provide trap with air gap in drain line when connecting to waste (sewer) line. Refer to Figure 6. Figure 6 I Condensate Condensate Line Trap Sewer Line t LINE CONNECTIONS Figure 7 Coil Connection Tube Size (inch) Model Size PERSONALINJURY Line Air Gap Above uid Level l REFRIGERANT Drain to Waste HAZARD Liquid Suction 18 (1 Y2ton) 3/8 5/8 Failure to relieve pressure in the coil could result in personal injury. 24 (2 ton) 3/8 5/8 30 (2Y2ton) 3/8 3A Wear eye protection. Coil is factory charged with 15 psi nitrogen. Pierce the centers of both rubber tubing plugs to relieve pressure before removing plugs. 36 (3 ton) 3/8 34 42 (4Y2ton) 3/8 7/8 48 (4 ton) 3/8 7_8 60 (5 ton) 3/8 7_8 NOTE: Factory nitrogen charge may escape past rubber plugs during storage. This does not indicate a leaking coil nor warrant return of the coil. Figure 8 l Refrigerant Lines Size and install refrigerant lines according to information provided with outdoor unit. Coil connection tube sizes are shown in Figure 7. Route refrigerant lines to the coil in a manner that will not obstruct service access to the unit or removal of the filter. 1, 2. Remove cabinet door. Remove tubing plate with rubber grommets and slide plate with grommets onto the refrigerant lines (field line-set), away from braze joints. Remove rubber plugs from coil stubs using a pulling and twisting motion. Hold coil stubs steady to avoid bending or distorting. 3, Wrap TXV and nearby tubing with a heat-sinking material such as a wet cloth. 4, Fit refrigerant lines into coil stubs. Wrap a heat sinking material such as a wet cloth behind braze joints. NOTE: See outdoor unit Installation Instructions regarding requirements for installation of a filter-drier in the liquid line close to the indoor coil. Braze using a SiI-Fos or Phos-copper alloy. 5. 6, 4 RUBBER GROMMETS TUBING PLATE After brazing, allow joints to cool. Slide tubing plate with rubber grommets over joints. Position tubing at center of each grommet to ensure an air seal around the tube (refer to Figure 8), 484 01 3000 00 Strainer screen is factory installed inside the liquid tube stub (TXV tube). Leave the strainer screen in place during installation (refer to Figure 9). PRODUCT DAMAGE HAZARD Figure 9 J Strainer Screen Failure to follow this caution may result in product damage. F-q / > rainer Screen Braze with SiI-Fos or Phos-copper alloy on copper-to-copper joints and wrap a wet cloth around rear of fitting to prevent damage to TXV. TXV REFRIGERANT METERING DEVICE EBD and EBA coils have a factory installed hard shut-off TXV designed only for use with R-22 refrigerant. Use only with outdoor units designed for R-22. TXV is factory set and not field adjustable. PRODUCT DAMAGE HAZARD Failure to follow this caution may result in product damage. This Coil has a hard shut-off TXV metering device. A compressor Hard Start Kit is required in all applications where the matching outdoor unit has a single-phase reciprocating compressor. CHECK AND ADJUST AIR FLOW ELECTRICAL SHOCK HAZARD 3. Using the manometer (draft gauge or flow gauge), measure the static pressure drop across the dry coil and compare it to the numbers in Figure 10. 4. Find the corresponding CFM in Figure 10. Failure to shut of electric power could result in personal injury or death. Adjusting Before adjusting blower speed, shut off electric power to the furnace or blower module. If CFM is too low, increase the blower speed and measure the static pressure drop again. Determine CFM from Figure 10. It is important that the correct amount of air (CFM) flows through the coil. The installer must determine the required CFM based on the characteristics of the specific system (such as system size, ducting, components, and accessories). In general, 400 CFM per ton is the nominal required value, with a range of 350 - 450 CFM per ton. Check Static Pressure Drop and CFM Across Coil The amount of air (CFM) is related to a pressure drop. To determine the CFM, measure the pressure drop using an inclined manometer (sometimes called draft gauge or air flow gauge). 1. The coil should be dry and clean. The air filter must be clean and in place. All registers open. DO NOT run the outdoor unit when checking air flow. 2. Run the blower on cooling speed. 484 01 3000 00 Air Flow If CFM is too high, reduce the blower speed and measure the static pressure drop again. Determine CFM from Figure 10. NOTE: Change blower speed as shown in the instructions for the furnace or air handler. NOTE: It may not be possible to obtain a gauge reading exactly the same as shown in Figure 10. This is due to variations in duct systems and blower speeds. If the motor is at the highest speed and the CFM is still not high enough, replace the blower and/or motor with a larger size. If the unit has an adjustable belt driven blower, use an ammeter to check the motor current draw. If the current draw is higher than the motor name plate amps, replace the motor with one of greater horsepower. 5 Figure10 Coil Size 18B 11/2tons 24B 2 tons 24F 2 tons 30B 21/2tons 30F 21/2tons 36B 3 tons 36F 3 tons 36J 3 tons CFM and Pressure Drop CFM Across Coil 500 600 Static Pressure Drop Across Coil (Inches Water Column) Wet Dry 0,096 0,127 0,106 0,140 700 700 0,161 0,134 0,183 0,141 800 900 0,166 0,200 0,176 0,215 700 800 900 0,110 0,134 0,160 0,118 0,146 0,176 800 900 0,137 0,169 0,143 0,174 1000 1100 0,204 0,241 0,211 0,251 800 900 0,101 0,121 0,106 0,129 1000 1100 1000 0,143 0,168 0,188 0,154 0,181 0,202 1100 1200 0,224 0,262 0,240 0,281 1300 1400 0.303 0,349 0,325 0,374 1000 1100 1200 0,133 0,154 0.177 0,139 0,163 0,189 1300 0,203 1400 1000 1100 0,227 0,104 0,121 1200 1300 0,139 0,159 0,144 0,166 1400 0,181 0,190 Coil Size 42J Static Pressure Drop Across Coil (Inches Water Column) Dry Wet 0,129 0,137 0,148 0,159 1400 1500 0,168 0,189 0,180 0,203 1600 1200 0,211 0,114 0,228 0,142 1300 1400 1500 0,130 0,146 0,164 0,161 0,182 0,202 1600 1400 0,182 0,250 0,222 0,263 1500 1600 0,284 0,320 0,297 0,336 1700 1800 0,358 0,398 0,376 0,418 1400 1500 1600 0,192 0,219 0,245 0,196 0,225 0,253 1700 1800 0,273 0,303 0,283 0,314 1400 1500 0,180 0,198 0,193 0,214 1600 1700 1800 0,222 0,247 0,275 0,241 0,270 0,296 0,216 1700 0,260 0,285 0,245 0,106 0,124 1800 1900 0,288 0,316 0,315 0,346 2000 2100 2200 0,347 0,378 0,409 0,381 0,413 0,447 1700 1800 1900 0,232 0,256 0,283 0,263 0,291 0,321 2000 2100 2200 0,308 0,335 0,363 0,354 0,386 0,419 31/2tons 42L 31/2tons 48F 4 tons 48J 4 tons 48L 4 tons 60J 5 tons 60L 5 tons START-UP CFM Across Coil 1200 1300 PROCEDURE Refer to outdoor unit Installation Instructions for refrigeration system start-up instructions and refrigerant charging method details, 6 484 01 3000 00
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