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 compres-
sor in the outdoor unit,
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and
NOTE
The signal words DANGER, WARNING, CAU-
TION, and NOTE are used to identify levels of haz-
ard seriousness. The signal word DANGER is only
used on product labels to signify an immediate haz-
ard. The signal words WARNING, CAUTION, and
NOTE will be used on product labels and through-
out this manual and other manuals that may apply
to the product.
DANGER - Immediate hazards which will result in
severe personal injury or death.
WARNING - Hazards or unsafe practices which
could result in severe personal injury or death.
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 opera-
tion.
Signal Words in Manuals
The signal word WARNING is used throughout this
manual in the following manner:
The signal word CAUTION is used throughout this
manual in the following manner:
Signal Words on Product Labeling
Signal words are used in combination with colors
and/or pictures on product labels,
TABLE OF CONTENTS
Installation .................................. 2 - 3
Condensate Drain .............................. 3
Waste Line Connection .......................... 4
Refrigerant Line Connections ................. 4 - 5
Refrigerant Metering Device ..................... 5
Check and Adjust Airflow ..................... 5 - 6
Start-Up Procedure ............................ 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 heat-
er(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 fur-
nace or air handler cabinet to prevent condensation in-
side the cabinet. Position the collar plate as shown in
Figure 1, with the flanges pointing down, towards the fur-
nace or air handler cabinet. Size the plenum or fabricate
spacers to seal against the outside of the collar and pre-
vent air bypass.
Figure 1 |EBA Collar Plate
.L
EBD Cased Coils are designed to fit furnaces and air han-
dlers 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 dis-
tribute evenly.
When a loose coil is installed on any GAS furnace,
the drain pan must be at least 2"away from the fur-
nace 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 fur-
nace heat exchanger to avoid drain pan damage.
Collar Plate
under drain pan
Flanges down
PROPERTY DAMAGEHAZARD
Failure to follow this caution may result in proper-
ty damage
A field fabricated auxiliary drain pan, with a sepa-
rate 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 aux-
iliary drain pan for ANY horizontal installation.
Figure 2 1Adapters for Coils Wider or Narrower than Furnace or Air Handler
3" MIN.
f
WIDER FURNACE
ADAPTER
(FIELD SUPPLIED)
ADAPTER (2)
(FIELD SUPPLIED) NARROWER
FURNACE
2 484 01 3000 00
NOTE: When coil is used in a heat pump application with
electric heat, coil must be installed upstream of the elec-
tric heater (refer to Figure 3). This prevents electric heat
from driving up refrigeration system pressure during heat-
ing cycle.
Heat Pump Coil Position Relative
Figure 3 to Electric Heat
ELECTRIC HEATER
BLOWER
NOTE: When coil is installed to a gas or oil furnace, coil
must be installed downstream of the furnace heat ex-
changer (refer to Figure 4). This reduces condensate
formation in the furnace heat exchanger during the cool-
ing cycle.
Coil Position Relative to Gas or
Figure 4 Oil Furnace Heat Exchanger
FURNACE
HEAT EXCHANGER
BLOWER
NOTE: When coil is installed with a Heat Pump in con-
junction with a fossil fuel heating system, a Fossil Fuel
Kit must be used. Refer to Product Specification litera-
ture for kit part number.
NOTE: On furnace installations where the coil is located
in an unconditioned space, nuisance sweating may oc-
cur 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.
CONDENSATE DRAIN
Coil is provided with two 3_,,NPT condensate drain con-
nections. The connection with the larger internal open-
ing 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 con-
nection. Run this drain to a place in compliance with local
installation codes where it will be noticed when unit is op-
erational. Condensate flowing from secondary (overflow)
drain indicates a plugged primary drain - unit requires
service or water damage will occur.
1. Connect drain lines to the appropriate drain connec-
tions. Drain lines should not be smaller than the
drain connections (3_"),
2. 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
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 hori-
zontal 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 conden-
sate pump. Install the pump as close to the indoor
section as possible.
Figure 5 J Recommended Condensate Trap
2" MIN
484 01 3000 00 3
WASTE LINE CONNECTION
If the condensate line is to be connected to a waste (sew-
er) 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 in-
jury, death, or property damage.
Provide trap with air gap in drain line when con-
necting to waste (sewer) line. Refer to Figure 6.
Figure 6
Condensate
Line
Trap
ICondensate Drain to Waste Line
Air Gap Above
uid Level
l Sewer Line t
REFRIGERANT LINE CONNECTIONS
PERSONALINJURY HAZARD
Failure to relieve pressure in the coil could result
in personal injury.
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.
NOTE: Factory nitrogen charge may escape past rubber
plugs during storage. This does not indicate a leaking coil
nor warrant return of the coil.
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, 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.
2. 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 sink-
ing material such as a wet cloth behind braze joints.
NOTE: See outdoor unit Installation Instructions re-
garding requirements for installation of a filter-drier
in the liquid line close to the indoor coil.
5. Braze using a SiI-Fos or Phos-copper alloy.
6, 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),
Figure 7 Coil Connection Tube Size (inch)
Model Size Liquid Suction
18 (1Y2ton) 3/8 5/8
24 (2 ton) 3/8 5/8
30 (2Y2ton) 3/8 3A
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
Figure 8 l Refrigerant Lines
RUBBER
GROMMETS
TUBING PLATE
4 484 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).
Figure 9 J Strainer Screen
F-q
rainer Screen
TXV
>
/
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Braze with SiI-Fos or Phos-copper alloy on cop-
per-to-copper joints and wrap a wet cloth around
rear of fitting to prevent damage to 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 ap-
plications where the matching outdoor unit has a
single-phase reciprocating compressor.
CHECK AND ADJUST AIR FLOW
ELECTRICAL SHOCK HAZARD
Failure to shut of electric power could result in
personal injury or death.
Before adjusting blower speed, shut off electric
power to the furnace or blower module.
It is important that the correct amount of air (CFM) flows
through the coil. The installer must determine the re-
quired 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.
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.
Adjusting Air Flow
If CFM is too low, increase the blower speed and measure
the static pressure drop again. Determine CFM from Fig-
ure 10.
If CFM is too high, reduce the blower speed and measure
the static pressure drop again. Determine CFM from Fig-
ure 10.
NOTE: Change blower speed as shown in the instruc-
tions 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 larg-
er size.
If the unit has an adjustable belt driven blower, use an am-
meter 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.
484 01 3000 00 5
Figure10
CFM
Coil Across
Size Coil
500
18B 600
11/2tons 700
700
24B 800
2 tons 900
700
24F 800
2 tons 900
800
30B 900
21/2tons 1000
1100
800
30F 900
21/2tons 1000
1100
1000
1100
36B 1200
3 tons 1300
1400
1000
1100
36F 1200
3 tons 1300
1400
1000
1100
36J 1200
3 tons 1300
1400
Static Pressure Drop Across
(Inches Water Column)
Dry
0,096
0,127
0,161
0,134
0,166
0,200
0,110
0,134
0,160
0,137
0,169
0,204
0,241
0,101
0,121
0,143
0,168
0,188
0,224
0,262
0.303
0,349
0,133
0,154
0.177
0,203
0,227
0,104
0,121
0,139
0,159
0,181
Wet
0,106
0,140
0,183
0,141
0,176
0,215
0,118
0,146
0,176
0,143
0,174
0,211
0,251
0,106
0,129
0,154
0,181
0,202
0,240
0,281
0,325
0,374
0,139
0,163
0,189
0,216
0,245
0,106
0,124
0,144
0,166
0,190
CFM and Pressure Drop
Coil CFM Static Pressure Drop Across Coil
Coil Across (Inches Water Column)
Size Coil Dry Wet
1200 0,129 0,137
1300 0,148 0,159
42J 1400 0,168 0,180
31/2tons 1500 0,189 0,203
1600 0,211 0,228
1200 0,114 0,142
1300 0,130 0,161
42L 1400 0,146 0,182
31/2tons 1500 0,164 0,202
1600 0,182 0,222
1400 0,250 0,263
1500 0,284 0,297
48F 1600 0,320 0,336
4 tons 1700 0,358 0,376
1800 0,398 0,418
1400 0,192 0,196
1500 0,219 0,225
48J 1600 0,245 0,253
4 tons 1700 0,273 0,283
1800 0,303 0,314
1400 0,180 0,193
1500 0,198 0,214
48L 1600 0,222 0,241
4 tons 1700 0,247 0,270
1800 0,275 0,296
1700 0,260 0,285
1800 0,288 0,315
60J 1900 0,316 0,346
5 tons 2000 0,347 0,381
2100 0,378 0,413
2200 0,409 0,447
1700 0,232 0,263
1800 0,256 0,291
60L 1900 0,283 0,321
5 tons 2000 0,308 0,354
2100 0,335 0,386
2200 0,363 0,419
START-UP PROCEDURE
Refer to outdoor unit Installation Instructions for refrigera-
tion system start-up instructions and refrigerant charging
method details,
6 484 01 3000 00
