ICP Evaporator Coils Manual L0604333
User Manual: ICP ICP Evaporator Coils Manual ICP Evaporator Coils Owner's Manual, ICP Evaporator Coils installation guides
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Theseinstructionsmustbe readandunderstoodcompletelybeforeattemptinginstallation. 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 .................................. Refrigerant Line Connections Refrigerant Metering Device 2 - 3 .................... ..................... 3 4 Condensate Drain .............................. 4 Waste Line Connection .......................... 4 Check and Adjust Airflow ........................ 5 Start-Up Procedure ............................ Airflow vs. CFM Chart ........................... 5 6 R-410A Quick Reference Guide .................. 7 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 3100 00 January 2006 INSTALLATION EHD Coils are designed to be used for air conditioning or heat pump operation within horizontal runs of HVAC ductwork. The ductwork may be a new or existing system, associated with a furnace, air handler, blower cabinet, or other air moving device. Air can flow in either direction through the coil. gas or oil furnace, a Fossil Fuel Kit must be used. This coordinates heat properly between furnace and heat pump. Refer to Product Specification Literature for kit part number. Verify that the ductwork is suitable for cooling operation. Externally insulated ductwork must have an adequate vapor barrier. The vapor barrier prevents condensation from forming in the insulating material, which would result in loss of insulating value and deterioration of the insulation material. NOTE for Heat Pump with Electric Heat: When coil is used in a Heat Pump application with electric heat, coil must be installed upstream of the electric heater (refer to Figure 1). This prevents electric heat from driving up refrigeration system pressure during heating cycle. NOTE for Gas or Oil Furnace: When coil is used in an Air Conditioning or Heat Pump application combined with a gas or oil furnace, coil must be installed downstream of the furnace heat exchanger (refer to Figure 1). This reduces condensate formation in the furnace heat exchanger during the cooling cycle. NOTE for Heat Pump with Gas or Oil Furnace: When coil is used in a Heat Pump application combined with a Figure 1 1. 2. If the connecting ductwork is larger or smaller than the coil casing openings, fabricate transition pieces. NOTE: Make the transition pieces long enough so that the angle from horizontal is 30 ° or less (refer to Figure 1). Provide at least 3 feet of straight duct immediately before the inlet to the coil (refer to Figure 1). 3. Position coil so that it slopes slightly (Ys")towards the condensate drain openings. 4. Support coil either with braces from underneath, or with hangers from above. Position fasteners (screws) so that they will not contact the coil tubing. UNIT DAMAGE HAZARD Failure to follow damage this caution may result in unit When securing braces or supports to unit, select a location where drill and fasteners will not contact refrigeration components. Coil Position Relative to Furnace or Electric Heat (Heat Pump) 3' MINIMUM STRAIGHT BOTH SIDES @® Y EHD 30 ° MAXIMUM TRANSITION HEAT PUMP with ELECTRIC HEAT GAS or OIL FURNACE 2 484 01 3100 00 PROPERTY DAMAGE HAZARD 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. REFRIGERANT LINE CONNECTIONS Figure 3 PERSONALINJURY HAZARD J EHD Coil (end view) O Failure to relieve pressure in the coil could result in personal injury. O Tubing Cover Plate -_ - Oe 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. 0 0 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 2. Route refrigerant lines to the coil in a manner that will not obstruct service access to the unit. 1. 2. Slide tubing cover plate 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. After brazing, allow joints to cool. Slide tubing cover plate over joints. Figure Model 2 Size Coil Connection Liquid Tube Size (inch) Suction 24 (2 ton) 3/8 5/8 30 (2Y2 ton) 3/8 3A 36 (3 ton) 3/8 3A 42 (3Y2 ton) 3/8 7/8 48 (4 ton) 3/8 7/8 60 (5 ton) 3/8 7/8 484 01 3100 00 Secondary Drain (smaller opening) Primary Drain (larger opening) 3 REFRIGERANT METERING DEVICE EHD2X 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. EHD4X coils have a factory installed hard shut-off TXV designed only for use with R-410A refrigerant. Use only with outdoor units designed for R-410A. TXV is factory set and not field adjustable. CONDENSATE 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. 2. 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. 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 (refer to Figure 3). Use PVC fittings on the plastic condensate pan. Finger tighten plus 11/2turns. Do not over-tighten. Use pipe dope. 1. PRODUCT DAMAGE HAZARD 3. 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 4 for minimum trap dimensions. Route to the outside or to a floor drain. Check local codes before connecting to a waste (sewer) line. 4. Prime all traps, test for leaks, and insulate drain lines where sweating could cause water damage. 5. If a gravity drain cannot be used, install a condensate pump. Install the pump as close to the indoor section as possible. Figure 4_ J. Recommended Condensate Trap 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 (negative pressure). When coil is installed on the supply side (positive pressure) it is not necessary to install traps and better drainage is usually achieved without traps. Install properly sized condensate traps in the drain line as close to the coil as possible. Install drain lines below the bottom of the drain pan and pitch the drain lines down from the coil at least ¼ inch per foot of run. Horizontal runs over 15 feet long must also ' 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 5). 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 5. Figure 5 Condensate Line Air Gap Above Liquid Level Condensate Line Trap l 4 Drain to Waste Sewer Line t 484 01 3100 00 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 6. 4. Find the corresponding CFM in Figure 6. 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 6. 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. START-UP Air Flow If CFM is too high, reduce the blower speed and measure the static pressure drop again. Determine CFM from Figure 6. 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 6. 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. PROCEDURE Refer to outdoor unit Installation Instructions for refrigeration system start-up instructions and refrigerant charging method details. 484 01 3100 00 5 Figure6 Coil Size CFM Across Coil CFM and Pressure Drop Static Pressure Drop Across Coil (Inches Water Column) Wet 400 Dry 0.060 0.069 500 0,081 0,096 24 600 700 0.104 0,129 0,129 2 tons 800 0.155 900 0,186 0,237 1000 0.217 0,278 30 2Y2tons 36 3 tons Coil Size CFM Across Coil Static Pressure Drop Across Coil (Inches Water Column) Wet 6OO Dry 0.063 0,080 7OO 0,076 0,101 8OO 0.091 0.123 0,162 9OO 0,105 0,149 0,198 1000 0,121 0.175 1100 0,138 0,206 1200 0,157 0,215 1300 0,175 0,231 48 4 tons 400 0,044 0,050 500 0.060 0,071 1400 0,195 0,261 600 0,077 0,093 1500 0,217 0,291 700 800 0,097 0,116 1600 0,238 0,325 0,116 0,144 1700 0,260 0,361 900 0.140 0,172 1800 0,284 0,394 1000 0,165 0,203 800 0,051 0,063 1100 0.190 0,235 900 0,060 0,076 1200 0,219 0,269 1000 0,069 0,089 400 0,043 0.048 1100 0,079 0.102 500 0,058 0,066 1200 0,090 0,118 600 0,074 0,086 1300 0,101 0,135 700 0,089 0,104 1400 0,113 0.155 800 900 0,107 0,128 1500 0,125 0,175 0,127 0,154 1600 0,138 0,193 1000 0,150 0,182 1700 0,153 0.214 6O 5 tons 1100 0,172 0,212 1800 0,165 0.235 1200 0,197 0,245 1900 0.180 0.258 1300 0,224 0,280 2000 0.195 0.279 1400 0,252 0,317 2100 0.211 0.302 600 0,065 0,076 2200 0.227 0.325 700 0,079 0,094 800 0,095 0,114 900 0,113 0,137 42 1000 1100 0,134 0,163 0,154 0,189 3Y2tons 1200 0,176 0,215 1300 0,197 0,245 1400 0,220 0,273 1500 0,246 0,303 1600 0,268 0,332 6 484 01 3100 00 R-410A QUICK REFERENCE GUIDE • R-410A refrigerant operates at 50% - 70% higher pressures than R-22. replacement components are designed to operate with R-410A. Be sure that servicing equipment and • R-410A refrigerant cylinders are rose colored. • Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400. • R-410A systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose. • Manifold sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard. • Use hoses with 750 psig service pressure rating. • Leak detectors should be designed to detect HFC refrigerant. • R-410A, as with other HFC refrigerants, is only compatible with POE oils. • POE oils absorb moisture rapidly. Do not expose oil to atmosphere. • POE oils may cause damage to certain plastics and roofing materials. • Vacuum pumps will not remove moisture from oil. • A liquid line filter-drier is required on every unit. • Do not use liquid line filter-driers with rated working pressures less than 600 psig. • Do not install a suction line filter-drier • Wrap all filter-driers in liquid line. and service valves with wet cloth when brazing. • Do not use with an R-22 TXV. • If indoor unit is equipped with an R-22 TXV, it must be changed to an R-410A TXV. • Do not use capillary tube indoor coils. • Never open system to atmosphere while it is under a vacuum. • When system must be opened for service, break vacuum with dry nitrogen and replace all filter-driers. • Do not vent R-410A into the atmosphere. • Observe all WARNINGS, 484 01 3100 00 CAUTIONS, NOTES, and bold text. 7
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