IMPORTANT: Please read all instructions before
servicing this equipment. Pay attention to all safety
warnings and any other special notes highlighted in the
manual. Safety markings are used frequently throughout
this manual to designate a degree or level of seriousness
and should not be ignored. WARNING indicates a
potentially hazardous situation that if not avoided, could
result in personal injury or death. CAUTION indicates a
potentially hazardous situation that if not avoided, may
result in minor or moderate injury or property damage
WARNING:
These instructions are primarily intended
to assist qualifi ed individuals experienced
in the proper installation of Heating and Air
Conditioning equipment including the iQ Drive
System. Local codes may require licensed
installation / service personnel for this type of
Improper installation, service, adjustment,
or maintenance may cause explosion, fi re,
electrical shock or other hazardous conditions
which may result in personal injury or property
damage. Unless otherwise noted in these
instructions, only factory authorized kits or
accessories may be used with this product.
WARNING:
PROPOSITION 65 WARNING: This product
contains chemicals known to the state of
California to cause cancer, birth defects or
other reproductive harm.
GENERAL INFORMATION
iQ Drive® cased coils are designed for upfl ow or horizontal
applications. These coils are equipped with ESX step motor
expansion valve which provides precise fl ow control for
maximum effi ciency and reliability.
These coils are also equipped with a coil temperature
sensor (to monitor coil temperature during dehumidifi cation mode) and with braze type refrigerant connections
for easy installation.
• Read the installation manual supplied with the outdoor
unit for: refrigerant line connection procedures,
required line sizes, and connection of additional
components of the iQ Drive® system.
• Verify that the air delivery of the furnace/air handler
is adequate to handle the static pressure drop of the
coil, fi lter, and duct work.
• If precise forming of refrigerant lines is required, a
copper tubing bender designed for the size lines used
is recommended. Avoid sharp bends and contact of
the refrigerant lines with metal surfaces.
• Refrigerant lines should be wrapped with pressure
sensitive neoprene or other suitable material where
they pass through roughly edged holes.
COIL INSTALLATION
WARNING:
Shut off all electrical power to the furnace and
outdoor condensing unit before performing any
maintenance or service on the system.
Note: All condensate pans have primary and secondary
drain connections to meet FHA requirements. If the
application is located in or above a living space
where damage may result from condensate overfl ow,
a separate 3/4 inch drain must be provided from
the secondary drain connection and a secondary
drain pan must be installed under the entire unit.
Run secondary drain lines to a place where they are
noticeable if used.
Upfl ow Furnace
1. Disconnect all electrical power to the furnace.
2. Remove the lower coil access door.
3. Remove the drain pan (horizontal applications) and
install the coil as level as possible.
Horizontal Left Installations
1. Disconnect all electrical power to the furnace.
2. Remove the lower coil access door.
3. Remove the plug and knockout from one of the
threaded holes in the horizontal drain pan.
CAUTION:
The knockout must be removed and discarded
to ensure proper condensate drainage. Improper
drainage may result in structural damage,
premature equipment failure, or possible
personal injury.
4. Install plug (from horizontal drain pan) in the open
drain hole in the drain pan at the bottom of the unit.
This will block bypass air from entering the system.
5. Remove the drain line knockout from the coil access
door. This will allow access to the horizontal drain.
6. Connect the refrigerant lines as outlined in the
Refrigerant Lines Connection section.
7. Seal the enclosure as required to minimize air
leakage.
8. Proceed with EXV System Installation as shown on
page 4.
Horizontal Right Installations
1. Disconnect all electrical power to the furnace.
2. Remove the lower coil access door.
3. Remove the plug and knockout from one of the
threaded holes in the horizontal drain pan.
CAUTION:
The knockout must be removed and discarded
to ensure proper condensate drainage. Failure
to do so may result in structural damage,
premature equipment failure, or possible
personal injury.
CAUTION:
The coil must be level to ensure proper
condensate drainage. An unlevel installation
may result in structural damage, premature
equipment failure, or possible personal
injury.
4. Connect the refrigerant lines as outlined in the
Refrigerant Lines Connection section.
5. Seal the enclosure as required to minimize air
leakage.
6. Proceed with EXV System Installation as shown on
page 4.
2
4. Place the horizontal drain pan on the opposite side
of the coil. (If unit has 2 sets of knockouts, remove
the other set of knockouts in the coil spacing plates
and insert support rod).
5. Install plug (from horizontal drain pan) in the open
drain hole in the drain pan at the bottom of the unit.
This will block bypass air from entering the system.
6. Slide the coil and the horizontal drain pan assembly
back into the unit.
7. Remove the drain line knockout from the coil access
door. This will allow access to the horizontal drain.
8. Connect the refrigerant lines as outlined in the
Refrigerant Lines Connection section.
9. Seal the enclosure as required to minimize air
leakage.
10. Proceed with EXV System Installation as shown on
page 4.
Refrigerant Line Connections
WARNING:
14. Reposition the sensing bulb on the suction
line to the 4 o'clock or 8 o'clock position
(Horizontal models only).
15. Properly dispose of all removed parts.
NITROGEN
HEALTH
FLAMMABILITY
REACTIVITY
0 Minimal Hazard
1
0
0
1 Slight Hazard
This coil is pressurized with Nitrogen.
Avoid direct face exposure or contact with
valve when gas is escaping. Always ensure
adequate ventilation is present during the
depressurization process. Any uncertainties
should be addressed before proceeding
1. Remove grommet from the suction line stub.
2. Remove the valve cap from the end of the liquid line stub
and depress the valve. This will relieve all pressure from
the coil.
3. Remove the valve core and valve core holder on the
liquid line. DO NOT reuse the valve, threaded valve
holder or O-ring.
4. Unbraze and remove the cap on the suction line.
CAUTION:
.
It is recommended that a wet rag be wrapped
around the suction line between the sensing
bulb and the line set braze joint before applying
heat. Failure to keep components cool during
brazing may result in structural damage,
premature equipment failure, or possible
personal injury.
5. Cut the line set tubing to the proper length in
accordance with the outdoor unit specifi cations.
6. Inspect both refrigerant lines, ensuring ends of the
lines are round, clean, and free of any burrs.
7. Position grommet on line set while allowing suffi cient
distance to braze joint.
8. Install the suction line set tube into the coil suction
tube stub until it bottoms out.
9. Slip the nut from the Schrader valve holder onto the
liquid line while maintaining correct orientation.
10. Insert liquid line into liquid line stub until it bottoms
out. NOTE: Liquid line stub is shipped with the coil
but is not attached.
11. Braze the individual connections with dry nitrogen
fl owing through the joints. This will prevent internal
oxidation and scaling from occurring.
12. Fasten nut to secure the liquid line to the bulkhead
fi tting. No O-ring is required.
13. Check the assembly for leaks.
Condensate Drain
CAUTION:
The coil must be level to ensure proper
condensate drainage. An unlevel installation
may result in structural damage, premature
equipment failure, or possible personal
injury.
1. The coil condensate pan is designed with 3/4"
NPSC drain connections. Use a PVC or similar
material fi tting to attach the drain line to the pan.
IMPORTANT NOTE: The fi tting should be hand
tightened only. Overtightening may crack the drain
pan and cause condensate to leak.
2. Connect the drain line and run to a suitable drain
avoiding sharp bends and pinching of the line. Install
a condensate trap and prime with water.
3. During system checkout, inspect the drain line and
connections to verify proper condensate disposal.
Air Filter
Air fi lters are not supplied as an integral part of this coil;
however, a fi lter must be installed upstream of the coil and
inspected frequently. When the fi lter becomes clogged
with dust or lint, it should be replaced (disposable type)
or cleaned (washable type). It is recommended that fi lters
be inspected and replaced at least twice during the year.
Generally it is best to replace or clean the fi lters at the
start of each heating and cooling season.
Panels
Reinstall all inner and outer panels of the coil case and
furnace that were previously removed.
Refrigerant Charging
These cased indoor coils are not factory charged with
refrigerant.
Always evacuate the indoor coil and line set prior to
charging. Refer to the outdoor unit installation manual
for detailed charges and instructions.
Maintenance and Service
WARNING:
Shut off all electrical power to the furnace and
outdoor condensing unit before performing any
maintenance or service on the system
To ensure optimum performance and to minimize possible
equipment failure, the following maintenance tasks should
be performed periodically on this equipment:
.
3
W
H
OWOW
5/85/8
20 3/420 3/4
HLHL
HSHS
4
17 1/417 1/4
COIL SPECIFICATIONS
Figure 1 Coil Dimensions
Coil Model C6BH
1, 2
Nominal Capacity BTUH
3
E36-BE36-CE48-CE48-D
36,00036,00048,00048,000
Nominal Airfl ow (CFM)1,2001,2001,6001,600
W - Width (in.)17 1/2212124 1/2
H - Height (in.)26 3/426 3/430 1/430 1/4
HL - Height of Liquid Line (in.)23 1/223 1/22727
HS - Height of Suction Line (in.)21 1/221 1/22525
Connection - Liquid Line3/83/83/83/8
Connection - Suction Line3/47/87/87/8
NOTES:
1. Refer to sales specifi cation sheets for Listed/Certifi ed combinations of equipment and required accessories
2. “E” in the model description designates factory installed electronic TXV for R-410a refrigerant.
3. Refer to the current ARI Directory for certifi ed ratings of split systems.
Table 1. Coil Specifi cations
4
1. The air fi lter installed with the system should be checked
and cleaned or replaced twice per year.
2. Check the coil, drain pan, and condensate drain line
for cleanliness at the start of each heating and cooling
season. Clean as needed.
CAUTION:
Do not operate the system without a suitable
fi lter in the return air duct system. Always
replace the fi lter with the same size and type.
EXV INSTALLATION
These Instructions describe an update to the electronic
expansion valve (EXV) system which has been installed
on this equipment, as part of an iQ Drive® 23 SEER split
air conditioning system.
The ESX valve is controlled to maintain constant superheat
in a wide range of conditions via a pressure transducer
and a temperature sensor installed on the coil suction
header.
On iQ Drive® systems whose indoor equipment is made up
of a separate coil and blower (furnace or furnace blower
kit), the updated EXV system must be interconnected
between these parts. Models that this applies to include
one of the following coil assemblies plus either the furnace
blower kit or a gas furnace listed in Table 2.
WARNING:
To avoid electric shock, personal injury, or death,
turn off the electric power at the disconnect
or the main service panel before making any
electrical connections to EXV System
1. Remove the lower door from the coil assembly and
the furnace’s blower compartment.
2. Locate the bundled set of cables in the coil case and
cut the wire ties.
3. Route the following cables out through hole “C”
(Figure 2):
• EXV coil cable (6-wire) with 6-pin connector plug
(1).
• Pressure Transducer cable (3-wire) with 4-pin
connector plug (2).
• Suction Line Thermistor cable (2 red wires) with
2-pin connector (3).
• Indoor Coil Temperature Sensor cable (4).
Hole “C”
.
COIL ASSEMBLIESSKU
C6BH-E36C-B 920162
C6BH-E36C-C920163
C6BH-E48C-C920164
C6BH-E48C-D920165
C6BA-E36U-B FRU920409
C6BA-E36U-C FRU920410
C6BA-E48U-C FRU920411
C6BA-E48U-D FRU920412
FURNACE BLOWER KITSSKU
A Cabinet variable speed, high
effi ciency, VSHE
B Cabinet variable speed, high
effi ciency, VSHE
C Cabinet variable speed, high
effi ciency, VSHE
D Cabinet variable speed, high
effi ciency, VSHE
GAS FURNACESSKU
Any furnace with an iSEER ™ variable
speed blower
Table 2. Coils, Blower Kits, and Furnaces
904876
904877
904878
904879
Wire
Ties
Figure 2. Cables with wire ties
4. Remove EXV circuit board from packaging and install
on upper cabinet as shown in Figure 3.
EXV coil
cable
Strain
Relief
Indoor Coil
Temperature
Sensor Cable
Figure 3. Control Board and Cables
Suction Line
Thermistor
Cable
Pressure
Transducer
Cable
5
VSHE
BOARD
C R R C W2 W H Y
COIL T
FURNACE BOARD
HUMIDIFIER
(OPTIONAL)
INDOOR COIL TEMPERATURE SENSOR
(FOR DEHUMIDIFICATION)
PRESSURE
TRANSDUCER
SUCTION LINE
THERMISTOR
6-WIRE HARNESS
24 V TRANSFORMER
115 VAC LINE24 VAC SECONDARY
115 VAC LINE
INDOOR SECTION
W
W2
H
EXV OUT
R
C
Y
EXV BOARD
BLOWER
G - +
BLOWER
MOTOR
EXV
P2P3
634679
634680
iQ THERMOSTAT
R
IMPORTANT NOTE: When connecting the cables to
the control board in steps 5 - 7, the “tabs” on the cable
connectors must face inward on the board.
5. Connect the EXV coil cable (6-pin connector) to the
control board’s P1 (“EXV”) terminal.
6. Connect the Suction Line Thermistor cable (two
pin connector) to the control board’s P2 (“THERM”)
terminal.
7. Connect the Pressure Transducer cable (4-pin
connector) to the control board’s P3 (“THERM/
PRESS”) terminal.
8. Install strain relief (PN 632199) around cables in steps
4-7 and inside of hole “C”.
9. Connect the provided yellow, red, and gray terminated
wires to the proper terminals on the EXV Board. (See
Figure 4 and the wiring diagram in Figure 5).
Red wire
Yellow wire to “Y” terminal
to “R”
terminal
Grey wire to
“C” terminal
Figure 4. Control Board with Y, R, & C Wires
VSHE
BOARD
R
DX+
DX-
C
B-
A+
C
6
Figure 5. Wiring Diagram
10. Route the following wires thru the hole in the EXV
board box (Figure 6):
• Terminated red, yellow, and grey wires.
• Indoor coil temperature sensor cable.
EXV
Board
Box
Strain
Relief
Figure 6. EXV Board Box
11. Route the red, yellow, and grey wires and the Indoor
Coil Temperature Sensor cable down the side of the
cabinet into any available hole opposite of the gas
line. Run wires inside of the furnace until they are
routed to the control board.
12. Connect the wires in the Indoor Coil Temperature
Sensor Cable to the Motor Control Board (Figure 7)
located in the blower compartment:
• Attach the red wire to the terminal labeled SENSOR
(1).
• Attach the black wire to the terminal labeled
GROUND (2).
W_OUT
Y/Y2_OUT
Y1_OUT
OUTPUT TERMINALS
H_OUT
4
R
C
EXPANSION PORT
5
CONNECTION TO
FURNACE CONTROL
NOT FOR
FIELD USE
BOARD
3
RED
STATUS LIGHTS
CONNECTION TO
IQ THERMOSTAT
(IF APPLICABLE)
RED
OFF ON
GREEN
FAN SPEED
1 2 345 6 7
COOL
HEAT
1
MOTOR WIRING
HARNESS
L2-OUT
8
L1-IN
L1-OUT
DHUM_IN
Y1_IN
SENSOR
GROUND
L2-IN
INPUT TERMINALS
2
Figure 7. Motor Control Board
13. Connect the other end of the terminated wires to the
Motor Control Board (Figure 6).
• Attach the yellow wire to the “Y/Y2_OUT” Terminal
(3).
• Attach the red wire to the “R” Terminal (4).
• Attach the GREY wire to the “C” Terminal (5).
14. Proceed to the System Checkout section after all
wiring is connected. DO NOT install the control box
cover or blower compartment door
System Checkout
Normally, adjustments are not required, and system
checkout is just a precautionary measure for verifying
communication of the EXV system and electrical operation
of the valve.
The iQ Drive
®
thermostat does not communicate with,
and cannot provide information about the status of the
EXV system.
Confi guration
The EXV circuit board contains DIP switches (white
switches on a red plastic block) that are confi gured
at the factory (except for replacement boards).
Numbers appear on one side of the red block. If a switch
is near the number, this indicates that the switch is ON.
Compare/set switch positions to the row in Table 3 based
on the nominal size in tons of the unit.
Switch #12345678
2 TONONOFFONOFFOFFOFFONON
3 TONONOFFOFFOFFONOFFONON
4 TONONONOFFONONOFFONON
Table 3. Dip Switch Settings
Startup and Operation
1. Use an alternative (but temporary) means to prop
the door switch on the blower compartment so that
when the control power is applied, the closed switch
will allow the unit to operate. This will allow observing
the EXV board in a powered-up state.
2. Switch on the control power. The following are
indications of a normal operating EXV system:
• After the fi rst few seconds, the green LED on the
EXV board should remain lit.
• During initial power-up and when the valve is
moving to a new position, a soft but audible clicking
sound may be heard, indicating that the valve is
operating.
System Shutdown
1. When the checkout has been successfully completed,
turn off power and remove the prop that was used to
temporarily close the door switch.
2. Install strain relief (PN 632199) around the four wires
and inside of hole in the EXV board box.
3. Using four screws, install EXV board box (fi gure 12)
on front of cabinet
CAUTION:
Do not allow the wiring to come into contact
with any sharp edges on the wire ties or the
metal casing.
7
4. Secure the wires and cable against the side of the
cabinet with adhesive-backed wire tie anchors and
wire ties.
5. Install the doors on the coil assembly and the blower
compartment.
6. Restore control power.
WARNING:
Upon completion of the furnace installation,
carefully inspect the entire fl ue system both
inside and outside the furnace to assure it is
properly sealed. Leaks in the fl ue system can
result in serious personal injury or death due
to exposure of fl ue products, including carbon
monoxide.
Vopsig
0.715.0-35° F -31° C
0.822.5-26° F -32° C3.0187.5 65° F18° C
0.930.0-17° F -27° C3.1195.0 68° F20° C
1.037.5-10° F -23° C3.2202.5 69° F21° C
1.145.0-4° F-20° C3.3210.0 72° F22° C
1.252.52° F-16° C3.4217.5 74° F23° C
1.360.08° F-13° C3.5225.0 76° F24° C
1.467.512° F -11° C3.6232.5 78° F25° C
1.575.017° F-8° C3.7240.0 80° F26° C
1.682.521° F-6° C3.8247.5 83° F28° C
1.790.026° F-3° C3.9255.0 84° F29° C
1.897.529° F-1° C4.0262.5 86° F30° C
1.9105.0 33° F0° C4.1270.0 88° F31° C
2.0112.5 37° F2° C4.2277.5 90° F32° C
2.1120.0 40° F4° C4.3285.0 92° F33° C
2.2127.5 43° F6° C4.4292.5 94° F34° C
2.3135.0 46° F7° C4.5300.0 96° F35° C
2.4142.5 49° F9° C4.6307.5 97° F36° C
2.5150.0 52° F11° C4.7315.0 99° F37° C
2.6157.5 55° F12° C4.8322.5 100° F 38° C
2.7165.0 58° F14° C4.9330.0 102° F 39° C
2.8172.5 60° F15° C5.0337.5 104° F 40° C
Tsat
(R410a)
Vopsig
2.9180.0 62° F16° C
Tsat
(R410a)
Service Reference Information
Pressure Transducer Output Interpretation:
• Vo is the DC volts between WHT(+) and GRN(-)
wires when connected to the board, powered up.
The values shown apply when BLK(+) to GRN(-)
is exactly 5.00 volts (See Table 4).
Suction Line Thermistor Resistance Interpretation:
• Measure sensor leads when disconnected from
the board (See Table 5).
TemperatureOhms
-40° F-40° C336K
-31° F-35° C243K
-22° F-30° C177K
-13° F-25° C130K
-4° F-20° C97.1K
5° F-15° C72.9K
14° F-10° C55.3K
23° F-5° C42.3K
32° F0° C32.7K
41° F5° C25.4K
50° F10° C19.9K
59° F15° C15.7K
68° F20° C12.5K
77° F25° C10.0K
86° F30° C8.06K
95° F35° C6.53K
104° F40° C5.33K
113° F45° C4370
122° F50° C3603
131° F55° C2986
140° F60° C2488
149° F65° C2083
158° F70° C1752
167° F75° C1480
176° F80° C1255
Table 5. Suction Line Thermistor
Resistance Interpretation
Table 4. Pressure Transducer
Output Interpretation
8
SYMPTOMSOLUTION
Green LED is not lit and there is no indication
of valve closing (clicking) when power is
turned on.
Green LED is lit with power on, but there is
no indication of valve operation.
There is no indication of valve opening
(clicking) when the system is running in
cooling mode.
Green LED blinks 1 second on, 1 second off
when unit is running.
Valve opens, but green LED continually fl ashes
on and off rapidly (1/3 second each).
Green LED blinks in a heartbeat pattern (1/6
sec. on, 1/6 sec. off, 1/4 sec. on, 1 sec off)
when unit is running.
Troubleshooting
Measure AC volts across the R and C terminals on the EXV board. Expected reading is 22-28 vac. If
voltage is absent, check wiring and voltage back to the interface board R and C terminals
Check for proper wiring and connections of the EXV coil 6-wire cable. Using a DC voltmeter, check for
non-zero voltage between orange and gray wire terminals (with the plug connected) when the valve is
in the process of opening or closing (e.g., upon fi rst power-up). (No precise voltage value can be given
since it is a pulsed signal.) If no pulsed signal is detected, the EXV board may be defective.
Measure AC volts across the Y and C terminals on the EXV board when system is running in cooling
mode. Expected reading is 22-28 vac. If voltage is 0, check voltage between Y and R. If this voltage
is 22-28 vac, turn off power and swap the wires connected to R and C (from the interface board), and
check the voltages in this test again.
This indicates that one of the sensor readings is out of range. With control power on, check for voltages
on the 3-wire pressure transducer connection (at the circuit board, connected) as follows with a DC
voltmeter:
NOTE: If local space temperature exceeds 104° F, this symptom (out of range – high) will occur when
the system is off or just starting.
• BBLK (+) to GRN (-) should be 4.90 to 5.10 DC volts. If this is 0 when 24 vac power is confi rmed to
the board, check with the plug to the transducer disconnected (at the board).
• If there is 5 DC volts with the plug disconnected but 0 DC volts with it connected, there is a short in
the transducer or its cable. If there is 0 DC volts when it is disconnected with power confi rmed to the
board, the board is defective.
• WHT (+) to GRN (-) should normally be somewhere between 1.0 to 5.0 DC volts, depending on
pressure in the line. With the unit off, check the suction pressure with gages. If the BLK-GRN voltage
is 5.00 DC volts, the expected voltage is: [Volts WHT-GRN] = psig/75 + 0.5
• If this reads 0 DC volts with 5 volts between BLK and GRN, check the connection between the
transducer cable and the transducer. If that connection appears to be good and not corroded, the
transducer or transducer cable is defective. If the voltage is greater than 0.5 but very low, check for
loss of charge.
• With control power off, disconnect the 2-wire thermistor plug from the board and check the resistance
between the leads at the plug. Resistance should be somewhere between 25.4 k (at 41° F) to 8.1
k (at 86° F), decreasing as temperature increases. (Note: This check is not valid if the sensor is still
connected to the board!) If reading is 0 or out of range (infi nite) on the meter, the sensor or its cable
is defective. See chart of resistances below. NOTE: If local space temperature exceeds 104° F, this
symptom (out of range – high) will occur when the system is off or just starting.
This indicates that DIP switches 2-5 are not set properly. Cycle each switch on and off, and set as
directed above.
This indicates EXV board is operating in fi xed opening mode. Press and hold the black button on the EXV
board for more than 3 seconds. If green LED is still not on steady, check other troubleshooting steps.
9
10
11
CERTIFICATION APPLIES
ONLY WHEN THE
COMPLETE SYSTEM IS
LISTED WITH ARI
The installer performing this work assumes all responsibility for this installation. These instructions are primarily
intended to assist qualifi ed individuals experienced in the proper installation of these components. Some local
codes require licensed installation/service personnel for this type of equipment. Safety should always be the
deciding factor when installing this product and using common sense plays an important role as well. Improper
installation of the components or failure to follow safety warnings could result in serious injury, death, or property
damage. After completing the installation, return these instructions to the Homeowner’s Package for owner-user’s
future reference.
O’Fallon, MO
¢708937Q¤
708937A
Specifi cations and illustrations subject to change
708937A (Replaces 7089370)
without notice or incurring obligations.
Printed in U.S.A. (08/08)
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