Lennox CBA27UHE-018, CBA27UHE-024, CBA27UHE-030, CBA27UHE-036, CBA27UHE-048 Installation Instructions Manual

...

INSTALLATION

THIS MANUAL MUST BE LEFT WITH THE

HOMEOWNER FOR FUTURE REFERENCE

WARNING

This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional HVAC installer or equivalent, service agency, or the gas supplier.

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.

INSTRUCTIONS

Elite® Series CBA27UHE Air Handler Units

MULTI-POSITION AIR HANDLERS 507674-01 3/2017

Table of Contents

CBA27UHE Upow and Downow Unit Dimensions ..... 2

CBA27UHE Horizontal Left- and Right-Hand Discharge

Unit Dimensions .............................................................3

General Information ....................................................... 4

Shipping and Packing List .............................................4

Requirements ................................................................4

Installing the Unit ........................................................... 4

Brazing Connections .....................................................6

Installing the Condensate Drain ....................................7

Inspecting and Replacing Filters ...................................8

Sealing the Unit .............................................................8

Measuring Static Pressure ............................................9

Adjusting the Blower Speed ..........................................9

Making Electrical Connections ....................................12

Repairing or Replacing Cabinet Insulation .................. 15

Homeowner Maintenance ............................................15

Check-Out Procedures ................................................ 16

IMPORTANT: Special procedures are required for cleaning the all-aluminum coil in this unit. See page 15 in this instruction for information.

IMPORTANT INFORMATION FOR INSTALLER

CHECK FOR AND REMOVE THESE ITEMS BEFORE OPERATING UNIT.

TOP CAP SHIPPING

BRACKET (REPLACE

SCREWS IN TOP CAP

BLOWER HOUSING

SUPPORT PAD

HORIZONTAL DRAIN PAN (SEE PAGES 4 AND 6)

REFRIGERANT LINE PLUGS

(SEE PAGE 6)

AFTER REMOVAL)

DRIP SHIELD. (USED FOR -060 UNITS HORIZONTAL APPLICATIONS ONLY.) (SEE PAGE 5.) SHOWN INSTALLED ON DRAIN PAN IN -060 UNIT.

Page 1

CBA27UHE Upow and Downow Unit Dimensions – Inches (mm)

3/4 (19)

11‐1/16 (281)

LINE VOLTAGE

INLETS (TOP

AND LEFT SIDE)

TOP VIEW

FLOW

RETURN AIR

FRONT VIEW

SUPPLY AIR

AIR

OPENING

LOW VOLTAGE

INLETS (TOP AND

RIGHT SIDE)

5/8 (16)

3/4 (19)

5/8 (16)

ELECTRIC HEAT

(FIELD-INSTALLED)

FILTER ACCESS

UP-FLOW POSITION

OPTIONAL

SUCTION

LINE

LIQUID

LINE

FILTER

2‐3/4 (70)

PIPING PLAT E DETAIL

1‐3/4 (44)

4‐3/8 (111)

3‐1/2 (89)

(FOR UP-FLOW AND DOWN-FLOW POSITIONS)

1‐1/8 (29)

(51)

5‐3/8

(137)

FILTER

SUCTION

BLOWER

COIL

RETURN AIR

)52( 1)61( 8/5

SIDE VIEW

5/8 (16)

LINE

LIQUID

LINE

OPTIONAL

ELECTRIC HEAT

(FIELD-INSTALLED)

LOW VOLTAGE

(RIGHT SIDE)

LINE VOLTAGE

(LEFT SIDE)

SUCTION LINE

CONDENSATE DRAINS (2) (HORIZONTAL)

LIQUID LINE

CONDENSATE DRAINS (2) (UP-FLOW AND DOWN-FLOW)

COIL

BLOWER

SUPPLY

11‐1/16 (281)

AIR

SIDE VIEW

5/8 (16)

DOWN-FLOW POSITION

5/8 (16)

Air Opening

1 (25)

TOP VIEW

AIR FLOW

SUPPLY AIR

FRONT VIEW

5/8 (16)

Return

FILTER ACCESS

5/8 (16)

CBA27UHE Common Dimensions - Inches (mm)

Dim. -018/-024 -030/-036 -042/-048 -060

49-1/4 (1251) 51 (1295) 58-1/2 (1486) 62‐1/2 (1588)

21-1/4 (540) 21-1/4 (540) 21‐1/4 (540) 21‐1/4 (540)

20-5/8 (524) 22‐5/8 (575) 24-5/8 (625) 24-5/8 (625)

19-3/4 (502) 19-3/4 (502) 19‐3/4 (502) 19‐3/4 (502)

19 (483) 21 (533) 23 (584) 23 (584)

20 (508) 20 (508) 20 (508) 20 (508)

24-5/8 (625) 26‐3/8 (670) 27‐7/8 (708) 27‐7/8 (708)

24-5/8 (625) 24-5/8 (625) 30-5/8 (778) 34‐5/8 (879)

Page 2

CBA27UHE Horizontal Left- and Right-Hand Discharge Unit Dimensions – Inches (mm)

5‐3/8 (137)

CONDENSATE

DRAINS (2)

(UP-FLOW

AND

DOWN-FLOW)

CONDENSATE

DRAINS (2)

(HORIZONTAL)

PIPING PLAT E

DETAIL

5/8 (16)

5‐3/4

(46)

RETURN AIR

OPENING

END VIEW

Horizontal Position

(Left‐Hand Air

Discharge)

1‐3/4

(44)

(51)

1‐1/2

(38)

1 (25)

FILTER ACCESS

LIQUID

LINE

SUCTION

LINE

1‐1/8

(29)

4‐3/8 (111)

FILTER

Horizontal Position

(Right‐Hand Air

Discharge)

Coil

LIQUID

SUCTION

LINE

TOP VIEW

AIR

FLOW

FRONT VIEW

BLOWER

OPTIONAL ELECTRIC

HEAT (FIELD-INSTA LLED)

Coil

5/8 (16)

INLETS (BOTTOM

LINE VOLTAGE

INLETS (TOP

AND RIGHT

SIDE)

LOW VOLTAGE

AND RIGHT

SIDE)

FOR DIMENSIONS “A” THROUGH

“H”, SEE CHART ON PAGE 2.

11‐1/16

3/4 (19)

(281)

Supply

4‐3/8 (111)

1‐1/8

(29)

Air

Opening

END VIEW

3/4 (19)

LOW VOLTAGE

3/4 (19)

11‐1/16

(281)

Supply

Air Opening

LINE VOLTAGE INLETS

(BOTTOM AND LEFT SIDE)

END VIEW

INLETS (TOP AND

LEFT SIDE)

OPTIONAL ELECTRIC

HEAT (FIELD INSTALLED)

5/8 (16)

CONDENSATE DRAINS (2)

(HORIZONTA L)

Air Flow

FILTER

TOP VIEW

FRONT VIEW

SUCTION

LINE

1‐3/4

(44)

LIQUID

LINE

5‐3/4 (146)

SUCTION LINE

PIPING PLAT E

DETAIL

FILTER ACCESS

1‐1/2 (38)

LIQUID

LINE

1 (25)

Return

Air Opening

END VIEW

(51)

5‐3/8 (137)

5/8 (16)

Page 3

CAUTION

As with any mechanical equipment, contact with sharp sheet metal edges can result in personal injury. Take care while handling this equipment and wear gloves and protective clothing.

General Information

The Elite® CBA27UHE series air handler with all-aluminum coil is designed for installation with optional eld-in-

stalled electric heat and a matching HFC-410A outdoor unit.

This instruction is intended as a general guide and does not supersede local or national codes in any way. Consult authorities having jurisdiction before installation.

Shipping and Packing List

Package 1 of 1 contains: 1 – Assembled air handler unit

1 – Horizontal drip shield (CBA27UHE-060 only) 1 – Pipe nipple (Sch80, 3/4" I.D. x 5"

1 – Warranty card

NOTE – For downow applications, order kit number

83M57.

Check the air handler for shipping damage; if found, immediately contact the last carrier.

Requirements

IMPORTANT

This unit must be matched with an indoor coil as specied

in the Lennox Engineering Handbook. Coils previously

charged with HCFC-22 must be ushed.

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), shall conform with the following National Fire Protection Association (NFPA) standards:

• NFPA No. 90A - Standard for Installation of Air Conditioning and Ventilation Systems

• NFPA No. 90B - Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems

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.

To disassemble:

1 - Remove access panels.

2 - Remove both blower and coil assemblies. This will

lighten the cabinet for lifting.

3 - Remove one screw from the left and right posts

inside the unit. Remove one screw from each side on the back of the unit. Unit sections will now separate.

To reassemble:

1 - Align cabinet sections together.

2 - Reinstall screws.

3 - Replace blower and coil assemblies.

4 - Replace access panel.

UPFLOW APPLICATION

Use the following procedures to congure the unit for upow operations:

1 - Remove access panels.

2 - Remove and discard the horizontal drip shield (-060

model, used only on horizontal applications) and the corrugated padding between the blower and coil assembly.

3 - The horizontal drain pan must be removed when

the coil blower is installed in the upow position.

Removing the horizontal drain pain will allow proper

air ow and increased efciency.

4 - After removing the horizontal drain pan, place the

unit in the desired location. Set unit so that it is level. Connect return and supply air plenums as required

using sheet metal screws as illustrated in gure 1.

5 - Install units that have no return air plenum on a

stand that is at least 14" from the oor to allow for proper air return. Lennox offers an optional upow

unit stand as listed in table 1.

HORIZONTAL DRAIN PAN (MUST BE REMOVED)

UP-FLOW / DOWN-FLOW DRAIN PAN

Installing the Unit

These units are factory-congured for upow and horizontal right-hand discharge installation. For downow or horizontal left-hand discharge, certain eld modications

are required.

DISASSEMBLE/REASSEMBLE AIR HANDLER UNITS

The air handler units consists of two factory-assembled sections. It may be necessary to disassemble the sections when positioning the unit for installation.

FIGURE 1. Upow Conguration

TABLE 1. Optional Side-Return Unit Stand

(Upow Only)

Model Kit Number

All unit sizes 45K32

Page 4

HORIZONTAL RIGHT-HAND DISCHARGE

UP-FLOW / DOWN-FLOW DRAIN

HORIZONT PA

FRONT VIEW END VIEW

TOP CAP ROTATED TO

APPLICATION

Use the following procedures to congure the unit for horizontal right-hand discharge operations:

NOTE – For horizontal applications, a secondary drain pan is recommended. Refer to local codes.

1 - Before operating the unit, remove access panels

and the horizontal drip shield (-060 model) and the corrugated padding between the blower and coil assembly. Discard the corrugated padding.

2 - Install the horizontal shield on the front edge of the

horizontal drain pan as illustrated in gure 2.

3 - No further adjustment is necessary. Set unit so that

it is sloped 1/4" towards the drain pan end of the unit.

4 - 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" to avoid damaging the

coil or lter as illustrated in gure 3. Use sheet

metal screws to connect the return and supply air plenums as required.

HORIZONTAL DRIP SHIELD (-060 MODELS)

PAN

1/2" SCREWS MAXIMUM

ANGLE IRON OR

SHEET METAL

ELECTRICAL INLET CLEARANCE 4" (102 mm)

FIGURE 3. Suspending Horizontal Unit

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 rightor left-hand applications. The coil may tip into the drain pan once it is clear of the cabinet. Support the coil when removing it.

HORIZONTAL LEFT-HAND DISCHARGE APPLICATION

NOTE – For horizontal applications, a secondary drain pan is recommended. Refer to local codes.

CABINET

SUPPORT

DRIP

SHIELD

CORRECT POSITION

TOP CAP SCREWS

FIGURE 2. Right-Hand Discharge Conguration

HORIZONTAL RIGHT-HAND DISCHARGE APPLICATION IN HIGH-HUMIDITY AREAS

For horizontal applications in high humidity areas, remove

the downow rail closest to the drain pan.

To remove rail:

1 - Remove the screws from the rail at the back of unit

and at the cabinet support rail.

2 - Remove the downow rail then replace screws.

3 - Seal around the exiting drain pipe, liquid line, and

suction line to prevent humid air from inltrating into

the unit.

AL DRAIN

NO ADJUSTMENT IS NECESSARY

DOWN-FLOW RAIL

90º

BEND

DRAIN PAN

REINSTALLED

HERE

REINSTALLED HERE REMOVED FROM HERE

COIL SHOWN IN UPLOAD POSITION FOR EASY CONVERSION

TOP CAP

90º

BEND

———— DRAIN PLUGS ————

ALIGN HOLES WITH HOLES IN COIL END PLATE. STARTING WITH THE ROUND HOLES ON THIS END.

BACK COIL END SEAL

FIGURE 4. Field Modication for

Left-Hand Discharge

DRAIN PAN

SHIPPING

LOCATION

Page 5

Use the following procedures to congure the unit for hor-

HORIZONTAL DRIP SHIELD (-060 MODEL)

DRAIN PAN

izontal left-hand discharge operations:

1 - Before operating the unit, remove access panels

and the horizontal drip shield (-060 model) and the corrugated padding between the blower and coil assembly. Discard the corrugated padding.

2 - Pull the coil assembly from unit. Pull off the

horizontal drain pan.

3 - Remove the drain plugs from back drain holes on

horizontal drain pan and reinstall them on front holes.

IMPORTANT

After removal of drain pan plug(s), check drain hole(s) to verify that drain opening is fully open and free of any debris. Also check to make sure that no debris has fallen into the drain pan during installation that may plug up the drain opening.

4 - Rotate drain pan 180º front-to-back and install it on

the opposite side of the coil.

5 - Remove screws from top cap. Remove horizontal

drip shield screw located in the center of the back

coil end seal as illustrated in gure 4 on page 5.

6 - Rotate horizontal drip shield 180º front-to-back.

7 - Remove plastic plug from left hole on coil front

end seal and reinstall plug in back hole. Reinstall horizontal drip shield screw in front coil end seal. Drip shield should drain downward into horizontal drain pan inside coil.

10 - Install the horizontal shield (-060 model) on the

front edge of the horizontal drain pan as illustrated

in gure 5 on page 6.

NOTE – For horizontal applications in high humidity ar- eas, remove the downow rail closest to the drain pan. To remove rail, remove screw from rail at back of unit and at cabinet support rail. Remove downow rail then replace screws. Also, seal around the exiting drain pipe, liquid and suction lines to prevent inltration of humid air.

11 - Knock out drain seal plate from access door. Secure

plate to cabinet front ange with screw provided.

12 - Flip access door and replace it on the unit.

13 - Set unit so that it is sloped 1/4ʺ toward the drain

pan end of the unit. Connect return and supply air plenums as required using sheet metal screws.

14 - If suspending the unit, it must be supported along the

entire length of the cabinet. If using chain or strap, use a piece of angle iron or sheet metal attached to the unit (either above or below) so that the full length of the cabinet is supported. Use securing

screws no longer than 1/2ʺ to avoid damage to coil or lter, as illustrated in gure 3 on page 5. Connect

return and supply air plenums as required using sheet metal screws.

DOWNFLOW APPLICATION

NOTE – If downow application is required, separately order kit number 83M57 and install per kit’s instructions. Also use metal or class I supply and return air plenums.

Use the installation instruction provided with the downow kit.

DOWN-FLOW RAIL FRONT EDGE OF HORIZONTAL

FIGURE 5. Left-Hand Discharge Conguration

8 - Rotate top cap 180º front-to-back and align with

unused screw holes. Holes must align with front and back coil end plates. The top cap has a 45º bend on one side and a 90º bend on the other. The 90º bend

must be on the same side as the horizontal drain

pan as illustrated in gure 4 on page 5.

NOTE – Be very careful when reinstalling the screws into the coil end plate engaging holes. Misaligned screws may damage the coil.

9 - From the upow position, ip cabinet 90º to the

left and set into place. Replace blower assembly. Secure coil in place by bending down the tab on the

cabinet support rail as illustrated in gures 4 and 5.

IMPORTANT

If electric heat section with circuit breakers (ECB29) is

installed in a CBA27UHE unit in a downow application,

the circuit breakers must be rotated 180° to the UP position. See ECB29 installation instructions for more details.

Brazing Connections

IMPORTANT

To prevent the build-up of high levels of nitrogen when purging, it must be done in a well-ventilated area. Purge low-pressure nitrogen (1 to 2 psig) through the refrigerant piping during brazing. This will help to prevent oxidation and the introduction of moisture into the system.

All coils are equipped with a factory-installed, internally mounted check/expansion valve.

The air handler’s coil line sizes are listed in table 2. Use Lennox L15 (sweat) series line sets (refer to the outdoor

unit Product Specications (EHB) for proper size, type and application). For eld-fabricated refrigerant lines, see

the piping section of the Lennox Unit Information Service Manual.

Page 6

WARNING

Danger of explosion! Can cause equipment damage, injury, or

death. When using a high pressure gas such as dry

nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).

AIR HANDLER UNIT

LIQUID LINE

FIGURE 6. Brazing Connections

NOTE – CBA27UHE series air handlers use nitrogen or dry air as a holding charge. If there is no pressure when the rubber plugs are removed, check the coil for leaks before installing. After installation, pull a vacuum on the line set and coil before releasing the unit charge into the system.

NOTE – See outdoor unit instructions on how to ow nitro- gen through line sets.

1 - Remove access panel.

2 - Remove the refrigerant line caps from the refrigerant

lines.

3 - Use a wet rag to protect TXV sensing bulb (or

remove it) when brazing suction line connections.

4 - Place a wet rag against piping plate and around

the suction line connection. The wet rag must be in place to guard against damage to the paint.

5 - With the wet rag in place, position a eld provided

elbow tting to the air handler’s suction line and line set. Start nitrogen ow before brazing.

6 - After the procedure is completed then remove the

wet rag.

7 - Place wet rag against piping plate and around the

liquid line connection. Position liquid line elbow to air handler’s suction line and to line set. Start nitrogen

ow and begin brazing both connections and after

procedure is completed then remove both wet rags.

8 - Refer to instructions provided with outdoor unit for

leak testing, evacuating and charging procedures.

9 - Install access panel.

TABLE 2. Refrigerant Line Sizes

Model

-018

-024

-030

-036

-042

-048

-060

Liquid

Line

3/8ʺ

(10mm)

3/8ʺ

(10mm)

3/8ʺ

(10mm)

Vapor

Line

3/4ʺ

(19mm)

7/8"

(22mm)

7/8"

(22mm)

Line Sets

L15 line set sizes are dependant on unit match-up. See Product

Specications (EHB) for

outdoor unit to determine correct line set sizes

Field fabricated

Installing the Condensate Drain

MAIN DRAIN

Connect the main drain and route downward to drain line or sump. Do not connect drain to a closed waste system.

See Figure 8 for typical drain trap conguration.

OVERFLOW DRAIN

It is recommended that the overow drain is connected to an overow drain line for all units. If overow drain is not

connected, it must be plugged with provided cap.

For downow orientation, the overow drain MUST be connected and routed to a overow drain line. See Figure 7 for main and overow drain locations based on coil

orientation.

LEFT-HAND AIR

DISCHARGE

OVERFLOW

DRAIN ON LEFT

UP-FLOW OR DOWN-FLOW

FIGURE 7. Main and Overow Drain Locations

Based on Coil Orientation

BEST PRACTICES

The following best practices are recommended for the condensate removal process:

• Main and overow drain lines should NOT be smaller than both drain connections at drain pan.

• Overow drain line should run to an area where home- owner will notice drainage.

• It is recommended that the overow drain line be vented and a trap installed. Refer to local codes.

• Condensate drain lines must be congured or provided with a cleanout to permit the clearing of blockages and for maintenance without requiring the drain line to be cut.

RIGHT-HAND AIR

DISCHARGE

MAIN DRAIN ON

RIGHT

Page 7

ABOVE

FINISHED

SPACE?

OVERFLOW DRAIN LINE

ALWAYS RUN AN OVERFLOW DRAIN LINE. IF NOT POSSIBLE TO ROUTE OVERFLOW DRAIN LINE, INSTALL LOW VOLTAGE OVERFLOW SWITCH KIT. WIRE KIT TO SHUT DOWN COMPRESSOR PER INSTRUCTIONS.

YES

LENNOX #

X3169

CLEAN OUT

VENT

PRESS IN

(DO NOT GLUE)

VENT MUST EXTEND

ABOVE HEIGHT OF

COIL DRAIN PAN BY

TWO INCHES (51MM)

1” X 3/4” X 3/4”

REDUCING

TEE WITH

PLUG

LENNOX

P-TRAP

49P66, J-TRAP #

91P90 OR ANY

PVC SCH 40 P- OR

J-TRAP 3/4”

OVERFLOW

DRAIN

AIR HANDLER DRAIN PA N

WHEN A COIL IS LOCATED ABOVE A FINISHED SPACE, A 3/4” (19.1MM) SECONDARY DRAIN LINE MUST BE:

CONNECTED TO SECONDARY DRAIN PAN

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).

DRAIN LINE SHOULD SLOPE A MINIMUM OF ONE INCH PER 10 FEET (25MM PER 3 METERS)

NOTE — WHEN A AIR HANDLER IS LOCATED ABOVE A FINISHED SPACE THE SECONDARY DRAIN PA N MUST HAVE A LARGER FOOTPRINT THAN THE AIR HANDLER.

MAIN

DRAIN

TO APPROVED

DRAIN

FOR NEGATIVE PRESSURE COILS (BLOWER AFTER COIL) TRAPS ARE REQUIRED ON ALL DRAIN LINES CONNECTED TO COIL.

COMPACT OVERFLOW SWITCH WITH 3/4” FEMALE SLIP INLET AND MALE ADAPTER, TWO PART DESIGN FOR USE WHERE OBSTRUCTIONS PREVENT DIRECT THREADING

SECONDARY

DRAIN PAN

2”

(51MM)

TRAP DEPTH

LENNOX P-TRAP 49P66 REQUIRES A LARGER INSTALLATION SPACE THAN THE J-TRAP 91P90.

PIPE NIPPLE PROVIDED IN BAG ASSEMBLY - SCH 80, 3/4” I. D. X 5” - 34K7401 (1): CUT THE PIPE IN HALF AND USE IT TO ROUTE THE MAIN DRAIN.

MAIN

DRAIN

PROVIDED

PIPE NIPPLE

CUT TO

REQUIRED

LENGTH

SIDE VIEW

Inspecting and Replacing Filters

IMPORTANT

Filter access panel must be in place during unit operation. Excessive warm air entering the unit may result in water blow-off problems.

Filters may be duct-mounted or installed in the cabinet. A

lter is installed at the factory. Note that lter access door ts over access panel. Air will leak if the access panel is placed over the lter door.

Filters should be inspected monthly and must be cleaned or replaced when dirty to assure proper air handler operation.

Reusable lters supplied with some units can be washed

with water and mild detergent. Some units are equipped with standard throw-away type lters which should be replaced when dirty.

To replace lter:

1 - Loosen the thumbscrews holding the lter panel in

place. Remove the dirty lter.

2 - Insert new lter and replace panel.

FIGURE 8. Typical Main and Overow Drain

-018, -024, -030, -036 20" x 20" (508mm x 508mm)

CBA27UHE Filter Size – In. (mm)

-042, -048, -060 20" x 24" (508mm x 610mm)

Sealing the Unit

There must be an airtight seal between the bottom of

the air handler and the return air plenum. Use berglass

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 replace) is installed.

Seal the unit so that warm air is not allowed into the cabinet. Warm air introduces moisture, which results in water blow-off problems. This is especially important when the unit is installed in an unconditioned area.

Page 8

TABLE 3. Filter Dimensions

WARNING

Make sure the liquid line and suction line entry points are

sealed with either the provided exible elastomeric thermal insulation, or eld provided material (e.g. Armaex,

Permagum or equivalent). Any of the previously mentioned materials may be used to seal around the main and auxiliary drains, and around open areas of electrical inlets.

Measuring Static Pressure

1 - Measure tap locations as shown in gure 9.

MANOMETER

SUPPLY

RETURN

These settings are for nominal tonnage match-ups with the CBA27UHE units. When matched with other sizes, it is recommended that the CFM be adjusted to approximately 400 CFM per ton.

To change blower motor speed tap remove the speed tap from Y2 on the terminal strip and insert the desired speed tap. Use the Blower Data tables on pages 10 and 11 for the desired CFM setting.

IMPORTANT

The high-efciency programmable motor features

programmed electronic braking. The integral control brakes the motor near the end of the supply blower operation, allowing the motor to maintain a more controlled ramping shut-down.

HORIZONTAL DISCHARGE LEFT POSITION

UNIT SHOWN IN

FIGURE 9. Static Pressure Test

2 - Punch a 1/4ʺ (6mm) diameter hole in supply and

return air plenums. Insert manometer hose ush

with inside edge of hole or insulation. Seal around the hose with permagum. Connect the zero end of the manometer to the discharge (supply) side of the system. On ducted systems, connect the other end of manometer to the return duct as above. For systems with non-ducted returns, leave the other end of the manometer open to the atmosphere.

3 - With only the blower motor running and the

evaporator coil dry, observe the manometer reading. Adjust blower motor speed to deliver the air desired according to the job requirements.

4 - For best air performance external static pressure

drop must not exceed 0.5" W.C. (1.2 kPa). Refer to blower data tables for CFM and external static.

5 - Seal around the hole when the check is complete.

Adjusting Blower Speed

MOTOR SPEED TAPS

NOTE – Motor is programmed for a 45-second delayed OFF on all speed taps except TAP #1 (continuous fan speed).

Table 4 lists the recommended factory blower speed tap selections for CBA27UH series units.

TABLE 5. Motor Speed Taps

Tap Operation Remarks

Continuous fan speed is

Continuous or low-speed fan (for

two-speed heat pumps or AC units)

Low-speed

operation on

high-static system

Cooling speed

setting

Heat pump with

electric heat

High-static

applications

energized (24volt input to G) when either G or Y1 has a 24 volt signal (24 volt input from Y1 passes through the room thermostat’s Fan Automatic contacts to the G terminal).

CFM set at 1/2 ton less than nominal of unit (e.g. 3-ton set at 1000 CFM).

CFM set at 400 cfm per nominal ton at ARI minimum static allowed, as follows:

1.5 to 2.0 ton - 0.10

2.5 to 3.5 ton - 0.15

4 to 5 ton - 0.20

CFM set at 400 cfm per nominal ton at .4 static. Energized when electric heat element has a call for heat.

CFM set at 400 cfm per nominal ton at .8 static.

TABLE 4. Recommended Blower Speed Tap Selection

Operation CBA27UHE Outdoor Unit Tap

Cooling

ALL SIZES

Heating*

*Minimum setting for heat

Air conditioner 3

Heat pump 3

Air conditioner with electric heat only

Heat pump with electric heat

Page 9

BLOWER DATA

CBA27UHE-018 BLOWER PERFORMANCE

External

Static

Pressure

in. w.g.

.10 717 66 707 63 735 74 781 81 959 133 .20 596 58 570 54 636 70 737 91 922 144 .30 473 56 430 48 603 77 697 101 877 150 .40 402 61 335 54 540 81 651 105 846 161 .50 358 67 302 60 492 92 607 117 811 173 .60 295 74 248 63 434 94 561 121 769 179 .70 262 79 202 72 399 103 507 131 727 187 .80 N/A N/A N/A N/A 348 108 459 137 695 196

CBA27UHE-024 BLOWER PERFORMANCE

External

Static

Pressure

in. w.g.

.10 767 78 753 75 826 88 957 131 1095 189

.20 662 68 648 66 791 100 937 142 1063 199

.30 615 76 612 77 750 108 895 149 1040 211

.40 561 83 539 83 711 116 861 160 1010 226

.50 522 87 507 89 681 126 821 172 970 230

.60 450 96 438 93 628 134 778 175 944 237

.70 419 100 411 103 584 142 750 186 905 248

.80 365 110 358 108 521 147 702 194 864 256

CBA27UHE-030 BLOWER PERFORMANCE

External

Static

Pressure

in. w.g.

.10 1061 115 1104 126 1169 154 1212 166 1278 200

.20 941 103 973 118 1070 144 1157 173 1241 210

.30 789 90 848 104 1019 151 1121 185 1201 223

.40 640 83 789 111 991 165 1077 199 1169 233

.50 525 93 728 118 946 175 1038 209 1124 244

.60 469 101 629 128 900 181 1006 215 1100 256

.70 434 104 581 139 851 194 956 230 1051 268

.80 365 116 521 155 754 208 915 237 1000 275

CBA27UHE-036 BLOWER PERFORMANCE

External

Static

Pressure

in. w.g.

.10 1074 134 1099 147 1264 206 1343 240 1498 340

.20 962 121 1027 143 1222 220 1291 253 1467 344

.30 887 126 989 153 1192 234 1269 266 1433 364

.40 852 136 944 164 1144 242 1224 280 1391 378

.50 791 150 894 172 1111 257 1194 286 1365 383

.60 717 160 820 186 1067 266 1153 297 1320 398

.70 649 168 745 202 1037 270 1118 309 1290 407

.80 606 183 697 213 999 284 1081 317 1247 422

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

Air Volume and Motor Watts

Air Volume and Motor Watts at 208V

Page 10

BLOWER DATA

CBA27UHE-042 BLOWER PERFORMANCE

External

Static

Pressure

in. w.g.

.10 1282 177 1346 201 1497 261 1489 261 1723 396

.20 1143 159 1278 204 1475 281 1461 273 1690 408

.30 1067 162 1233 209 1447 297 1427 290 1656 434

.40 1024 175 1199 223 1406 315 1407 305 1639 436

.50 920 189 1154 235 1376 320 1360 324 1599 462

.60 923 197 1099 252 1345 338 1328 336 1573 473

.70 838 204 1022 267 1294 358 1303 351 1541 485

.80 815 218 1003 275 1238 375 1228 373 1494 515

CBA27UHE-048 BLOWER PERFORMANCE

External

Static

Pressure

in. w.g.

.10 1359 190 1509 257 1718 362 1773 401 1903 511

.20 1238 174 1473 273 1690 380 1758 419 1899 515

.30 1135 172 1453 289 1658 397 1707 434 1868 535

.40 1090 180 1450 290 1619 412 1687 449 1830 553

.50 1032 195 1374 315 1588 431 1660 465 1801 558

.60 980 204 1336 331 1561 440 1618 472 1770 582

.70 929 223 1295 339 1510 457 1593 493 1733 600

.80 867 235 1227 363 1488 473 1552 508 1703 618

CBA27UHE-060 BLOWER PERFORMANCE

External

Static

Pressure

in. w.g.

.10 1404 206 1704 340 1886 453 1928 481 2268 800

.20 1295 194 1658 349 1849 467 1905 510 2228 829

.30 1256 204 1631 365 1806 489 1869 525 2192 830

.40 1199 217 1594 386 1784 505 1842 546 2169 856

.50 1145 236 1549 394 1751 523 1799 548 2136 870

.60 1091 248 1508 413 1720 534 1775 569 2106 894

.70 978 270 1474 433 1683 549 1741 592 2089 907

.80 946 279 1440 453 1655 566 1709 611 2050 925

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

Air Volume and Motor Watts

Page 11

Making Electrical Connections

Ground unit at disconnect switch or to an earth ground.

cuit connections are made in t

Install room thermostat (ordered separately) on an inside wall

in the center of the conditioned area and 5 feet (1.5m)

It should not be installed on an outside wall or where it

WARNING

Run 24V Class II wiring only through specied low

voltage opening. Run line voltage wiring only through

specied high voltage opening. Do not combine voltage

in one opening.

NOTE – Connect conduit to the unit using a proper conduit tting. Units are approved for use only with copper conductors. A complete unit wiring diagram is located on the back side of the unit’s access panel.

3 - Install low voltage wiring from outdoor to indoor unit

and from thermostat to indoor unit.

NOTE – For proper voltages, select thermostat wire gauge per the following chart:

CAUTION

USE COPPER CONDUCTORS ONLY.

This unit is provided with knock-outs for conduit. Refer

to gure 11 on page 13 for unit wiring diagram, which includes all eld wiring. Separate openings have been pro-

vided for 24V low voltage and line voltage. Refer to the

dimension illustration on page 2 or 3 for specic location.

Wiring must conform to the current National Electric Code ANSI/NFPA No. 70, or Canadian Electric Code Part I, CSA Standard C22.1, and local building codes. Refer to following wiring diagrams. See unit nameplate for minimum circuit ampacity and maximum overcurrent protection size.

Select the proper supply circuit conductors in accordance with tables 310-16 and 310-17 in the National Electric Code, ANSI/NFPA No. 70 or tables 1 through 4 in the Canadian Electric Code, Part I, CSA Standard C22.1.

The motor speed is set by the speed tap connection to the low voltage terminal strip in the control section. The speed can be increased by swapping wires as shown in

gure 11.

WIRING CONNECTIONS

1 - Install line voltage power supply to unit from a

properly installed circuit breaker.

2 - Ground unit at unit disconnect switch or to an earth

ground.

TABLE 6. Run Length (Class II Rated Wiring)

Wire Run Length AWG # Insulation / Core Types

Less than 100' (30m) 18

More than 100' (30m) 16

approximately from the floor. can be affected by sunlight or drafts.

THERMOSTAT

5 FEET

(1.5M)

he control panel.

NOTE — Units are approved for use only with copper conductors.

Color coded, temperature rating 95°F (35°C) minimum, solid core

FIGURE 10. Thermostat Installation

Page 12

FIGURE 11. Typical System Wiring Diagram

Page 13

FIGURE 12. Typical System Wiring Diagram – 460V, Single- and Three-Phase Units (-036, -048 and -060 only)

Page 14

Repairing or Replacing Cabinet Insulation

IMPORTANT

DAMAGED INSULATION MUST BE REPAIRED OR REPLACED before the unit is put back into operation. Insulation loses its insulating value when wet, damaged, separated or torn.

Matte- 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 corrosion 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.

WARNING

Electric Shock Hazard. Can cause injury or death. Foil-faced insulation has conductive

characteristics similar to metal. Be sure there

are no electrical connections within 1/2ʺ

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 electrical shock hazard that could cause personal injury or death.

Homeowner Maintenance

IMPORTANT

Do not operate system without a lter. A lter is required

to protect the coil, blower, and internal parts from

excessive dirt and dust. The lter is placed in the return

duct by the installer.

• Inspect air lters at least once a month and replace or

clean as required. Dirty lters are the most common

cause of inadequate heating or cooling performance.

• Replace disposable lters. Cleanable lters can be cleaned by soaking in mild detergent and rinsing with cold water.

• Install new/clean lters with the arrows on the side point-

ing in the direction of air ow. Do not replace a cleanable (high velocity) lter with a disposable (low velocity) lter unless return air system is properly sized for it.

• If water should start coming from the secondary drain line, a problem exists which should be investigated and

corrected. Contact a qualied service technician.

Professional Maintenance

1. CUT INSULATION IN X PATTERN

2. APPLY GLUE

3. PRESS GLUED TABS AGAINST CABINET

FIGURE 13. Repairing Insulation

NOTICE !

Failure to follow instructions will cause damage to the unit.

This unit is equipped with an aluminum coil. Aluminum coils may be damaged by exposure to solutions with a pH below 5 or above 9. The aluminum coil should be cleaned using potable water at a moderate pressure (less than 50psi). If the coil cannot be cleaned using water alone, Lennox recommends use of a coil cleaner with a pH in the range of 5 to 9. The coil must be rinsed thoroughly after cleaning.

In coastal areas, the coil should be cleaned with potable water several times per year to avoid corrosive buildup (salt).

Page 15

Check-out Procedures

IMPORTANT

During installation, service or maintenance, make sure that copper tubing does not rub against metal edges or other copper tubing. Care should also be taken to ensure that tubing does not become kinked. Use wire ties to secure tubing to prevent movement.

Do not secure electrical wires to tubing that carries hot refrigerant gas. Heat from the tubing may melt the wiring insulation, causing a short circuit.

NOTE – Refer to outdoor unit installation instructions for system start-up instructions and refrigerant charging instructions.

PRE-START-UP CHECKS

• Is the air handler properly and securely installed?

• If horizontally congured, is the unit sloped up to 1/4 inch toward drain lines?

• Will the unit be accessible for servicing?

• Has an auxiliary pan been provided under the unit with

separate drain for units installed above a nished ceiling or in any installation where condensate overow

could cause damage?

• Have ALL unused drain pan ports been properly plugged?

• Has the condensate line been properly sized, run, trapped, pitched, and tested?

• Is the duct system correctly sized, run, sealed, and insulated?

• Have all cabinet openings and wiring been sealed?

• Is the indoor coil factory-installed TXV properly sized for the outdoor unit being used?

• Have all unused parts and packaging been disposed of?

• Is the lter clean, in place, and of adequate size?

• Is the wiring neat, correct, and in accordance with the wiring diagram?

• Is the unit properly grounded and protected (fused)?

• Is the thermostat correctly wired and in a good location?

• Are all access panels in place and secure?

CHECK BLOWER OPERATION

• Set thermostat to FAN ON.

• The indoor blower should come on.

CHECK COOLING OPERATION

• Set thermostat to force a call for cooling (approximately 5ºF lower than the indoor ambient temperature).

• The outdoor unit should come on immediately and the indoor blower should start between 30 - 60 seconds later.

• Check the air ow from a register to conrm that the system is moving cooled air.

• Set the thermostat 5ºF higher than the indoor temperature. The indoor blower and outdoor unit should cycle off.

CHECK ELECTRIC HEAT (IF USED)

• 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.

• Set the thermostat so that it does not call for heat. Allow up to 5 minutes for all sequencers to cycle off.

Use of Air Handler During Construction

Lennox does not recommend the use of its air handler unit during any phase of construction. Very low return air temperatures, harmful vapors and operation of the unit with

clogged or misplaced lters will damage the unit.

Air handler units may be used for heating (heat pumps) or cooling of buildings under construction, if the following conditions are met:

• A room thermostat must control the air handler. The use

of xed jumpers is not allowed.

• Air lter must be installed in the system and must be maintained during construction.

• Air lter must be replaced upon construction comple- tion.

• The air handler evaporator coil, supply fan assembly and duct system must be thoroughly cleaned following

nal construction clean-up.

• All air handler operating conditions must be veried ac- cording to these installation instructions.

Page 16

Technician’s Name:_______________________Date Start−Up & Performance Check Completed__________

Installing Contractor’s Name_______________________ Installing

Contractor’s Phone_______________________

Job

Installing Date_______________________________

Address____________________________________

Temperature

Duct

System

Duct Static

Air Handler Model #__________________________

Thermostat

SUPPLY

AIR

Disconnect

Switch

Line Voltage

Integrated Control

Blower Motor Amps

Electric Heat Amps

RETURN

AIR

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

Filter

TOTAL EXTERNAL STATIC (dry coil)

Supply External Static ______ ______

Return External Static ______ ______

Total External Static = ______ ______

ELECTRIC HEAT AMPS____________

INDOOR BLOWER AMPS___________

INDOOR BLOWER CFM____________

TEMPERATURE DROP (Cooling Mode)

Return Duct Temperature ___________

Supply Duct Temperature − ___________

TEMPERATURE RISE (Heating Mode)

Return Duct Temperature __________

Supply Duct Temperature − __________

THERMOSTAT

Adjusted and Programmed

Operation Explained to Owner

Drain Line

dry coil wet coil

Temperature Drop = ___________

Temperature Rise = __________

Explained Operation of System to Homeowner

FIGURE 14. Start-up and Performance Checklist (Upow Conguration)

Page 17

Technician’s Name:_______________________Date Start−Up & Performance Check Completed__________

Installing Contractor’s Name_______________________ Installing

Contractor’s Phone_______________________

Job

Installing Date_______________________________

Address____________________________________

Thermostat

Duct System

Integrated

Control

Filter

Air Handler Model #__________________________

Disconnect

Switch

Line Voltage

Duct System

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

RETURN

Drain Line

AIR

Duct Static

Electric Heat Amps

Blower motor Amps

Temperature

TOTAL EXTERNAL STATIC (dry coil)

Supply External Static ______ ______

Return External Static ______ ______

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

SUPPLY

AIR

dry coil wet coil

Explained Operation of System to Homeowner

FIGURE 15. Start-Up and Performance Checklist (Horizontal Conguration)

Page 18

Lennox CBA27UHE-018, CBA27UHE-024, CBA27UHE-030, CBA27UHE-036, CBA27UHE-048 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual