Lennox CBA38MV User Manual

INSTALLATION INSTRUCTIONS

THIS MANUAL MUST BE LEFT WITH THE

HOMEOWNER FOR FUTURE REFERENCE

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.

NOTICE

A thermostat is not included and must be ordered separately.

• A Lennox communicating thermostat must be used in communicating applications.

• In non-communicating applications, the Lennox ComfortSense® thermostat may be used, as well as other non-communicating thermostats.

In all cases, setup is critical to ensure proper system operation.

Field wiring for both communicating and noncommunicating applications is illustrated in diagrams, which begin on page 13.

IMPORTANT: Special procedures are required for cleaning the all-aluminum coil in this unit. See page 43 in this instruction for information.

Dave Lennox Signature® Collection CBA38MV Units

MULTI-POSITION AIR HANDLERS 507725-02 12/2019

Table of Contents

CBA38MV Upow and Downow Unit Dimensions ....... 2

CBA38MV Horiz. LH/RH Discharge Unit Dimensions ...3

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

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

Installation Clearances ..................................................4

Requirements ................................................................5

Installing the Unit ........................................................... 5

Brazing Connections .....................................................9

Installing the Condensate Drain .................................. 11

Inspecting and Replacing Filters .................................12

Sealing the Unit ...........................................................12

Field Control Wiring ..................................................... 13

Air Handler Control Button, Display and Jumpers ....... 25

Target CFM Tables ......................................................30

Unit Operating Sequences ..........................................32

Unit Operating Sequences ..........................................34

Heat Pump Operation (Heating and Cooling) .............. 39

Cooling Operation ........................................................40

Error Code / Recall Mode ............................................ 41

Indoor Blower Test ....................................................... 42

Operation ..................................................................... 42

Repairing or Replacing Cabinet Insulation .................. 43

Homeowner Maintenance ............................................43

Professional Maintenance ...........................................43

IMPORTANT INFORMATION FOR INSTALLER

CHECK FOR AND REMOVE THE FOLLOWING ITEMS BEFORE OPERATING UNIT.

BLOWER HOUSING SUPPORT PAD.

Important Update: The CBA38MV Air Handler Control (AHC) has been enhanced to automatically configure (set-up) the electric heat when the ECBA38 electric heat harness is connected to CBA38MV air handler. Manual Configuration of the electric heat using the push button is no longer required. See page 32.

HORIZONTA L DRAIN PA N (SEE

UPFLOW APPLICATIONS ON PAGE 5 AND DOWNFLOW APPLICATIONS ON PAGE 8 )

CONFIGURE ELECTRIC HEAT

REFRIGERANT LINE PLUGS (SEE

BRAZING CONNECTION ON PAGE 9) .

ECB38

Page 1

CBA38MV 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)

CBA38MV 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

CBA38MV 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)

Air Flow

(HORIZONTA L)

FRONT VIEW

FILTER

TOP 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

Model Number Identication

230CB 38 036-01

060 = 5 tons (17.6 kW)

--6

Unit Type

CB = Air Handler

Coil Type

A = Aluminum Coil

Series

Configuration

MV = Multi-Position, Variable

speed blower motor

Nominal Cooling Capacity

018/024 = 1.5 to 2 tons (5.3 to 7 kW) 030 = 2.5 tons (8.8 kW) 036 = 3 tons (10.6 kW) 042 = 3.5 tons (12.3 kW)

048 = 4 tons (14.1 kW)

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

This indoor unit with all-aluminum coil is designed for

installation with optional eld-installed electric heat and a

matched outdoor unit that is charged with HFC-410A refrigerant. These units, designed for indoor installation in

multiple positions, are completely assembled for upow

and horizontal right-hand discharge before being shipped from the factory.

All CBA38MV air handlers are equipped with a factory-installed, internally mounted check / expansion valve, which is suitable for use in HFC-410A applications.

This air handler is compatible with the ComfortSense® non-communicating thermostat and non-communicating outdoor units. In addition, this unit has the enhanced capability of communicating with the communicating thermostats and communicating outdoor units using the Lennox RSBus protocols.

NOTE - For downow or horizontal left-hand air discharge, certain eld modications are required.

These instructions are intended as a general guide and do not supersede local or national codes in any way. Consult authorities having jurisdiction before installation.

Minor Revision Number

Refrigerant Metering Device

2 = Fixed Orifice 3 = TXV - Bleed port (indoor unit)

4 = TXV - Non-bleed port (indoor unit) 5 = TXV - Non-bleed port (outdoor unit) 6 = TXV - R410A Non-bleed port (indoor unit)

Voltage

230 = 208/230V-60hz-1ph

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

Installation Clearances

Cabinet 0 inch (0 mm)

To Plenum 0 inch (0 mm)

To Outlet Duct within 3 feet (914 mm) 0 inch (0 mm)

Floor See Note #1

Service / Maintenance See Note #2

Units installed on combustible oors in the downow position with

electric heat require optional downow additive base.

Front service access – 24 inches (610 mm) minimum.

NOTE - If cabinet depth is more than 24 inches (610 mm), allow a minimum of the cabinet depth plus 2 inches (51 mm).

IMPORTANT

This unit must be matched with an indoor coil as

specied in the Lennox Product Specications (EHB). Coils previously charged with HCFC-22 must be ushed.

WARNING

During blower operation, the ECM motor emits energy that may interfere with pacemaker operation. Interference is reduced by both the sheet metal cabinet and distance.

Shipping and Packing List

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

1 – Pipe nipple (Sch80, 3/4" I.D. x 5")

1 – Downow shields and foam tapes (required for down-

ow conguration only)

1 – Horizontal drip shield (CBA38MV-060 only)

1 – Warranty card

Page 4

WARNING

Improper installation of the air handler can result in personal injury or death.

Do not allow external combustion products or other contaminants to enter the return air system or to be mixed with air that will be supplied to the living space. Use sheet metal screws and joint tape or duct mastic to

seal return air system to air handler. In platform installations, the air handler should be sealed airtight to the return air plenum. A door must never be used as a portion of the return air duct system. The base must provide a stable support and an airtight seal to the air handler. Allow absolutely no sagging, cracks, gaps. etc.

For no reason should return and supply air duct systems ever be connected to or from other heating devices

such as a replace or stove. etc. Fire, explosion, carbon

monoxide poisoning, personal injury and/or property damage could result.

Requirements

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.

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 e󰀩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 o󰀨ers 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.

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.

FIGURE 1. Upow Conguration

TABLE 1. Optional Side-Return Unit Stand

(Upow Only)

Model Kit Number

All unit sizes

45K32

HORIZONTAL RIGHT-HAND DISCHARGE 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.

NOTE – When air handler is located above a nished space, the secondary drain pan must have a larger footprint than the air handler. In addition, a 3/4" (19.1mm) overow drain line must be:

• Connected to secondary drain pan

• Connected to the overow drain outlet of the air handler drain pan.

Page 5

NOTE - (-060 Model Only) Before operating the unit, re-

UP-FLOW / DOWN-FLOW DRAIN

HORIZONT PA

FRONT VIEW END VIEW

move access panels and the horizontal drip shield and the corrugated padding between the blower and coil assembly. Discard the corrugated padding and the downow drip shields.

NOTE - (-060 Model Only) Install the horizontal shield on the front edge of the horizontal drain pan as illustrated in gure 2.

1 - No further adjustment is necessary. Set unit so that it

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

2 - 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

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.

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.

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.

AL DRAIN

NO ADJUSTMENT IS NECESSARY

DOWN-FLOW RAIL

HORIZONTAL LEFT-HAND DISCHARGE APPLICATION

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

NOTE - (-060 Model Only) Before operating the unit, re- move access panels and the horizontal drip shield and the corrugated padding between the blower and coil assembly. Discard the corrugated padding and the downow drip shields. (The shields are used for downow applications only.)

Page 6

HORIZONTAL DRIP SHIELD (-060 MODEL)

DRAIN PAN

CABINET

SUPPORT

DRAIN PAN

REINSTALLED

HERE

TOP CAP ROTATED TO

CORRECT POSITION

90º

BEND

TOP CAP SCREWS

3/16” PLASTIC PLUG (REAR COIL END SEAL)

HORIZONTA L DRIP SHIELD SCREW (FRONT COIL END SEAL)

DRAIN PAN SHIPPING LOCATION

INSTALL DRAIN PAN

BETWEEN TA B AND

EXTERIOR INNER WALL.

DETAIL C

REINSTALLED HERE REMOVED FROM HERE

———— DRAIN PLUGS ————

FRONT VIEW

COIL SHOWN IN UPFLOW POSITION FOR EASY

CONVERSION (LEFT-HAND AIR DISCHARGE )

DETAIL A

FIGURE 4. Field Modication for Left-Hand Discharge

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

1 - Pull the coil assembly from unit. Pull o󰀨 the horizontal

drain pan.

2 - 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.

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

the opposite side of the coil.

4 - 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.

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

6 - 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.

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

7 - 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.

TOP CAP

DETAIL B

BEND

90º

DOWN-FLOW RAIL FRONT EDGE OF HORIZONTAL

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

BACK COIL END SEAL

FIGURE 5. Left-Hand Discharge Conguration

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

front edge of the horizontal drain pan as illustrated

in gure 5.

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.

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

plate to cabinet front ange with screw provided.

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

11 - 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.

Page 7

DOWNFLO

1” WIDE FOAM TAPE (LONGER PIECE)

12 - 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 6. Connect

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

DOWNFLOW APPLICATION

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

IMPORTANT

If electric heat section with circuit breakers (ECB29/

ECB31) is installed in a CBA38MV unit in a downow

application, the circuit breakers must be rotated 180° to the UP position. See ECB29/ECB31 installation instructions for more details.

HORIZONTA L DRAIN P

(REMOVE FROM UNIT)

UP-LOAD /

DRAIN PAN

FIGURE 6. Downow Discharge Position

Table 2 outlines the sizes of the various drip shields.

NOTE - (-060 Model Only) Remove access panels and horizontal drip shield from the corrugated padding between the blower and coil assembly.

1 - Remove the coil assembly from the unit.

2 - For best e󰀩ciency and air ow, remove the

horizontal drain pan from the units in downow positions as illustrated in gure 6.

3 - Rotate cabinet 180º from the upright position. See

gure 6. You may need to rst remove the blower

assembly to lighten the cabinet for lifting.

4 - Foam tape that is provided creates a seal between

the drip shield and the coil so that water does not leak into the air stream. The foam tape pieces are precut. Apply the tape to the drip shields as

illustrated in gure 7 and specied as follows:

• Apply two pieces of foam tape provided down both ends of each shield. The tape should measure

4-3/4ʺ X 2ʺ (120 X 25 mm). Ensure that the tape

covers both sides of the shield equally.

• Apply the longer piece of 1 inch wide foam tape between the end pieces of tape.

5 - From the underside of the coil, install the downow

drip shield rmly in place as illustrated in gure 8.

TABLE 2. Downow Drip Shields (Tape Required)

Units Length Width

-018/024 Not Required Not Required

-030 15-7/8ʺ 4-11/16ʺ

-036, -042 17-7/8ʺ 4-11/16ʺ

-048, -060 19-7/8ʺ 4-11/16ʺ

DRIP SHIELD

SIDE

VIEW

2” WIDE FOAM TAPE

FIGURE 7. Applying Foam Tape to Drip Shield

COIL

DRIP SHIELD

DRIP PAN

FIGURE 8. Downow Drip Shields

6 - Replace the coil assembly and blower if you have

removed it. Replace the coil access panel.

7 - Set the unit so that it is level. Using sheet metal

screws, connect the return and supply air plenums as required.

NOTE - For downow application, metal or Class I supply and return air plenums must be used.

Page 8

AIR

HANDER

UNIT

COMBUSTIBLE FLOOR

PROPERLY SIZED

FLOOR OPENING

ADDITIVE BASE

FIGURE 9. Downow Combustible Flooring Base

8 - For downow installation on combustible ooring,

an additive base must be used as illustrated in gure 9 on page 9. See CBA38MV Product Specications (EHB) for downow combustible ooring base kits

available for this air handler.

9 - Cut an opening appropriately sized for combustible

base. Base dimensions are illustrated in gure 10.

After opening has been cut, set the additive base into opening. Connect outlet air plenum to the additive base. Set the unit on the additive base so

anges of the unit drop into the base opening and

seal against the insulation strips. The unit is now locked in place. Install return air plenum and secure with sheet metal screws.

Brazing Connections

WARNING

Polyol ester (POE) oils used with HFC-410A refrigerant absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as possible. DO NOT remove line set caps or service valve stub caps until you are ready to make connections.

WARNING

Danger of re. Bleeding the refrigerant

charge from only the high side may result in pressurization of the low side shell and suction tubing. Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture. Check the high and low pressures before applying heat.

WARNING

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

death. When using a high pressure gas such as

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).

1‐5/8 (41)

20 (508)

1‐5/8 (41)

5/8 (16)

TOP VIEW

11‐3/8

(289)

SUPPLY AIR OPENING

22‐5/8 (575) -018/024

24‐5/8 (625) -030, 036

26‐5/8 (676) -042, 048, 060

13‐1/2 (343)

OPENING

SIDE VIEW

23-1/4 (591)

INCHES (MM)

3 (76)

FIGURE 10. Downow Combustible Base Dimensions

CAUTION

Brazing alloys and ux contain materials which are

hazardous to your health. Avoid breathing vapors or fumes from brazing operations.

Perform operations only in well ventilated areas. Wear gloves and protective goggles or face shield to

protect against burns. Wash hands with soap and water after handling brazing

alloys and ux.

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.

Page 9

LINE.

PLEASE READ IMPORTANT ISSUES CONCERNING BRAZING

NOTE — REFER TO OUTDOOR UNIT INSTALLATION INSTRUCTIONS FOR REFRIGERANT PIPING SIZE REQUIREMENTS .

NOTE - Use silver alloy brazing rods with five or six percent minimum silver alloy for copper-to-copper brazing, 45 percent alloy for copper-to-brass and copper-to-steel brazing.

REMOVE ACCESS PANEL

REMOVE RUBBER PLUG FROM BOTH LIQUID

AND SUCTION LINES

NOTE — CBA38MV SERIES UNITS 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.

EITHER REMOVE OR PUSH PIPE WRAPPING BACK

THROUGH HOLE IN PIPING PLATE BEFORE LINE SET CONNECTION AND BRAZING.

OPERATIONS ON PAGE 10 BEFORE PROCEEDING.

USE A WET RAG TO PROTECT CTXV

SENSING BULB WHEN BRAZING SUCTION LINE CONNECTIONS.

LOW

HIGH

PIPING PLATE

CONNECT PIPES

NOTE — REFRIGERANT LINE SETS SHOULD BE ROUTED TO ALLOW FILTER ACCESSIBILITY.

REPEAT PREVIOUS PROCEDURE FOR LIQUID

FLOW REGULATED NITROGEN (AT 1 TO 2 PSIG)

THROUGH THE REFRIGERATION GAUGE SET INTO THE VALV E STEM PORT CONNECTION ON THE OUTDOOR UNIT LIQUID LINE SER VICE VALVE AND OUT OF THE VALV E STEM PORT CONNECTION ON THE SUCTION SERVICE VALVE.

PLACE A WET RAG AGAINST PIPING

PLATE AND AROUND THE SUCTION LINE CONNECTION. A

BRAZE CONNECTION. ALLOW PIPE TO

COOL BEFORE REMOVING WET RAG FROM CTXV SENSING BULB AND PIPING PANEL AREA.

FIGURE 11. Brazing Connections

CONNECT GAUGES AND

START NITROGEN FLOW

REFER TO INSTRUCTIONS PROVIDED WITH OUTDOOR UNIT FOR LEAK TESTING, EVACUATING AND CHARGING PROCEDURES

NITROGEN

Page 10

TABLE 3. CBA38MV Refrigerant Connections and

LEFT-HAND AIR

UP-FLOW OR

RIGHT-HAND AIR

Line Set Requirements

Model

-018/ 024

-030

-036

-042

-048

-060

NOTE - Some applications may require a eld-provided 7/8ʺ to 1-1/8ʺ adapter.

Liquid

Line

3/8ʺ

(10mm)

3/8ʺ

(10mm)

3/8ʺ

(10mm)

3/8ʺ

(10mm)

Vapor

Line

3/4ʺ

(19mm)

3/4ʺ

(19mm)

7/8"

(22mm)

7/8"

(22mm)

L15 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

NOTE - When installing refrigerant lines longer than 50 feet, see the Lennox Refrigerant Piping Design and Fabrication Guidelines, CORP. 9351-L9, or contact Lennox Technical Support Product Applications for assistance.

Installing the Condensate Drain

IMPORTANT

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 13 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 12 for main and overow drain locations based on coil

orientation.

DISCHARGE

OVERFLOW

DRAIN ON LEFT

DOWN-FLOW

DISCHARGE

MAIN DRAIN ON

RIGHT

FIGURE 12. 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.

Page 11

ABOVE

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 MA IN DRAIN.

FINISHED

SPACE?

OVERFLOW DRAIN LINE

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

LENNOX #

X3169

COMPACT OVERFLOW SWITCH WITH 3/4” FEMALE SLIP INLET

AND MALE ADAPTER, TWO PA RT DESIGN FOR USE WHERE OBSTRUCTIONS PREVENT DIRECT THREADING

CLEAN OUT

PRESS IN

(DO NOT GLUE)

VENT MUST EXTEND

ABOVE HEIGHT OF

COIL DRAIN PAN BY

TWO INCHES (51MM)

VENT

MAIN

DRAIN

PIPE NIPPLE

AIR HANDLER DRAIN PA N

OVERFLOW

DRAIN

YES

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.

DRAIN

SECONDARY

DRAIN PAN

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).

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

FIGURE 13. Typical Main and Overow Drain Installations

CUT TO

REQUIRED

LENGTH

PROVIDED

SIDE VIEW

1” X 3/4” X 3/4”

REDUCING

TEE WITH

PLUG

P-TRAP

LENNOX

49P66, J-TRAP #

91P90 OR ANY

PVC SCH 40 P- OR

J-TRAP 3/4”

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

2”

(51MM)

TRAP DEPTH

TO APPROVED

DRAIN

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

Inspecting and Replacing Filters

IMPORTANT

Filter access door must be in place during unit operation. Excessive warm air entering the unit from unconditioned

space may result in water blow-o󰀨 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 furnace operation.

To replace lter:

1 - Loosen the thumbscrews holding the lter panel in

place.

2 - Slide the lter out of the guides on either side of

cabinet.

3 - Insert new lter.

4 - Replace panel.

See table 4 for replacement lter sizes.

TABLE 4. Filter Dimensions

CBA38MV Filter Size – In. (mm)

-018/024, -030, -036 20 x 20 x 1 (508 x 508 x 25)

-042, -048, -060 20 x 24 x 1 (508 x 610 x 25)

Sealing the Unit

WARNING

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-o󰀨 problems. This is especially important when the

unit is installed in an unconditioned area.

Page 12

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.

Field Control Wiring

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 a ½ʺ 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 electric shock hazard that could cause personal injury or death.

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 over-current protection size.

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

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.

Separate openings have been provided for 24V low voltage and line voltage. Refer to the dimension illustration of

specic location.

CAUTION

USE COPPER CONDUCTORS ONLY.

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.

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:

ELECTROSTATIC

DISCHARGE

(ESD)

Precautions and

Procedures

CAUTION

Electrostatic discharge can a󰀨ect

electronic components. Take care during unit installation and service to protect the unit’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the unit, the control and the technician at the same electrostatic potential. Touch hand and all tools on an unpainted unit surface before performing any service procedure to neutralize electrostatic charge.

Page 13

Cut Size: 7" wide x 10" tall

FIGURE 14. CBA38MV Air Handler Unit Typical Wiring Diagram

Page 14

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