installation instructions - inspectapedia.com instructions direct---expansion ... start--up and...

CAHZCOIL408A00CAHZCOIL412A00CAHZCOIL208A00CAHZCOIL212A00CAVTCOIL408A00CAVTCOIL412A00CAVTCOIL208A00CAVTCOIL212A00

Installation Instructions

DIRECT---EXPANSIONHORIZONTAL AND VERTICAL

EVAPORATOR COILS

IMPORTANT: Read these instructions completely beforeattempting to install this accessory.

TABLE OF CONTENTSSAFETY CONSIDERATIONS 1. . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete Pre--Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Direct Furnace--to--Coil Installation (CAVT series coils) 7. . . .

Duct Transition Installation (CAVT series coils) 7. . . . . . . . . .

Horizontal Furnace or Ductwork Installation 7. . . . . . . . . . . .

REFRIGERANT PIPING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAVT Series Coils 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAHZ Series Coils 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION LINE PIPING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIQUID LINE PIPING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSATE DRAIN PIPING 8. . . . . . . . . . . . . . . . . . . . . .

START--UP 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coil Removal 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY CONSIDERATIONSInstallation, start--up and servicing of this equipment can behazardous due to system pressures, electrical componentsand equipment location (roofs, elevated structures, etc.)Untrained personnel can perform the basic maintenancefunctions. All other operations should be performed bytrained service personnel. When working onair--conditioning equipment, observe precautions in theliterature, tags and labels attached to the unit, and othersafety precautions that may apply.Follow all safety codes. Wear safety glasses and workgloves.Recognize safety information. This is the safety--alert

symbol . When you see this symbol on the unit and ininstructions or manuals, be alert to the potential forpersonal injury.Understand the signal words DANGER, WARNING, andCAUTION. These words are used with the safety--alertsymbol. DANGER identifies the most serious hazardswhich will result in severe personal injury or death.WARNING signifies a hazard which could result inpersonal injury or death. CAUTION is used to identifyunsafe practices which may result in minor personal

injury or product and property damage. NOTE is used tohighlight suggestions which will result in enhancedinstallation, reliability, or operation.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause in personalinjury or death.

Before performing service or maintenance operationson unit, always turn off main power switch to unit andinstall lockout tag. Unit may have more than onepower switch.

! WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause in personalinjury,death and/or equipment damage.

R--410A refrigerant systems operate at higherpressures than standard R--22 systems. Do not useR--22 service equipment or components on R--410Arefrigerant equipment.

! WARNING

PERSONAL INJURY AND ENVIRONMENTALHAZARD

Failure to follow this warning could cause in personalinjury or death.

Adequate ventilation is required during any welding orbrazing process; ensure that fumes do not migratethrough ductwork to occupied areas.

Never pressurize equipment in excess of specified testpressures.

Relieve pressure and recover all refrigerant beforesystem repair or final unit disposal.

Wear safety glasses and gloves when handlingrefrigerants. Keep torches and other ignition sourcesaway from refrigerants and oils.

When welding or flame--cutting, contain sparks toprotect adjacent flammable material. Have afire--extinguisher available.

! WARNING

2

CUT HAZARD

Failure to follow this caution may result in personalinjury.

Sheet metal parts may have sharp edges or burrs. Usecare and wear appropriate protective clothing, safetyglasses and gloves when handling parts and servicingthese units.

CAUTION!

INTRODUCTIONThese instructions apply to CAHZ and CAVT seriesdirect--expansion evaporator coils. The cooling assembliesconsist of the cooling coil, insulated coil housing,insulated condensate pan with external drain connection,internal suction line piping, thermostatic expansion valve,and a refrigerant distributor. See Table 1 for physical data;dimensions are shown in Figs. 1 through 4.

INSTALLATIONEnsure that furnace blowers have sufficient air handlingcapacity for the total air flow (cfm) required, as well asthe resistance imposed by ductwork and cooling coil.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipmentdamage.

Make sure that furnaces installed are approved fortwinning.

CAUTION!

Complete Pre--InstallationUNPACKING

1. Remove the coils from the packaging; avoiddamaging the coil fins.

2. Inspect the coils; file a claim with the shippingcompany if the coils are damaged.

MOVING1. Lift the coils by the casing, never the pipe

connections. See Table 1 for coil weights.2. Avoid bending or mutilating the fins.

STORAGE (For More Than 2 Weeks) —Storage surface should be level, rigid, free of debris, and dry.Do not store coils in a heavy traffic area or on a vibratingsurface.When storing the coils outside in a heavy rain area, wrap thecoils with a waterproof tarp or plastic sheet. Do not movethe wrap or connection caps until you install the unit.

Table 1 – Physical Data

UNITCAVTCOIL4 CAVTCOIL2 CAHZCOIL4 CAHZCOIL2

08 12 08 12 08 12 08 12

OPERATING WT (lb) 156 202 156 202 168 222 168 222

REFRIGERANT R---410A R---22 R---410A R---22

DISTRIBUTIONNOZZLE SIZE* E5 J4 E6 J4 E5 E8 E6 E10

FACE AREA (sq ft) 7.3 9.2 7.3 9.2 6.7 10 6.7 10

ROWS...FINS/IN. 4...12 4...12

NUMBER OFCIRCUITS 1 2 1 2 1 1 1 1

NUMBER OF TXVMETERING DEVICES{ 1 2 1 2 1 1 1 1

AIR QUANITY (Cfm)Nominal –Range} –

30002255---3335

40003000---4500

30002255---3335

40003000---4500

30002255---3335

40003000---4500

30002255---3335

40003000---4500

* Refrigerant control is factory installed.{ Factory installed.} Air quantities in excess of values shown may result in moisture blow---off.

3

.875 ODCONDENSATE DRAIN

LIQUID .625 ODSUCTION 1.125 OD

40.4.8 (TYP)

18.6

.8

03.

44.

3

01.5

13.816.3

22.2

42.0

13.9(OPENING

DEPTH)

33.2(OPENING WIDTH)

5.3 3.5

4.1 (TYP).8 (TYP)

13.816.3

1.5(TYP)

1.420.5

TXV ACCESSDOOR

TOP VIEW

SUCTION (ALT)

LIQUID (ALT)

LEFT SIDEVIEW

FRONT VIEW

NOTES:

ALL DIMENSIONS ARE IN INCHES.1.

CONNECTION TYPES ARE SWT.2.

BOTTOM VIEWC11310

Fig. 1 -- CAVTCOIL*08 Unit Dimensions

4

TXV ACCESSDOOR

53.4

22.2

TOP VIEW

20.4

0

5.07.2

13.015.7LIQUID LINE

(ALT)

SUCTION LINE(ALT)

0

2.0

1.0

1.5

3.4

LEFT SIDELEFT SIDEVIEWVIEW

01.65.07.2

13.015.7

02.

93.

9

SUCTION (CIRC 1) .875 ODSUCTION (CIRC 2) .875 OD

LIQUID (CIRC 1) .500 ODLIQUID (CIRC 2) .500 OD

COND DRAIN .875 OD

51.61.0 (TYP)

.8

18.6

FRONT VIEW

4.8 (TYP)2.0 (TYP)

12.6(OPENING

DEPTH)

5.7

43.9OPENING WIDTH)

3.8

NOTES:


CONNECTION TYPE IS SWT.2. BOTTOM VIEWC11311

Fig. 2 -- CAVTCOIL*12 Unit Dimensions

5

TXV ACCESSDOOR

10.8

1.0(TYP)

1.9(TYP)

44.1 48.0

TOP VIEW

AIRFLOW

AFRONT VIEW

25.9

SUCTION 1.125 O.D.

LIQUID .625 O.D.

(3/4 FPT TYP)COND DRAIN W/AUX

1.0 (TYP)

NOTES:


REFRIG CONNECTION TYPE IS SWT.2.

2.5 (TYP)

1.2

28.3

1.2

RIGHT SIDEVIEW

DETAIL A

0

1.52.1

4.0

5.5

0

4.6

5.3

7.3

6.7

C11312

Fig. 3 -- CAHZCOIL*08 Unit Dimensions

6

28.3

1.2

2.5(TYP)

RIGHT SIDE VIEW

TXV ACCESSDOOR

01.52.1

4.0

5.5

0

5.3

4.6

7.3

6.7

DETAIL A

NOTES:


REFRIG CONNECTION TYPE IS SWT.2.

AIRFLOW

10.8

64.1 68.0

1.9(TYP)

1.0(TYP)

TOP VIEW

1.0 (TYP)

SUCTION 1.375 ODLIQUID .625 OD

(3/4 FPT TYP)COND DRAIN W/ AUX

25.9

AFRONT VIEW

1.2

C11313

Fig. 4 -- CAHZCOIL*12 Unit Dimensions

7

Direct Furnace--to--Coil Installation(CAVT series coils) —As shown in Fig. 5, remove screws on top of each furnaceand install the coil as follows:

1. Seal duct openings with a 3/4--in. wide strip of heatresistant gasket (1/8--in. to 1/4--in. thick) to preventair leakage. See Fig. 5.

APPLY SEALANTALONG SEAM

SELF-TAPPING HEX HEAD SCREWS

DISCHARGEOUTLET FLANGE

HEATRESISTANTGASKET STRIPS

FLUE STACKS

FURNACES

C11314

Fig. 5 -- Top Surfaces of Factory--Approved TwinnedFurnaces with Heat Resistant Gasket Strips and

Sealant (Typical)

2. Position coil firmly and squarely on top of duplexfurnaces as shown in Fig. 6.

SEE NOTE

NOTE: CAVT series coils have an equal overhang on both sides of the unit.The overhang distance varies depending on CAVT unit and furnace type used.

C11315

Fig. 6 -- Panel Removed from CAVT Series CoilInstalled on Factory--Approved Twinned Furnaces

(CAVTCOIL*08 Shown)

Duct Transition Installation(CAVT series coils) —Seal top edge between furnaces and gaskets as shown inFig. 5 and install coil as follows:

1. Attach connection flange of duct transition pieceoutlet to coil casing inlet; secure with sheet metalscrews.

2. Insulate duct transition piece with a minimum of1--in. Fiberglass insulation; insulation should have afoil or vinyl vapor seal.

3. Remove hexhead screws on top of furnaces asshown in Fig. 5.

4. Position assembled coil and duct squarely on top offurnaces as shown in Fig. 6; secure furnace dischargeflanges with sheet metal screws.

5. Seal all connections with duct tape.

Horizontal Furnace or Ductwork Installation(CAHZ series coils) —Install CAHZ series coil directly on flanged outsidesection of horizontal furnace or downstream in horizontalductwork. Locate in immediate furnace area or adjacentarea. See Figs. 7 and 8 for typical installations.

HANGERS

AIR-FLOW

DUCTWORKCANVASCONNECTOR COIL SECTION

FURNACE

C11316

Fig. 7 -- Typical Overhead SuspensionCAHZCOIL Installation

COIL SECTION CANVASCONNECTOR

FURNACE

AIR-FLOW

AUXILIARYCONDENSATE PAN ISOLATION PAD

C11317

Fig. 8 -- Typical Attic or Overhead Crawl SpaceCAHZCOIL Installation

REFRIGERANT PIPINGCAVT Series CoilsThermostatic expansion valve (TXV), distributor, andnozzle are factory installed on CAVT series coils. Fieldfabricate liquid and suction piping through front accesspanel or knockouts on end panels of casing. Sweatconnections to field piping. See Figs. 1 and 2 forconnection sizes and locations.

CAHZ Series CoilsRefrigerant lines are designed for sweat connections onsuction line and liquid line to thermostatic expansionvalve. See Figs. 3 and 4 for connection sizes andlocations.

8

UNIT PERFORMANCE HAZARD

Failure to follow this caution will result in equipmentdamage and inaccurate sensor readings.

Locate sensor bulb in a horizontal position from the9:00 to 3:00 position or in a vertical position. Securethe bulb to the suction piping with straps and insulate.Ensure that sensor bulb is properly installed beforeoperating system to avoid slugging or liquid to thecompressor.

CAUTION!

SUCTION LINE PIPING1. Remove screws holding panels to front of unit and

remove panels.2. Set small access panel in place to ensure proper

piping.3. Determine location of sensing bulb with respect to

suction line as shown in Fig. 9 and clean suctionline at contact area.

TXVSENSING BULB

ATTACHINGSTRAP WITHLOCKING CLIP

TXV CAPILLARY

LIQUID LINE OPENING

INSULATION AROUNDBULB

12″

SUCTION LINE

CONDENSATE DRAIN

C11319

Fig. 9 -- Recommended Suction Line and Sensing BulbInstallation for CAVT or CAHZ Coils

4. Attach TXV sensor bulb to suction line with straps.5. Insulate suction line and TXV sensor bulb. Ensure

that insulation extends to unit casing.

LIQUID LINE PIPING1. Measure and install piping and elbows required for

joining thermostatic expansion valve inlet portthrough access panel to the external liquid line.

2. Replace access panel and secure with screws.

CONDENSATE DRAIN PIPINGUnits are designed to dispose of accumulated water throughcondensate drain connections located at front of coil casing.Sweat connection to metal tubing, or if flexible hose is used,secure with hose clamps. Install plugged tees at all turns tofacilitate condensate drain cleaning. Provide a 3--in. trap toprevent spillover, as well as to prevent air leakage. Pitch

drain line to open sump. See Fig. 10. Clean condensate draintrap yearly with brush and flush condensate pan with cleanwater. Ensure that the water flows freely through condensatedrain.

CONDENSATEDRAIN

TO OPEN SUMP

3″ MIN

C11320

Fig. 10 -- Condensate Drain Trap

START--UPCAVT and CAHZ series coils are shipped with nitrogenholding charge. Refer to GTAC II manual, Module 4,System Dehydration for instructions on evacuating coiland piping prior to start--up. Refer to condensing unitinstructions for operating charge and start--up procedure.

SERVICECoil service is normally not required when furnace filtersare properly maintained.

Coil Removal —Disconnect piping and remove access panels. Disconnectfurnace flue pipes. Remove coil. See Fig. 11. Inspect coilperiodically and clean with brush, vacuum cleaner, orlow--pressure air.

THERMOSTATICEXPANSIONVALVE

SUCTIONLINE

RAILS

7/8" ODDRAINLINE

C11321

Fig. 11 -- Coil Removal from Casing(CAVT Coil Shown)

9

Table 2 – Coil Pressure Drop (in WG) -- Vertical Coils

Model CFM Pressure Drop

CAVTCOIL*08A00

1969 0.22

2100 0.25

2231 0.27

2363 0.30

2494 0.33

2625 0.36

2756 0.39

2888 0.42

3019 0.45

3150 0.49

3281 0.52

CAVTCOIL*12A00

2625 0.22

2756 0.24

2888 0.26

3091 0.28

3150 0.30

3500 0.36

3631 0.38

3763 0.40

3894 0.43

4025 0.45

4156 0.48

Table 3 – Coil Pressure Drop (in WG) -- Horizontal Coils

Model CFM Pressure Drop

CAHZCOIL*08A00

1969 0.25

2100 0.27

2231 0.30

2363 0.34

2494 0.37

2625 0.40

2756 0.44

2888 0.47

3019 0.51

3150 0.55

3281 0.59

CAHZCOIL*12A00

2625 0.23

2756 0.25

2888 0.27

3019 0.29

3150 0.31

3500 0.38

3631 0.40

3763 0.43

3894 0.45

4025 0.48

4156 0.51

10

Table 4 – 08 Size Vertical Coil — R--410A Capacity TableCAVTCOIL408A00

ENT(F)

SET(F)

CFM @ 80_F EDB2250 3000 3750

AIR ENTERING TEMPERATURE EWB (F)57 62 67 72 77 57 62 67 72 77 57 62 67 72 77

85

35

TC 82.3 99.6 124.7 153.5 184.5 101.0 117.6 147.0 179.7 215.7 117.2 132.4 164.6 200.1 242.0SHC 82.3 79.3 75.6 71.5 66.1 101.0 96.2 90.4 83.8 76.1 117.2 111.1 102.9 93.7 84.3LDB 46.5 47.8 49.4 51.2 53.5 49.1 50.7 52.6 54.7 57.1 51.3 52.9 55.0 57.4 59.8LWB 42.1 45.5 48.0 50.5 53.5 43.5 47.7 50.6 53.7 57.1 44.5 49.3 52.6 56.1 59.6PD 1.1 1.7 2.6 3.8 5.2 1.7 2.3 3.6 5.1 7.1 2.3 3.0 4.4 6.3 8.8BF 0.2 0.2 0.2 0.0 0.0 0.3 0.2 0.2 0.0 0.0 0.3 0.2 0.3 0.0 0.0

40


45


50


95

35


40


45


50


105

35


40


45


50


NOTE: See page 18 for Capacity Table Notes & Legend

11

Table 5 – 12 Size Vertical Coil — R--410A Capacity TableCAVTCOIL412A00

ENT(F)

SET(F)

CFM @ 80_F EDB3000 4000 5000


85

35


40


45


50


95

35


40


45


50


105

35


40


45


50



12

Table 6 – 08 Size Horizontal Coil — R--410A Capacity TableCAHZCOIL408A00

ENT(F)

SET(F)

CFM @ 80_F EDB2250 3000 3750


85

35


40


45


50


95

35


40


45


50


105

35


40


45


50



13

Table 7 – 12 Size Horizontal Coil — R--410A Capacity TableCAHZCOIL412A00

ENT(F)

SET(F)

CFM @ 80_F EDB3000 4000 5000

AIR ENTERING TEMPERATURE EWB (F)57.0 62.0 67.0 72.0 77.0 57.0 62.0 67.0 72.0 77.0 57.0 62.0 67.0 72.0 77.0

85

35


40


45


50


95

35


40


45


50


105

35


40


45


50



14

Table 8 – 08 Size Vertical Coil — R--22 Capacity TableCAVTCOIL208A00

ENT(F)

SET(F)

CFM @ 80_F EDB2250 3000 3750


85

35


40


45


50


95

35


40


45


50


105

35


40


45


50



15

Table 9 – 12 Size Vertical Coil — R--22 Capacity TableCAVTCOIL212A00

ENT(F)

SET(F)

CFM @ 80_F EDB3000 4000 5000


85

35


40


45


50


95

35


40


45


50


105

35


40


45


50



16

Table 10 – 08 Size Horizontal Coil — R--22 Capacity TableCAHZCOIL208A00

ENT(F)

SET(F)

CFM @ 80_F EDB2250 3000 3750


85

35


40


45


50


95

35


40


45


50


105

35


40


45


50



17

Table 11 – 12 Size Horizontal Coil — R--22 Capacity TableCAHZCOIL212A00

ENT(F)

SET(F)

CFM @ 80_F EDB3000 4000 5000


85

35


40


45


50


95

35


40


45


50


105

35


40


45


50



18

Legend and Notes for Capacity Tables (Tables 4 – 11)NOTES:1. SHC is based on 80_F EDB of air entering coil. Use the following formulas to correct the SHC based on other EDB.Correction Factor = 1.1 x (1---BF) x (EDB --- 80)SHC (New) = Correction Factor x CFM/1000) = SHC (MBH) (from Capacity Tables above)

2. Direct interpolation is permissible. Do not extrapolate.3. Performance assumes 10 deg subcooling and superheat.

LEGEND:BF --- Bypass FactorEDB --- Entering Dry---Bulb (_F)EWB --- Entering Wet---Bulb (_F)LDB --- Leaving Dry---Bulb (_F)LWB --- Leaving Dry---Bulb (_F)PD --- Refrig Pressure Drop (psi)ENT --- Entering Liquid Temperature (_F)SET --- Saturated Evap Temperature (_F)SHC --- Sensible Capacity (MBH)TC --- Total Capacity (MBH)

20

Copyright 2011 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 07/11

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Catalog No: IIK---CAHZ---VT4---2---01

Replaces: New

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