ICP EDM Series User manual

These instructions must be read and understood completely before attempting installation.
It is important that the Blower and Duct System be properly sized to allow the system to operate at full capacity. Poorly
designed systems will not give satisfactory cooling or economy. They may even shorten the service life of the
compressor in the outdoor unit.
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and
NOTE Signal Words in Manuals
The signal words DANGER, WARNING, CAU- The signal word WARNING is used throughout this
TION, and NOTE are used to identify levels of haz- manual in the following manner:
ard seriousness. The signal word DANGER is only
used on product labels to signify an immediate haz- 7IN WARN i NG
ard. The signal words WARNING, CAUTION, and
NOTE will be used on product labels and through- The signal word CAUTION is used throughout this
out this manual and other manuals that may apply manual in the following manner:
to the product.
DANGER - Immediate hazards which will result in yi CAUTION
severe personal injury or death.
WARNING - Hazards or unsafe practices which Signal Words on Product Labeling
could result in severe personal injury or death. Signal words are used in combination with colors
CAUTION - Hazards or unsafe practices which and/or pictures on product labels.
may result in minor personal injury or product or
property damage.
NOTE - Used to highlight suggestions which will
result in enhanced installation, reliability, or opera-
tion.
TABLE OF CONTENTS
Installation... eee eee 2-4
Condensate
Drain
4-5
7
IN
WARN
i
NG
Waste Line Connection ........ 0... cece eee ees 5 ELECTRICAL SHOCK HAZARD
Refrigerant Line Connections ................0 00s 6 Failure to turn off electric power could result in
Refrigerant Metering Device ......... 0.2.00 eee 7 personal injury or death.
Check and Adjust Airflow ............. 0000s 7-8 Before installing or servicing system, turn off
Start-Up Procedure ...... 00... cece eee e eens g | main power to the system. There may be more than
R-410A Quick Reference Guide...............0.. 9 ee switch, including accessory heat-
484 01 3001 03 Nov 2007

INSTALLATION
EDA Loose Coils are shipped with a metal collar plate
approximately the same size as the drain pan. The collar
plate must be installed between the drain pan and the
furnace or air handler cabinet to prevent condensation
inside the cabinet. Position the collar plate as shown in
Figure 1, with the flanges pointing down, towards the
furnace or air handler cabinet. Size the plenum or
fabricate spacers to seal against the outside of the collar
and prevent air bypass.
EDA Collar Plate Figure 1
Collar Plate SS
under drain ez
pos oN
a ~~
Flanges down $s
EDM and EDD Cased Coils are designed to fit furnaces
and air handlers of the same width with no modifications.
When an EDM or EDD Cased Coil is applied to a narrower
or wider furnace or air handler, afield fabricated adapter is
required. Refer to Figure 2 for examples of field fabricated
adapters.
EDM coils are designed for installation in any position -
upflow, downflow, horizontal left, or horizontal right -
without modification to the drain pans or casing. The
drain pans remain in the same positions in the casing no
matter which direction the air moves.
A CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
When a narrower coil is installed on a wider gas
furnace (upflow, downflow, or horizontal), a field
fabricated adapter must create 3” minimum space
between furnace and coil to allow airflow to dis-
tribute evenly.
When a loose coil is installed on any GAS furnace,
the drain pan must be at least 2” away from the fur-
nace heat exchanger to avoid drain pan damage.
When a loose coil is installed on any OIL furnace,
the drain pan must be at least 5” away from the fur-
nace heat exchanger to avoid drain pan damage.
CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in proper-
ty damage
A
A field fabricated auxiliary drain pan, with a sepa-
rate drain is REQUIRED for all installations over a
finished living space or in any area that may be
damaged by overflow from a restricted main drain
pan. In some localities, local codes require an aux-
iliary drain pan for ANY horizontal installation.
484 01 3001 03

Figure 2 Adapters for Coils Wider or Narrower than Furnace or Air Handler
NARROWER
COIL
3” MIN.
:
WIDER FURNACE !
ADAPTER
(FIELD SUPPLIED)
ADAPTER (2)
(FIELD SUPPLIED)
NARROWER
FURNACE
NOTE: When coil is used in a heat pump application with
electric heat, coil must be installed upstream of the
electric heater (refer to Figure 3). This prevents electric
heat from driving up refrigeration system pressure during
heating cycle.
NOTE: When coil is installed to a gas or oil furnace, coil
must be installed downstream of the furnace heat
exchanger (refer to Figure 4). This reduces condensate
formation in the furnace heat exchanger during the
cooling cycle. When the gas or oil furnace is in downflow
application on a combustible floor, Sub-Base accessory
must be installed between coil and floor. Refer to
Product Specification literature for accessory part
number.
NOTE: When coil is installed with a Heat Pump in
conjunction with a fossil fuel heating system, a Fossil
Fuel Kit must be used. Refer to Product Specification
literature for kit part number.
NOTE: On furnace installations where the coil is located
in an unconditioned space, nuisance sweating may
occur in the area around the cabinet to supply duct joint.
Wrap the joint between the cabinet and the supply duct
with a 6” wide piece of insulation with vapor barrier.
Figure 3 Heat Pump Coil Position Relative to Electric Heat
UPFLOW POSITION DOWNFLOW POSITION
( J
ELECTRIC HEATER
BLOWER
BLOWER
bse) ELECTRIC HEATER
HORIZONTAL LEFT POSITION
©
eo Qo
ELECTRIC
HEATER
BLOWER
HORIZONTAL RIGHT POSITION
BLOWER
ELECTRIC
HEATER
38-20-19a
484 01 3001 03

HEAT EXCHANGER
FURNACE
HEAT EXCHANGER
BLOWER
:
Oo
Figure 4 Coil Position Relative to Gas or Oil Furnace Heat Exchanger
UPFLOW POSITION DOWNFLOW POSITIO HORIZONTAL LEFT POSITION
c
Wd
we a
BLOWER WZ he
s6 | 8
ax 9
rc ae) a
=
FURNACE Ww
SUB-BASE ACCESSORY
HORIZONTAL RIGHT POSITION
BLOWER
FURNACE
HEAT
EXCHANGER
CONDENSATE DRAIN
Coil is provided with two %” NPT condensate drain
connections. (EDM models have two connections for
upflow/downflow, and two more connections for
horizontal.) The connection with the larger internal
opening is the primary drain, and the connection with
the smaller internal opening is the secondary
(overflow) drain. Condensate drain lines should be
installed in a manner that does not obstruct access to the
filter. Use PVC fittings on the plastic condensate pan.
Finger tighten plus 114 turns. Do not over-tighten. Use
pipe dope.
If coil is located in or above a living space where damage
may result from condensate overflow, a separate 4” drain
must be provided from secondary (overflow) drain
connection. Run this drain to a place in compliance with
local installation codes where it will be noticed when unitis
operational. Condensate flowing from secondary
(overflow) drain indicates a plugged primary drain - unit
requires service or water damage will occur.
NOTE: For downflow electric furnace, the secondary
(overflow) drain connection must be installed to prevent
possibility of water dripping onto live electrical
components.
1. Connect drain lines to the appropriate drain
connections. Drain lines should not be smaller than
the drain connections (&’).
2. NOTE: Traps must be used when the coil is
installed on the return air side of the system. When
coil is installed on the supply side (outlet air) it is not
necessary to install traps and better drainage is
usually achieved without traps.
Install properly sized condensate traps in the drain
line as close to the coil as possible. Install drain lines
below the bottom of the drain pan and pitch the drain
lines down from the coil at least % inch per foot of
run. Horizontal runs over 15 feet long must also
have an anti-siphon air vent (stand pipe), installed
ahead of the horizontal run. An extremely long
horizontal run may require an oversized drain line to
eliminate air trapping.
Refer to Figure 5 for minimum trap dimensions.
Route to the outside or to a floor drain. Check local
codes before connecting to a waste (sewer) line.
Prime all traps, test for leaks, and insulate drain
lines where sweating could cause water damage.
If a gravity drain cannot be used, install a
condensate pump. Install the pump as close to the
indoor section as possible.
Figure 5 Recommended Condensate Trap
UNIT
2” MIN
2” MIN
484 01 3001 03

NOTE: EDM coils 3 tons and larger feature two wires
fastened between the horizontal drain pan and splash
guards, at the top of the A-coil. These are for water
management only. These wires have NO electrical
significance whatsoever. They are only for channeling
condensate from the splash guards to the drain pan in
horizontal applications. Refer to Figure 6.
Figure 6 Condensate Wires
Condensate Management Wire
(both sides)
WASTE LINE CONNECTION
If the condensate line is to be connected to a waste
(sewer) line, an open trap must be installed ahead of the
waste line to prevent escape of sewer gases
(refer to Figure 7).
4& WARNING
EXPLOSION HAZARD
Failure to provide trap could result in personal in-
jury, death, or property damage.
Provide trap with air gap in drain line when con-
necting to waste (sewer) line. Refer to Figure 6.
Figure 7 Condensate Drain to Waste Line
Air Gap Above
Liquid Level
Condensate
Line
Trap
484 01 3001 03

REFRIGERANT LINE CONNECTIONS
4& WARNING
PERSONAL INJURY HAZARD
Failure to relieve pressure in the coil could result
in personal injury.
Wear eye protection.
Coil is factory charged with 15 psi nitrogen. Pierce
the centers of both rubber tubing plugs to relieve
pressure before removing plugs.
NOTE: Factory nitrogen charge may escape past rubber
plugs during storage. This does not indicate a leaking coil
nor warrant return of the coil.
Size and install refrigerant lines according to information
provided with outdoor unit. Coil connection tube sizes are
shown in Figure 8. Route refrigerant lines to the coil ina
manner that will not obstruct service access to the unit or
removal of the filter.
1. Remove cabinet door. Remove tubing plate with
rubber grommets and slide plate with grommets
onto the refrigerant lines (field line-set), away from
braze joints.
2. Remove rubber plugs from coil stubs using a pulling
and twisting motion. Hold coil stubs steady to avoid
bending or distorting.
3. Wrap TXV and nearby tubing with a heat-sinking
material such as a wet cloth.
4. Fit refrigerant lines into coil stubs. Wrap a heat
sinking material such as a wet cloth behind braze
joints.
NOTE: See outdoor unit Installation Instructions
regarding requirements for installation of a
filter-drier in the liquid line close to the indoor coil.
5. Braze using a Sil-Fos or Phos-copper alloy.
6. After brazing, allow joints to cool. Slide tubing plate
with rubber grommets over joints. Position tubing at
center of each grommet to ensure an air seal
around the tube (refer to Figure 9).
Figure 8 Coil Connection Tube Size (inch)
Model Size Liquid Suction
18 (1% ton) % ¥%
24 (2 ton) % ¥%
30 (2% ton) % %
36 (3 ton) % %
42 (4% ton) % %
48 (4 ton) % %
60 (5 ton) % %
Figure 9 Refrigerant Lines
RUBBER
GROMMETS
TUBING PLATE
Strainer screen is factory installed inside the liquid tube
stub (TXV tube). Leave the strainer screen in place during
installation (refer to Figure 10).
Figure 10 Strainer Screen
yo Screen
TXV
A
CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Braze with Sil-Fos or Phos-copper alloy on cop-
per-to-copper joints and wrap a wet cloth around
rear of fitting to prevent damage to TXV.
484 01 3001 03

REFRIGERANT METERING DEVICE
EDM2, EDD2, EDA2 Models:
These Coils have a factory installed hard shut-off TXV
designed only for use with R-22 refrigerant. Use only with
outdoor units designed for R-22.
EDM4, EDD4, EDA4 Models:
These Coils have a factory installed hard shut-off TXV
designed only for use with R-410A refrigerant. Use only
with outdoor units designed for R-410A.
TXV is factory set and not field adjustable.
CHECK AND ADJUST AIR FLOW
A CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
This Coil has a hard shut-off TXV metering device.
Acompressor Hard Start Kit is required in all ap-
plications where the matching outdoor unit has a
single-phase reciprocating compressor.
4& WARNING
ELECTRICAL SHOCK HAZARD
Failure to shut of electric power could result in
personal injury or death.
Before adjusting blower speed, shut off electric
power to the furnace or blower module.
It is important that the correct amount of air (CFM) flows
through the coil. The installer must determine the
required CFM based on the characteristics of the specific
system (such as system size, ducting, components, and
accessories). In general, 400 CFM per ton is the nominal
required value, with a range of 350 - 450 CFM per ton.
Check Static Pressure Drop and CFM Across Coil
The amount of air (CFM) is related to a pressure drop. To
determine the CFM, measure the pressure drop using an
inclined manometer (sometimes called draft gauge or air
flow gauge).
1. The coil should be dry and clean. The air filter must
be clean and in place. All registers open. DO NOT
run the outdoor unit when checking air flow.
2. Run the blower on cooling speed.
3. Using the manometer (draft gauge or flow gauge),
measure the static pressure drop across the dry coil
and compare it to the numbers in Figure 11.
4. Find the corresponding CFM in Figure 11.
Adjusting Air Flow
If CFM is too low, increase the blower speed and measure
the static pressure drop again. Determine CFM from
Figure 11.
If CFM is too high, reduce the blower speed and measure
the static pressure drop again. Determine CFM from
Figure 11.
NOTE: Change blower speed as shown
instructions for the furnace or air handler.
in the
NOTE: It may not be possible to obtain a gauge reading
exactly the same as shown in Figure 11. This is due to
variations in duct systems and blower speeds.
If the motor is at the highest speed and the CFM is still not
high enough, replace the blower and/or motor with a
larger size.
If the unit has an adjustable belt driven blower, use an
ammeter to check the motor current draw. If the current
draw is higher than the motor name plate amps, replace
the motor with one of greater horsepower.
484 01 3001 03

Figure 11 | CFM and Pressure Drop |
CFM Static Pressure Drop Across Coil CFM Static Pressure Drop Across Coil
Coil Across (Inches Water Column) Coil Across (Inches Water Column)
Size Coil Dry Wet Size Coil Dry Wet
188 500 0.096 0.106 1200 0.129 0.137
tystons FO 0.127 0.140 40) 1300 0.148 0.159
700 0.161 0.183 1400 0.168 0.180
700 0.134 0.141 32 tons [F509 0.189 0.203
248
800 0.166 0.176 1600 0.211 0.228
2tons [399 0.200 0.215 1200 0.114 0.142
700 0.110 0.118 1300 0.130 0.161
24F 800 0.134 0.146 42L 1400 0.146 0.182
2tons [399 0.160 0.176 32 tons [F509 0.164 0.202
800 0.137 0.143 1600 0.182 0.222
30B 900 0.169 0.174 1400 0.250 0.263
2 tons | 1000 0.204 0.211 ABE 1500 0.284 0.297
1100 0.241 0.251 1600 0.320 0.336
800 0.101 0.106 4tons [7799 0.358 0.376
30F 900 0.121 0.129 1800 0.398 0.418
2 tons | 1000 0.143 0.154 1400 0.192 0.196
1100 0.168 0.181 48) 1500 0.219 0.225
1000 0.188 0.202 1600 0.245 0.253
368 1100 0,224 0.240 4tons [7799 0.273 0.283
1200 0.262 0.281 1800 0.303 0.314
Stons [73909 0.303 0.325 1400 0.180 0.193
1400 0.349 0.374 48L 1500 0.198 0.214
1000 0.133 0.139 1600 0.222 0.241
36F 1100 0.154 0.163 4tons [7799 0.247 0.270
1200 0.177 0.189 1800 0.275 0.296
Stons [7309 0.203 0.216 1700 0.260 0.285
1400 0.227 0.245 60U 1800 0.288 0.315
1000 0.104 0.106 5tons | 1900 0.316 0.346
36) 1100 0.121 0.124 2000 0.347 0.381
1200 0.139 0.144 1700 0.232 0.263
Stons [7309 0.159 0.166 60L 1800 0.256 0.291
1400 0.181 0.190 5tons | 1900 0.283 0.321
1200 0.180 0.208 2000 0.308 0.354
1300 0.201 0.231
ae tone 1400 0.228 0.275
1500 0.267 0.314
1600 0.291 0.348
8 484 01 3001 03

START-UP PROCEDURE
Refer to outdoor unit Installation Instructions for
refrigeration system start-up instructions and refrigerant
charging method details.
R-410A QUICK REFERENCE GUIDE
« R-410A refrigerant operates at 50% - 70% higher pressures than R-22. Be sure that servicing equipment and
replacement components are designed to operate with R-410A.
¢« R-410A refrigerant cylinders are rose colored.
« Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
« R-410A systems should be charged with liquid refrigerant. Use a commercial type metering device in the
manifold hose.
¢ Manifold sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard.
« Use hoses with 750 psig service pressure rating.
* Leak detectors should be designed to detect HFC refrigerant.
*« R-410A, as with other HFC refrigerants, is only compatible with POE oils.
* POE coils absorb moisture rapidly. Do not expose oil to atmosphere.
* POE coils may cause damage to certain plastics and roofing materials.
« Vacuum pumps will not remove moisture from oil.
¢ A liquid line filter-drier is required on every unit.
¢ Do not use liquid line filter-driers with rated working pressures less than 600 psig.
¢ Do not install a suction line filter-drier in liquid line.
¢ Wrap all filter-driers and service valves with wet cloth when brazing.
« Do not use with an R-22 TXV.
¢ [f indoor unit is equipped with an R-22 TXV, it must be changed to an R-410A TXV.
¢« Do not use capillary tube indoor coils.
¢« Never open system to atmosphere while it is under a vacuum.
« When system must be opened for service, break vacuum with dry nitrogen and replace all filter-driers.
¢« Do not vent R-410A into the atmosphere.
¢ Observe all WARNINGS, CAUTIONS, NOTES, and bold text.
484 01 3001 03 9