Lennox CH35 Series - User Manual

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Page 1

THIS MANUAL MUST BE LEFT WITH THE

HOMEOWNER FOR FUTURE REFERENCE

WARNING

Improper installation, adjustment, alteration, service or

maintenance can cause personal injury, loss of life, or

damage to property.

Installation and service must be performed by a licensed

professional installer (or equivalent) or a service agency.

WARNING

Risk of explosion or fire.

Can cause injury or death.

Recover all refrigerant to relieve pressure before

opening the system.

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.

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.

INSTALLATION

INSTRUCTIONS

CH35 Series Units

INDOOR COILS WITH ALL-ALUMINUM COIL

507656-01

7/2018

NOTE - Not available in all areas. Contact your nearest

Lennox Sales Office for details.

Table of Contents

General 1......................................

Shipping and Packing List 1......................

Specifications 2.................................

Releasing Air Charge 3..........................

Installation 3....................................

Refrigerant Line Connections 5...................

Leak Testing, Evacuating and Charging 6..........

Sealing Ducts 6.................................

Condensate Drain Connection 6..................

Blower Speed Connection 7......................

Maintenance 8..................................

General

CH35 all-aluminum coil horizontal evaporator coils are

designed for use with air conditioners and heat pumps.

Each coil is equipped with a compression fitting that

provides convenient field installation of a properly sized,

separately ordered expansion valve.

The coil drain pan is high quality engineering polymer with

a maximum service temperature of 500°F. However,

adequate space must be provided between the drain pan

and furnace heat exchanger. At least 2" space is required

for heat exchanger and 4" for drum-type or oil-fired furnace

heat exchanger. Closer spacing may damage the drain

pan and cause leaking.

Refer to the CH35 Product Specification bulletin (EHB) for

proper use of these coils with specific furnaces, air

conditioners, heat pumps and line sets.

These instructions are intended as a general guide and do

not supersede local or national codes in any way. Consult

authorities who have jurisdiction before installation.

IMPORTANT: Special procedures are required for

cleaning the aluminum coil in this unit. See page 8 in this

instruction for information.

Shipping and Packing List

Package 1 of 1 contains the following:

1 - CH35 evaporator coil

Check the components for shipping damage. If you find

any damage, immediately contact the last carrier.

Main Page

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Summary

Installation Instructions

General Coil Information

Overview of the CH35 all-aluminum coil and its application with AC/heat pumps.

Shipping and Packing List

Details package contents and checks for shipping damage.

Technical Specifications

Lists technical specifications for the CH35 series indoor coils.

Safety and Preparation

Covers safety warnings and initial preparation steps like releasing air charge.

Model Number Identification

Unit Type and Series Explanation

Explains the unit type (Indoor Coil - Horizontal) and series designation.

Nominal Cooling Capacity Tonnage

Details the cooling capacity tonnage represented by model number digits.

Cabinet and Metering Device Codes

Explains cabinet width designations and metering device types.

Refrigerant and Installation Steps

Releasing Air Charge Procedure

Safely releases the factory air charge from the coil.

Coil Mounting and Orientation

Instructions for mounting the coil and its orientation for airflow.

Duct and Coil Connections

Supply Duct Securing

Secures the supply duct to the coil cabinet.

System Leak Testing

Refers to outdoor unit instructions for leak testing procedures.

D-Width Coil with C-Width Furnace

Application notes for specific coil and furnace width combinations.

Refrigerant Line Connections

Line Set Sizing Recommendations

Guidance on sizing refrigerant line sets according to outdoor unit instructions.

Suction Line Brazing Procedure

Step-by-step instructions for brazing the suction line connection.

Liquid Line Orifice Replacement

Procedure for removing the factory orifice and installing an expansion valve.

Condensate Drain and Duct System

Condensate Drain Best Practices

Recommended practices for optimal condensate removal.

Duct System Sizing

Importance of properly sizing and installing duct systems.

Drainage and Airflow Measurement

Main and Overflow Drain Line Setup

Diagrams and instructions for typical main and overflow drain installations.

Static Pressure Test Procedure

Instructions for measuring static pressure to ensure proper airflow.

Maintenance and Coil Cleaning

Air Volume and Static Pressure Table

Table relating air volumes, static pressure drop, and cabinet width.

Coil Cleaning Procedure

Step-by-step guide for cleaning the aluminum coil using recommended methods.

This document provides installation and maintenance instructions for CH35 Series Indoor Coils with All-Aluminum Coils, specifically model number 507656-01, dated July 2018.

Function Description:

The CH35 all-aluminum coil horizontal evaporator coils are designed for use with air conditioners and heat pumps. Each coil is equipped with a compression fitting for convenient field installation of a properly sized, separately ordered expansion valve. These coils are intended to be installed adjacent to a furnace or air handler, forming part of a complete HVAC system. They facilitate the heat exchange process in cooling and heating cycles, removing heat and humidity from the indoor air.

Important Technical Specifications:

The CH35 series offers a range of nominal cooling capacities from 1.5 tons to 5 tons.

Line Connections: Suction/Vapor o.d. sweat connections are typically 3/4 inch for 1.5 to 3.5 ton units and 7/8 inch for 3.5 to 5 ton units. Liquid o.d. sweat connections are consistently 3/8 inch across all models.
Condensate Drain: All models feature a 3/4 inch female pipe thread (fpt) condensate drain connection.
Evaporator Coil:
- Net face area varies by model, ranging from 1.75 sq. ft. (1.5 ton) to 7.94 sq. ft. (5 ton).
- Tube diameter is 3/8 inch for all models.
- Number of rows varies from 2 to 3.
- Fins per inch (FPI) ranges from 12 to 19, depending on the specific model.
Cabinet Width: Available in multiple designations: A (14-1/2 in.), B (17-1/2 in.), C (21 in.), and D (24-1/2 in.). These widths are designed to physically match corresponding furnace cabinet widths.
Coil and Furnace Height: Ranges from 14-1/2 inches to 24-1/2 inches.
Shipping Data: Weight per package ranges from 43 lbs (1.5 ton) to 78 lbs (5 ton).
Drain Pan: The coil drain pan is made of high-quality engineering polymer with a maximum service temperature of 500°F.
Air Charge: The coil is shipped from the factory pressurized with a 10 + 3 psig dry air holding charge.

Usage Features:

Installation Flexibility: The coils can be installed in left-hand or right-hand air discharge configurations. For right-hand air discharge with a field-provided spacer, a minimum of 6 inches is recommended for proper installation.
Slope Requirement: The coil must have a 1/2 inch slope from the rear of the cabinet to the drain to ensure proper condensate removal. When connected directly to a condensing furnace, the coil can be level from the return end to the supply end, with the front (access side) pitched downward up to 1 inch to accommodate a 1/2-inch pitched coil.
Metering Device: The CH35 is shipped with a factory-installed refrigerant metering orifice. This orifice must be removed and replaced with a properly sized expansion valve (field-provided and installed) before making liquid line connections.
Refrigerant Line Connections: Brazing guidelines are provided, emphasizing the use of wet rags or heat shields to prevent heat damage to the unit cabinet and piping during connections.
Condensate Drain Connections: Main and overflow drain lines should not be smaller than the drain connections at the drain pan. Overflow drain lines should run to an area where drainage will be noticed by the homeowner. It is recommended that overflow drain lines be vented and a trap installed, adhering to local codes. For negative pressure coils (blower after coil), traps are required on all drain lines connected to the coil.
Duct Sealing: Ducts must be secured and all joints properly sealed to the coil cabinet flanges to ensure an airtight seal between the furnace and the return air plenum.
Blower Speed Connection: Proper air volume over the evaporator coil is crucial. A blower motor speed tap should be selected to provide 400 ± 50 CFM per 12,000 Btuh of cooling capacity (wet coil). Static pressure readings are taken to verify proper airflow.

Maintenance Features:

Coil Cleaning: The coil should be inspected twice a year and cleaned at least once a year or more, if necessary, by a licensed professional service technician.
Cleaning Procedure:
1. Turn off all power to the indoor unit.
2. Wear protective gear (safety glasses, face shield, waterproof clothing, gloves).
3. Remove the coil from the indoor unit cabinet and take it to a suitable cleaning area.
4. Vacuum or brush the coil to remove matted and surface debris from the fins, using attachments that will not damage the fins.
5. Use only clean potable water at moderate pressure (less than 50 psi) to clean the coil, spraying at a vertical angle of 30 to 45 degrees. Avoid spraying from a horizontal direction.
6. Direct the spray to wash debris out of the coil and basepan. Hot water is generally not necessary for residential units.
7. For units in coastal regions, fresh water should be used to wash coils at least every six months to dissolve salt deposits and prevent corrosive buildup.
Chemical Cleaners: Aluminum coils can be damaged by solutions with a pH below 5 or above 9. If water alone is insufficient, Lennox recommends using a coil cleaner with a pH in the range of 5 to 9. The coil must be rinsed thoroughly after cleaning. Hydrofluoric acid, alkaline, or similar chemicals are not recommended as they can damage the fin coating and increase corrosion.
Reassembly: After cleaning, replace the coil into the cabinet or plenum, ensuring proper routing and securing of refrigerant tubing. Distributor lines must not rub together or be kinked, with adequate clearance from other metal parts. Wire ties should be used to secure tubes and prevent movement.