LENNOX Evaporator Coils Manual L0806274

User Manual: LENNOX LENNOX Evaporator Coils Manual LENNOX Evaporator Coils Owner's Manual, LENNOX Evaporator Coils installation guides

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®
,t_2007 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
WARNING
INSTALLATION
INSTRUCTIONS
CH33 Series Units
EVAPORATOR COILS
505,264M (65484504)
10/07
Supersedes 09/06
_puTeCh ical
n
blications
Litho U.S.A.
CH33 Series Coils ............................. 1
General ...................................... 1
Shipping and Packing List ...................... 1
Releasing Air Charge .......................... 2
Unit Installation ............................... 2
Refrigerant Line Set ........................... 3
Connections .................................. 4
Refrigerant Metering Device .................... 4
Leak Testing, Evacuating and Charging .......... 6
Blower Speed Connection ...................... 6
Condensate Drain Connection .................. 7
Maintenance .................................. 7
WARNING
CAUTION
CH33 horizontal evaporator coils are designed for use with
air conditioner or heat pump units. Each coil is equipped
with a compression fitting that provides convenient field
installation of a refrigerant metering device. Either a
refrigerant metering orifice (factory installed in coils and
provided with some Lennox air conditioner units) or a
thermostatic expansion valve (ordered separately) may be
used in air conditioner unit applications. A check
expansion valve (ordered separately) is the only metering
device approved for use in heat pump applications.
Refer to the CH33 Engineering Handbook for proper use of
these coils with Lennox furnaces, air conditioner units,
heat pumps and line sets.
IMPORTANT
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.
Package 1 of 1 contains the following:
1 -- CH33 evaporator coil
Check the components for shipping damage. If you find
any damage, immediately contact the last carrier.
10/07
[[IHHI[IIIII[HI[[III[IIIH[[II[[III Page 1 505,264M (65484504)
[III[IHHIIII[IH[IHI[IIH[[IImHI[[III
Table 1. Orifice Size Shipped with CH33
Model Number. Orifice Size
CH33-18A-2F 0.053
CH33-19A-2F 0.053
CH33-24/30A-2F 0.062
CH33-25A-2F 0.062
CH33-25B-2F 0.062
CH33-31A-2F 0.071
CH33-31 B-2F 0.071
CH33-36A-2F 0.076
CH33-36B-2F 0.076
CH33-36C-2F 0.076
CH33-42B-2F 0.082
CH33-43B-2F 0.082
CH33-43C-2F 0.082
CH33-44/48-2F 0.082
CH33-48C-2F 0.091
CH33-49C-2F 0.091
CH33-50/60C-2F 0.091
CH33-60D-2F 0.099
CH33-62D-2F 0.099
1, Install the furnace per the installation instructions
provided with the unit.
2, Place a field-provided heat shield, such as a wet rag,
against the piping plate and around the piping stubs,
and sweat in the suction line. The heat shield must be
in place to guard against heat damage to the paint.
NOTE -In areas of high humidity, the suction line section in
the air stream in the cabinet should be insulated with foam
tape. See figure 1.
FOAM
TAPE
CAUTION
The CH33 coil are shipped with a 15+ 3 psi dry air holding
charge. Ensure that the coil is void of pressure by
performing the following procedure:
aWARNING I
1. Remove valve stem cap,
2, Press the liquid line valve stem,
NOTE -If there is no pressure when the valve core is
pressed, check the coil for leaks before continuing with the
installation,
Page 2
505264M 10/07
Figure 1. Discharge End of Coil
3, Left-Hand and Right-Hand Discharge--The coil
must have a 1/2" slope from the rear of the cabinet
to the drain. Position the coil adjacent to the furnace
cabinet and align the six screw clearance holes in the
coil casing with the furnace engagement holes. Use
six field-provided #8 X 1" screws to secure the coil
casing to the furnace (see figures 2 and 3),
4, Right-Hand Air Discharge with Field-Provided
Spacer--The coil must have a 1/2" slope from the
rear of the cabinet to the drain. Position the coil in
the left-to-right configuration connection on the
service access side of the furnace (see figure 4).
Position the field-provided spacer between the
furnace and the coil. Use field-provided screws to
secure the coil casing, spacer and the furnace
together. The spacer should be long enough to allow
room for proper installation (approximately six inches
minimum).
NOTE: When the coil is connected directly with a
condensing furnace, the coil must be level from return end
to supply end. The front (access side) of the furnace may
be pitched down up to one-inch to accommodate a 1/2"
pitched coil.
5, Secure the supply duct to the coil cabinet,
6, Refer to the instructions provided with the condensing
unit for leak testing, evacuating and charging
procedures. Always check the entire system for
leaks before charging.
7, Applications using CH33-62 "D" width unit with
"C" width furnace--Figure 5 shows an application
that includes a "D" width coil and a "C" width furnace.
This application requires an insulated, field-supplied
block-off plate be constructed to cover the open space
on the coil housing,
Supply Test Hole Supply Air Unit Rear
Coil _ "Air Unit
Back
Front
Slope 112"
(13 mm) Coil
_ Drain
_l (Supply Air End View) 90% Gas
Furnace Drain Plumbing
Connections
Supply Air Unit Front
Figure 2. Left-Hand Air Discharge
Supply Air Unit Rear Plumbinq Connections Supply Air Unit _. [' Coil
Supply Air b
Unit Front
Supply Air Unit Front
Slope 1/2"
II T/ i
Test Hole
NOTE -Use of this orientation is acceptable for 80% AFUE
furnaces. Do not use this orientation for 90% condensing furnaces.
(Supply Air End View)
Figure 3. Right-Hand Air Discharge
Test Hole
Coil
Front
Drain
Supply Air Unit Rear
iiiiiiiiiiiiiiii!!!!!!!!!!!!!!!!!_i!iii!i_iil;!i
.....
\/
Supply Air Unit Front
Field-fabricated
insulated
block-of[ plate
Supply Air
Unit Rear
Plumbing Connections
Spacer
(6 in. 152 mm min.)
Figure 4. Right-Hand Air Discharge with Spacer
Sealing Ducts - Ensure ducts are secured and all joints
Test
Hole
Plumbing
Connections
properly sealed to either the coil cabinet flanges or the
furnace cabinet flanges.
IMPORTANT
SupplyAir
Unit Front
Figure 5. "D" Width Coil wl"C" Width Furnace
Leak Testing, Evacuating,Charging - Refer to the
instructions provided with the outdoor unit for leak testing,
evacuating and charging procedures. Always leak check
entire system before charging.
The refrigerant line sets should be sized according to the
recommendations given in the outdoor unit installation
instructions. See table 1 for sweat connection sizes. A
field-provided adapter may be required to match line set
connections.
Page 3
CH33 SERIES
Table . Refrigerant Line Connections
CH33 Model
-18-F
-19-F
-24/30-F
-25-F
-31-F
-36-F
-42-F
-43-F
-44/48-F
-48-F
-49-F
-50/60-F
-60-F
-62-F
Suction (Vapor) Liquid
Line Sweat Size -
314 Inch (19mm)
Line Sweat Size -
7/8 Inch (22mm)
Line Sweat Size -
3/8 Inch (9.5mm)
If replacement parts are necessary, order kit 69J46. The kit
includes:
•10 -- Brass nuts for liquid line assemblies
• 20 -- Teflon rings
• 10 -- Liquid line orifice housings
• 10 -- Liquid line assemblies
PISTON
LIQUID LINE ORIFICE HOUSINGS (10)
/TEFLON RINGS (20) _/RETAINER
!/BRASS NUTS (I0)
"_ _ _11111_1 L_ _ STRAINER
L,QU,DUNEASSEMBL,ES" O%ER
(INCLUDES STRAINER) (10) LIQUID LINE
ASSEMBLY
Figure 6. 69J46 Kit Components
Use a silver alloy brazing rod (5 or 6 percent silver alloy for
copper-to-copper connections or 45 percent silver alloy for
copper-to-brass or copper-to-steel connections).
BRAZE SUCTION/VAPOR LINE
Use the following procedure to connect the vapor line to
the indoor coil unit:
1. Remove rubber plug.
2. Place a field-provided heat shield, such as a wet rag,
against the piping plate and around the piping stubs,
and sweat in the suction line. The heat shield must be
in place to protect the paint from heat damage.
3. Braze connection.
4. Remove the heat shield after brazing and allow the
connections to cool.
CONNECT LIQUID LINE
Use the following procedure to connect the liquid line to the
indoor coil unit:
1. Slide the liquid line compression nut onto the provided
liquid line fitting (the liquid line fitting comes attached
to the front of the delta plate of the uncased coils).
2. Insert the field-supplied liquid line into the liquid line
stub for brazing.
The CH33 coils are shipped with a factory-installed fixed
orifice, CH33 coils are compatible with either HFC-410A
fixed orifice or TXV/CTXV metering devices.
The previously reference TXV/CTXV metering devices will
be referred to in this instruction as TXV,
DETERMINING CORRECT FIXED ORIFICE
A properly sized fixed orifice may be provided with the
outdoor unit. Refer to the outdoor unit instruction to ensure
proper sizing of the refrigerant flow control orifice. An
improperly sized RFC orifice can lead to diminished
capacities and/or efficiencies, as well as potential damage
to the unit, RFCs shipped with the units are identified in
table 1.
I/2TURN
Figure 7. Tightening Distance
TYPICAL FIXED ORIFICE REMOVAL PROCEDURE
1. On fully cased coils, remove the coil access and
plumbing panels.
2. Remove any shipping clamps holding the liquid line
and distributor assembly.
3. Using two wrenches, disconnect liquid line from
distributor. Take care not to twist or damage distributor
tubes during this process.
4. Remove and discard orifice, valve stem assembly if
present and Teflon ring as illustrated in figure 8.
5. Retain brass nut to be using later with the liquid line
assembly.
505264M 10/07
Page 4
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
TEFLON RING REMOVE AND DISCARD
ORIFICE VALVE STEM ASSEMBLY
(IF PRESENT)
BRASS NUT
/
VALVE STEM
VALVE STEM CAP
LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
(Uncased Coil Shown)
Figure 8. Typical Fixed Orifice Removal
TYPICAL FIXED ORIFICE INSTALLATION
PROCEDURE
1. Ensure that the orifice is installed with the nylon seat
pointing toward the liquid line orifice housing,
2. Insert the Teflon ring securely into the liquid line orifice
housing. Lightly lubricate the threads of the liquid line
orifice housing and the expose surface of the Teflon
ring,
3. Connect the liquid line assembly with the brass nut to
the liquid line orifice housing. Finger tighten and use an
appropriately sized wrench to turn an additional 1/2
turn clockwise as illustrated in figure 7, or 20 ftqb,
4. Place the supplied fixed orifice sticker on the indoor
cabinet after installation.
\
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
TEFLON RING
ORIFICE
J BRASS NUT
/
LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
(Uncased Coil Shown
Figure 9. Typical Fixed Orifice Installation
TYPICAL TXV INSTALLATION PROCEDURE
The TXV unit can be installed internal or external to the
indoor coil. In applications where an uncased coil is being
installed in a field-provided plenum, install the TXV in a
manner that will provide access for field servicing of the
TXV, Refer to figure 10 for reference during installation of
TXV unit,
TWO PIECE
PATCH PLATE
dNCASED COIL
)ISTRIBUTOR
TUBES
(Uncased Coil Shown)
LIQUID LINE
ORIFICE STUB END
HOUSING TXV
RING
SENSING
LINE
MALE EQUALIZER LINE
FITTING (SEE FIGURE
12 FOR FURTHER
DETAILS)
Sensing bulb insulation is
required if mounted external to
the coil casing. See figure 11 for
bulb positioning.
Figure 10. Typical TXV Installation
LIQUID
LINE
Figure 11. TXV Sensing Bulb Installation
1. Insert one of the provided Teflon rings into the stubbed
end of the TXV. Lightly lubricate the threads of the
stubbed end of the TXV and the expose surface of the
Teflon ring.
2. Attach the stubbed end of the TXV to the liquid line
orifice housing, Finger tighten and use an appropriately
sized wrench to turn an additional 1/2 turn clockwise
as illustrated in figure 7, or 20 ft-lb,
3. Place the remaining Teflon ring around the other end
of the TXV and lightly lubricate the threads of the that
end of the TXV, and the expose surface of the Teflon
ring,
Page 5
CH33 SERIES
4, Attach the liquid line assembly with brass nut to the
TXV. Finger tighten and use an appropriately sized
wrench to turn an additional 1/2 turn clockwise as
illustrated in figure 7, or 20 if-lb.
5, Attach the sensing bulb of the TXV in the proper
orientation as illustrated in figure 11 to the suction line
using the clamp and screws provided in the TXV kit.
6, Connect the equalizer line from the TXV to the
equalizer suction port on the suction line. Finger
tighten the flare nut plus 1/8 turn (7 ft-lbs) as illustrated
in figure 7,
AIMPORTANT
FLARE SEAL ,miD,, [ "_'1 r 1
CAP
I
I
]
[_ _ FLARE NUT
COPPER
OR ._ FLARESEAL
BONNET
_I (REMOVE)
I
,R SSE? ,ZER
SUCTION/VAPOR LINE
Figure 12. Copper Flare Seal Bonnet Removal
NOTE -To prevent any possibility of water damage,
properly insulate all parts of the TXV assembly that may
sweat due to temperature differences between the valve
and its surrounding ambient temperatures.
See the CH33 Engineering Handbook for approved TXV
match-ups and application information. Typically, the TXV
kits include the following:
1 -- TXV
2 -- Teflon rings
1 -- 1 1/4" wide copper mounting strap for sensing bulb
2 -- #10 hex head bolts and nuts for securing sensing bulb
AND NUTS (2)
@ TEFLON %/'/
RINGS (2) /%
COPPER
MOUNTING
STRAP (1)
Figure 13. TXV Kit Components
Refer to the outdoor unit instruction for leak testing,
evacuating and charging procedures, Always leak check
entire system before charging,
Proper air volume must be provided over the evaporator
coil. Select a blower motor speed tap that will provide 400 _+
50 CFM per 12,000 Btuh of cooling capacity (wet coil).
A static pressure reading must be taken to see if the
pressure drops are within the proper range. See figure 14
to see for an example to obtain an accurate reading.
Left-HandAir Discharge(TopView)
TEST HOLE 1 Supply Air Unit Rear
AIR
TEST
HOLE 2 Supply Air Unit Front
AIR
RETURN
DUCT
)
Figure 14. Static Pressure Test
To ensure accuracy, test the air on both sides of the coil
(figure 14 exemplifies the two test hole locations).
CAUTION
Table 2. Air Volume/Static Pressure Drop
Across Coil
Model Cabinet Volume: Drop: in. w.g. (Pa)
CH33 Width in (mm) CFM (L/s) [Dry] [Wet]
-18-F 14-1/2 (394) 600 (285) .14 (35) .17 (42)
-19-F 14-1/2 (394) 800 (380) .15 (37) .17 (42)
-25-F 14-1/2 (394) 800 (380) .15 (37) .19 (47)
-25-F 17-1/2 (444) 800 (380) .09 (22) .11 (27)
-24/30-F 14-1/2 (394) 1000 (470) .22 (55) .30 (80)
-31-F 14-1/2 (394) 1000 (470) .24 (60) .27 (67)
-31-F 17-1/2 (444) 1000 (470) .14 (35) .16 (40)
-36-F 14-1/2 (394) 1200 (565) .27 (67) .30 (75)
-36-F 17-1/2 (444) 1200 (565) .17 (42) .21 (52)
-36-F 21 (533) 1200 (565) .17 (42) .21 (52)
-42-F 17-1/2 (444) 1400 (660) .22 (55) .28 (70)
-43-F 14-1/2 (394) 1400 (660) .26 (65) .31 (77)
-43-F 17-1/2 (444) 1400 (660) .18 (45) .21 (52)
-44/48-F 17-1/2 (444) 1400 (660) .18 (45) .23 (57)
-48-F 21 (533) 1600 (755) .17 (42) .21 (52)
49-F 21 (533) 1600 (755) .25 (62) .29 (72)
-50/60-F 21 (533) 1600 (755) .23 (57) .29 (72)
-60/62-F 24-1/2 (622) 2000 (945) .21 (52) .27 (67)
505264M 10/07
Page 6
1, Drilla5/16"(8mm)testholeinthecoilcase1"from
thefurnaceflange(figure14,testhole1).
2. Drilla5/16"(8mm)testholeintotheairsupplyduct
connectedto thecoil.(testhole2infigure14),
3, Connectthezero end of the draft gauge scale to the
furnace end of the coil. Insert the hoses so that 1/4" (6
mm) extends inside the duct or end seal, Seal around
holes with Permagum.
4, Turn on the electrical power to the furnace and set the
thermostat to initiate a cooling demand.
5, Table 2 lists the range of air volumes and equivalent
draft gauge readings for this unit. Observe the draft
gauge reading and if below the required air volume,
increase the blower speed; if above the required air
volume, decrease the blower speed. Refer to the
furnace wiring diagram for blower speed settings.
6. When the required draft gauge readings are obtained,
remove the draft gauge lines and insert snaphole
plugs into the test holes,
3. If the auxiliary drain line is to be used, remove the plug
and route the drain line so that water draining from the
outlet will be easily noticed by the homeowner.
4. After removal of drain pan plugs, check the drain port
to see if holes have been drilled. If not drilled, use a
19/32" bit to drill out the primary drain hole; use a 3/8"
drill bit for the secondary drain hole. Remove all drill
shavings.
5. Make sure drain ports and drain pan are free of all
debris.
6. Plug and check any unused drain pan openings for
tightness. Torque plugs to 30 in. lb. to prevent water
leaks or seepage from the drain pan.
XkIMPORTANT
IMPORTANT
Vent must extend above the height of the coil
drain pan by 2 inches (51 mm). VENT
DRAIN PAN
Trap must be deep enough to offset k k _
maximum static difference (Generally, _v_
2 inches [51ram]). TRAP
Drain line should slope a minimum (49P66) _,
1 inch per 10 feet (25 mm per 3 m) TO APPROVED DRAIN
Figure 15. Typical Condensate Drain Connection
CH33 evaporator coils have both main and auxiliary drain
connections, The auxiliary drain removes accumulated
condensate if the main drain becomes plugged,
1, Install a trap in both drain lines per local codes. Ifa vent
tee is required to reduce friction and static pressure,
the trap should be installed between the unit outlet and
the vent tee. See figure 15,
2. Make drain connections at the 3/4" female threaded
pipe using condensate lines of the same size. Pitch the
main drain line down to an open drain or sump,
A trained technician or service agency must perform
maintenance and service on equipment. At the beginning
of each heating or cooling season, indoor coils should be
cleaned.
Do not use hydrofluoric acid, alkaline, or similar chemicals
on all coils. These chemicals are not necessary to dissolve
salt, and may damage the fin coating. Acid washes are
used to dissolve oils and greases, which generally are not
present on most installations.
Alkaline washes are useful for dissolving oxides such as
zinc oxide, aluminum oxide, and iron oxide (rust). These
three oxides are more corrosion resistant than base
metals, so dissolving or removing them will cause an
increase in corrosion.
Xk CAUTION
Page 7
CH33 SERIES
CLEANING THE COIL:
1, Remove the coil from the cabinet or plenum, and take
the coil to an appropriate place to clean it,
2, Vacuum or brush the coil to remove matted and
surface debris from the fin. Use vacuum attachments
and/or brushes that are non-destructive to fins,
3, If oil deposits are present, spray the coil with ordinary
household liquid detergent, Allow detergent to soften
deposits, Wait 10 minutes,
NOTE -For units in coastal regions, fresh water will
dissolve away any salt deposits. (Wash coils with fresh
water at least every six months.)
4, Spray the coil at a vertical angle of 30 to 45 degrees
with a constant stream of water at moderate pressure.
A pressure washer with a fan nozzle will work best, Do
not spray the coil from a horizontal direction,
5, Direct the spray so that any debris is washed out of the
coil and basepan, For most residential units, hot water
is not necessary,
NOTE -Attempting to back flush from the inside of the coil
will require removing parts from the unit, and it may be very
difficult to flush the whole coil surface. Attempting to blow
water through a coil will slow the water stream and reduce
the flushing action of the outer fin surface.
6, Replace the coil into the cabinet or plenum. Ensure
that you have followed the proper procedure for
routing and securing the refrigerant tubing,
AIMPORTANT
505264M 10/07
Page 8

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