Lennox 507167-02 C35 / CX35 Series Coils Indoor Coil 2 Ton Instruction Manual

INSTALLATION INSTRUCTIONS
C35 / CX35 Series Coils
INDOOR COILS
507167-02 (0655942-13)THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE

507167-02 C35 / CX35 Series Coils Indoor Coil 2 Ton

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.
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: Special procedures are required for cleaning the aluminum coil in this unit. See page  7 in this instruction for information.

General Information

The CX35 upflow evaporator coils are available cased only. The C35 coil is available cased or uncased and includes a factory-installed HFC-410A fixed orifice (RFC) metering device that must be replaced if the system match with the coil requires a field-installed check/expansion valve.
The CX35 coil includes an externally equalized factory-installed HFC-410A check/expansion valve.
The coil drain pan has a maximum service temperature of 500°F. The drain pan must be at least 2″ away from a standard gas-fired furnace heat exchanger and at least 4″ away from any drum-type or oil-fired furnace heat exchanger. Closer spacing may damage the drain pan and cause a leak.
Refer to the Product Specification bulletin (EHB) for the proper use of these coils with specific furnaces, air handlers and line sets.
These instructions are intended as a general guide and do not supersede local or national codes in any way. Authorities who have jurisdiction should be consulted before installation.

**Shipping and Packing List

**

Package 1 of 1 contains:
C35
1 – Evaporator coil
1 – Patch plate with nameplate label (uncased coils only)
1 – Metering device label (uncased coils only)
CX35
1 – Evaporator coil
Check the components for shipping damage; if found, immediately contact the last carrier.

Model Number Identification

C35 Optional Adjustable Coil Adapter / Seal Applications

ADJUSTABLE COIL ADAPTOR/SEAL DIMENSIONS — inches

ADJUSTABLE COIL ADAPTOR/SEAL DETAIL

Releasing Air Charge

CAUTION
The coil is shipped from the factory pressurized with dry air. Pierce a hole in the rubber plug that seals the vapor line to relieve the pressure before removing the plugs.
NOTE – If there is no pressure released when the vapor line rubber plug is pierced, check the coil for leaks before continuing with the installation.
The C35 and CX35 coils are shipped with a 10 + 3 psi dry air holding charge. Puncture the suction line rubber plug to release the charge. Remove the rubber plug. Ensure that the coil is void of pressure.

Installation

WARNING
Risk of explosion or fire.
Can cause injury or death.
Recover all refrigerant to relieve pressure before opening the system.
Install the furnace or air handler according to the installation instructions provided with the unit.
Position the cased coil on top of the furnace or air handler cabinet and secure it using field-provided screws.
NOTE – If the coil is to be installed on an oil furnace, it may be necessary to install a field-installed transition between the furnace and the coil to prevent airflow restriction and possible damage to the coil drain pan. See the oil furnace installation instructions for details.
NOTE – The coil cabinet has six screw clearance holes which should be aligned with the furnace engagement holes. Secure the coil cabinet to the furnace or air handler using six field-provided #8 X 1″ screws.

Refrigerant Line Connections

LINE SIZES
The refrigerant line sets should be sized according to the recommendations given in the air conditioner unit installation instructions. Use either table 1 or 2 to determine correct braze connection sizes. A field-provided adapter may be required to match line set connections.
Table 1. Refrigerant Line Connections – Model C35

18/24-2F
24-2F
30-2F
30/36-2F
36-2F| 3/4 Inch| 3/8 Inch
48-2F
49-2F
50/60-2F
60-2F| 7/8 Inch

Table 2. Refrigerant Line Connections – Model CX35

18/24-6F
24-6F
30-6F
30/36-6F
36-6F| 3/4 Inch| 3/8 Inch
48-6F
49-6F
50/60-6F
60-6F| 7/8 Inch

REPLACEMENT PARTS
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

BRAZING GUIDELINES
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).
Before making brazed connections, place a field-provided heat shield, such as a wet rag, against the unit cabinet and around the piping stubs, expansion valve and sensing bulb. The heat shield must be in place to prevent heat damage during brazing. See figure 2.

SUCTION LINE CONNECTION
Use the following procedure to connect the suction line to the indoor coil:

1. Remove rubber plug from the stubbed connection.
2. Position the properly sized refrigerant piping and make the brazed connection following the brazing guidelines.
3. Do not remove the water-saturated rags from the cabinet and piping until the piping has cooled completely.

C35 Suction Line Equalizer Fitting
Remove the copper flare seat bonnet if present from the male equalizer line fitting (see figure 3).
IMPORTANT
When removing the flare nut, ensure that the copper flare seal bonnet is removed as illustrated in figure 3.

C35 LIQUID LINE CONNECTION
NOTE – C35 coils are shipped with a factory-installed HFC-410A fixed orifice (RFC) metering device. Some system  matches with this coil require use of a check/expansion valve.
If the system match requires an HFC-410A check/expansion valve, the factory- installed refrigerant metering orifice must be removed and a check/expansion valve field-installed before the liquid line connections are made. The fixed orifice device must be removed BEFORE a check/expansion valve is installed if necessary. CX35 coils include a factory-installed HFC-410A check/expansion valve.
C35 Fixed Orifice Removal (If necessary)

1. Remove the coil access and plumbing panels.
2. Remove any shipping clamps that secure the liquid line and distributor assembly.
3. Using two wrenches, disconnect the liquid line stub from the orifice housing. Take care not to twist or damage the distributor tubes during this process.
4. Remove and discard the existing orifice, valve stem assembly (if present) and Teflon ring as illustrated in figure 4.
5. Retain brass nut to be used later with the liquid line assembly.

C35 Expansion Valve / Liquid Line Installation
Some system matches for the C35 coil require a check/expansion valve. The expansion valve must be installed external to the indoor coil cabinet. Refer to the instructions provided with the expansion valve kit for proper installation of the valve and sensing bulb. See the C35 Product Specification bulletin (EHB) for approved expansion valve match-ups and application information.

1. After the expansion valve, equalizer line and sensing bulb have been installed per the kit instructions, braze the properly sized refrigerant piping into place. Carefully follow brazing guidelines and use wet rags to prevent heat damage.
2. Do not remove the water-saturated rags from the cabinet and piping until the piping has cooled completely.

NOTE – To prevent any possibility of water damage, properly insulate all parts of the expansion valve assembly that may sweat due to temperature differences between the valve and its surrounding ambient temperatures.
CX35 LIQUID LINE CONNECTION
CX35 coils include a factory-installed HFC-410A check/ expansion valve metering device.
Connect the properly sized field-provided liquid line to the liquid line stub as shown in figure 5 using one of the following procedures:

1. Position the properly sized refrigerant piping and make the brazed connection following the brazing guidelines.
2. Do not remove the water-saturated rags from the cabinet and piping until the piping has cooled completely.

OR

1. Cut the copper liquid line on a vertical or horizontal section. Use a field-provided coupling to join the properly sized field-provided refrigerant piping and and the liquid line stub on the coil. Follow the brazing guidelines.
2. Do not remove the water-saturated rags from the cabinet and piping until the piping has cooled completely.

Leak Testing, Evacuating and Charging
Refer to the outdoor unit instruction for leak testing, evacuating and charging procedures.
Always leak check entire system before charging.
Sealing Ducts
WARNING
There must be an airtight seal between the bottom of the furnace and the return air plenum. Use fiberglass 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 the air handler or any gas-fueled appliance (i.e., water heater), or carbon monoxide-producing device (i.e., wood fireplace) is installed.
The coil cabinet MUST be sealed after installation to ensure against air leaks, which can impact system performance. The material, and method, used should be capable of enduring the range of temperature and humidity levels expected in the specific install location.
Ensure that the duct is secured and all joints are properly sealed to the coil cabinet flanges.
Condensate Drain Connections
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.
MAIN DRAIN
Connect the main drain and route drain tubing downward to drain line or sump. Do not connect drain to a closed waste system. See figure 6 for typical drain trap configuration.
OVERFLOW DRAIN
It is recommended that the overflow drain stub be connected to an overflow drain line for all units. If the overflow drain is not connected to a drain line, it must be plugged with the provided cap.
CONDENSATE DRAIN RECOMMENDATIONS
The following practices are recommended to ensure better condensate removal:

• Main and overflow drain lines should NOT be smaller than both drain connections at drain pan.
• Overflow drain line should run to an area where homeowner will notice drainage.
• It is recommended that the overflow drain line be vented and a trap installed. Refer to local codes.

Blower Speed Selection

CAUTION
Take care when drilling test holes into the furnace flange and the duct. Drill holes away from refrigerant piping. Test holes should be drilled where specified in order to avoid unit damage.
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 drop falls within the proper range.
To ensure accuracy, air must be read from below the coil and above the coil. See figure 7 for an example to obtain an accurate reading.

1. Drill one 5/16″ air test hole into the delta plate between the coil slabs.
2. Drill one 5/16″ air test hole into the duct above the top of the coil.
3. Connect the instrument for static pressure measurement hoses to the air entering side of coil. Insert the hoses so that 1/4″ extends inside the duct or end seal. Seal around holes with Permagum®.
4. Turn on electrical power to the furnace and set the thermostat to initiate a cooling demand.
5. Tables 3 and 4 list air volumes and equivalent static pressure readings for these units. Observe the static pressure reading. If the reading is below the required air volume, increase the blower speed; if the reading is above the required air volume, decrease the blower speed. Refer to the furnace wiring diagram for blower speed settings.
6. When the required static pressure readings are obtained, remove the test hose lines and insert snap hole plugs into test holes.

Table 3. Air Volume / Static Pressure Drop Across Coil – Model C35

Table 4. Air Volume / Static Pressure Drop Across Coil – Model CX35

Maintenance

NOTICE!
Failure to follow instructions will cause damage to the unit.
This unit is equipped with an aluminum coil. Aluminum coils may be damaged by exposure to solutions with a pH below 5 or above 9. The aluminum coil should be cleaned using potable water at a moderate pressure (less than 50psi). If the coil cannot be cleaned using water alone, Lennox recommends use of a coil cleaner with a pH in the range of 5 to 9. The coil must be rinsed thoroughly after cleaning.
In coastal areas, the coil should be cleaned with potable water several times per year to avoid corrosive buildup (salt).
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 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.
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 fins. Use vacuum attachments and /or brushes that are nondestructive to fins.

3. If oil deposits are present, spray the coil with a mild household liquid detergent to soften deposits. Do not leave the detergent on the coil for more than 10 minutes. Flush the coil thoroughly with potable water.
   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 base pan. 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.

IMPORTANT
Ensure that the distributor lines are not rubbing together or kinked. All tubes must have enough clearance from other metal parts. Use wire ties to secure tubes to prevent movement that could cause the refrigerant tubing to fail.

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