ICP EBX2400A1, EBX3600A1, EBX4800A1, EBX6000A1, EBXX2400A1 Installation Guide

These instructions must be read and understood

completely before attempting installation.

These instructions covers the installation of replacement
coil kit into fan coils (see Figure 1) The kit is designed to

allow easy replacement of existing slope or A-coils. A 3/4
to 5/8 inch reducing bushing is included inthe coil kit for

use on the field vapor connection tube, when necessary.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,

maintenance, or use can cause explosion, fire,
electrical shock, or other conditions which may cause

death, personal injury, or property damage. Consult a
qualified installer, service agency, or your distributor or

branch for information or assistance. The qualified
installer or agency must use factory-authorized kits or

accessories when modifying this product. Refer to the
individual instructions packaged with the kits or

accessories when installing.
Follow all safety codes. Wear safety glasses, protective

clothing, and work gloves. Use quenching cloth for
brazing operations. Have fire extinguisher available.

Read these instructions thoroughly and follow all

warnings or cautions included in literature and
attached to the unit. Consult local building codes and

National Electrical Code (NEC) for special
requirements.

Recognize safety information. This is the safety-alert

symbol/_ When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for

personal injury. Understand these signal words;
DANGER, WARNING, and CAUTION. These words

are used with the safety-alert symbol. DANGER
identifies the most serious hazards which will result in

severe personal injury or death. WARNING signifies
hazards which could result in personal injury or death.

CAUTION is used to identify unsafe practices which
would result in minor personal injury or product and

property damage. NOTE is used to highlight
suggestions which will result in enhanced installation,
reliability, or operation.

ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in

personal injury or death.
Before installing, modifying, or servicing

system, main electrical disconnect switch
must be in the OFF position. There may be

more than one disconnect switch. Lock out
and tag switch with a suitable warning label.

PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in proper-

ty damage
R-410A systems operate at higher pressures than

R-22 systems. When working with R-410A sys-
tems, use only service equipment and replace-

ment components specifically rated or approved
for R-410A service.

ELECTRICAL SHOCK HAZARD
Failure to turn off electric power could result in

personal injury or death.
Before installing or servicing system, turn off

main power to the system. There may be more than
one disconnect switch, including accessory heat-
er(s).

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DESCRIPTION AND USAGE

Figure 1 JTypical Fan Coil

The replacement coil kit is designed for use when

replacement of an existing slope of A-coil is required.
NOTE: Replacement of an indoor slope or A-coil must

include recovery and recycling of refrigerant currently in

the system. Provided the refrigerant has not been

contaminated with moisture, acid, solid particulate, or
non-condensibles, it may be recovered by following the

procedures listed below. However, if the refrigerant is
contaminated, recycling or reclaiming methods are
required. If leaks are present in the system, meaning the

refrigerant may be contaminated, recycling or reclaiming
methods MUST be used. Installation of new filter drier(s)

is required. The filter drier-type will depend up on the
contaminants in the system. See Split-System

Residential Air Conditioners and Heat Pumps Service
manuals for further information.

PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in person-

al injury or property damage
Relieve pressure and recover all refrigerant before

system repair or final unit disposal to avoid per-
sonal injury.
Use all service ports and open all flow-control
devices including the solenoid valves.

INSTALLATION

If it is determined that the system does not have leaks,

and the refrigerant is not contaminated, proceed as
follows:

1. Recover system refrigerant
a. Attach gage/manifold set to service valves.

b. Start unit in cooling mode.
c. Front seat (close) liquid line service valve.
d. Operate unit until vapor pressure reaches 5 psig

(35kPa), or until suction line LPS opens.

e. Turn off electrical supply to outdoor unit.
f. Front seat (close) vapor service valve.
g. Recover any remaining refrigerant.

NOTE: All condenser coils hold only a factory-supplied
amount of refrigerant. Excess refrigerant, such as in

long-line applications, may cause compressor internal
pressure relief valve to open (indicated by sudden rise in

vapor pressure) before refrigerant is recovered. If this
occurs, turn off electrical supply to outdoor unit

immediately, front seat (close) vapor service valve, and
recover any remaining refrigerant.

2. Turn off electrical supply to indoor unit.

3. Disconnect condensate drain line.

FIRE HAZARD
Failure to follow this warning could result in per-

sonal injury or death.
Use of torch may cause oil to catch fire. To remove

use tubing cutter only.

4. Disconnect liquid and vapor lines from indoor coil.
Use a tubing cutter to cut the lines.

5. Remove coil access panel.

6. Remove clip securing fitting panel to condensate
drain pan and remove fitting panel.

7. Remove all shipping clips (if present), including
horizontal pan clip. Slide coil and condensate pan

assembly out of unit.

8. Remove horizontal condensate drain pan from coil (if
present) and condensate pan assembly. (See Fig. 2.)

9. Remove 4 coil brackets if present. (See Fig. 2.)

10. Remove screws at delta plates and remove coil from

vertical condensate drain pan. (See Fig. 2.)

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11. Thermostatic Expansion Valve (TXV) units only-To

use original TXV with new coil, remove TXV from original
coil and install onto new coil as follows:

a. If TXV has a sweat joint on the valve outlet, unbraze

sweat joint as shown in Fig. 3.

(1.) Remove equalizer tube. Use file to score and break

off tube at old coil suction header, or unbraze.

Remove bulb from old coil. The TXV should now be

completely separated from old coil.

(2.) Install TXV onto new coil. Remove liquid line fitting

tube from new coil, and remove piston from piston
body. Use tubing cutters to cut off elbow. (See Fig. 4.)

(3.) Braze remaining tube and nut onto TXV outlet. (See

Fig. 5.)

(4.) Install resulting TXV/nut assembly onto new coil in

same location as on old coil.

(5.) Install equalizer tube onto new coil by scoring

extension tube near brazed tip of tube, and sliding
equalizer tube into extension tube. Braze equalizer

tube to extension tube. (See Fig. 6.)

(6.) Install thermal bulb into suction header of new coil in

10 o'clock or 2 o'clock position.

b. If valve has a mechanical joint at valve outlet, use

wrenches to separate valve outlet from old coil.

(1.) Remove equalizer tube. Use file to score and break

off tube at old coil suction header, or unbraze.

Remove bulb from old coil. The TXV should now be

completely separated from old coil.

(2.) Install TXV onto new coil. Remove liquid line fitting

tube from new coil using wrenches. Remove piston.

Install valve onto new coil using wrenches. If TXV

outlet is flare type, use adapter tube provided.

(3.) Install equalizer tube onto new coil by scoring

extension tube near brazed tip of tube, and sliding
equalizer tube into extension tube. Braze equalizer

tube to extension tube.

(4.) Install thermal bulb into suction header of new coil in

10 o'clock or 2 o'clock position.

c. If replacement coil has a mechanical connection with

no piston body, install TXV to flare nut or new coil.

(1.) Remove equalizer tube. Use file to score and break

off tube at old suction header, or braze. Remove bulb
from old coil.

(2.) Install TXV onto new coil. Install valve onto new coil

onto coil using wrenches.

(3.) Install equalizer tube onto new coil by scoring and

breaking extension tube near brazed tip of tube. Slide
equalizer tube into extension tube and braze
connection.

(4.) Install thermal bulb onto suction header of new coil in

10 o'clock or 2 o'clock position.

12. Horizontal Applications Only--Remove coil top seal
(attached with 4 screws) and J-shaped tube from original

coil, and install them in same position on new coil. (See
Fig. 2.)

13. Place coil assembly in plastic condensate pan and

secure with 4 screws through delta plate. (See Fig. 2.)

14. Horizontal and Upflow Applications Only--Attach 4
coil brackets to coil and pan assembly. (See Fig. 2.)

15. Horizontal Applications Only--Place horizontal
condensate pan into position on coil and pan assembly.

NOTE: Installation of horizontal condensate pan is not
necessary for upflow or downflow applications.

16. Slide completed assembly into unit.

17. Reinstall fitting panel and reconnect clip securing

fitting panel to condensate drain pan.

18. Horizontal Applications Only--Reinstall horizontal
pan clip and secure with 1 screw. (See Fig. 2.)

19. Reinstall coil access panel.

20. Reconnect liquid and vapor refrigerant lines and
condensate drain line. Install new filter drier(s).

NOTE: If a torch is used to unbraze the line set, protect

the fitting panel with a wet cloth or braze shield as

necessary.

21. Evacuate line set and indoor coil to 500 microns, back

seat (open) liquid and vapor service valves.

22. Turn on electrical supplies to indoor and outdoor
units.

23. Check system refrigerant charge and operation. See
Split- System Residential Air Conditioners and Heat

Pump Service Manuals for further information.

UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit

damage
When securing braces or supports to unit, select

a location where drill and fasteners will not con-
tact refrigeration components.

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