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HD SERIES HORIZONTAL DUCT COILS FOR
ISO 9001
Certified Quality
Management System
INSTALLATION MANUAL
COIL
TXV - BULB
TXV
COOLING/HEAT PUMPS
FIELD INSTALLED TXV - FLEX COILS
MODELS: HD
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
COIL METERING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DUCT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
CONDENSATE DRAIN CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . 4
LIST OF FIGURES
Component Location - HD Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Coil - HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Proper Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Horizontal Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
LIST OF TABLES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Coil Air Flow Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury
CAUTION indicated a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to alert
against unsafe practices and hazards involving only property damage.
.
.
REFRIGERANT LINE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . .4
COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
AIR SYSTEM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INSTALLATION VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Drain Pan Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TXV Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Drain Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Air Flow Data - Static Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . .4
The furnace area must not be used as a broom closet or for any other
storage purposes, as a fire hazard may be created. Never store items
such as the following on, near or in contact with the furnace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
2. Soap powders, bleaches, waxes or other Cleaning com-
3. Paint thinners and other painting compounds.
4. Paper bags, boxes or other paper products
Never operate the furnace with the blower door removed. To do so
could result in serious personal injury and/or equipment damage.
cleaners or other cleaning tools.
pounds; plastic items or containers; gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids or other volatile fluid.
SECTION II: GENERAL INFORMATION
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance
can cause injury or property damage. Refer to this manual for assistance or additional information, consult a qualified installer or service
agency.
This product must be installed in strict compliance with the enclosed
installation instructions and any applicable local, state, and national
codes including, but not limited to building, electrical, and mechanical
codes.
This instruction covers the installation of the following coils with 80+ or
90+ AFUE furnaces or MA/MX/MV air moving systems.
The coils have sweat connect fittings. All coils are shipped with a low
psi nitrogen holding charge.
FIGURE 1: Component Location - HD Coil
900590-UIM-B-0613
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900590-UIM-B-0613
1-3/4
D
5-5/8
A
B
C
3-3/4
2-5/8
1-3/8
OPENING
FOR
VAPOR
CONN.
OPENING
FOR
LIQUID
CONN.
OPENING
FOR
3/4 NPT
SECONDARY
DRAIN CONN.
OPENING
FOR
3/4 NPT
PRIMARY
DRAIN CONN.
7/8
1-7/8
4-1/8
1-3/8
OUTLET SAME
SIZE AS INLET
(3/4” FLANGE)
NOTICE
INSPECTION
As soon as a coil is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage
should be noted on the carrier’s delivery receipt. A separate request for
inspection by the carrier’s agent should be made in writing. See Local
Distributor for more information. Check drain pan for cracks or breakage.
CLEARANCES
During Installation
Clearance must be provided for:
1. Refrigerant piping and connections
2. Maintenance and servicing access - including cleaning the coil
3. Condensate drain line
4. Filter removal / change
5. Removal of coil assembly
FIGURE 2: Coil - HD
TABLE 1:
Dimensions
Models
Height Width Opening Widths Line Size
ABCDLiquidVapor
HD24S 24 28-3/4 21-5/8 23-3/4
HD36S 28 28-3/4 25-5/8 23-3/4
HD60S 30 34-3/4 27-5/8 29-3/4
1. All dimensions are in inches.
2. Refrigerant line sizes may require larger lines for extended line lengths. See Application Data part number 247077.
LIMITATIONS
These coils should be installed in accordance with all national and local
safety codes. Check Tables 2, 3, and 4 for operating limitations.
TABLE 2:
2
Coil Air Flow Limits
Coil
Size
24
36
48
60
Outdoor Unit
Tons
CFM Limits
Minimum Maximum
1 350 450
1-1/2 525 675
2 700 900
2 700 900
2-1/2 875 1125
3 1050 1250
3 1050 1250
3-1/2 1225 1575
4 1400 1750
4 1400 1750
5 1750 2200
Dimensions
1
Refrigerant Connections
3/4
3/8
7/8HD48S 28 34-3/4 25-5/8 29-3/4
SECTION III: COIL METERING DEVICES
The coil will require a TXV to be installed in the field. Refer to installation manual with TXV kit. It is recommended to install the TXV kit prior
to installation of coil and brazing line sets.
TXV METERING DEVICE
Please refer to Tables 1 and 2 to verify proper and recommended line
set sizes and that this is a valid system match for the AC or HP unit
installed.
The temperature sensing bulb should be attached to the suction line
set. Refer to Figure 3.
For models that have factory installed TXV’s, take caution not to apply
high temperatures to the TXV assembly or equalizer line while brazing.
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FIGURE 3: Proper Bulb Location
TXV BULB
(Cover completely
with insulation)
SCREW
CLAMP
NUT
SUCTION HEADER
SUCTION LINE
(FIELD INSTALLED)
NOTICE
AIR
FLOW
SUPPLY
DUCTWORK
FLEXIBLE
CONNECTIONS
MINIMUM 45°
TRANSITION
AIR FLOW
COIL
DUCTWORK
DETAIL “A”
DUCTWORK
DRAIN PAN
EXTENSION
“S” CLIP
FASTENERS
(3)
COIL FLANGES
FOR DUCTWORK
FASTENING
DRAIN PAN
COIL UNDER PRESSURE.
Relieve pressure by depressing schrader core. Coil may have factory
installed TXV or may require TXV to be added. See outdoor unit documentation for correct TXV to be used. Refer to coil nameplate for
TXV identification for this unit.
The coil should be open to the air for no more than 2 minutes to keep
moisture and contaminates from entering the system. If the coil cannot be brazed into the refrigeration system in that time, the ends
should be temporarily closed or plugged. For a short term delay, use
masking tape over the ends of the copper tubing to close the tube to
the air. For a longer term delay, use plugs or caps. There is no need
to purge the coil if this procedure is followed.
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COIL INSTALLATION
These horizontal coils are designed for installation with a horizontal
(gas or oil fired) furnace or modular blower. A minimum 45° transition
must be field fabricated to allow proper air distribution through the coil.
Airflow direction must be as shown in Figure 4.
Connect ductwork/transition only to coil duct flanges. DO NOT drill
holes in coil cabinet.
FIGURE 4: Horizontal Coil Installation
DRAIN PAN EXTENSION INSTALLATION
These coils are shipped with a drain pan extension fastened to the air
leaving side duct flanges. Drain pan extension must be removed.
coil and refasten the extension to the air leaving side of the coil drain
pan as shown in Figure 5, before completing ductwork. The extension
will extend into the duct work as shown.
Install
FIGURE 5: Drain Pan Extension Installation
SECTION IV: DUCT CONNECTIONS
This coil is suited for horizontal applications only.
The vast majority of problems encountered with combination heating
and cooling systems can be linked to improperly designed or installed
duct systems. It is therefore highly important to the success of an installation that the duct system be properly designed and installed.
Use flexible duct collars to minimize the transmission of vibration/noise
into the conditioned space.
Use 1/2" screws to connect ductwork to unit. If pilot holes are drilled,
drill only through field duct and unit flange.
Where return air duct is short, or where sound may to be a problem,
sound absorbing glass fiber should be used inside the duct. Insulation
of duct work is a must where it runs through an unheated space during
the heating season or through an uncooled space during the cooling
season. The use of a vapor barrier is recommended to prevent absorption of moisture from the surrounding air into the insulation. The supply
air duct should be properly sized by use of a transition to match unit
opening. All ducts should be suspended using flexible hangers and
never fastened directly to the structure. Duct work should be fabricated
and installed in accordance with local and/or national codes. This
includes the standards of the National Fire Protection Association for
Installation of Air Conditioning and Ventilating Systems, NFPA No. 90B.
Equipment should never be operated without filters.
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900590-UIM-B-0613
NOTICE
NOTICE
NOTICE
NOTICE
SECTION V: CONDENSATE DRAIN
CONNECTIONS
All drain lines should be pitched away from unit drain pan and should be
no smaller than the coil drain connection.
Route the drain line so that it doesn’t interfere with accessibility to the
coil, furnace, air handling system or filter and will not be exposed to
freezing temperatures.
Instruct the owner that the evaporator coil drain pan should be
inspected and cleaned regularly to prevent odors and assure proper
drainage.
When the coil is installed in an attic or above a finished ceiling, an
auxiliary drain pan must be provided under the coil as is specified by
most local building codes.
Coils should be installed level or pitched slightly toward the drain end.
Suggested pitch should not exceed 1/4-inch per foot of coil.
If the coil is provided with a secondary drain it should be piped to a location that will give the occupant a visual warning that the primary drain is
clogged. If the secondary drain is not used it must be capped.
Avoid Double Trapping.
Threaded drain connections should be hand tightened, plus no more
than 1 turn.
DO NOT
sealant may cause damage and premature failure of the drain pan.
use TeflonTM tape, “pipe dope”, or other sealants. The use of a
If the coil is installed in a draw-thru application (modular air handler),
it is recommended to trap the primary and secondary drain line. If the
secondary drain line is not used, it must be capped.
Connect lines as follows:
Route the refrigerant lines to the coil in a manner that will not obstruct
service access to the coil, air handling system, furnace flue or filter.
1. Suction and liquid line connections are made outside the cabinet.
Leave the tubing connection panel attached to the cabinet with the
tubes protruding through it. The lines are swedged to receive the
field line set tubes.
2. Wrap a water soaked rag around the coil connection tubes.
3. Remove grommets where tubes exit the cabinet to prevent burning
them during brazing.
4. Purge refrigerant lines with dry nitrogen.
5. Braze the suction and liquid lines.
6. Re-attach the grommets to the lines carefully to prevent air leakage.
7. Install the TXV Bulb to the suction line set, Figure 3 and wrap with
insulation.
Refer to Outdoor unit Installation Manual for evacuation, leak check and
charging instructions.
Lines should be sound isolated by using appropriate hangers or strapping.
All evaporator coil connections are copper-to-copper and should be
brazed with a phosphorous-copper alloy material such as Silfos-5 or
equivalent. DO NOT use soft solder.
SECTION VII: COIL CLEANING
If the coil needs to be cleaned, it should be washed with Calgon CalClean (mix one part CalClean to ten parts water). Allow solution to
remain on coil for 30 minutes before rinsing with clean water. Solution
should not be permitted to come in contact with painted surfaces.
SECTION VIII: AIR SYSTEM ADJUSTMENT
To check the CFM, measure the static pressure drop across the coil
using a portable manometer and static pressure tips. To prepare coil for
static pressure drop measurements - the system should have been
recently operational in cooling mode.
SECTION VI: REFRIGERANT LINE
CONNECTION
Coil is under inert gas pressure. Relieve pressure from coil by
depressing schrader core.
Dry nitrogen should always be supplied through the tubing while it is
being brazed, because the temperature required is high enough to
cause oxidation of the copper unless an inert atmosphere is provided.
The flow of dry nitrogen should continue until the joint has cooled.
Always use a pressure regulator and safety valve to insure that only
low pressure dry nitrogen is introduced into the tubing. Only a small
flow is necessary to displace air and prevent oxidation.
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Table 4 below has WET coil data. Run system for approximat ely 15
minutes in cooling mode prior to taking measurements.
Drill 2 holes, one 3" after the coil (before any elbows in the ductwork)
and one 3” before the coil. Insert the pressure tips and read the pressure drop from the manometer. See Table 4 to determine the air flow,
and make the necessary adjustments to keep the CFM within the air
flow limitations of the coil.
TABLE 3:
Air Flow Data - St atic Pressure Drop
HD Coil
Size
24 360 560 760 960 1160
36 1025 1150 1275 1400 1525
48 1200 1367 1533 1700 1867
60 1449 1664 1879 2093 2308
CFM @ Static Pressure Drop - IWG
(Based on wet coil)
0.10 0.15 0.20 0.25 0.30
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SECTION IX: INSTALLATION
Was the coil still under pressure when received?
Depress schrader
core to check for
pressure one time.
Is coil metering device installed correctly?
Was the correct TXV installed per the outdoor unit instructions?
Is the TXV Bulb positioned correctly?
Is Bulb Insulated?
Is Equalizer Line connected?
SECONDARY
PRIMARY
3” MIN
Were the primary and secondary
drains trapped correctly?
VERIFICATION
900590-UIM-B-0613
FIGURE 7: TXV Check List
FIGURE 6: Pressure Check
FIGURE 8: Drain Traps
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NOTES
Subject to change without notice. Published in U.S.A. 900590-UIM-B-0613
Copyright © 2013 by Johnson Controls, Inc. All rights reserved. Supersedes: 900590-UIM-A-1012
*900590
York International Corp.
5005 York Drive
Norman, OK 73069
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