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.
!
WARNING
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.
!
WARNING
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
cleaners or other cleaning tools.
2. Soap powders, bleaches, waxes or other Cleaning compounds; plastic items or containers; gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids or other volatile fluid.
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.
5353649-UIM-A-0617
Page 2
5353649-UIM-A-0617
SECTION II: GENERAL INFORMATION
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.
Coil Access
Panel
Suction Line
Connection
Liquid Line
Connection
Label
Primary Drain
Secondary Drain
Bottom Door Panel
FIGURE 1: Component Location - Coil MC & FC
Alternate Drain Location
Drain Location
Horizontal Application
(on MC Coils Only)
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.
Location
Suction Line
Connection
Liquid Line
Connection
Coil Access
Panel
Primary Drain
Secondary Drain
Bottom Door Panel
FIGURE 2: Component Location - Coil PC
Alternate Drain Locations
Label Location
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
TABLE 1: Dimensions
BOTTOM OPENING
DIMENSIONS
1. All dimensions are in inches.
2. Refrigerant line sizes may require larger lines for extended line lengths. See Application Data part number 247077.
2. Refrigerant line sizes may require larger lines for extended line lengths. See Application Data part number 247077.
Refrigerant
Connections
3/4
7/8FC36B24-1/217-1/216-3/816-1/2
3/8
3/4
7/8
Refrigerant
Connections
3/4
3/8
2
2
7/8PC36B23-1/817-1/216-3/816-1/2
7/8
3
Page 4
5353649-UIM-A-0617
LIMITATIONS
These coils should be installed in accordance with all national and local
safety codes.
TABLE 4:
36, 37, 38
60, 62, 64
Coil Air Flow Limits
Coil
Size
181-1/2525675
24
30, 32
35
42
43
48, 49
Outdoor Unit
Tons
1-1/2525675
2700900
2700900
2-1/28751125
2-1/28751125
310501200
2-1/28751125
310501350
310501350
3-1/212251575
310501350
3-1/212251575
310501350
3-1/212251575
414001800
416001800
517502250
CFM Limits
MinimumMaximum
SECTION III: COIL METERING DEVICES
An orifice or a TXV to be installed in the field. Refer to installation manual with TXV kit. It is recommended to install the orifice or TXV kit prior
to installation of coil in cabinet and brazing line sets.
Consult the outdoor installation guide for outdoor units that require an
orifice as a metering device for the indoor coil. The orifice and the
Schraeder core are supplied with the outdoor unit. Install Schraeder
core in the suction line Schraeder body and cap with the supplied plastic cap.
Vapor
Line
Thermal
Expansion
Valve Bulb
(Wrapped with
insulation)
Liquid
Line
Thermal
Expansion
Valve
SCREW
TXV BULB
(Cover completely
with insulation)
CLAMP
FIGURE 4: Proper Bulb Location
COIL UNDER PRESSURE.
Relieve pressure by depressing schrader stem. Coil requires orifice
or TXV to be added. See outdoor unit documentation for correct orifice or TXV to be used.
NUT
!
CAUTION
SUCTION LINE
NOTICE
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.
SECTION IV: COIL INSTALLATION
DUCT FLANGES
Four flanges are provided to attach ductwork to the coil. These flanges
are rotated down for shipment. In order to use the flanges, remove the
screw holding an individual flange, rotate the flange so it is in the
upward position and reinstall the screw then repeat this for all 4 flanges.
If the flanges are not used, they must remain in the down position as
shipped.
DUCT ATTACHMENT
IF NEEDED
FACTORY
INSTALLED
TXV
Equalizer
Line
FIGURE 3: TXV Bulb Installation
4
Distributor
Body
FIGURE 5: Duct Flanges - Coils FC/MC
Page 5
Furnace
Furnace
UPFLOW
FIGURE 6: Vertical Applications with Furnaces
DOWNFLOW
For upflow or downflow applications (FC/MC Models):
These coils are factory shipped for installation in either upflow or downflow applications with a minor conversion.
1. Remove and reposition the coil duct flanges as shown in figure 5 if
needed.
2. Position the coil on the furnace opening (or the furnace on the coil
for downflow) as shown in Figure 6.
3. Place the ductwork over the coil (or furnace) duct flanges and
secure.
4. Check for air leakage between the furnace and coil casing and seal
appropriately. Three tie plates are provided with the coils. If
needed, secure the coil to the furnace using these tie plates.
5. See sections on “Refrigerant Line Connections” and “Condensate
Drain Connections” for further installation instruction.
For horizontal applications (MC models only):
MC model coils are supplied ready to be installed in a horizontal position. A horizontal drain pan is factory installed.
1. Remove and reposition the coil duct flanges as shown in figure 5 if
needed.
2. Position the coil and furnace as shown in Figure 7.
3. Place the ductwork over the coil or furnace duct flanges and
secure.
4. Check for air leakage between the furnace and coil casing and seal
appropriately. Three mounting plates are provided with the coils.
The mounting plates must be used to secure the top edges of the
furnace and coil together. See figures 7 and 8.
5. See sections on “Refrigerant Line Connections” and “Condensate
Drain Connections” for further installation instruction.
Furnace
FIGURE 7: Horizontal Right Application with Furnaces
5353649-UIM-A-0617
Furnace
FIGURE 8: Horizontal Left Application with Furnaces
FURNACE ASSEMBLY - PC
The PC coils are designed for installation on top of upflow furnaces
only.
If the coil is used with a furnace of a different size, use a 45° transition
to allow proper air distribution through the coil.
1. Remove and reposition the coil duct flanges as shown in figure 5 if
needed.
2. Position the coil casing over the furnace opening as shown in Figure 9.
3. Place the ductwork over the coil duct flange and secure.
4. Check for air leakage between the furnace and coil casing and seal
appropriately.
NOTICE
Refer to the heat pump add-on control instruction before installing an
add-on heat pump coil.
C
(Min.)
D
Flexible Duct
Collar
Field
Fabricated
Ductwork
Upflow Coil
Upflow Furnace
Primary Drain
FIGURE 9: Upflow - PC Coil Installation with Furnace
TABLE 5:
Dimension “C” should be at least 2/3 of dimension “D”. See Figure 9.
Coil Projection Dimensions - PC Coils
COIL SIZEDIMENSION “C” INCH
PC183-1/2
PC244-1/2
PC30, PC32, PC354-1/2
PC42, PC43, PC36, PC375-1/2
PC486-1/2
PC609
Secondary Drain
DO NOT Drill or
Screw this Flange
Alternate
Drain Location
5
Page 6
5353649-UIM-A-0617
CRITICAL COIL PROJECTION
The coil assembly must be located in the duct such that a minimum distance is maintained between the top of the coil and the top of the duct.
Refer to Table 5.
SECTION V: DUCT CONNECTIONS
Air supply and return may be handled in one of several ways best
suited to the installation. Upflow, horizontal or downflow applications
may be used.
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.
!
WARNING
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.
!
CAUTION
Equipment should never be operated without filters.
SECTION VI: 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.
!
CAUTION
Threaded drain connections should be hand tightened, plus no more
than 1 turn.
DO NOT use TeflonTM tape, “pipe dope”, or other sealants. The use of
a sealant may cause damage and premature failure of the drain pan.
NOTICE
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.
SUCTION FEEDER TUBE CONDENSATE
DEFLECTOR
Upflow or Downflow
No action required. See Figure 10.
Condensate
Deflector
S-Clips (3)
FIGURE 10: Condensate Deflector on Vertical Drain Pan
Horizontal Left or Right
Use an appropriate tool to pry out water deflector with two or three sclips from the vertical drain pan. See Figure 11. Relocate the deflector
with s-clips on the Horizontal Drain Pan lined up to the coil support
bracket. See Figure 12. This positions the deflector below the feeder
tubes to channel the condensate to the drain pan.
Vertical Drain Pan
NOTICE
The condensate deflector should be installed in the s-clip section
which is inside the drain pan edge. See Figure 12.
NOTICE
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.
!
CAUTION
Avoid Double Trapping.
6
Feeder
Tubes
Condensate
S-Clips on Horizontal Pan
FIGURE 11: Condensate Deflector on Horizontal Drain Pan Edge
Deflector
Page 7
5353649-UIM-A-0617
Condensate
Deflector
Drain Pan
Wall
S-Clip
FIGURE 12: S-Clip Installation
SECTION VII: REFRIGERANT LINE
CONNECTION
!
CAUTION
Coil is under inert gas pressure. Relieve pressure from coil by removing rubber plug or by depressing schrader core.
!
CAUTION
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.
Connect lines as follows:
NOTICE
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. Coil access panel should be removed
for brazing. The lines are expanded to receive the field line set
tubes.
2. Cut the end of the suction tube using a tube cutter. Place the tube
cutter as close as possible to the end of the tube to allow more
space for the connection and brazing of the suction line.
3. Wrap a water soaked rag around the coil connection tubes inside
the cabinet to avoid damaging the TXV bulb.
4. Remove grommets where tubes exit the cabinet to prevent burning
them during brazing.
5. Purge refrigerant lines with dry nitrogen.
6. Braze the suction and liquid lines.
7. Re-attach the grommets to the lines carefully to prevent air leakage.
8. Attach the coil access panel to the cabinet.
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 VIII: COIL CLEANING
If the coil needs to be cleaned, it should be washed with Calgon CalClean (mix one part CalClean to seven 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 IX: 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.
NOTICE
Table 6 below has WET coil data. Run system for approximately 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.