INSTALLATION INSTRUCTIONS Evaporator Coil

INSTALLATION INSTRUCTIONSEvaporator CoilThese instructions must be read before any installation.WARNINGYour safety and the safety of others are very important.We have provided many important safety messages inthis manual and on your appliance. Always read andobey all safety messages.This is the safety alert symbol.This symbol alerts you to potential hazards that can killor hurt you and others.All safety messages will follow the safety alert symboland signal word. These signal words mean the following:DANGERYou can be killed or seriously injuredif you don’t immediately followinstructions.WARNINGIndicate a potentially hazardoussituation, which, if not avoided, couldresult in death or serious injury.CAUTIONIndicates a potentially hazardoussituation, which, if not avoided, mayresult in minor or moderate injury.Caution may also be used to alertagainst unsafe practices.NOTICEIndicates a statement of companypolicy as the message relates directlyor indirectly to the safety of personnelor protection of property.IMPORTANTMore detailed information concerningthe statement of company policyas the message relates directly orindirectly to the safety of personnel orprotection of property.Manufactured ByAllied Air Enterprises LLCA Lennox International, Inc. Company215 Metropolitan DriveWest Columbia, SC 2917040228K016*65821003*All safety messages will tell you what the potentialhazard is, tell you how to reduce the chance of injury,and tell you what can happen if the instructions are notfollowed.65821003Save these instructions for future reference65821003 / 40228K016Issue 1810Page 1 of 6

GeneralEvaporator coils are designed for use with AC condensingunits or heat pump units. These instructions are intendedas a general guide and do not supersede local codes inany way. Consult with local authorities having jurisdictionbefore installation. This installation must comply with alllocal and state laws as well as national electrical codes forthe U.S. or Canada where applicable.Verify the efficiency performance requirements, suchas SEER, EER, and/or HSPF, are appropriate with thematched condensing or heat pump units. Check outdoorunit manufacturer for proper line sizing.WARNINGBefore performing maintenance operations on system,turn off all main power switches to indoor and outdoorunits. Turn off accessory heater power switch, ifapplicable. Electrical shock could cause personal injuryor death.Air LeakageAll indoor cabinets MUST be taped after installation to sealagainst any air leaks. System performance and efficiencywill be reduced if air leakage exists.Air FiltersWARNINGCoils are shipped with a 10 psi dry air holding charge.Puncture rubber plug on suction line to release chargebefore removing plugs. The absence of pressure doesnot verify a leak. Check the coil for leaks before installingor returning it to your wholesaler.Properly-sized air filters MUST be installed on all return airducts. If air filters are not used or maintained regularly asrequired, equipment damage can occur, system capacityand efficiency will be reduced and the warranty coveragemay be void.Filter DryerInspection of ShipmentA new filter dryer MUST be installed on all systems. Thefilter dryer is typically shipped with the outdoor unit; if not,add one. Do not install more than one filter dryer in thesystem; it can reduce the system capacity and efficiency.Before installation, inspect the coil for any shippingdamage. Notify the carrier or the distributor of any damagedequipment; do not install a damaged coil.Metering DeviceInstallationWARNINGInstallation and servicing of air conditioning equipmentcan be hazardous due to internal refrigerant pressureand live electrical components. Only trained andqualified service personnel should install or servicethis equipment. Installation and service performed byunqualified persons can result in property damage,personal injury, or death.Page 2 of 6The indoor coils are shipped with either a piston orexpansion valve (TXV) based on the coil model. Theselection of the metering device type and size must followthe outdoor unit technical specification and the AHRI listing.PistonsThe piston shipped with the indoor coil may not be thecorrect size for the outdoor unit being installed. Theoutdoor unit specification gives the correct size and thecorrect piston is usually shipped with the outdoor unit.To replace the piston with another piston, perform thefollowing procedure:1.Loosen the piston housing hex nut on coil liquid tube.Use TWO wrenches to avoid damage to the distributortubes.2.Replace the existing piston with the new piston3.Always use a new Teflon O-ring4.Re-assemble the housing and torque to 10-20 ft-lbusing TWO wrenchesIssue 181065821003 / 40228K016

Figure 1. Changing an OrificeExpansion Valves (TXV)Factory shipped coils with installed TXV are available. TXVkits are also available to convert a piston-shipped coil toa TXV coil; the kit part number is specific to the outdoormodel (see the outdoor unit technical specification).For proper TXV installation, follow the installationinstruction provided with the TXV kit in addition to thefollowing procedure:1.Loosen the piston housing hex nut on coil liquid tube.Use TWO wrenches to avoid damage to the distributortubes.Figure 2. Metering Device InstallationRefrigerant Line Sets Line set size must be selected per the outdoor unitinstructions Brazed connections MUST be purged with nitrogenduring brazing Service valves MUST be wrapped with wet rag duringbrazing Line sets MUST be sealed at all times until brazed toprevent contaminantsSuction line MUST be insulated2.Replace the existing piston with the new TXV3.Always use a new Teflon O-ring4.Re-assemble the housing and torque to 10-20 ft-lbusing TWO wrenches 5.Connect the external equalizer tube to the equalizerport on the suction line and tighten to 8 ft-lb6.Attach the TXV bulb at the 10 to 2 o’clock position onthe suction line outside the cabinet no more than onefoot from the coil7.Insulate the bulbAfter brazing and before releasing/adding charge intothe system, the system MUST be evacuated to at least500 microns with a refrigeration vacuum pump. Afterevacuation, shut off the pump and monitor the vacuumgauge to ensure that the system is holding the vacuum.When it is time to release the charge from the outdoor unitinto the system, always slowly open the suction servicevalve first before opening the liquid service valve.System VacuumFigure 3. Condensate Drain65821003 / 40228K016Issue 1810Page 3 of 6

System ChargingThe system MUST be charged per the outdoor unitinstallation instructions. Remove auxiliary (horizontal) drain pans from the coilcabinet for upflow installationWARNINGCondensate DrainCoils are equipped with multiple drain connections.Determine the drain connections to be used and note thedifference between the primary (green) and secondary(red) openings. Drain plugs are provided for all openings;remove and discard the appropriate plugs with 1/2” driveratchet and verify that remaining plugs are tight (2.5 ft-lbs).Attach drain line to pan with 3/4” male pipe thread PVCfittings. Hand tight is adequate - do not over tighten anddo not reduce drain line size. Apply foil face tape around the entire cabinet to preventair leaks and insulate the suction lineDownflow InstallationAir FlowFURNACERoute drain line(s) so they will not be exposed to freezingtemperatures and do not interfere with accessibility tothe coil, air handling system or filter. The drain should bepitched downward 1” per 10” with a 2” trap as close tothe coil as possible. If line makes a second trap, or hasan extended run before termination, a vent tee should beinstalled after the trap closest to the pan. See Figure 3.The drain pan is made of material that can withstand450 F. However, the clearance between the furnace andthe drain pan must be 4 inches for an oil furnace or 2inches for a gas furnace.If the coil is located in or above a living space wheredamage may result from condensate overflow, a separate3/4” drain must be provided from the secondary drainconnection. Run this drain to a place in compliance withlocal installation codes where it will be noticed when unitis operational. Condensate flowing from the secondarydrain indicates a plugged primary drain. Prime the trapwith water. Test line for leaks. Test water flow with unit inoperation. An auxiliary drain pan should also be installedunder the unit as specified by most local building codes.Upflow InstallationRemoveHorizontalDrain PanRemoveHorizontalDrain PanFigure 5. Downflow Installation When the indoor coil is installed with a furnace unit, itis highly recommended to use the same width coil asthe furnace Install coil with slight slope towards the drain connection Remove auxiliary (horizontal) drain pans from the coilcabinet for downflow installation Airflow face velocity above 350 ft/min is notrecommended due to potential for water blow-offFURNACEWARNINGWater shields must be installed on all downflowapplications on the inside of the drain pan on both sidesof the coil (downflow kit).Air FlowFigure 4. Upflow Installation When the indoor coil is installed with a furnace unit, itis highly recommended to use the same width coil asthe furnaceInstall coil with slight slope towards the drain connectionPage 4 of 6IMPORTANTUse foil face tape to secure the top edge of the coilinsulation to the cabinet to prevent delamination and airflow blockage.Issue 181065821003 / 40228K016

Apply foil face tape around the entire cabinet toprevent air leaks Install splash guard at the coil outlet as shown(included with horizontal coils) Air flow should be set for 350 CFM per ton or as ratedfor the matched systemEvaporator CoilAir FlowFigure 7. Horizontal Left InstallationWaterShieldsAir FlowFigure 6. Water Shield InstallationHorizontal Installation For installation above ceilings, a secondary drainpan with overflow switch must be installed and mustcomply with local codes When the indoor coil is installed with a furnace unit, itis highly recommended to use the same width coil asthe furnace Install coil with slight slope towards the drainconnection and level with the furnace Do not remove auxiliary (horizontal) drain pans fromthe coil cabinet. Position the drain pan according to thehorizontal position installation (right or left position). Itis most preferred and most efficient that the outlet ofthe furnace be facing the bottom of the coil instead ofthe top of the coil4Figure 8. Horizontal Right InstallationHorizontal Conversion (Right or Left)See Figure 10 Remove front panels (1) and slide coil outside thecabinet Remove horizontal pan (3) and re-install on theopposite side Remove top plate (4) and reverse the position of thediverter plate (5) as shown. This will allow the water toslope downwards towards the middle of the coil insidethe horizontal drain pan6Note: Access panel mayneed to be notchedto allow access tosuction header2&951107811123Figure 10. Horizontal Conversion65821003 / 40228K016Issue 1810Page 5 of 6