International comfort products END4X Instruction Manual

484 01 3600 00 April 2010
INSTALLATION INSTRUCTIONS
Cased N Coil, Upflow−Downflow
END4X, ENW4X
NOTE: Read the entire instruction manual before starting
the installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1........................
INTRODUCTION 2...................................
INSTALLATION 2....................................
Airflow 2...........................................
TXV 2.............................................
Inspect Equipment 2................................
Select Installation Procedure 2.......................
Installation of Furnace Coils 3........................
Connect Refrigerant Piping 5.........................
Connect Refrigerant Liquid and Suction Lines 5.........
Refrigerant Metering Device 5........................
Condensate Drain Line Connection 5..................
Waste Line Connection 6............................
Humidifier Application 6..............................
Model Number Identification 7........................
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 warning or cautions
included in literature and attached to the unit. Consult local
building codes and the current editions of the National
Electrical Code (NEC) NFPA 70.
In Canada, refer to the current editions of the Canadian
Electrical Code CSA C22.1.
Recognize safety information. When you see this symbol
on the unit and in instructions or manuals, be alert to the
potential for personal injury. Understand the signal words
DANGER, WARNING, CAUTION, and NOTE. 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 may 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.
IMPORTANT: Nitrogen can leak out through the hole that
the needle pierced in the plugs. This does not indicate a
leaking coil nor warrant return of the coil.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying or servicing system, always
turn off main power to system. There may be more than
one disconnect switch. Lock out and tag switch with a
suitable warning label.
!WARNING
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal
injury.
This coil contains Nitrogen precharge of 15 PSIG.
Release of this pressure through the center of the
rubber plugs is required before removing the plugs.
CAUTION
!
ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental
pollution.
Remove and recycle all components or materials (i.e.
oil, refrigerant, etc.) before unit final disposal.
CAUTION
!
CUT HAZARD
Failure to follow this caution may result in personal
injury.
Sheet metal parts may have sharp edges or burrs. Use
care and wear appropriate protective clothing and
gloves when handling parts.
CAUTION
!

2484 01 3600 00
INTRODUCTION
Use this instruction manual to install indoor coils on upflow
or downflow furnaces. Do not install coil in horizontal
position. Coils are enclosed in a painted casing have
factory−installed TXV’s. These coils are used with R−410A
refrigerant systems.
NOTE: Models with tin−plated copper coils, “T” in the 8th
position of the model number, are installed the same as
standard copper coils.
INSTALLATION
These units can be installed in multiple configurations.
Before installation, there are several performance
requirements that must be considered because poor
installation can negatively alter performance. This section
will briefly discuss those factors.
Airflow
Airflow amount and distribution are vital to adequate system
performance. Problems that can be experienced with
incorrect airflow include:
Slow system performance
Srestricted TXV
Sfrosted coil
Spoor humidity control
Swater blow−off
When attaching the coil and building the plenum, pay
special attention to the effect these details will have on
airflow. After system start−up, check the cfm to insure that it
is correct. (Generally, the cfm should be 350 to 400 cfm/ton
during normal cooling operation.)
TXV
A thermal expansion valve is utilized in this coil design to
optimize performance and comfort throughout the entire
operating range of the system. Special attention needs to be
taken to the TXV when installing the coil
SDo not overheat valve. Temperatures that exceed 212_F
(100_C) can harm valve performance. Use a wet cloth or
heat sink when brazing.
SPlace liquid filter dryer near ID unit to reduce the risk of
debris clogging the valve.
SMake sure TXV bulb is securely fastened and wrapped in
the indentation on vapor line tube.
END4X, ENW4X coils have a factory−installed hard−shutoff
TXV designed only for use with R−410A refrigerant. Use
only with outdoor units designed for R−410A.
NOTE: All TXV’S have preset superheat settings and are
not field−adjustable.
Cabinet Sweating
If this unit is installed in a garage, attic, or other
unconditioned space, special attention needs to be given to
the potential of cabinet sweating. A 6−in (152 mm) wide
piece of insulation should be wrapped around the coil
casing and supply duct connection point.
Inspect Equipment
File claim with shipper if equipment is damaged.
Select Installation Procedure
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property
damage.
Installing coils rotated 90_from the front of the furnace,
in upflow or downflow applications, may cause water
blow−off or coil freeze−up due to the concentration of air
on one slab of the coil or lack of air to a slab in the coil.
It is recommended that on this type of application, a
field−supplied adapter be placed between the coil and
furnace to allow air to distribute properly between all
slabs of the coil.
CAUTION
!
NOTE: Furnace coils are not approved to be used in fan
coil or “draw−through” type applications.
To install cased coils in upflow applications, follow the
instructions below, Upflow Cased Coil Installation.
To install cased coils in downflow applications, follow the
instructions below, Downflow Cased Coil Installation.
See Table 1 for dimensions and overhang options. Refer to
instructions for placement of coil casing on furnace.

484 01 3600 00 3
Table 1 END4X, ENW4X COIL INFORMATION
MODEL NUMBER TONS
FLUSH FIT TO
FURNACE WIDTH
inches (mm)
COIL CONNECTION
TUBE SIZE
inches (mm)
SHELF WIDTH
(See Figure 1,
Dim. A)
inches (mm)
FITS NEXT SMALLER FURNACE
Equal
Overhang
Overhang with
Transition Offset Left
Liquid Suction
END4X18(C,T)14A 1-1/2 14-3/16 (360) 3/8 5/8 12-7/8 (327) N/A N/A N/A
END4X19(C,T)17A 1-1/2 17-1/2 (445) 3/8 5/8 16-3/16 (411) No Yes Yes
END4X24(C,T)14A 2 14-3/16 (360) 3/8 5/8 12-7/8 (327) N/A N/A N/A
END4X24(C,T)17A 2 17-1/2 (445) 3/8 5/8 16-3/16 (411) No Yes Yes
END4X30(C,T)14A 2-1/2 14-3/16 (360) 3/8 3/4 12-7/8 (327) N/A N/A N/A
END4X30(C,T)17A 2-1/2 17-1/2 (445) 3/8 3/4 16-3/16 (411) No Yes Yes
END4X31(C,T)17A 2-1/2 17-1/2 (445) 3/8 3/4 16-3/16 (411) No Yes Yes
END4X36(C,T)17A 3 17-1/2 (445) 3/8 3/4 16-3/16 (411) No Yes Yes
END4X36(C,T)21A 3 21 (533) 3/8 3/4 19-5/8 (498) No Yes Yes
END4X37(C,T)17A 3 17-1/2 (445) 3/8 3/4 16-3/16 (411) Yes No No
END4X42(C,T)17A 3-1/2 17-1/2 (445) 3/8 7/8 16-3/16 (411) No Yes Yes
END4X42(C,T)21A 3-1/2 21 (533) 3/8 7/8 19-5/8 (498) No Yes Yes
END4X43(C,T)24A 3-1/2 24-1/2 (622) 3/8 7/8 23-1/8 (587) No Yes Yes
END4X48(C,T)21A 4 21 (533) 3/8 7/8 19-5/8 (498) No Yes Yes
END4X48(C,T)24A 4 24-1/2 (622) 3/8 7/8 23-1/8 (587) No Yes Yes
END4X60(C,T)24A 5 24-1/2 (622) 3/8 7/8 23-1/8 (587) No Yes Yes
END4X61(C,T)24A 5 24-1/2 (622) 3/8 7/8 23-1/8 (587) No Yes No
ENW4X36(C,T)17A 3 17-1/2 (445) 3/8 3/4 16-3/16 (411) Yes No No
ENW4X42(C,T)21A 3-1/2 21 (533) 3/8 7/8 19-5/8 (498) Yes No No
ENW4X48(C,T)21A 4 21 (533) 3/8 7/8 19-5/8 (498) Yes No No
ENW4X60(C,T)24A 5 24-1/2 (622) 3/8 7/8 23-1/8 (587) Ye s No No
NOTES:
For the model number; C = standard copper and T= tin plated copper
Field-supplied
Plenum
Field
Coil
Support Shelf
Furnace
See
Table 1
A
1
3
⁄ 16 ″
1
1
⁄ 16 ″
2
1
⁄ 4 ″
1
⁄ 2 ″
6″
19
3
⁄ 16 ″
(487)
(13)
(27)
(30) (152) (57)
A08336
Figure 1 −Correct Orientation of Coil Support on Furnace
Installation of Furnace Coils
Upflow Cased Coil Installation
NOTE: On upflow installations where the indoor coil is
placed in an unconditioned space, a 6 inch (152 mm) wide
piece of insulation should be applied and wrapped around
the outside of coil casing and supply duct contact point.
1. Set coil in place on upflow furnace discharge air
opening. See Figure 2.
2. When coil front width matches furnace front width, the
coil can be placed directly on furnace.
3. Ensure coil is level for proper condensate drainage.
Do not tip coil toward condensate drain. Coil
enclosure need not be fastened or screwed to
furnace.
Supply
Upflow
Furnace
Downflow
Furnace
Evaporator
Coil
Return
Return
Supply
A05411
Figure 2 −Typical Coil Installation

4484 01 3600 00
NOTE: When ENW4X coils are applied to same width
furnace, remove block−off plates at casing base by
removing 2 screws per plate from side of casing. See
Figure 3.
Block-Off
Plates
A05412
Figure 3 −Block−Off Plate Removal
ENW4X MODEL COILS APPLIED CENTERED OVER
NARROW FURNACE
1. There is no transition required for this application.
2. Remove coil from packaging and place on top of
furnace with 1 5/8 inch (41 mm) overhang on both
sides. See Figure 4, Alternative A.
3. Continue with normal installation practices. See
Connect Refrigerant Piping.
STANDARD MODEL COILS APPLIED CENTERED OVER
NARROW FURNACE REQUIRE A MINIMUM TRANSITION
AS SPECIFIED IN Figure 5.
1. Prepare transition, following recommended transition
drawing. See Figure 5.
2. Place transition on top of gas furnace. See Figure 4,
Alternative B. Secure with sheet metal screws. Place
coil on top of transition. Make sure coil rests evenly
on top of transition and gas furnace.
3. Secure coil to transition using sheet metal screws.
4. Continue with normal installation practices. See
Connect Refrigerant Piping.
NOTE: If coil is not being installed in the standard
orientation (front of coil matching front of furnace) then coil
must be raised above furnace as specified in Figure 5.
STANDARD MODEL COILS APPLIED DIRECTLY ON TOP
AND OFFSET TO THE LEFT ON NARROW FURNACE
1. Notch support rail on underside of coil cabinet to
provide clearances for gas furnace flange. This rail is
not visible from front of coil. To locate position of
notch, place coil directly on top of gas furnace with
overhanging portion entirely on left side as in
Figure 4, Alternative C. Mark location of gas furnace
flange on coil casing. Remove coil from top of
furnace. Using tin snips, make a notch in rail large
enough to allow clearance for gas flow furnace flange.
2. Place coil on top of gas furnace. Make sure coil is
shifted completely to left side, and notch is sufficient
so coil rests on top of furnace cabinet.
3. Prepare and install block−off plate. See Figure 4,
Alternative C. Using field−supplied sheet metal, cut a
block−off plate to be attached to bottom left side of
coil casing. This plate prevents air leakage from
overhanging portion of coil. Attach plate using sheet
metal screws.
4. Continue with normal installation practices. See
Connect Refrigerant Piping.
ALTERNATIVE
B
MODELS: T036, T042,
T048, AND T060 ONLY
ALTERNATIVE
A
ALTERNATIVE
C
WRONG
Field
Fabricated
Block-off
Plate
2 1/4” (57)
ENW4X Models Only
A08337
Figure 4 −Alternative Coil Mounting Positions
Downflow Cased Coil Installation
1. Place N−coil on supply duct opening.
2. When coil width matches furnace width, furnace can
be placed directly on the cased coil.
NOTE: In downflow installation with a 4−way multipoise
furnace, break off perforated duct flanges on furnace. See
Furnace Installation Instructions.
3. Coils that under−hang (narrower than furnace) must
have a field−fabricated transition between furnace
and N−coil casing as specified in Figure 5.
4. Coils that overhang (wider than furnace) do not
require a transition in downflow application. However,
a field−supplied furnace shelf should be constructed
to fit furnace to coil opening.
5. Place furnace on top of N−coil casing, or
field−supplied furnace shelf.

484 01 3600 00 5
A
(Inside Opening)
Furnace Outlet
Front Bracket
Rear Bracket
Coil Casing Width
Side Bracket
Side Bracket
NOTE: Weld 3 places
in 4 corners
19 1/2” (495)
(Outside)
3/4” (19)
Flanges
(Where Shown)
B
c
ABC
12-3/4 (324) 17-1/2 (445) 2-1/4 (57)
16-1/16 (408) 21 (533) 2-1/4 (57)
19-9/16 (497) 24-1/2 (622) 2-1/4 (57)
17-5/8 (448) 19-3/8 (492) 4 (102)
21-1/4 (540) 23 (584) 4 (102)
23 (584) 24-1/2 (622) 4 (102)
DIMENSIONS Inches (mm)
A09395
Figure 5 −Recommended Transition
Connect Refrigerant Piping
Use accessory tubing package or field−supplied tubing of
refrigerant grade. Suction tube must be insulated. Do not
use damaged, dirty, or contaminated tubing because it may
plug refrigerant flow−control device. ALWAYS evacuate the
coil and field−supplied tubing before opening outdoor unit
service valves.
Connect Refrigerant Liquid and Suction
Lines
For matched and mismatched systems, use line sizes
recommended in outdoor unit Installation Instructions.
The coil can be connected to outdoor units using accessory
tubing packages or field−supplied tubing of refrigerant
grade. Always evacuate tubing and reclaim refrigerant when
making connections or flaring tubing. Leak check
connections before insulating entire suction line.
Suction Line
Suction line is designed for field sweat connection. Line is
plugged to keep out moisture and dirt. Remove these plugs
only when ready to make connection.
See Table 1 for coil connection tube size.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
To avoid valve damage to the refrigerant control device
while brazing, valves must be wrapped with a
heat−sinking material such as a wet cloth.
CAUTION
!
1. Remove cabinet access door.
2. Remove rubber plugs from coil stubs using a pulling
and twisting motion. Hold coil stubs steady to avoid
bending or distorting.
3. Wrap TXV and nearby tubing with a heat sinking
material such as a wet cloth.
4. Use 1/2 psig Nitrogen purge in the suction and out the
liquid line.
5. Braze using a Sil−Fos or Phos−copper alloy. Do not
use soft solder.
6. After brazing, allow joints to cool. Slide rubber
grommets over joints. Position tubing at center of
each grommet to ensure an air seal around the tube.
7. Always evacuate lines and reclaim refrigerant when
making connections or flaring refrigerant lines. Leak
check connections before insulating entire suction line.
8. If outdoor equipment will not be installed until a later
date, braze liquid and suction lines closed outside. Add
a Schraeder port test fitting to the suction line outside.
Refrigerant Metering Device
END4X, ENW4X coils have a factory−installed hard shut−off
TXV designed only for use with R−410A refrigerant. Use
only with outdoor units designed for R−410A.
NOTE: ALL TXV’S HAVE PRESET SUPERHEAT
SETTINGS AND ARE NOT FIELD−ADJUSTABLE.
Condensate Drain Line Connection
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property
damage.
When installing over a finished ceiling and/or living area,
install a field−fabricated secondary condensate pan
under the entire unit.
CAUTION
!
The coil is designed to dispose of accumulated water
through built−in condensate drain fittings. It is recommended
that PVC fittings be used on the condensate pan. Do not
over−tighten. Finger tighten plus 1−1/2 turns. Be sure to
install plastic plug in unused condensate drain fitting. Two
3/4 inch female threaded pipe connections are provided in
each coil condensate pan.
A trap is not necessary on the condensate line. Consult
local codes for additional restrictions or precautions. If local
codes require a trap then the following guidelines are
suggested to assure proper drainage. Install a trap in
condensate line of coil as close to the coil as possible. Make
trap at least 3 inches (76 mm) deep and no higher than the
bottom of unit condensate drain opening (See Figure 6).

6484 01 3600 00
Pitch condensate line 1 inch (25.4 mm) for every 10 ft. of
length to an open drain or sump. Make sure that the outlet
of each trap is below its connection to condensate pan to
prevent condensate from overflowing the drain pan. Prime
all traps, test for leaks, and insulate traps and lines if located
above a living area.
3” / 76mm
A08067X
Figure 6 −Condensate Trap
NOTE: If unit is located in or above a living space, where
damage may result from condensate overflow, a
field−supplied, external condensate pan should be installed
underneath the entire unit, and a secondary condensate line
(with appropriate trap) should be run from the unit into the
pan. Any condensate in this external condensate pan
should be drained to a noticeable place. As an alternative to
using an external condensate pan, some localities may
allow the running of a separate 3/4 inch (19 mm)
condensate line (with appropriate trap) per local code to a
place where the condensate will be noticeable. The owner
of the structure must be informed that when condensate
flows from secondary drain or external condensate pan, the
unit requires servicing or water damage will occur. To further
protect against water damage, install a float switch to shut
the unit off if the water in the secondary pan gets too high.
NOTE: To avoid drainage problems, test the primary drain
line by slowly pouring water into the pan. Check piping for
leaks and proper condensate drainage. Using the
secondary drain as explained in the previous note provides
further protection against overflow due to a clogged primary
drain.
NOTE: In applications where return air humidity levels stay
at 70% or above for a prolonged period of time,
condensation can form on the bottom of pan and drip.
WASTE LINE CONNECTION
If the condensate line is to be connected to a waste (sewer)
line, an open trap must be installed ahead of the waste line
to prevent escape of sewer gases (See Figure 7).
A10216
Figure 7 −Condensate Drain to Waste Line
EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury or death.
Provide trap with air gap in drain line when connecting
to waste (sewer) line.
!WARNING
Humidifier Application
When installing a humidifier in a system which contains an
N−coil, consideration must be given to location of coil slabs.
See Fig. 8.
1. The humidifier should be mounted to the supply
plenum or return duct whenever possible. If
necessary, humidifiers can be mounted to the left side
of coil casing. The right side of the coil casing must
not be used to mount the humidifier.
2. Care must be taken to prevent damage of N−coil
when attaching humidifier to coil casing or plenum.
3. Ensure that humidifier has adequate airflow.
Supply
Evaporator
N-Coil
Upflow
Furnace
A05414
Figure 8 −Installation of Humidifier in System with
N−Coil

484 01 3600 00 7
COIL MODEL NUMBER IDENTIFICATION GUIDE
Digit Position 1 2 3 4 5 6,7 8 9,10 11 12
E N D 4 X 18 C 14 A 1
E = Evaporator
B = Builder
D = Standard
N = N Coil TYPE
A = Uncased
D = Cased Upflow/Downflow
M = Cased Multiposition (Upflow/Downflow/Horizontal)
W = Cased Upflow/Downflow for narrower furnaces
H = Cased Horizontal INSTALLATION
4 = Environmentally Sound R−410A REFRIGERANT
P = Piston
X = TXV METERING DEVICE
18 = 18,000 BTUH = 1½tons
19 = 18,000 BTUH = 1½tons
24 = 24,000 BTUH = 2 tons
30 = 30,000 BTUH = 2½tons
31 = 30,000 BTUH = 2½tons
36 = 36,000 BTUH = 3 tons
37 = 36,000 BTUH = 3 tons
42 = 42,000 BTUH = 3½tons
43 = 42,000 BTUH = 3½tons
48 = 48,000 BTUH = 4 tons
60 = 60,000 BTUH = 5 tons
61 = 60,000 BTUH = 5 tons NOMINAL CAPACITY
C = Plain Copper
L = Aluminum
T = Tin Coated Copper HAIRPIN MATERIAL
14 = 14.5”
17 = 17.5”
21 = 21”
24 = 24.5”
BB = 15.5”
FF = 19.1”
JJ = 22.8”
LL = 24.5” WIDTH
Sales Digit (Major Revision)
Engineering Digit (Minor Revision)
International Comfort Products, LLC
Lewisburg, TN 37091 USA