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

⁄

″

⁄

″

⁄

″

⁄

″

6″

⁄

″

(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

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

MODELS: T036, T042,

T048, AND T060 ONLY

ALTERNATIVE

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

(Inside Opening)

Furnace Outlet

Front Bracket

Rear Bracket

Coil Casing Width

Side Bracket

NOTE: Weld 3 places

in 4 corners

19 1/2” (495)

(Outside)

3/4” (19)

Flanges

(Where Shown)

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

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