Nordyne C5DA User manual

Installation Instructions
Split System Indoor Coils
These instructions are primarily intended to assist qualified individuals
experienced in the proper installation of this appliance. Some local and
national codes require licensed installation/service personnel for this
type of equipment. Read all instructions carefully before starting the
installation.
CAUTION:
Read the installation instructions supplied with the furnace/air
handler and observe all safety requirements outlined in the in-
structions and/or furnace/air handler markings before proceeding
with the installation of the coil.

Table of Contents
1. General Information ............................................................................................................... 3
2. Coil Specifications ................................................................................................................. 3
3. Coil Installation....................................................................................................................... 4
• Upflow Furnace/Air Handler
• Downflow Electric Furnace
• Downflow Electric Furnace/Air Handler with Integral Coil Cabinet or Optional Coil Cabinet
4. Verify Pressurization .............................................................................................................. 5
5. Refrigerant Line Connections ............................................................................................... 6
6. Completing the Installation ................................................................................................... 7
• Condensate Drain
• Air Filters
• Close-off Plates and Panels
• Refrigerant Charging
7. Maintenance and Service ...................................................................................................... 8

3
1. GENERAL INFORMATION
C(*)DA coils are designed for upflow and down-
flow furnace/air handler applications.The C(*)DA
coils are furnished with down-turned refrigerant
connections, ready for brazing.
Read the installation manual supplied with the
outdoor unit for refrigerant line connection pro-
cedure, required line sizes, and other information
pertaining to the system installation.
1. Make certain that the air delivery of the
furnace/air handler is adequate to handle
the static pressure drop of the coil, filter, and
duct work.
2. In orifice style models check the orifice size
of the coil's expansion device and confirm
that it is suitable for application with the
intended outdoor unit.
3. Where precise forming of the refrigerant
lines is required, a copper tubing bender
designed for the size lines used is recom-
mended. Avoid sharp bends and contact of
the refrigerant lines with metal surfaces.
4. Refrigerant lines should be wrapped
with pressure sensitive neoprene or other
suitable material where they pass through
the raw edges of holes.
5. The coil enclosure (if provided) and suction
line must be insulated as needed to prevent
condensate from forming and causing
property damage.
6. Coil must be level for proper conden-
sate drainage.
7. Do not remove seals from the coil until the
tubing connections are ready to be made.
NOTE: Optional cooling/heating equipment must
be properly sized and installed in accordance
with the furnace manufacturer’s specifications
and approved recommendations.“Heating only”
furnace air circulators may have to be replaced
with multi-speed “Heating/Cooling” blowers to
upgrade the air delivery (CFM) when an add-on
coil is installed. Refer to Coil Specifications for
recommended CFM and allow for pressure drop
across the coil and filters.
2. COIL SPECIFICATIONS
1. Refer to sales specification sheets
for Listed/Certified combinations
of equipment and required acces-
sories.
2. Refer to the current ARI Direc-
tory for certified ratings of split
systems.
Nominal (2)
Capacit
y
BTUH
Nominal Airflow
CFM
Width (in.) W
Height (in.) H
Depth (in.) D
Connections
Liquid Line
Suction Line
Installed Orifice
Size (in.)
Extra Orifice
(in.) supplied
0.060
(use for 024) 0.075
(use for 042)
0.063
(use for 030)
N/A N/A
C3DA
C5DA T25 T30 T36 T37 T41 T43 T47 T48 T49 T60
Nominal (2)
Capacity BTUH 24,000 30,000 36,000 36,000 42,000 42,000 48,000 48,000 48,000 60,000
Nominal Airflow
CFM 800 1000 1200 1200 1400 1400 1600 1600 1600 2000
Width (in.) 18 1/8 18 1/8 18 1/8 18 1/8 18 1/8 18 1/8 18 1/8 18 1/8 21 21
Height (in.) 20 20 20 20 20 24 20 24 28 28
Depth (in.) 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2 19 1/2
Connections
Liquid Line 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Suction Line 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
Metering Device TXV TXV TXV TXV TXV TXV TXV TXV TXV TXV

4
3. COIL INSTALLATION
WARNING:
Electric furnaces may be connected to
more than one supply circuit.
Upflow Furnace:
1. Disconnect all electrical power to
the furnace.
2. Install the coil in the coil cabinet and level
it as needed to allow proper condensate
drainage or make a plenum to enclose the
coil or drop the duct directly over it.
3. Seal the enclosure as required to minimize
air leakage.
4. Connect the refrigerant lines as outlined
in the Refrigerant Lines section.
Downflow FE/E* Electric Furnace:
1. Ensure that all electrical power to the
furnace is off.
2. Use the appropriate Coil Conversion Kit
which includes 2 air filters, close-off plates
(2 sets) and a coil hold down bracket.
3. Remove the filter located at the top of the
furnace cabinet.
4. Remove the refrigerant line knockouts lo-
cated at the top and bottom of the furnace
cabinet.
5. Install the coil and level it as needed to
ensure proper condensate drainage.
6. Secure the coil hold down bracket with
screws.
7. Add air filters to the sides of the coil.
8. Cut the floor opening for the refrigerant lines
and drain line (See Figure 6).
9. Connect the refrigerant lines as outlined in
the Refrigerant Line Connection section.
Connect the drain line and ensure that there
is a water trap in the water line.
Downflow Furnace with Integral Coil
Cabinet or Optional Cabinet
1. Ensure that all electrical power to the furnace
is off.
2. On the optional cabinet, refer to its installa-
tion instructions for assembly details.
3. Remove the knockout in the left bottom cor-
ner of the furnace and cut an appropriately
sized hole in the floor. See Figure 6.
Figure 1. Upflow Furnace/Air Handler
Figure 2. Downflow Furnace without Coil
Cabinet
4. Remove the interior coil panel. Install the
coil and level it as needed to ensure proper
condensate drainage.
5. Remove the knockout for the refriger-
ant lines in the secondary covers and
replace in the furnace.
NOTE: Modifications to the panel may be
required.

5
MOUNTING
HOLE
SMALL
PLATE
LARGE
PLATE
SMALL
PLATE
TAB
LARGE
PLATE
TABS OFFSET
MOUNTING
HOLES (2)
TABS
Figure 3. Bottom Close-Off Plates Figure 4. Close-Off Plates for Opening at
Top of Furnace
6. Slide the close-off plates around the re-
frigerant lines and install with the dart clips
provided. See Figure 5.
7. Snap the bushings around the lines and into
the close-off panels.
8. Connect the refrigerant line as outlined in
the refrigerant line section.
4. VERIFY PRESSURIZATION
WARNING:
This coil is pressurized with Nitrogen.
Avoid direct face exposure or contact
with valve when gas is escaping. Al-
ways ensure adequate ventilation is
present during the depressurization
process. Any uncertainties should be
addressed before proceeding.
VERIFY PRESSURIZATION:
- Test by depressing Schrader valve and listen
for escaping gas
- If no pressure is found, test coil for leak
- If no leak is found, install coil
- If leak is found, clearly mark leak
location and return coil to your distributor
for processing
Figure 5. Exploded View for
Close-Off Plates
NITROGEN
HEALTH
FLAMMABILITY
REACTIVITY
0 Minimal Hazard 1 Slight Hazard
1
0
0



20" (508 mm)
Floor Cut Out
for Refrigerant Lines
and Drain Hose
3 3/4"
(95 mm)
5 3/8"
(133 mm)
19 1/16"
(500 mm)
FURNACE OUTLINE
REAR WALL (CLOSET OR ALCOVE)
3/4" (19 mm)
Furnace Outer Door
4 1/2" (114 mm) MAX
Figure 6. Location of Floor Cut-Out for
Refrigerant Lines and Drain Line

6
Figure 7. Downflow Furnace with Coil
Cabinet
SMALL
PLATE
LARGE
PLATE TABS
MOUNTING
HOLE
OFFSET
Figure 8. Close-Off Plates (Supplied with
appropriate blower conversion package)
5. REFRIGERANT LINE
CONNECTIONS
WARNING:
This coil is pressurized with Nitrogen.
Avoid direct face exposure or contact
with valve when gas is escaping. Al-
ways ensure adequate ventilation is
present during the depressurization
process. Any uncertainties should be
addressed before proceeding.
Note: For coils with factory installed TXV valve
proceed to step #8.
Note: Before proceeding with the connection of
the refrigerant lines, confirm that the orifice size
meets the requirements outlined in the outdoor
unit installation manual. Factory installed orifice
sizes are listed in the Specifications section. If
the restrictor orifice must be replaced, follow
the steps below:
1. Remove the valve cap from the end of the
liquid line. Relieve all pressure from the coil
by depressing the valve. Remove the valve
core. Properly dispose of all removed parts.
2. Loosen the orifice body halves by applying
two wrenches and squeezing them together
as shown in Figure 9, to turn the assembly
nut counter-clockwise.
3. Continue to unscrew the assembly nut to
separate it from the distributor body.
4. Insert a light-gauge wire hook between the
distributor body and the restrictor orifice to lift
the orifice out of the body. (See Figure 10)
Carefully remove the restrictor orifice being
careful not to scratch either part.
5. Check the actual size of the new orifice. The
size is stamped on its side. Do not use pin
gauges to measure the orifice diameter.
6. Insert the new orifice in the distributor body,
rounded end down. (See Figure 11)
7. After installing the orifice in the distributor
body, realign the assembly nut to the
distributor body. Mark a line along both
bodies after hand tightening and then
tighten an additional 1/4 turn. Caution: Do
not overtighten! The misalignment of the two
lines will show how much the nut is tightened.
If a torque wrench is used, tighten to 10-12
ft. lbs. or 14-16 Nm.
8. Remove the valve cap from the end of the
liquid line. Relieve all pressure from the coil
by depressing the valve. Remove the valve
core.
Note: On models which use a TXV, it is
recommended to wrap a wet rag around the
suction line between the sensing bulb and
the line set braze joint before applying any
heat.
9. Unbraze and remove the cap on the suction
line. Unbraze and remove the valve core
holder on the liquid line.
10.Properly dispose of all removed parts.
NITROGEN
HEALTH
FLAMMABILITY
REACTIVITY
0 Minimal Hazard 1 Slight Hazard
1
0
0

7
Line Connections:
11.Cut the line set tubing to the proper
length. Be sure that the tubing has been
sized in accordance with the outdoor unit
specifications.
12.Inspect both refrigerant lines.The ends of the
lines must be round, clean, and free of any
burrs.
13.Insert the line set tubes into the coil tube
stubs until they bottom out.
Note: On models which use a TXV, it is
recommended to wrap a wet rag around the
suction line between the sensing bulb and
the line set braze joint before applying any
heat.
14.Braze the individual connections with dry
nitrogen flowing through the joint to eliminate
internal oxidation and scaling.
15.Check the assembly for leaks.
16.On horizontal applications of models with
TXV valve, re-position the sensing bulb on
the suction line so it is in the 4 o'clock position
on the suction tube.
6. COMPLETING THE INSTALLATION
CAUTION:
The indoor coil must be checked to
ensure a level installation.Failure to do
so may result in improper condensate
disposal, causing structural damage,
premature equipment failure, or pos-
sible personal injury.
Condensate Drain:
1. Thread the 3/4" drain fitting (included) into
the lowest tapped hole on the condensate
pan. Hand tighten the fitting. If a different
configuration is required, use only PVC or
similar material for the fitting.
NOTE: Overtightening the fitting may crack
the drain pan and create a condensate
leak.
2. Slip the drain line over the end of the fitting,
add the clamp provided and run to a suit-
able drain. Avoid bending or pinching of the
line.
3. During the system checkout, inspect the
drain line and connections to verify proper
condensate disposal.
Figure 9. Wrenches on
Distributor Body and Assembly Nut
Figure 11. Restrictor
Insertion in Distributor Body
Air Filter — Air filters are not provided as an
integral part of this coil, however, a filter must
be installed upstream of the coil and inspected
frequently. When the filter becomes clogged
with dust or lint, it should be replaced (dispos-
able type) or cleaned (washable type).The filter
should be inspected and replaced or cleaned at
least twice during the year, generally at the start
of each heating and cooling season.
Close-Off Plates and Panels — Install the nec-
essary air close-off plates around the refrigerant
Figure 10. Removal of Orifice

lines and drain line where required. Reinstall
all inner and outer panels of the furnace/air
handler that were previously removed to install
the indoor coil.
Refrigerant Charging — C(*)Q series indoor
coils contain a "holding charge" to prevent
entrance of moisture and contaminants during
shipment. The total system operating charge
of R-22 refrigerant is in the outdoor unit and is
adequate for the matched listed system including
15 feet of line set.
WARNING:
Ensure that all electrical power to the
furnace and outdoor (condensing) unit
is off before performing any mainte-
nance or service on the system.
It will be necessary to evacuate the indoor coil
and line set prior to charging.Refer to the outdoor
unit installation manual for detailed charging
instructions.
7. MAINTENANCE AND SERVICE
To ensure optimum system performance and
to minimize the possibility of equipment failure,
the following periodic maintenance should be
performed on the coil:
1. The air filter installed with the system should
be checked and cleaned or replaced twice
per year.
2. Check the coil, drain pan, and condensate
drain line for cleanliness at the start of each
heating and cooling season. Clean and
remove any debris as required.
CAUTION:
Do not operate the system without hav-
ing a suitable filter in place in the return
air duct system. Always replace the
filter with the same size and type.
7087240
Specifications and illustrations subject to change
without notice and without incurring obligations.
Printed in U.S.A. (02/07)
¢7087242¤
7087240
O'Fallon, MO
INSTALLER: PLEASE LEAVE THESE INSTALLATION
INSTRUCTIONS WITH THE HOMEOWNER