Nordyne R-410A User manual

Installation Instructions
Split System Indoor Coils
!
CAUTION:
ReadtheInstallationInstructionssup-
plied with furnace/air handler and ob-
serveallsafetyrequirementsoutlined
ininstructionsand/orfurnace/airhan-
dler markings before proceeding with
installationofthe coil
These instructions are primarily intended to
assist qualified individuals experienced in the
properinstallationofthisappliance. Somelocal
andnationalcodesrequirelicensedinstallation/
service personnel for this type of equipment.
Read all instructions carefully before starting
the installation.

2
TableofContents
1. General Information ............................................................................................................. 3
2. Coil Specifications ............................................................................................................... 4
3. Coil Installation..................................................................................................................... 5
• Upflow Furnace
• Downflow Furnace
• Horizontal Furnace
• Horizontal Ready Coils for Horizontal Left Installation
• Horizontal Ready Coils for Horizontal Right Installation
4. Refrigerant Line Connections............................................................................................ 6
5. Completing the Installation ................................................................................................ 7
• Condensate Drain
• Air Filters
• Close-off Plates and Panels
• Refrigerant Charging
6. Maintenance and Service .................................................................................................... 8

3
1. GENERALINFORMATION
Standard cased coils are designed for upflow/
downflowapplicationsorhorizontalapplications
when used in conjunction with our horizontal
drain pan kit (See page 5). Accessory kits are
not required for factory ready horizontal coils.
Coils are equipped with braze type refrigerant
connections for easy installation.
Read the installation manual supplied with the
outdoor unit for refrigerant line connection pro-
cedure, required line sizes, and other informa-
tion pertaining to the system installation.
1. Make certain that the air delivery of the
furnace/air handler is adequate to handle
thestaticpressuredropofthecoil,filter,and
duct work.
2. Check the orifice size of the coil’s expan-
siondeviceandconfirmthatitissuitablefor
application with the intended outdoor unit.
NOTE: Some C4 series coils (R-410A re-
frigerant) employ a thermostatic expansion
valve (TXV) as the metering device (See
page 4).
H
20
3
/
4
"
B
16
5
/
8
"
W
A3/4"
13
3/8"
155/8"
19 3/4"
Figure 1.
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 suit-
able material where they pass through the
raw edges of holes.
5. Coil must be level for proper condensate
drainage.
NOTE: Optional cooling/heating equipment
must be properly sized and installed in accor-
dance with the furnace manufacturer’s specifi-
cationsandapproved recommendations. “Heat-
ing 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 Speci-
fications for recommended CFM and allow for
pressure drop across the coil and filters.

4
2.COIL SPECIFICATIONS
(1) Refer to sales specification sheets for Listed/
Certified combinations of equipment and re- quired accessories.
(2) Refer to the current ARI Directory for certified
ratings of split systems.
(3) Orificesizeisfor10SEERsystems.Additional
orifices may be supplied with the coil.
(4) Allows application of larger coil cases to
smaller furnace cabinet.
(5) This coil is for 4 ton 12 SEER match. (6) An X in the model description designates
factory installed TXV.
Coil Model
(1)
C3BA-
024C-A
C3BH-
024C-A
C3BA-
030C-A
C3BH-
030C-A
C3BA-
036C-A
C3BH-
036C-A
C3BA-
043C-A
C3BA-
030C-B
C3BA-
036C-B
C3BH-
036C-B
C3BA-
042C-B
C3BH-
042C-B
C3BA-
048C-B
C3BH-
048C-B
(5)
C3BA-
050C-B
C3BA-
048C-C
C3BA-
060C-C
C3BH-
060C-C
Nominal Capacity BTUH
(2)
24,000 24,000 30,000 30,000 36,000 36,000 43,000 30,000 36,000 36,000 42,000 42,000 48,000 48,000 48,000 48,000 60,000 60,000
Nominal Airflow 900 900 1100 1100 1200 1200 1400 1100 1350 1350 1500 1500 1500 1500 1500 1500 1800 1800 Installed Orifice Size
(3)
0.060 0.060 0.063 0.063 0.067 0.067 0.080 0.063 0.067 0.067 0.075 0.075 0.080 0.080 0.080 0.080 0.093 0.093
Width (in.) W 14 1/4 14 1/4 14 1/4 14 1/4 14 1/4 14 1/4 14 1/4 19 3/4 19 3/4 19 3/4 19 3/4 19 3/4 19 3/4 19 3/4 19 3/4 22 1/2 22 1/2 22 1/2 Height (in.) H 20 20 20 26 20 26 26 20 20 26 20 26 20 26 26 20 26 26 Top F 12 7/8 12 7/8 12 7/8 12 7/8 12 7/8 12 7/8 12 7/8 18 3/8 18 3/8 18 3/8 18 3/8 18 3/8 18 3/8 18 3/8 18 3/8 21 1/8 21 1/8 21 1/8 Connections (in.) Liquid Line 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 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 3/4 3/4 3/4 3/4 7/8 3/4 7/8 7/8
Horizontal Drain Kit 914633 - 917492 - 917492 - 914634 917492 917492 - 917492 - 917492 - 914634 914633 914634 - Coil Case Adapter
(4)
- - - - - - - 913963 913963 913963 913963 913963 913963 913963 913963 913964 913964 913964
R - 22 Units
Coil Model
(1) (6) C4BA-X24C
-
B
C4BH-X24C
-
B
C4BA-X36C
-
B
C4BH-X36C
-
B
C4BA-X48C
-
C
C4BH-X48C
-
C
C4BA-X60C
-
C
C4BH-X60C
-
C
Nominal Capacity BTUH (2) 24,000 24,000 36,000 36,000 48,000 48,000 60,000 60,000 Nominal Airflow 900 900 1350 1350 1500 1500 1800 1800 Metering Device TXV TXV TXV TXV TXV TXV TXV TXV Width (in.) W 19 3/4 19 3/4 19 3/4 19 3/4 22 1/2 22 1/2 22 1/2 22 1/2 Height (in.) H 20 26 26 26 29 29 29 29 Top F 18 3/8 18 3/8 18 3/8 18 3/8 21 1/8 21 1/8 21 1/8 21 1/8 Connections (in.)
Liquid Line 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Suction Line 3/4 3/4 7/8 7/8 7/8 7/8 7/8 7/8
Horizontal Drain Kit 917492 - 914634 - 917188 - 917188 - Coil Case Adapter (4) 913963 913963 913963 913963 913964 913964 913964 913964
R - 410A Units

5
3.COILINSTALLATION
!
WARNING:
Electricfurnacesmaybeconnectedto
more than one supply circuit.
Upflow Furnace —
1. Disconnect all electrical power to the fur-
nace.
2. If needed, use one of the coil case adapter
kits to match the coil to the furnace air
dischargeopening. Referto the CoilSpeci-
fications Section for proper kit numbers.
3. Install the coil and level it as needed to
ensure proper condensate drainage. (See
Figure 2)
4. Seal the enclosure as required to minimize
air leakage.
5. Connect the refrigerant lines as outlined in
the Refrigerant Lines section.
Downflow — These coils may be installed in
downflow applications. Installation of the coils
in these applications only require that the fur-
nace and coil cabinets are securely mounted
together before setting in place. Fossil fuel
applications require coil to be placed in the
supply air stream only.
Horizontal — Standard coils may also be
installedinhorizontalapplications. Installationof
the standard coils in these applications only
require that the furnace and coil cabinets are
securelymountedtogetherand thatahorizontal
drainpankit be installed.Referto the Specifica-
tions Section for proper kit numbers.
To Configure Horizontal Ready Coils for
Horizontal LEFT Installations:
1) Remove the coil access door.
2) IMPORTANT:Removetheplugfromoneof
the threaded holes in the horizontal drain
pan. Completely remove the webbing lo-
catedinthethreadedholesofthehorizontal
drain pan. If webbing is not removed, the
drain will not function properly and ceiling
damage may occur.
3) Insert a plug(from the horizontaldrainpan)
into the open and unused drain hole in the
drain pan at the bottom of the unit to block
bypass air.
4) Removethecorrespondingdrainlineknock-
out from the coil access door to allow
access to the horizontal drain.
5) Replace the door.
NOTE: Installdrainpan extension (supplied)on
C3BH060 models.
To Configure Horizontal Ready Coils for
Horizontal RIGHT Installations:
1) Remove the coil access door. Unscrew the
line-set tube close-off plate from the front
left cabinet rail.
2) Slidethecoilanddrainpanassemblyoutof
the unit.
3) IMPORTANT: Remove the plug from one
ofthethreadedholesinthehorizontaldrain
pan. Completely remove the webbing lo-
catedinthethreadedholesofthedrainpan.
If webbing is not removed, the drain will not
function properly and ceiling damage may
occur.
4) Remove the sheet metal hairpin covers (if
supplied) from the back of the coil and
discard.
5) Place the horizontal drain pan on the oppo-
site side of the coil. On units with 2 sets of
knockouts, remove the other set of knock-
outs in the coil spacing plates and insert
support rod.
6) Insert a plug(from the horizontaldrainpan)
into the open and unused drain hole in the
drain pan at the bottom of the unit to block
bypass air.
7) Slide the coil and the horizontal drain pan
assembly back into the unit. Reattach the
tube close off plate.
Figure 2. Upflow Furnace Application

6
8) Removethecorrespondingdrainlineknock-
out from the coil access door to allow
access to the horizontal drain.
9) Replace the door.
Note: All condensate pans have primary
and secondary drain connections to meet
FHA requirements. If the application is lo-
cated in or above a living space where
damage may result from condensate over-
flow, a separate 3/4 inch drain must be
provided from the secondary drain connec-
tion and a secondary drain pan must be
installed under the entire unit. Run second-
ary drain lines to a place where they are
noticeable if used.
4. REFRIGERANT LINE
CONNECTIONS
NOTE – Move to instruction step #7 when
installing a C4 series (R-410A refrigerant) coil
with factory installed TXV valve.
NOTE – Before proceeding with the connection
of refrigerant lines, confirm that the orifice size
meets the requirements outlined in the outdoor
unitinstallationmanual.Factory-installedorifice
sizes are listed in the Specifications section. If
theorificesizeisincorrect,itshouldbereplaced,
following the steps below:
1. Loosen the orifice/distributor body halves
by applying two wrenches and squeezing
themtogether,asshowninFigure3,toturn
the assembly nut counter-clockwise.
2. Continue to unscrew the assembly nut to
separateitfromthedistributorbodyportion.
3. Insert a light-gauge wire hook between the
distributor body and the orifice to lift the
orifice out of the body. (See Figure 4)
Remove the orifice being careful not to
scratch either part.
4. Checktheactualsizeoftheneworifice(the
size is stamped on the side of the orifice).
Do not use pin gauges to measure the
orifice diameter.
Figure 4. Removal of Orifice
Figure 3. Wrenches on Distributor Body
and Assembly Nut

7
5. Insert the new orifice in the distributor body
rounded end down as shown in Figure 5.
6. After installing the orifice in the distributor
body, realign the assembly nut to the dis-
tributorbody. Mark alinealong both bodies
after hand tightening and then tighten an
additional 1/4 turn. Caution: Do not over-
tighten! The misalignment of the two lines
will show how much the nut is tightened. If
atorque wrenchis used, tightento 10-12 ft.
lbs. or 14-16 Nm.
Line Connections:
7. Remove the protective caps from the coil
andrefrigerantlinesetandalsoremovethe
hole grommets and tube close-off insula-
tion from around the tubes.
8. Cut the line set tubing to the proper length.
Be sure that the tubing has been sized in
accordance with the outdoor unit specifica-
tions.
9. Inspect both refrigerant lines. The ends of
the lines must be round, clean, and free of
any burrs.
10. Insert the line set tubes into the coil tube
stubs until they bottom out.
11. Braze the individual connections with dry
nitrogen flowing through the joints to elimi-
nate internal oxidation and scaling.
NOTE: On C4 (R-410A refrigerant) models
which use a TXV, it is recommended to
Figure 5. Orifice Insertion in Distributor Body
wrap a wet rag around the sensing bulb
located on the suction line while brazing.
12. Check the assembly for leaks with dry
nitrogen.
13. On horizontal applications of C4 (R-410A
refrigerant) models with TXV valve, re-
positionthesensingbulbonthesuctionline
so it is in the 10 o'clock to 2 o'clock position
on the suction tube.
14. Replace the tube close-off insulation.
5. COMPLETING THE
INSTALLATION
Condensate Drain:
!
CAUTION:
The indoor coil must be checked to
ensurealevelinstallation.Failuretodo
somayresultinimpropercondensate
disposal, causing structural damage,
premature equipment failure, or pos-
siblepersonal injury.
1. The coil condensate pan is furnished with
3/4" NPSC drain connections. Use a PVC
or similar material fitting to attach the drain
line to the pan. The fitting should be hand
tightenedonly. Overtighteningmaycrack
the drain pan and cause a condensate
leak.

INSTALLER: PLEASE LEAVE THESE
INSTALLATION INSTRUCTIONS WITH
THE HOMEOWNER
708360B(Replaces708360A)
Specifications and illustrations subject to change
without notice and without incurring obligations.
Printed in U.S.A. (11/04)
O'Fallon,MO
¢708360¬¤
708360B
2. Connect the drain line and run to a suitable
drainavoiding sharpbends and pinchingof
theline. Installacondensatetrapandprime
with water.
3. During the system checkout, inspect the
drain line and connections to verify proper
condensate disposal.
Air Filter — Air filters are not provided as an
integralpartofthiscoil,however,afiltermustbe
installed upstream of the coil and inspected
frequently. When the filter becomes clogged
with dust or lint, it should be replaced (dispos-
abletype)orcleaned(washabletype). Thefilter
should be inspected and replaced or cleaned at
leasttwice during theyear,generally at thestart
of each heating and cooling season.
Close-Off Plates and Panels — Install the
necessary air close-off plates around the refrig-
erant lines and drain line where required. Rein-
stallallinnerandouterpanelsofthecoilcaseand
furnace that were previously removed to install
the indoor coil.
Refrigerant Charging — These cased indoor
coils are not factory charged with refrigerant.
It will be necessary to evacuate the indoor coil
and line set prior to charging. Refer to the
outdoor unit installation manual for detailed
charges and instructions.
6. MAINTENANCEANDSERVICE
!
WARNING:
Ensure that all electrical power to the
furnaceandoutdoor(condensing)unit
is off before performing any mainte-
nance or service on the system.
To ensure optimum performance and to mini-
mize possible equipment failure, the following
periodic maintenance should be performed on
this equipment:
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 as needed.
!
CAUTION:
Do not operate the system without
having a suitable filter in place in the
returnairductsystem.Alwaysreplace
the filter with the same size and type.