Winchester MC User manual

Model MC Installation Instructions
Sweat Connect Air Conditioning & Heat Pump Evaporator Coils
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PLEASE READ INSTRUCTIONS COMPLETELY PRIOR TO INSTALLATION
INTRODUCTION
W inchester Indoor Coils are designed specifically for
use w ith various m odels of residential gas or electric
furnaces or air handlers in downflow, upflow or
horizontal applica tions.
These instructions are prim arily inten ded to assist
qualified individuals trained and experienced in the
proper installation of this type o f eq uipm ent. Som e
state codes require installation and service personnel
to be licensed. R efer to authorities having jurisdiction
for additional guidance. Rem em ber that the C lean Air
Act of 1990 requires technician certification for handling
refrigerant.
NOTE: EFFICIENCY AND CAPACITY RATINGS
ARE LISTED IN CURRENT ARI DIRECTORY FOR
WINCHESTER COILS MIX-MATCHED WITH MANY
BRANDS OF OUTDOOR CONDENSING OR HEAT
PUMP UNITS. AIR CONDITIONING COIL MIX-
MATCHES ARE LISTED IN INDOOR COIL
MANUFACTURER AIR CONDITIONING SECTION.
HEAT PUMP COIL MIX-MATCHES ARE LISTED IN
INDOOR COIL MANUFACTURER HEAT PUMP
SECTION.
GENERAL COIL INSTALLATION NOTES
1. Most W inchester Coils are equipped with a schrader
valve port to allow field installation of therm al
expansion valve w ithout ha ving to sw eat it in. This
schrader valve can also serve the useful purpose of
checking for leaks prior to installation. Unscrew the
schrader valve cap and pre ss the depressor. IF
THERE IS NO NITROGEN PRESSURE PRESENT,
THE COIL MAY HAVE DEVELOPED A LEAK
DURING SHIPMENT AND SHOULD BE RETURNED
TO THE POINT OF PURCHASE FOR EXCHANGE. If
pressure is present, then go ahead and relieve the
pressure in the coil by continuing to depress the
schrader valve. W hen there is no pressure then cut off
the ends of the copper tubes.
IF THERE IS NO NITROGEN PRESSURE PRESENT,
THE COIL MAY HAVE DEVELOPED A LEAK
DURING SHIPMENT AND SHOULD BE RETURNED
TO THE POINT OF PURCHASE FOR EXCHANGE.
2. The blo w er and duct system m ust be properly sized
in order to provide adequate cooling and heating
pe rfo rm ance. Select the correct m otor speed tap on the
furnace blower to give th e required C FM needed for
rated cooling capacity. Return air filters of generous
size m ust be provided, in order to avoid contam inating
the coil, blower and ductw ork, or restricting necessary
air flow .
3. It is essential that the indoor coil and outdoor u nit be
properly m atched and that the flow rator in the coil be
equipped with the proper orifice. A flow rator piston with
an orifice size that is too sm all w ill cause starving and
one that is too large w ill cause flooding of the coil with
refrigerant.
Im proper sizing of orifice or incorrect charge w ill result
in inefficient operation. S ee m ore details in installations
for coils with flowrators.
4. W here ratings require addition of an expansion
valve, kits are available that can norm ally be added to
Sum m it coils in the field without cutting or brazing. S ee
instructions for coil with expansion valve.
BE SURE THAT THE FLOWRATOR PISTON HAS
BEEN REMOVED FROM FLOWRATORS
DISTRIBUTOR BODY PRIOR TO INSTALLATION OF
EXPANSION VALVE.
5. For optim um perform ance and efficiency of air
conditioning or heat pum p coils, adjust system charge
an d/o r superheat as reco m m en ded by o utdoor u nit
m an ufactu rers. Procedures will differ betw een
m an ufactu rers.
6. It is recom m ended that coil be sprayed w ith liquid
detergent thoroughly and rinsed thoroughly before
installation to assure proper drainage of condensate
from the coil fins to elim inate w ater blowoff and to
assure m axim um coil perform ance. If not sprayed,
approxim ately 50 hours of break in tim e is required to
achieve the sam e results.
7. Alwa ys be sure coil is installed level or sloped
slightly tow ard prim ary and secondary (the higher of
the tw o) drain fittings. C onnect both drain lines to open
drain, but never to a closed sewer. Pitch drain lines
aw ay from drain pan. Alw ays, test drain lines with
water before operating. R eduction in size of the drain
line s is not reco m m en ded.
8. A WATER TRAP is reco m m en ded on a ll coil
applications, but IS REQUIRED ON PULL THROUGH
INSTALLATIONS ON ELECTRIC FURNACES.
FAILURE TO PROVIDE CAN RESULT IN IMPROPER
DRAINAGE OR POTENTIAL SHOCK HAZARD.
ALL WINCHESTER COILS ARE SHIPPED
FROM OUR FACTORY PRESSURIZED WITH
NITROGEN. THEY DO NOT CONTAIN ANY
HCFC22
CAUTION!
61BE0010/022008
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9. Refrigerant piping is critical on any coil installation
when th e outdoor unit is to be located below the level of
the coil. F o r proper piping design con siderations, refer
to the guidelines furnished by the m anufacturer of the
outdoor unit.
10. C heck all field installed refrigerant connections with
electronic leak detector, halide torch, or soap bubbles.
11. Refer to installation instructions provided with the
outdoor unit, furnace or air hand ler and line sets for
com pletion of system installation.
SPECIAL INSTRUCTIONS FOR COILS WITH
FLOWRATORS
The sizing of the flowrator orifice piston should be
based strictly on the rated capacity of the outdoor unit
an d c oil m a tc h.
W inchester provides capacity perform ance ratings that
m atch both sam e size and upsized C oils with a specific
m anufacturers outdo or units. At the Sum m it
distributor’s requ est, the flowrator orifice piston is
selected and installed in each coil for the specific range
of coolin g capacities likely to be encountered. The
factory installed orifice piston size is m arked on the
flowrator body and on the front of the coil carton.
W hen using this coil with an outdoor unit of another
capacity, select an orifice piston from the table below if
the capacity range for the coil and outdoor unit to be
used differs.
Failure to install the proper orifice piston can lead to
poor system perform ance and possible com pressor
dam age. A variation of one piston size is not norm ally
critical. W inchester reserves the right to substitute a
factory installed piston one size sm aller or greater if the
piston size ordered is out of stock.
A selection of replacem ent orifice pistons is available
from your W inchester supplier.
Condensing Unit Proper Coil Orifice
Cooling Capacity Piston ID Size
(BTUH) (1/1000")
18,000 49
24,000 59
30,000 63
36,000 71
42,000 76
48,000 82
60,000 90
For indoor coils with flo w rators, the flowrator distributor
assem bly consists of flowrator distributor body w ith
attached tubes feeding the coil, a piston with an internal
orifice of a specific ID size, and a he x nut to attach the
piston retainer and liquid line. S ee Diagram below.
DIAGRAM 1
FLOWRATOR DISTRIBUTOR
IF A COMBINATION IS USED THAT REQUIRES A
PISTON SIZE CHANGE, CHANGE THE PISTON IN
THE DISTRIBUTOR ON THE INDOOR COIL
BEFORE INSTALLING THE COIL OR CONNECTING
THE REFRIGERANT LINESET OR CHARGING THE
SYSTEM.
Use the follow ing procedure:
Using a back-up wrench on the flow rator distributor
body, unscrew the hex nut thus detaching the liquid line
from the flow rator distrib utor body.
Use a fine wire w ith hook on one end to insert into the
hole in the piston that is in the flowrator body. C arefully
rem ove the piston and replace with a proper sized one,
installing piston w ith teflon seal end of the piston in
distributor first. D o not force piston into flowrator
distributor.
NOTE: W ith piston in flowrator distributor, THE
TEFLON SEAL END OF THE PISTON SHOULD BE
DOWN AND SHOULD NOT BE SEEN BY LOOKING
IN THE END OF THE FLOWRATOR DISTRIBUTOR.
The piston m ust be free to rotate and m ove up and
dow n. M ake sure piston is free to m ove in flowrator
distributor body. Make sure that the teflon ring seal on
the flowrator distributor bo dy is still in place.
Replace the hex nut and liquid line on the flow rator
distributor body and torque from 10 to 30 inch lbs. DO
NOT OVER TIGHTEN. Be sure to use a back -up
wrench on flo wrator distributor body.
Re-m ark piston size on outside of flow rator distributor
body with a perm anent m arking pen. Check fittings
for leaks after installation.
IT IS MANDATORY TO USE AN EMERGENCY
AUXILIARY DRAIN PAN WITH ANY COIL OR AIR
HANDLER INSTALLED IN AN ATTIC OR ABOVE A
FINISHED CEILING. IT MUST HAVE ITS OWN
DRAIN LINE (A WATER TRAP IS NOT NECESSARY)
WITH ITS OUTPUT INTO AN OPEN DRAIN (NOT A
CLOSED SEWER). IT SHOULD ALLOW EASY
VISUAL INSPECTION SO THAT IF CONDENSATE
FLOW IS SEEN THE HOMEOWNER KNOWS THAT
THE COIL DRAIN PAN LINES ARE PLUGGED AND
NEED MAINTENANCE
CAUTION!
61BE0010/022008
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SPECIAL INSTRUCTIONS FOR COILS WITH
THERMAL EXPANSION VALVES
For indoor coils requiring expa nsion valves, both bleed
and non-bleed types are available in se veral sizes. The
expansion valve use d is externally equalized and the
superheat is non-adjustable. All W inchester expansion
valves have a built-in check m aking them heat pum p
capable. W hile therm al expansion valves can be
factory installed, they are norm ally available in kit form
for field installation. For the kit version, follow the
installation instructions provided with the kit. N orm ally
these can be field installed before system is charged
without requiring cutting and brazing.
Be sure that the expansion valve provided is the proper
size and type required to achieve rating. If a non-bleed
type valve is to be used, the outdoor u nit m ust be
equippe d w ith a hard start kit allow ing the outdoor unit
to start under load. C heck with our factory if necessary.
W hen a non-bleed expansion valve (TXV 2) is specified
in a Sum m it AC or H P R ating, the following
assum ptions are m ade:
a.) The TX V 2 is a field installed accessory to be
field installed in accordance with recom m ended TX V
practice.
b.) The com bination of this non-bleed valve and
the com pressor in the outdoor unit results in a system
that operates with a loaded condition on startup.
c.) The outdoor unit is capable of startin g against
this loaded condition or a hard start kit is to be fie ld
installed.
If any of the assum ptions don't fit the application and
the system starts un loaded, the AR I SE E R R ating m ust
be decreased by .4 SE E R .
In m ost cases a reciprocating com pressor with a T XV 2
will start loaded whereas a scroll com pressor will start
unloade d.
SPECIAL CONSIDERATIONS FOR
SELECTING HEAT PUMP COILS
The selection of in doo r heat pum p coils is m uch m ore
critical than selection of indoor coils for air conditioning
units. The differences are as follows:
1. O nly indoor coils with flow rators or expansion/check
valve flow control devices m ay be used w ith outdoor
heat pum p units. These devices perm it reversing
refrigerant flow in the coils when changing from cooling
to heating. CAP TUBE COILS MUST NOT BE USED
WITH HEAT PUMP.
2. M ix-m atching of indoor coils for heat pum ps
dem ands that the heat rejection capacity, internal
volum e, and equiva lent orifice o f th e m ix-m atch co il be
at least equal to that of the sm allest internal volum e
m atched coil recom m ended by outdoor u nit
m anufacturer for that outdoor unit.
3. It is im portant that selection be based on W inchester
recom m endation for a specific coil with a specific orifice
to be used w ith an outdoor he at pum p unit of a specific
m ake, serie s, and m odel num ber.
4. Failure to conform to proper selection requirem ents
will affect efficiency, cha rging, and reliability and m ay
result in dam age to the system .
5. The m ix-m atching of specific indoor heat pum p coils
with specific outdoor heat pum p units as certified in the
W inchester heat pum p section of the current AR I
Directory will assure proper and efficient operation of
heat pum p system s.
SPECIAL INSTRUCTIONS FOR
CHARGING HEAT PUMP COILS
Specific detailed instructions for refrigerant charging of
a heat pum p system as recom m ended by the outdoor
unit m anufa cturer should be followed. These
instructions will differ between m anufacturers, but in
general are as follow s:
WITH FLOWRATOR IN INDOOR COIL, USE
SUPERHEAT METHOD IN COOLING MODE.
M ea sure fo llowing values from s ystem : outsid e a m bien t
tem perature, suction pressure at gauge, suction line
tem pera ture a t com p res so r. Adjust charge to achieve
recommended superheat.
WITH EXPANSION/CHECK VALVE IN INDOOR
COIL, USE LIQUID LINE PRESSURE METHOD IN
COOLING MODE. Measure following values from
system : outside am bient tem perature, indoor wet bulb
tem perature, liquid line head pressure at gauge.
Adjust charge to achieve recommended liquid line
head pressure.
If the installer encounters a problem using the outdoor
m anufacturers suggeste d charging m ethod he should
contact the factory for assistance.
SPECIAL INSTRUCTIONS FOR
HORIZONTAL AND 4-WAY
CLOSE COUPLED COILS
1. The "M " (4 -W ay M ulti-P o sition) S eries coils are
designed to elim inate the need for a tra nsition b etw een
the coil and furnace in m ost new applications. In blow
through applications, the furnace and coil m ust be
sufficiently attached to allow uniform air distribution
across the coil surface. If this cannot be achieved w ith
a direct connection, then a m inim um of 18" length
transition m ust be field sup plied between the furnace
and coil housing.
BE SURE THAT THE FLOWRATOR PISTON
HAS BEEN REMOVED FROM FLOWRATOR
DISTRIBUTOR BODY PRIOR TO
INSTALLATION OF EXPANSION VALVE
ATTENTION!
IT IS MANDATORY TO USE AN
EMERGENCY AUXILIARY DRAIN PAN
WITH ANY COIL OR AIR HANDLER
INSTALLED IN AN ATTIC OR ABOVE A
FINISHED CEILING
CAUTION!
61BE0010/022008
3

2. "M " (4-W ay M ulti-P osition) S eries coils that fit flush
with M ulti-P osition furnace s som etim es have m arginal
air openings. In applications where the highest air flow
for a given furnace w idth as listed in furnace
m anufacturer's specification are desired , we
recom m end use of a w ider coil cabinet or reducing
m otor speed tap so as not to exce ed 400 CF M per
12,000 BTU H of rated cooling capacity. R educing the
airflow to cooling capacity ratio w ill also low er the
sensible to total ratio with better hum idity control
without reducing efficiency.
3. Care should be taken to insure no internal dam age is
done to the coil or furnace when fastening together or
suspending the coil and furnace assem bly (always
support both coil and furnace S EP A RA TELY ). Never
use screw s longe r than 1/2" in length and always
determ ine w hat is on the opposite side of the
penetration prior to inserting the screw.
4. "M " (4-W ay M ulti-Position) S eries coils are factory
supplie d for all positions: right to left, left to right,
upflow, and downflow . W hen fastening the coil to the
furnace, care should be taken to insure no internal
dam age to coil or furnace (see paragraph 3 above).
5. O n s om e "M " Se ries c oils wh ere the a ir e nte rs th e
open end of the "A " and the apex of the coil is
dow nstream from the air inlet, a condensate blowoff
guard is provided to be attached to the horizontal drain
pan to catch any condensate blowoff.
BE SURE TO CAP THE UNUSED DRAIN FITTINGS!
DIAGRAM 2
USE OF CONDENSATE BLOWOFF GUARD
6. "M " (4-W ay M ulti-Position) Series coils are provided
flat on both ends with separate flange that can be
located on either e nd as desired to change air direction
through coil. Air m ay blow into apex or open end of
coil.
7. On those coils used for downflow or reverse flo w
applications the top cap shipped m ust be rem oved and
repositioned as shown (D iagram 3). On reverse flow
the tw o-piece pan m ust be caulked to seal between the
pans and prevent air from blowing w ater out of
horizontal pa n. The air pressure drop is m uch higher so
air can blow w ater out between the pans in the corners
of the "A " end plate. S eal seam between horizontal
pan and "A " coil pan by caulking m ating surface on
horizontal pan and setting "A" pan in it. C enter "A" pan
in horizontal pan and add screws at corners
(D iagram 4) to hold in place while reassem bling pan.
All air leaks m ust be stop ped, it is recom m ended that
opposite hand coil be ordered to allow air to enter
bottom of "A” on coil.
DIAGRAM 3
(TOP CAP)
DIAGRAM 4
(REVERSE FLOW)
CONTACT US FOR HELP OR FOR ANY
COMMENTS ON OUR PRODUCTS.
As we strive to better serve our custom ers like you, we
are always ready to help you. W e also welcom e any
com m ents from our custom ers concerning quality and
im provem ents that could be m ade to o ur products.
Please visit us at w ww .HamiltonHomeProducts.com .
Thank you for the purchase of our product.
It is required that the horizontal drain pan
be removed for all down-flow applications
and recommended that it be removed for
all up-flow applications!
ATTENTION!
61BE0010/022008
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