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Installing a Home HVAC System

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Contents
Installing a Home HVAC System .................................................................................................... i Introduction ..................................................................................................................................... 3 Preparing the system and condenser ............................................................................................... 4 Preparing a system w/ Freon w/ a working ................................................................................. 4 w/ Freon w/ a bad compressor .................................................................................................... 5 Preparing system w/o Freon........................................................................................................ 6 Preparing the Furnace ..................................................................................................................... 7 Installation....................................................................................................................................... 9 Preparing furnace for installation................................................................................................ 9 Preparing condenser for installation ........................................................................................... 9 Condenser Installation .................................................................................................................. 10 Furnace Installation ....................................................................................................................... 13 Gas ............................................................................................................................................ 13 Evaporatibve Coil ..................................................................................................................... 14 Condensation PVC Line ........................................................................................................... 14 Flue Pipe ................................................................................................................................... 14 Low Voltage .............................................................................................................................. 14 High Voltage ............................................................................................................................. 15 Transition .................................................................................................................................. 16 Testing furnace .......................................................................................................................... 17 Supplies ......................................................................................................................................... 19 Index ............................................................................................................................................. 20

Introduction
This manual has been written for the purpose of Installing a Payne 16 SEER gas furnace and condenser in place of an existing gas HVAC system with a closet furnace. This manual was written for two HVAC licensed installers and/or installing technicians. Before starting you and your partner should refer to the Supplies section of this manual to ensure you have all the necessary tools and equipment to complete the job in a timely and efficient manner.

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Preparing the system and condenser

Preparing a system w/ Freon w/ a working

1. Beginning at the outdoor condenser, apply your gauges to the hi and low pressure Freon ports. 2. Now with your service wrench close the high pressure valve. 3. Remove the panel on the condenser concealing the contactor. 4. Move youre se4rvice wrench over to the low pressure valve 5. With an insulated driver or other tool press in the contactor and hold the contactor and the low pressure gauges needle should slowly start to drop, as the needle closes toward 0 begin closing the low pressure king valve. Once the low pressure gauge reads 0 close the king valve entirely trapping all of the systems Freon inside the condenser. 6. With copper tube cutters cut the condenser free on each line ~3 away from the king valves. a. Be sure to tape off the ends of the copper pipes leading to the house to prevent any moisture from entering the lines 7. With a pair of channel locks pinch the ends of copper still attached to the condenser until the tube 8. With your torch prepared, weld (braze) the lines attached to the condenser closed. 9. Remove the power key/flip the breaker off at the disconnect, 10. Confirm that there is no power to units contactor. 11. remove the ground, common and line voltage wires from the contactor and the ground from the condenser and disconnect the whip* from the condenser 12. Remove the 24 volt 2-wire from the contactor and pull free from condenser. 13. Using a suicide cord* attach 1 alligator clip to the line or the common wire of the whip* and attach the other 1 or 2 clips to the ground wire from the whip 14. Tape off the unused exposed wire coming from the whip 15. Replace the power key/turn the breaker on and you should have 120 volts form the 220 volt whip a. Check w/ meter 16. Plug in your recovery machine to the suicide cord

5 17. With the matching Freon recovery tank and an extra refrigeration hose begin the recovery of Freon a. Attach the unused yellow hose to the port labeled IN on your recovery machine. b. Attach the extra hose to the port labeled OUT on the recovery machine and the other end of the hose to the IN port on the recovery tank. c. Open your gauges on both sides and open the IN valve on your recovery bottle. d. Youll hear a rushing sound of freon stream into the tank, as soon as this sound stops that indicates the pressures have equalized.

e. Open both valves on your recovery machine and turn on your machine to begin the recovery.

18. Recovery will take some time, so while you wait for recovery to complete move indoors to begin the removal of the furnace.

w/ Freon w/ a bad compressor

1. Beginning at the outdoor condenser, apply your gauges to the hi and low pressure Freon ports. 2. Remove the panel on the condenser concealing the contactor. 3. Remove the power key/flip the breaker off at the disconnect, 4. Confirm that there is no power to units contactor. 5. Remove the ground, common and line voltage wires from the contactor and the ground from the condenser and disconnect the whip* from the condenser. 6. Remove the 24 volt 2-wire from the contactor and pull free from condenser. 7. Using a suicide cord* attach 1 alligator clip to the line or the common wire of the whip and attach the other 1 or 2 clips to the ground wire from the whip. 8. Tape off the unused exposed wire coming from the whip 9. Tape off the unused exposed wire coming from the whip 10. Replace the power key/turn the breaker on and you should have 120 volts form the 220 volt whip a. Check w/ meter to assure there is the proper voltage.

6 11. Plug in your recovery machine to the suicide cord 12. With the matching Freon recovery tank and an extra refrigeration hose begin the recovery of Freon a. Attach the unused yellow hose to the port labeled IN on your recovery machine. b. Attach the extra hose to the port labeled OUT on the recovery machine and the other end of the hose to the IN port on the recovery tank. c. Open your gauges on both sides and open the IN valve on your recovery bottle d. Youll hear a rushing sound of freon stream into the tank, as soon as this sound stops that indicates the pressures have equalized e. Open both valves on your recovery machine and turn on your machine to begin the recovery.

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13. Recovery will take some time, so while you wait for recovery to complete move indoors to begin the removal of the furnace.

Preparing system w/o Freon

1. Remove the panel on the condenser concealing the contactor. 2. Remove the power key/flip the breaker off at the disconnect, 3. Confirm that there is no power to units contactor. 4. Remove the ground, common and line voltage wires from the contactor and the ground from the condenser and disconnect the whip* from the condenser. 5. Remove the 24 volt 2-wire from the contactor and pull free from condenser.

7 6. With copper tube cutters cut the condenser free on each line ~3 away from the king valves. a. Be sure to tape off the ends of the copper pipes leading to the house to prevent any moisture from entering the lines.

Preparing the Furnace

1. Unplug the furnace and remove the pig tail from its connection in the furnace 2. Unwire the four or five 24 volt wires from the control board/relay and remove wire from furnace 3. Turn gas valve to the off position 4. With 2 wenches (crescent or pipe wrenches) undo the gas flex line at the nipple closest to the furnace and position the gas flex to the side and out of the work space. 5. Disconnect the flue pipe from the furnace and position it out of the work space, or remove completely. 6. With your PVC cutters cut the PVC at the nearest available spot to the coil, leaving the max amount of PVC possible. 7. Cut the copper lines at the coil, leaving as much excess on the line set as possible a. Make sure to tape off the ends going toward the condenser. 8. Disconnect the coil from the furnace by cutting through the foil tape/plaster cast on all sides. a. If plenum is metal, and cannot be disconnected by removing screws the use of sheet metal cutters is recommended. 9. Disconnect the supply plenum from the coil by cutting through the foil tape/plaster cast. a. If plenum is metal, and cannot be disconnected by removing screws the use of sheet metal cutters is recommended. 10. Remove any screws holding the furnace base to the wooden platform. 11. Remove coil from the closet. 12. Now remove the furnace. 13. If the furnace had a filter base which in most cases will not fit the newer smaller furnaces and this should be removed as well unless its size is a match for the new equipment.

Installation
Preparing furnace for installation
1. Looking at your platform for your furnace take note of which side each of your existing components is on and will come in the furnace on. a. Gas on left or right. b. 24 volt low voltage right or left. c. 120 volt high voltage left or right. 2. Unbox the new furnace. 3. Take off front plate and remove the three nuts covering the blower compartment and remove the metal baseplate. 4. With the knowledge you gathered in step 1 knock out the necessary holes on the sides of the furnace for your gas line and, your high and low voltage wires. 5. With either your bull-nose pliers or sheet metal benders bend the serrated metal on top of the furnace strait up on all 4 sides. 6. Now your equipment is ready for installation. 7. If the platform is in a closet, set and secure (with at least four sheet metal screws) your new filter base. 8. With a partner lift and place the furnace to your already in place filter base. 9. Place the Coil on top of the furnace and apply Foil tape to the seem where coil meets furnace on all sides. 10. Secure the furnace to the filter base in 4 corners with your sheet metal screws.

Preparing condenser for installation

1. Once the recovery machine has finished removing all the Freon from the old condenser. 2. Close the recovery bottle valves and recovery machine valves. 3. Pull the disconnects power key and undo your suicide cord. 4. Disconnect the refrigerant hoses from the old condenser. 5. Now you and a partner may now move the old condenser off the pap. 6. Place your new pad on top of the old pad and level it.

10 7. Unbox the new condenser 8. With your partner lift and a dolly lift and place the new condenser on the new pad. Lining up the copper line set with the copper lines protruding from the condenser. 9. You and your partner can now split up, while one works on the condenser the other can work inside on the furnace.

Condenser Installation
1. Remove electrical tape from the line set copper and remove plastic caps from condenser copper lines. 2. Insert copper lines from the line set into their corresponding sized condenser copper lines. (use joints and extra copper pipe if needed in order to reach condenser lines & use copper cutters if needed to shorten the copper line set to fit into the condenser lines.) 3. Using your torch and silfos rods weld (braze) the copper into place at all the joints and connections. (be sure not to overheat the lines too close to the king valves, as a precaution you could use a wet rag draped over the valves) 4. Remove the panel covering the contactor. 5. Punch out the hole in the bottom of the compartment for the proper whip size (should be or ) 6. Bring whip up through the hole you just punched and secure it in place with an electrical washer and nut. 7. Remove electrical tape from exposed whip wire tips 8. Insert the red wire from the whip under the fastening screw on the contactor's common side (yellow or red side) and tighten the screw on the wire. 9. Insert the black wire from the whip under the fastening screw on the contactor's line side (black side) and tighten the screw on the wire.

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http://www.askmehelpdesk.com/attachments/heating-air-conditioning/24263d1252180452-compressor-runs-blower-doesnt-sometimescontactor2.jpg

10. Place the ground wire from the whip under the ground nut and fasten tightly. 11. Now with the 24 volt 2-wire from the furnace crimp on a wire female terminal onto the end of each. 12. Attach one 24 volt wire to each side of the contactor, colors dont matter here. 13. Wait for your partner to complete the furnace installation before moving onto step #14 14. Remove the caps off both of the king valve 15. Crack the king valve on the 7/8s side allowing Nitrogen to pressurize the lines. 16. Listen and look for leaks hissing at all the joints outside at the condenser and indoors at the furnace. 17. If any leaks are found anywhere reweld the joint again adding more silfos. 18. Repeat steps 15-17 until all leaks have stopped. 19. Attach your red and blue refrigeration hoses on your manifold to the hi (red) and low (blue) ports on the condenser and the yellow hose to the vacuum pump. 20. Open up both king valves completely and tighten on their caps. 21. Attach your suicide cords black alligator clip to either side of the contactor, and clamp your red alligator clip to the ground wire. 22. Insert the power key into the disconnect and check for 120 volts with your multimeter. 23. Plug in your vacuum into the suicide cord, open your manifold valves and turn on the vacuum.

12 24. Once the vacuum has reached a pressure of -30 psi you can stop your vacuum as now all remaining nitrogen should be mostly absent from the system. 25. Disconnect the yellow hose from the vacuum and remove the suicide cord from the contactor and ground wire. And close off your manifold valves 26. Attach the yellow hose to your bottle of fresh Freon and turn bottle upside down and open valve on the bottle. 27. Charge the system up to 100 psi with Freon. 28. Turn on the system to Cool and Auto at the thermostat and take note of the temperature inside the home. 29. Allow for the condenser to come on and drop the pressure of the freon below 50 psi then 30. Once the system pressure gets below 50 psi you may open the low (blue) valve on your manifold and charge it up to the proper psi. The goal is to make the pressure on your green scale 35 degrees below the indoor temperature. 31. Once you have the system pressure holding stable at the right psi go inside and check your temperature split (the difference in temperature between the air intake vent and the air supply vent) to ensure the system is cooling properly. Split should be between 15-20 degrees.

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Furnace Installation
With furnace and the evaporative coil in place and all the proper access holes open. We'll begin with setting up the gas valve.

Gas
1. In most install cases the gas line will be to the left of the furnace in these cases you'll apply the gas putty to each end of a 6 black galvanized 1/2 diameter pipe and screw the pipe into the gas valve securely with your channel locks. 2. Screw on your coupling onto the other end of the galvanized pipe with a pair of channel locks. 3. Apply gas putty to the other end of the coupling and screw in the gas flex lines exposed nipple to the coupling and tighten with your channel locks. 4. Open the gas valve. 5. In cases when the gas line is on the right side you'll have to use 2 90 degree male-female black galvanized gas fittings and an extra coupling from the gas valve to aim the 6 galvanized pipe to the gas line on the right.

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Evaporatibve Coil
Evaporative Coil (Evap Coil)

1. Remove the electrical tape from the ends of your copper lines. 2. Bend the 3/8 line into the corresponding prt on the evap coil. 3. Using 3/4 copper fittings and excess 3/4 copper pipe pieces bring the copper line into its corresponding 3/4 port. 4. Weld (braze) the copper into place at each fitting joint and the ports.

Condensation PVC Line

1. Screw your threaded male-female slide PVC fitting into the evap coil's lowest condensation port and your pvc plug into the other. 2. With the old PVC condensation line use your excess PVC and fittings to connect the PVC into the female slide end of the threaded male-female slide PVC fitting making sure to glue each joint. Make sure to slope the PVC line downward to ensure a good flow of the condensation.

Flue Pipe
1. Remove as close to 4' of the old flue pipe as you are able from the furnace end. 2. Attach one end of your flexible flue pipe into the top of the draft connection on top of the furnaces 3. Flex and attach the other end to the remaining flue pipe extending toward the roof.

Low Voltage
1. Bring the low voltage 4-wire and 2-wire in through the punched out hole to the blower compartment. 2. Strip the ends of the 4-wires, you'll have a yellow, white, red and green wire.

15 3. Strip the ends of the 2-wire you'll have a read and a white white wire. 4. Twist together the ends of the red from the 2-wire with the yellow from the 4 wire. 5. At the control board in the blower compartment there will be 5 screws labeled R, W, Y, C, and G. 6. Insert the ends of the stripped 4-wire under the corresponding screws. Red-R, green-G, yellow/red-Y, white-W, and the white wire from the 2-wire under the C screw.

7. 8. Tighten all the screws and replace plate concealing the blower compartment.

High Voltage
1. With your pig tail unplugged strip the ends of the line, common and ground wires. 2. Insert the striped ends of wire into the punched out hole leading to the power compartment of the furnace. 3. Wire nut the wire from the stripped side of the pig tail to the white wire in the furnace. 4. Wire nut the wire from the solid side of the pig tail to the black wire. 5. Insert the middle (ground) wire under the grounding bolt of the furnace and secure it down.

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Transition
1. With your measuring tape measure and record the distance between the top corners of the coil to the corresponding bottom corners of the plenum as well as the lengths of the sides, fronts and backs of both the plenum and evap coil. 2. Now with your knife and ductboard cut our four pieces that will fill the gap between the coil and the plenum. The shapes of your pieces may vary from rectangular, trapezoids or rhombi. 3. Starting with the piece you cut for the back section insert the piece into the gap, shiny side out, and apply foil tape to the top and bottom of the piece attachint it to the plenum and coil. 4. Insert either your right or left piece into place and tape the top and bottom again as well as the seam where it touches the back piece. Repeat for the opposite side. 5. Before placing in the front piece, ready your soft cast plaster and brush coat each piece of foil tape with your plaster. 6. Place your final front piece into place. 7. Apply foil tape to the top, bottom and edges on the outside of each pieces and coat with soft cast plaster ensuring no air leaks.

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Testing furnace
1. At the thermostat, switch the system over to Heat and Auto and bring the desired temperature up. 2. Check your temperature split (the difference in temperature between the air intake vent and the air supply vent) which should be around 30 degrees to ensure heating side of the system is working properly.

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Supplies

Sheet metal cutters Sheet metal benders 2 channel locks 2 crescent wrenches Pipe wrench Hammer Impact drill Suicide cord Vacuum pump Flexible flue pipe 5 diameter Electrical tape foil tape Soft cast plaster & brush Phillips and flathead screwdriver 5/16 nut driver 1/4 nut driver Knife Duct board Wire strippers/cutters Multimeter w/ amp clamp Gas putty 1/2 diameter black galvanized gas pipe coupling

90 degree male-female 1/2 diameter galvanized gas pipex2 6 black galvanized gas pipe 1/2 diameter1/2 screws sheet metal wire nuts of varying sizes Refrigeration manifold gauges w/ an extra hose Torch with lighter & silfos rods Concrete condenser Pad Filter base Strait copper couplings 7/8 and 3/8 90 & 45 joints for 7/8 2 feet of 3/8 copper 2 feet of 7/8 copper Copper cutters PVC cutters Furnace Evaporative coil Condenser PVC 3/4 90 degree fittings PVC 3/4 threaded male-female slide fitting A stick of 3/4 PVC

PVC 3/4 plug PVC glue

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Index
condenser, 2, 4, 5, 6, 7, 8, 11, 12, 13, 14, 21 copper, 5, 8, 12, 16, 21 disconnect, 5, 6, 8, 11, 13 Evaporative Coil, 16 foil tape, 8, 9, 18, 21 freon, 6, 7, 14 Freon, 2, 5, 6, 7, 11, 14 furnace, 2, 4, 6, 7, 8, 9, 11, 12, 13, 15, 16, 17, 18, 19 gas, 4, 8, 11, 15, 21 multimeter, 13 pig tail, 8, 17 plenum, 8, 9, 18 screw, 12, 15, 17 Suicide cord, 21 system, 2, 4, 5, 7, 14, 19 thermostat, 14, 19 Voltage, 2, 16, 17