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A Step-by-Step Guide to Installing a Copper Pancake Coil in HVAC Systems

If you're looking to enhance the efficiency and performance of your HVAC system, installing a copper pancake coil can be a game-changer. With its compact design and excellent heat transfer properties, a copper pancake coil can optimize energy consumption and improve overall system effectiveness. In this blog post, we will provide you with a step-by-step guide to installing a copper pancake coil in your HVAC system.

Step 1: Prepare the Work Area

Before starting the installation process, ensure that the work area is clean, well-lit, and free from any potential hazards. It is crucial to follow safety guidelines, such as wearing appropriate protective gear, including gloves and safety glasses.

Step 2: Choose the Right Size and Type of Copper Pancake Coil

Select a copper pancake coil that matches the specifications and requirements of your HVAC system. Consider factors such as the coil's dimensions, refrigerant compatibility, and the system's capacity. Ensure that the coil's connection fittings align with your HVAC system's configuration.

Step 3: Turn off Power and Isolate the System

To avoid any accidents, turn off the power supply to the HVAC system. Additionally, isolate the system by shutting off the main water supply and disconnecting any electrical connections.

Step 4: Remove the Old Coil (If Applicable)

If you are replacing an existing coil, carefully disconnect and remove it from the HVAC system. Follow the manufacturer's instructions or consult an HVAC professional if you are unsure about the proper removal procedure.

Step 5: Prepare the Copper Pancake Coil

Inspect the new copper pancake coil for any damages or defects before installation. Ensure that the coil is clean and free from debris. If necessary, use a soft brush or compressed air to remove any dirt or particles that may have accumulated during storage.

Step 6: Position and Secure the Coil

Carefully position the copper pancake coil in the designated space within the HVAC system. Ensure that the coil is aligned properly and fits securely. Use brackets, clamps, or other recommended methods to secure the coil in place, following the manufacturer's guidelines.

Step 7: Connect the Refrigerant Lines

Connect the refrigerant lines to the coil's inlet and outlet fittings. Use appropriate tools to make clean and secure connections, such as flare fittings or compression fittings. Apply the recommended sealants or thread tape to prevent refrigerant leaks.

Step 8: Insulate the Connections (If Required)

To prevent condensation and optimize system efficiency, consider insulating the refrigerant line connections. Use insulation material specifically designed for HVAC systems to wrap around the connections and ensure a tight seal.

Step 9: Perform System Leak Test

Before restoring power and restarting the HVAC system, conduct a thorough leak test. Use a refrigerant leak detector or a soapy water solution to check all connections for leaks. If any leaks are detected, promptly address and fix them before proceeding.

Step 10: Restore Power and Test the System

Once you have confirmed that the system is leak-free, restore power to the HVAC system. Turn on the system and monitor its operation to ensure proper functionality. Check for any unusual sounds, vibrations, or fluctuations in temperature.


By following this step-by-step guide, you can successfully install a copper pancake coil in your HVAC system. Remember to consult the manufacturer's instructions and consider seeking professional assistance if you are uncertain about any aspect of the installation process. With a properly installed copper pancake coil, you can enjoy improved heat transfer, enhanced energy efficiency, and optimal performance from your HVAC system.

Find out the various sizes of our Copper Pancake Coils here:


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