Lennox 13ACX, 13ACX-018, 13ACX-024, 13ACX-030, 13ACX-036 Installation Instructions Manual
...
INSTALLATION
2010 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
WARNING
Improper installation, adjustment, alteration, service or
maintenance can cause personal injury, loss of life, or
damage to property.
Installation and service must be performed by a licensed
professional installer (or equivalent) or a service agency.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting of
refrigerant (CFCs, HCFCs and HFCs) as of July 1, 1992.
Approved methods of recovery, recycling or reclaiming
must be followed. Fines and/or incarceration may be
levied for noncompliance.
INSTRUCTIONS
Merit® Series 13ACX Units
AIR CONDITIONER
506374−01
03/10
Supersedes 11/09
TABLE OF CONTENTS
Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . . . .
General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Unit Parts Arrangement 2. . . . . . . . . . . . . . . . . . .
Model Number Identification 3. . . . . . . . . . . . . . . . . . . . . .
General Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Gauge Set and Service Valves 3. . . . . . . . . . .
Recovering Refrigerant from Existing System 5. . . . . . .
New Outdoor Unit Placement 6. . . . . . . . . . . . . . . . . . . . .
New or Replacement Line Set 6. . . . . . . . . . . . . . . . . . . . .
Metering Devices and Flushing the System 10. . . . . . . .
Testing for Leaks 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuating the System 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Unit Delivered Void of Charge 16. . . . . . . . . . .
Unit Start−Up 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Refrigerant 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and Installing Louvers 22. . . . . . . . . . . . . . . . .
System Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up and Performance Checklist 24. . . . . . . . . . . . . .
Shipping and Packing List
Litho U.S.A.
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox Engineering Handbook. Coils
previously charged with HCFC−22 must be flushed.
WARNING
Electric Shock Hazard. Can cause injury
or death. Unit must be grounded in
accordance with national and local
codes.
Line voltage is present at all components
when unit is not in operation on units with
single-pole contactors. Disconnect all
remote electric power supplies before
opening access panel. Unit may have
multiple power supplies.
03/10 506374−01
Check the unit for shipping damage and listed times below
are intact. If damaged, or if parts are missing, immediately
contact the last shipping carrier.
1 Assembled outdoor unit
1 Refrigerant flow control kit (Fixed Orifice)
1 Liquid line filter drier
General
13ACX, which will also be referred to in this instruction as
the outdoor unit, uses HFC−410A refrigerant. This outdoor
unit must be installed with a matching indoor unit and line
set as outlined in the Lennox 13ACX Engineering
Handbook.
This outdoor unit is designed for use in systems that use
one of the following refrigerant metering devices:
Thermal expansion valve (TXV)
Fixed orifice
Page 1
*2P0310* *P506374-01*
Unit Dimensions − Inches (mm)
A
OUTDOOR
COIL FAN
COMPRESSOR
B
SUCTION AND LIQUID
LINE CONNECTION
OPTIONAL UNIT
STANDOFF KIT (4)
SIDE VIEW
Model Numbers A B
−018 24−1/4 (616) 25−1/4 (641)
−024 24−1/4 (616) 25−1/4 (641)
−030 24−1/4 (616) 29−1/4 (743)
−036 24−1/4 (616) 29−1/4 (743)
−042 28−1/4 (724) 29−1/4 (743)
−048 28−1/4 (724) 37−1/4 (925)
−060 28−1/4 (724) 33−1/4 (845)
(FIELD INSTALLED)
DISCHARGE AIR
SIDE VIEW
A
Typical Unit Parts Arrangement
CONTROL
CAPACITOR
GROUND LUG
CONTACTOR
CUTOUT FOR HIGH
VOLTAGE CONDUIT
NOTE PLUMBING LAYOUT AND COMPRESSOR TYPE MAY VARY SLIGHTLY BETWEEN
MODEL SIZES.
COMPRESS0R
DISCHARGE LINE
COMPRESSOR
HARNESS
OUTDOOR COIL
HIGH PRESSURE
SWITCH (S4)
CONTROL WIRE
LOOP
506374−01 03/10
LIQUID LINE SERVICE VALVE
Page 2
SUCTION LINE SERVICE VALVE
Model Number Identification
AC X13 024 −
Nominal SEER
Unit Type
AC = Air Conditioner
Refrigerant
X = R−410A
WARNING
This product and/or the indoor unit it is matched with may
contain fiberglass wool.
Disturbing the insulation during installation,
maintenance, or repair will expose you to fiberglass wool
dust. Breathing this may cause lung cancer. (Fiberglass
wool is known to the State of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin, and
eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact your
supervisor.
Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379−9900
CAUTION
Physical contact with metal edges and corners while
applying excessive force or rapid motion can result in
personal injury. Be aware of, and use caution when
working near these areas during installation or while
servicing this equipment.
General Information
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
−−
230
2
Minor Revision Number
Voltage
230 = 208/230V−1phase−60hz
Cooling Capacity − Tons
018 = 1.5
024 = 2
030 = 2.5
036 = 3
042 = 3.5
048 = 4
060 = 5
IMPORTANT
Only use Allen wrenches of sufficient hardness (50Rc −
Rockwell Harness Scale minimum). Fully insert the
wrench into the valve stem recess.
Service valve stems are factory−torqued (from 9 ft−lbs for
small valves, to 25 ft−lbs for large valves) to prevent
refrigerant loss during shipping and handling. Using an
Allen wrench rated at less than 50Rc risks rounding or
breaking off the wrench, or stripping the valve stem
recess.
See the Lennox Service and Application Notes #C−08−1
for further details and information.
IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted
snugly over the cap before tightening.
When servicing or repairing HVAC components, ensure
the fasteners are appropriately tightened. Table 1 provides
torque values for fasteners.
Table 1. Torque Requirements
Parts Recommended Torque
Service valve cap 8 ft.− lb. 11 NM
Sheet metal screws 16 in.− lb. 2 NM
Machine screws #10 28 in.− lb. 3 NM
Compressor bolts 90 in.− lb. 10 NM
Gauge port seal cap 8 ft.− lb. 11 NM
Operating Gauge Set and Service Valves
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
TORQUE REQUIREMENTS
When servicing or repairing heating, ventilating, and air
conditioning components, ensure the fasteners are
appropriately tightened. Table 1 lists torque values for
fasteners.
USING MANIFOLD GAUGE SET
When checking the system charge, only use a manifold
gauge set that features low loss anti−blow back fittings.
Manifold gauge set used with HFC−410A refrigerant
systems must be capable of handling the higher system
operating pressures. The gauges should be rated for use
with pressures of 0 − 800 psig on the high side and a low
side of 30" vacuum to 250 psig with dampened speed to
500 psi. Gauge hoses must be rated for use at up to 800
psig of pressure with a 4000 psig burst rating.
Page 3
13ACX SERIES
OPERATING SERVICE VALVES
The liquid and vapor line service valves are used for
removing refrigerant, flushing, leak testing, evacuating,
checking charge and charging.
SERVICE VALVES
VARIOUS TYPES
OPEN TO BOTH INDOOR AND
OUTDOOR UNITS
SERVICE PORT CAP
SERVICE PORT
TO INDOOR
CORE
UNIT
SERVICE PORT
(VALVE STEM
SHOWN OPEN)
INSERT HEX
WRENCH HERE
Each valve is equipped with a service port which has a
factory−installed valve stem. Figure 1 provides information
on how to access and operating both angle and ball service
valves.
SERVICE PORT CAP
SERVICE PORT
(VALVE STEM SHOWN
CLOSED) INSERT HEX
WRENCH HERE
CLOSED TO BOTH
INDOOR AND OUTDOOR
UNITS
TO INDOOR UNIT
FRONT-SEATED
STEM CAP
SERVICE PORT
CORE
VALVE STEM
TO INDOOR
UNIT
TO OUTDOOR
UNIT
(FRONT−SEATED
STEM CAP
ANGLE−TYPE
SERVICE VALVE
CLOSED)
TO OUTDOOR UNIT
WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN TO THE
LINE SET AND INDOOR UNIT.
WHEN SERVICE VALVE IS OPEN, THE SERVICE PORT IS OPEN TO LINE SET,
INDOOR AND OUTDOOR UNIT.
To Access Service Port:
A service port cap protects the service port core from contamination and
serves as the primary leak seal.
1. Remove service port cap with an appropriately sized wrench.
2. Connect gauge set to service port.
3. When testing is completed, replace service port cap and tighten as follows:
With Torque Wrench: Finger tighten and torque cap per Table 1.
Without Torque Wrench: Finger tighten and use an appropriately
sized wrench to turn an additional 1/6 turn clockwise.
Operating Angle Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. Use a service wrench with a hex−head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve
sizes) to back the stem out counterclockwise as far as it will go.
ANGLE−TYPE SERVICE VALVE
(BACK−SEATED OPENED)
TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°.
TO CLOSE ROTATE STEM
CLOCKWISE 90°.
SERVICE PORT
SERVICE PORT CORE
SERVICE PORT CAP
TO OUTDOOR UNIT
1/6 TURN
12
11
10
9
8
1
2
3
4
5
7
6
BALL (SHOWN CLOSED)
BALL−TYPE SERVICE
VAL VE
STEM CAP
Operating Ball Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. Use an appropriately sized wrenched to open. To open valve, rotate stem counterclockwise 90°. To close rotate stem clockwise 90°.
VALVE STEM
Reinstall Stem Cap:
Stem cap protects the valve stem from damage and serves as the primary seal. Replace the stem cap and
tighten as follows:
With Torque Wrench: Finger tighten and then torque cap per Table 1.
Without Torque Wrench: Finger tighten and use an appropriately sized wrench to turn
an additional 1/12 turn clockwise.
NOTE A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
Figure 1. Angle and Ball Service Valves
506374−01 03/10
Page 4
9
10
8
11
1/6 TURN
12
1
2
3
4
5
7
6
Recovering Refrigerant from Existing System
RECOVERING
REFRIGERANT FROM SYSTEM
DISCONNECT POWER
Disconnect all power to the existing outdoor unit at the service
1
disconnect switch or main fuse box/breaker panel.
MAIN FUSE BOX/
BREAKER PANEL
SERVICE
DISCONNECT
SWITCH
RECOVERING REFRIGERANT
Remove existing HCFC−22 refrigerant using one of the following procedures:
3
IMPORTANT Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes,
and/or long line sets.
CONNECT MANIFOLD GAUGE SET
Connect a gauge set, clean recovery cylinder and a recovery
2
machine to the service ports of the existing unit. Use the
instructions provided with the recovery machine to make the
connections.
MANIFOLD GAUGES
RECOVERY MACHINE
LOW
CLEAN RECOVERY
CYLINDER
OUTDOOR UNIT
HIGH
METHOD 1:
Us this method if the existing outdoor unit is not equipped with shut−off valves, or if the unit is not operational and you plan to use the existing
HCFC−22 to flush the system.
Remove all HCFC−22 refrigerant from the existing system. Check gauges after shutdown to confirm that the entire system is completely void of
refrigerant.
METHOD 2:
Use this method if the existing outdoor unit is equipped with manual shut−off valves, and you plan to use new HCFC−22 refrigerant to flush the
system.
The following devices could prevent full system charge recovery into the outdoor unit:
Outdoor unit’s high or low−pressure switches (if applicable) when tripped can cycle the compressor OFF.
Compressor can stop pumping due to tripped internal pressure relief valve.
Compressor has internal vacuum protection that is designed to unload the scrolls (compressor stops pumping) when the pressure ratio meets
a certain value or when the suction pressure is as high as 20 psig. (Compressor suction pressures should never be allowed to go into a vacuum.
Prolonged operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips, drive bearings and
internal seals.)
Once the compressor can not pump down to a lower pressure due to one of the above system conditions, shut off the vapor valve. Turn OFF the
main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set.
Perform the following task:
A. Start the existing HCFC−22 system in the cooling mode and close the liquid line valve.
B. Use the compressor to pump as much of the existing HCFC−22 refrigerant into the outdoor unit until the outdoor system is full. Turn the outdoor unit
main power OFF and use a recovery machine to remove the remaining refrigerant from the system.
NOTE It may be necessary to bypass the low pressure switches (if equipped) to ensure complete refrigerant evacuation.
C. When the low side system pressures reach 0 psig, close the vapor line valve.
D. Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system.
Page 5
13ACX SERIES
New Outdoor Unit Placement
See Unit Dimensions on Page 2 for sizing mounting slab,
platforms or supports. Refer to Figure 2 for mandatory
installation clearance requirements.
*
INSTALL UNIT AWAY
FROM WINDOWS
NOTES:
*
*
*
Service panel access clearance of 30 in. (762 mm) must be
maintained.
Clearance to one of the other three sides must be 36 in. (914
Clearance on one of the remaining two sides may be 12 in. (305
.
mm)
mm) and the final side may be 6 in. (152 mm)
.
Clearance required on top of unit is 48 in. (1219 mm).
A clearance of 24 in. (610 mm) must be maintained between two
units.
Figure 2. Installation Clearances
POSITIONING CONSIDERATIONS
CAUTION
TWO 90 ELBOWS INSTALLED IN LINE SET
WILL REDUCE LINE SET VIBRATION
Figure 3. Outside Unit Placement
PLACING OUTDOOR UNIT ON SLAB
When installing a unit at grade level, the top of the slab
should be high enough above the grade so that water from
higher ground would not collect around the unit as
illustrated in Figure 4.
DISCHARGE AIR
BUILDING
STRUCTURE
MOUNTING
SLAB
GROUND LEVEL
In order to avoid injury, take proper precaution when lifting heavy objects.
Consider the following when positioning the unit:
Some localities are adopting sound ordinances based
on the unit’s sound level registered from the adjacent
property, not from the installation property. Install the
unit as far as possible from the property line.
When possible, do not install the unit directly outside
a window. Glass has a very high level of sound
transmission. For proper placement of unit in relation
to a window see the provided illustration in Figure 3.
506374−01 03/10
Figure 4. Typical Slab Mounting at Ground Level
Slab may be level or have a slope tolerance away from the
building of not more than two degrees, or 2 inches per 5
feet (51 mm per 1524 mm) as illustrated in Figure 4.
INSTALLING OUTDOOR UNIT ON ROOF
Install the unit at a minimum of 4 inches (102 mm) above
the surface of the roof. Ensure the weight of the unit is
properly distributed over roof joists and rafters. Redwood
or steel supports are recommended.
New or Replacement Line Set
This section provides information on installation or
replacement of existing line set. If line set is not being
installed or replace then proceed to Brazing Connections
on Page 9.
Page 6
If refrigerant lines are routed through a wall, seal and
isolate the opening so vibration is not transmitted to the
building. Pay close attention to line set isolation during
installation of any HVAC system. When properly isolated
from building structures (walls, ceilings. floors), the
refrigerant lines will not create unnecessary vibration and
subsequent sounds.
Also, consider the following when placing and installing a
high−efficiency air conditioner:
REFRIGERANT LINE SET
Field refrigerant line set consists of liquid and suction lines
from the outdoor unit to the indoor unit coil. Use Lennox
L15 (braze, non−flare) series line set, or field−fabricated
refrigerant lines that meet the specifications listed below.
Table 2. Refrigerant Line Set
Valve Field
−018
−024
−030
−036
−042
−048
−060
Connections
Liquid
Line
3/8 in.
(10 mm)
3/8 in.
(10 mm)
3/8 in.
(10 mm)
Suction
Line
(19 mm)
(22 mm)
1−1/8 in.
(29 mm)
3/4 in.
7/8 in.
Model
NOTE Some applications may required a field provided 7/8" to
1−1/8" adapter
Recommended Line Set
Liquid
Line
3/8 in
(10 mm)
3/8 in.
(10 mm)
3/8 in.
(10 mm)
Suction
Line
3/4 in.
(19 mm)
7/8in.
(22 mm)
1−1/8 in.
(29 mm)
L15 Line
Set
15 ft. − 50 ft.
(4.6 m −
15 ft. − 50 ft.
(4.6 m −
Fabricated
L15−41
15 m)
L15−65
15 m)
Field
NOTE − When installing refrigerant lines longer than 50
feet, contact Lennox Technical Support Product
Applications for assistance or Lennox piping manual. To
obtain the correct information from Lennox, be sure to
communicate the following points:
Model (13ACX) and size of unit (e.g. −060).
Line set diameters for the unit being installed as listed
in Table 2 and total length of installation.
Number of elbows and if there is a rise or drop of the
piping.
MATCHING WITH NEW OR EXISTING INDOOR COIL
AND LINE SET
The RFC1−metering line consisted of a small bore copper
line that ran from condenser to evaporator coil. Refrigerant
was metered into the evaporator by utilizing
temperature/pressure evaporation effects on refrigerant in
the small RFC line. The length and bore of the RFC line
corresponded to the size of cooling unit.
If the 13ACX is being used with either a new or existing
indoor coil which is equipped with a liquid line which served
as a metering device (RFCI), the liquid line must be
replaced prior to the installation of the 13ACX unit.
Typically a liquid line used to meter flow is 1/4" in diameter
and copper.
LIQUID LINE FILTER DRIER INSTALLATION
The filter drier (one is shipped with each 13ACX unit) must
be field installed in the liquid line between the outdoor unit’s
liquid line service valve and the indoor coil’s metering
device (fixed orifice or TXV) as illustrated in Figure 5. This
filter drier must be installed to ensure a clean,
moisture−free system. Failure to install the filter drier will
void the warranty. A replacement filter drier is available
from Lennox. See Brazing Connections on Page 9 for
special procedures on brazing filter drier connections to
the liquid line.
BRAZE CONNECTION
POINTS
LIQUID
LINE
OUTDOOR
UNIT
LIQUID LINE
SERVICE VALVE
LINE
LIQUID LINE
FILTER DRIER
Figure 5. Typical Liquid Line Filter Drier Installation
CAUTION
Brazing alloys and flux contain materials which are
hazardous to your health.
Avoid breathing vapors or fumes from brazing
operations. Perform operations only in well ventilated
areas.
Wear gloves and protective goggles or face shield to
protect against burns.
Wash hands with soap and water after handling brazing
alloys and flux.
IMPORTANT
The Environmental Protection Agency (EPA) prohibits
the intentional venting of HFC refrigerants during
maintenance, service, repair and disposal of appliance.
Approved methods of recovery, recycling or reclaiming
must be followed.
IMPORTANT
If this unit is being matched with an approved line set
or indoor unit coil which was previously charged with
mineral oil, or if it is being matched with a coil which
was manufactured before January of 1999, the coil
and line set must be flushed prior to installation. Take
care to empty all existing traps. Polyol ester (POE) oils
are used in Lennox units charged with HFC−410A
refrigerant. Residual mineral oil can act as an
insulator, preventing proper heat transfer. It can also
clog the expansion device, and reduce the system
performance and capacity.
Failure to properly flush the system per the
instructions below will void the warranty.
Page 7
13ACX SERIES
LINE SET
INSTALLATION
Line Set Isolation The following illustrations are
examples of proper refrigerant line set isolation:
REFRIGERANT LINE SET TRANSITION
FROM VERTICAL TO HORIZONTAL
ANCHORED HEAVY NYLON
WIRE TIE OR AUTOMOTIVE
MUFFLER-TYPE HANGER
AUTOMOTIVE
MUFFLER-TYPE HANGER
IMPORTANT Refrigerant lines must not contact structure.
REFRIGERANT LINE SET INSTALLING
VERTICAL RUNS (NEW CONSTRUCTION SHOWN)
NOTE Insulate liquid line when it is routed through areas where the
surrounding ambient temperature could become higher than the
temperature of the liquid line or when pressure drop is equal to or greater
than 20 psig.
IMPORTANT Refrigerant lines must not contact wall
OUTSIDE WALL
VAPOR LINE
LIQUID LINE
WALL
STUD
STRAP LIQUID LINE TO
VAPOR LINE
LIQUID LINE
NON−CORROSIVE
METAL SLEEVE
VAPOR LINE − WRAPPED
IN ARMAFLEX
REFRIGERANT LINE SET INSTALLING
HORIZONTAL RUNS
To hang line set from joist or rafter, use either metal strapping material
or anchored heavy nylon wire ties.
WIRE TIE (AROUND
VAPOR LINE ONLY)
8 FEET (2.43 METERS)
STRAPPING
MATERIAL (AROUND
VAPOR LINE ONLY)
TAPE OR
WIRE TIE
FLOOR JOIST OR
ROOF RAFTER
8 FEET (2.43 METERS)
NON−CORROSIVE
METAL SLEEVE
STRAP THE VAPOR LINE TO THE JOIST
OR RAFTER AT 8 FEET (2.43 METERS)
INTERVALS THEN STRAP THE LIQUID
LINE TO THE VAPOR LINE.
TAPE OR
WIRE TIE
WIRE TIE
INSIDE WALL
WOOD BLOCK
BETWEEN STUDS
SLEEVE
VAPOR LINE WRAPPED
WITH ARMAFLEX
OUTSIDE
WALL
PVC
PIPE
FIBERGLASS
INSULATION
CAULK
STRAP
NON−CORROSIVE
METAL SLEEVE
WIRE TIE
WOOD BLOCK
WIRE TIE
STRAP
LIQUID
LINE
NOTE Similar installation practices should be used if line set is
to be installed on exterior of outside wall.
FLOOR JOIST OR
ROOF RAFTER
506374−01 03/10
WARNING Polyol ester (POE) oils used with HFC−410A
refrigerant absorb moisture very quickly. It is very important that the
refrigerant system be kept closed as much as possible. DO NOT
remove line set caps or service valve stub caps until you are ready
to make connections.
Figure 6. Line Set Installation
Page 8
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