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506945-01
User Manual
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Lennox 506945-01 User Manual

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INSTALLATION
E2013 Lennox Industries Inc.
Dallas, Texas, USA
THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE
WARNING
GENERAL
This 13ACX outdoor unit is designed for use with HFC-410A refrigerant only. This unit must be installed with an approved indoor unit. See the Lennox 13ACX Product Specifications bulletin (EHB) for approved indoor component match ups.
These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.
INSTRUCTIONS
Merit® Series 13ACX Units
AIR CONDITIONER 506945-01
5/2013 Supersedes 7/2012
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.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.
CAUTION
As with any mechanical equipment, contact with sharp sheet metal edges can result in personal injury. Take care while handling this equipment.
Litho U.S.A.
STEP 1 -- SETTING THE UNIT -- Clearances
CLEARANCE ON ALL SIDES — INCHES (MILLIMETERS)
6 (152)
NOTES:
S Clearance to one of the other three
12 (305)
30 (762)
sides must be 36 inches (914mm).
S Clearance to one of the remaining
two sides may be 12 inches (305mm) and the final side may be 6 inches (152mm).
36 (914)
MINIMUM CLEARANCE BETWEEN TWO UNITS
7/2012 506945-01
LINE SET CONNECTIONS
24 (610)
FIGURE 1
Page 1
ACCESS
LINE SET
CONNECTIONS
MINIMUM CLEARANCE
ABOVE UNIT
48 (1219)
PANEL
*2P72012* *P506945-01*
UNIT DIMENSIONS - INCHES (MM)
A
B
SIDE VIEW
FIGURE 2
TABLE 1
UNIT DIMENSIONS
Model Numbers A B
13ACX-018-230 24-1/4 (616) 25-1/4 (641)
13ACX-024-230 24-1/4 (616) 25-1/4 (641)
13ACX-030-230 24-1/4 (616) 29-1/4 (743)
13ACX-036-230 24-1/4 (616) 29-1/4 (743)
13ACX-042-230 28-1/4 (718) 29-1/4 (743)
13ACX-048-230 28-1/4 (718) 33-1/4 (845)
13ACX-060-230 28-1/4 (718) 29-1/4 (743)
IMPORTANT !
This model is designed for use in check / expansion valve systems only. An indoor expansion valve ap proved for use with HFC-410A refrigerant must be or dered separately and installed prior to operating the system.
IMPORTANT !
Exhaust vents from dryers, water heaters and furnaces should be directed away from the outdoor unit. Pro longed exposure to exhaust gases and the chemicals contained within them may cause condensation to form on the steel cabinet and other metal components of the outdoor unit. This will diminish unit performance and longevity.
PLACEMENT
INSTALL UNIT AWAY
FROM WINDOWS
STEP 1 -- SETTING THE UNIT (CONTIN UED) -- Unit Placement
WARNING
To prevent personal injury, as well as damage to panels, unit or structure, observe the following:
While installing or servicing this unit, carefully stow all removed panels so that the panels will not cause injury to personnel, objects or nearby structures. Also, take care to store panels where they will not be subject to damage (e.g., being bent or scratched).
While handling or stowing the panels, consider any weather conditions (especially wind) that may cause panels to be blown around and damaged.
NOTICE !
Roof Damage! This system contains both refrigerant and oil. Some
rubber roofing material may absorb oil, causing the rubber to degrade. Failure to follow this notice could result in damage to roof surface.
TWO 90_ ELBOWS INSTALLED IN LINE SET
WILL REDUCE LINE SET VIBRATION
FIGURE 3
SLAB MOUNTING
Install unit level or, if on a slope, maintain slope tolerance of 2 degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from building structure.
BUILDING
STRUCTURE
DISCHARGE AIR
MOUNTING SLAB
GROUND LEVEL
FIGURE 4
Page 2
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
FIGURE 5
Page 3
13ACX SERIES
STEP 2 -- REFRIGERANT PIPING -- Flushing Existing Line Set and Indoor Coil
Flush the existing line set per the following instructions. For more information, refer to the Installation and Service Procedures manual available on DaveNet. CAUTION - DO NOT attempt to flush and re-use existing line sets or indoor coil when the system contains contaminants (i.e., compressor burn out).
NOTE - When installing refrigerant lines longer than 50 feet, refer to the Refrigerant Piping Design and Fabrication Guidelines manual available on DaveNet (Corp. 9351-L9), or contact the Technical Support Department Product Application group for assistance.
IMPORTANT !
If this unit is being matched with an approved line set or indoor unit coil that 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 insula tor, preventing proper heat transfer. It can also clog the expansion device and reduce system perfor mance and capacity.
Failure to properly flush the system per this instruc tion and the detailed Installation and Service Proce dures manual will void the warranty.
WARNING
When using a high pressure gas such as nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).
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.
Some scroll compressors have an internal vacuum protector that will unload scrolls when suction pres sure goes below 20 psig. A hissing sound will be heard when the compressor is running unloaded. Protector will reset when low pressure in system is raised above 40 psig. DO NOT REPLACE COMPRES SOR.
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 6. 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 page 7 for special procedures on brazing filter drier connections to the liquid line.
Typical Liquid Line Filter Drier Installation
WARNING
IMPORTANT !
BRAZE CONNECTION POINTS
WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly.
Failure to follow this warning may result in personal injury or death.
TABLE 2
REFRIGERANT LINE SET — INCHES (MM)
Model Number (-xx*)
13ACX-018-230 13ACX-024-230
13ACX-030-230 13ACX-036-230 13ACX-042-230
13ACX-048-230 13ACX-060-230
* Applicable to all minor revision numbers unless otherwise specified. ** Some applications may required a field-provided 1-1/8” to 7/8” adapter.
Liquid Line Suction Line L15 Line Set Model Line Set Length Catalog Number
3/8” (10 mm) 5/8“ (16 mm)
3/8” (10 mm) 3/4” (19 mm)
3/8” (10 mm) 7/8” (22 mm)
Valve Size Connections Recommended Line Sets
OUTDOOR
UNIT
LIQUID LINE
SERVICE VALVE
LINE
LIQUID LINE
FILTER DRIER
FIGURE 6
L15-26-20 20 feet (6.1 m) 89J52
L15-26-25 25 feet (9.1 m) 89J53
L15-26-35 35 feet (12.2 m) 89J54
L15-26-50 50 feet (15.2 m) 89J55
L15-41-20 20 feet (6.1 m) 89J56
L15-41-30 30 feet (9.1 m) 89J57
L15-41-40 40 feet (12.2 m) 89J58
L15-41-50 50 feet (15.2 m) 89J59
L15-65-30 30 feet (9.1 m) 89J60
L15-65-40 40 feet (12.2 m) 89J61
L15-65-50 50 feet (15.2 m) 89J62
LIQUID
LINE
Page 4
STEP 2 -- REFRIGERANT PIPING -- Removing Existing Indoor Metering Device
TYPICAL EXISTING FIXED ORIFICE
1A
DISTRIBUTOR
ASSEMBLY
A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps from the liquid line and distributor as
sembly.
C Using two wrenches, disconnect liquid line from liquid line orifice hous
ing. Take care not to twist or damage distributor tubes during this pro cess.
D Remove and discard fixed orifice, valve stem assembly (if present)
and Teflon® washer as illustrated above.
E Use a field-provided fitting to temporarily reconnect the liquid line to the
indoor unit's liquid line orifice housing.
(UNCASED COIL SHOWN)
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
TEFLON® RING
FIXED ORIFICE
REMOVE AND DISCARD
WHITE TEFLON
(IF PRESENT)
®
SEAL
LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
REMOVAL PROCEDURE
OR
BRASS NUT
1B
TWO-PIECE PATCH PLATE
CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE
2
CYLINDER CONTAINING CLEAN HCFC-22 TO BE USED FOR FLUSHING (Positioned to deliver liquid
A
refrigerant)
1
VAPOR LINE
SERVICE VALVE
EXISTING
INDOOR
UNIT
LIQUID LINE SERVICE
VALV E
RECOVERY
CYLINDER
VAPOR
LIQUID
OUTDOOR
B
NEW
UNIT
OPENED
C
D
RECOVERY MACHINE
A HCFC-22 cylinder with clean refrigerant (positioned to deliver liquid
refrigerant) to the vapor service valve.
B HCFC-22 gauge set (low side) to the liquid line valve. C HCFC-22 gauge set center port to inlet on the recovery machine with an
empty recovery tank connected to the gauge set.
D Connect recovery tank to recovery machine per machine instructions.
GAUGE
MANIFOLD
LOW HIGH
CLOSED
TANK RETURN
INLET
DISCHARGE
TYPICAL EXISTING EXPANSION VALVE REMOVAL PROCEDURE (UNCASED COIL SHOWN)
ORIFICE
HOUSING
EQUALIZER LINE
STUB END
TEFLON RING
VAPOR
EXPANSION
VALV E
®
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
LINE
TEFLON
(UNCASED COIL ONLY)
DISTRIBUTOR
TUBES
DISTRIBUTOR
ASSEMBLY
MALE EQUALIZER
LINE FITTING
A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps from the liquid line and distributor
assembly.
C Disconnect the equalizer line from the expansion valve equalizer
line fitting on the vapor line.
D Remove the vapor line sensing bulb. E Disconnect the liquid line from the expansion valve at the liquid line
assembly.
F Disconnect the expansion valve from the liquid line orifice housing.
Take care not to twist or damage distributor tubes during this process.
G Remove and discard expansion valve and the two Teflon® rings. H Use a field-provided fitting to temporarily reconnect the liquid line
to the indoor unit's liquid line orifice housing.
LIQUID LINE
SENSING BULB
FLUSHING LINE SET
The line set and indoor unit coil must be flushed with at least the same
3
amount of clean refrigerant that previously charged the system. Check the charge in the flushing cylinder before proceeding.
A Set the recovery machine for liquid recovery and start the
recovery machine. Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line
B
set and indoor unit coil.
B Position the cylinder of clean HCFC-22 for delivery of liquid
refrigerant and open its valve to allow liquid refrigerant to flow into the system through the vapor line valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine.
C After all of the liquid refrigerant has been recovered, switch the
recovery machine to vapor recovery so that all of the HCFC-22 vapor is recovered. Allow the recovery machine to pull the system down to 0.
D Close the valve on the inverted HCFC-22 drum and the gauge
set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off.
RING
®
SENSING
LINE
LIQUID
LINE
FIGURE 7
Page 5
13ACX SERIES
STEP 2 -- REFRIGERANT PIPING -- Brazing Procedures
CUT AND DEBUR
Cut ends of the refrigerant lines square (free from nicks or dents)
1
and debur the ends. The pipe must remain round. Do not crimp end of the line.
CUT AND DEBUR
LINE SET SIZE MATCHES
SERVICE VALVE CONNECTION
SERVICE VALVE
COPPER TUBE
REDUCER
CONNECTION
STUB
LINE SET SIZE IS SMALLER
THAN CONNECTION
REFRIGERANT LINE
DO NOT CRIMP SERVICE VALVE
CONNECTOR WHEN PIPE IS
SMALLER THAN CONNECTION
CAP AND CORE REMOVAL
Remove service cap and core from
2
both the suction / vapor and liquid line service ports.
SERVICE PORT
CAP
SERVICE
PORT
CORE
ANGLE-TYPE SERVICE
VALV E
BALL-TYPE SERVICE
VALV E
ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE VALVES
3
Flow regulated nitrogen (at 1 to 2 psig) through the low-side refrigeration gauge set into the liquid line service port valve, and out of the suction / vapor line service port valve.
A Connect gauge set low pressure side to
liquid line service valve (service port).
B Connect gauge set center port to bottle of
nitrogen with regulator.
C Remove core from valve in suction / vapor
line service port to allow nitrogen to escape.
ATTACH
GAUGES
HIGHLOW
USE REGULATOR TO FLOW
NITROGEN AT 1 TO 2 PSIG.
SERVICE
PORT CORE
SERVICE PORT CAP
SUCTION / VAPOR SERVICE PORT MUST BE
OPEN TO ALLOW EXIT POINT FOR NITROGEN
VAPOR LINE
INDOOR
UNIT
LIQUID LINE
C
LIQUID LINE SERVICE
SUCTION /
VAPOR LINE
SERVICE
VALV E
VALV E
FIGURE 8
CAUTION
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.
B
OUTDOOR
UNIT
WHEN BRAZING LINE SET TO
A
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
Danger of fire. Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing. Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture. Check the high and low pressures before applying heat.
NITROGEN
WARNING
Page 6
WRAP SERVICE VALVES
To help protect service valve seals during brazing, wrap water-saturated cloths around service valve bodies and copper tube stubs. Use
4
additional water-saturated cloths underneath the valve body to protect the base paint.
FLOW NITROGEN
Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and
5
out of the suction / vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set connections.
BRAZE LINE SET
Wrap both service valves with water -saturated cloths as illustrated here and as mentioned in step 4, before brazing to line set. Cloths must
6
remain water-saturated throughout the brazing and cool-down process.
LIQUID LINE SERVICE VALVE
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
IMPORTANT — Allow braze joint to cool. Apply
additional water-saturated cloths to help cool brazed joint. Do not remove water-saturated cloths until piping has cooled. Temperatures above 250ºF will damage valve seals.
LIQUID LINE
WATER-SATURATED CLOTH
WARNING
FIRE, PERSONAL INJURY, OR PROPERTY DAMAGE
may result if you do not wrap a water-saturated cloth around both liquid and suction line service valve bodies and copper tube stub while brazing the line set! The braze, when complete, must be quenched with water to absorb any residual heat.
Do not open service valves until refrigerant lines and indoor coil have been leak-tested and evacuated. Refer to Installation and Service Procedures manual found on DAVENET.
SUCTION / VAPOR LINE
PREPARATION FOR NEXT STEP
After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water-saturated cloths to both
7
services valves to cool piping. Once piping is cool, remove all water-saturated cloths.
SUCTION / VAPOR LINE
SERVICE VALVE
WATER-SATURATED CLOTH
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
FIGURE 9
Page 7
13ACX SERIES
STEP 2 -- REFRIGERANT PIPING -- Installing Indoor Expansion Valve
This outdoor unit is designed for use in systems that use either an fixed orifice (RFC) (included with outdoor unit), or expansion valve metering device (purchased separately) at the indoor coil. See the 13ACX Product Specifications bulletin (EHB) for approved expansion valve kit match ups. The expansion valve unit can be installed internal or external to the indoor coil. In applications where an uncased coil is being installed in a field-provided plenum, install the expansion valve in a manner that will provide access for field servicing of the expansion valve. Refer to below illustration for reference during installation of expansion valve unit. After installation of the indoor coil metering device, proceed to Step 5.
INDOOR EXPANSION VALVE INSTALLATION
TWO-PIECE
PATCH PLATE
(UNCASED
COIL ONLY)
DISTRIBUTOR
TUBES
DISTRIBUTOR
ASSEMBLY
MALE EQUALIZER LINE
FITTING (SEE
EQUALIZER LINE
INSTALLATION FOR
DETAILS)
Sensing bulb insulation is required if expansion valve is installed external to the coil casing. See sensing bulb installation for bulb positioning.
(Uncased Coil Shown)
LIQUID LINE
ORIFICE
HOUSING
STUB
END
TEFLON RING
EQUALIZER LINE
VAPOR
EXPANSION
VALV E
®
LIQUID LINE
ASSEMBLY WITH
LINE
TEFLON
RING
BRASS NUT
LIQUID LINE
®
SENSING
LINE
C Install one of the provided Teflon® rings around the
stubbed end of the expansion valve and use refrigerant oil to lightly lubricate the connector threads and ex posed surface of the Teflon
®
ring.
D Attach the stubbed end of the expansion valve to the
liquid line orifice housing. Finger tighten, then use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure to the right, or tighten to 20 ft-lb.
E Place the remaining Teflon
end of the expansion valve. Lightly lubricate connector threads and expose surface of the Teflon
®
washer around the other
®
ring with
refrigerant oil.
F Attach the liquid line assembly to the expansion valve.
Finger tighten, then use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or tighten to 20 ft-lb.
SENSING BULB INSTALLATION
A Attach the vapor line sensing bulb in the proper orienta
tion as illustrated below using the clamp and screws provided.
B NOTE - Though it is preferred to have the sensing bulb
installed on a horizontal run of the vapor line, installation on a vertical run of piping is acceptable if necessary.
NOTE — Confirm proper thermal contact between vapor line and expansion bulb before insulating the sensing bulb.
C Connect the equalizer line from the expansion valve to
the equalizer vapor port on the vapor line. Finger tighten the flare nut, then tighten an additional 1/8 turn (7 ft-lbs) as illustrated to the right.
1/2 Turn
11
10
9
8
7
1/8 Turn
11
10
9
8
7
12
1
2
3
4
5
6
12
1
2
3
4
5
6
EQUALIZER LINE INSTALLATION
A Remove and discard either the flare seal cap or flare nut with
copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure below.
B Remove the field-provided fitting that temporarily reconnected
the liquid line to the indoor unit's distributor assembly.
FLARE SEAL CAP
OR
FLARE NUT
COPPER FLARE SEAL BONNET
MALE BRASS EQUALIZER LINE FITTING
VAPOR LINE
VAPOR LINE
VAPOR LINE
FIGURE 10
Page 8
ON LINES SMALLER THAN 7/8”, MOUNT SENSING BULB AT EITHER THE 3 OR 9 O'CLOCK POSITION.
BULB
BULB
NOTE — NEVER MOUNT THE SENSING
BULB ON BOTTOM OF LINE.
12
12
BULB
ON 7/8” AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 4 OR 8 O'CLOCK POSITION. NEVER MOUNT THE SENSING BULB ON BOTTOM OF LINE.
BULB
STEP 3 -- LEAK TEST AND EVACUATION
LEAK TEST
LOW
B
NITROGEN
CONNECT GAUGE SET
1
A Connect the high pressure hose of an HFC-410A manifold gauge set to the vapor valve service port.
NOTE — Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the vapor port better protects the manifold gauge set from high pressure damage.
B With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of
the manifold gauge set.
NOTE — Later in the procedure, the HFC-410A container will be replaced by the nitrogen container.
HFC-410A
HIGH
MANIFOLD GAUGE SET
TO VAPOR
SERVICE VALVE
(ANGLE OR BALL
TYPE)
A
OUTDOOR UNIT
After the line set has been connected to the indoor and outdoor units, check the line set connections and
2
TEST FOR LEAKS
indoor unit for leaks. Use the following procedure to test for leaks:
A With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the
manifold gauge set. Open the valve on the HFC-410A cylinder (vapor only).
B Open the high pressure side of the manifold to allow HFC-410A into the line set and indoor unit. Weigh in
a trace amount of HFC-410A. [A trace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kPa) pressure.] Close the valve on the HFC-410A cylinder and the valve on the high pressure side of the manifold gauge set. Disconnect the HFC-410A cylinder.
C Connect a cylinder of nitrogen with a pressure regulating valve to the center port of the manifold gauge
set.
D Adjust nitrogen pressure to 150 psig (1034 kPa). Open the valve on the high side of the manifold gauge set
in order to pressurize the line set and the indoor unit.
E After a few minutes, open one of the service valve ports and verify that the refrigerant added to the
system earlier is measurable with a leak detector.
F After leak testing, disconnect gauges from service ports.
FIGURE 11
Page 9
13ACX SERIES
STEP 3 -- LEAK TEST AND EVACUATION (CONTINUED)
CONNECT GAUGE SET
NOTE — Remove cores from service valves (if not already done).
3
A Connect low side of manifold gauge set with
1/4 SAE in-line tee to vapor line service valve
B Connect high side of manifold gauge set to
liquid line service valve
C Connect available micron gauge connector
on the 1/4 SAE in-line tee.
D Connect the vacuum pump (with vacuum
gauge) to the center port of the manifold gauge set. The center port line will be used later for both the HFC-410A and nitrogen containers.
NITROGEN
HFC-410A
OUTDOOR
UNIT
VACUUM PUMP
EVACUATION
A
B
1/4 SAE TEE WITH SWIVEL COUPLER
500
C
MICRON
GAUGE
SERVICE VALVE
TO LIQUID LINE SERVICE VALVE
MINIMUM 3/8” HOSE
GAUGE SET
TO VAPOR
RECOMMEND
LOW
MANIFOLD
D
EVACUATE THE SYSTEM
A Open both manifold valves and start the vacuum pump.
4
B Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury).
NOTE — During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once. A rapid rise in pressure indicates a relatively large leak. If this occurs, repeat the leak testing procedure.
NOTE — The term absolute pressure means the total actual pressure above absolute zero within a given volume or system. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure.
C When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), perform the following:
S Close manifold gauge valves. S Close valve on vacuum pump. S Turn off vacuum pump. S Disconnect manifold gauge center port hose from vacuum pump. S Attach manifold center port hose to a nitrogen cylinder with pressure
regulator set to 150 psig (1034 kPa) and purge the hose.
S Open manifold gauge valves to break the vacuum in the line set and
indoor unit.
Possible equipment damage.
Avoid deep vacuum operation. Do not use compressors to evacuate a system. Extremely low vacuum can cause internal arcing and compressor failure. Damage caused by deep vacuum operation will void warranty.
S Close manifold gauge valves.
D Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the
nitrogen from the line set and indoor unit.
E Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and indoor unit until the
absolute pressure does not rise above 500 microns (29.9 inches of mercury) within a 20-minute period after shutting off the vacuum pump and closing the manifold gauge valves.
F When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to a
cylinder of HFC-410A positioned to deliver liquid refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit.
G Perform the following:
S Close manifold gauge valves. S Shut off HFC-410A cylinder. S Reinstall service valve cores by removing manifold hose from service valve. Quickly
install cores with core tool while maintaining a positive system pressure.
S Replace stem caps and finger tighten them, then tighten an additional one-sixth (1/6)
of a turn as illustrated.
WARNING !
10
9
8
1/6 TURN
12
11
7
HIGH
1
2
3
4
5
6
FIGURE 12
Page 10
STEP 4 -- ELECTRICAL -- Circuit Sizing and Wire Routing
In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC).
Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size.
24VAC TRANSFORMER
Use the transformer provided with the furnace or air handler for low‐voltage control power (24VAC - 40 VA minimum)
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.
ELECTROSTATIC
DISCHARGE
(ESD)
Precautions and
Procedures
IMPORTANT !
CAUTION
Electrostatic discharge can affect electronic components. Take care during unit installation and service to protect the unit's electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the unit, the control and the technician at the same electrostatic potential. Touch hand and all tools on an unpainted unit surface before performing any service procedure to neutralize electrostatic charge.
SIZE CIRCUIT AND INSTALL SERVICE
DISCONNECT SWITCH
Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR per NEC). Install power wiring and properly sized disconnect switch.
MAIN FUSE BOX/
BREAKER PANEL
SERVICE
DISCONNECT
SWITCH
NOTE — Units are approved for use only with copper conductors. Ground unit at disconnect switch or connect to an earth ground.
INSTALL THERMOSTAT
Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and 5 feet (1.5m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight or drafts.
THERMOSTAT
5 FEET
(1.5M)
NOTE — 24VAC, Class II circuit connections are made in the control panel.
FIGURE 13
Page 11
13ACX SERIES
STEP 4 -- ELECTRICAL (CONTINUED) -- High Voltage and Field Control Wiring
The following illustration provide an example of control wiring connections when using standard thermostat.
ROUTING HIGH VOLTAGE, GROUND AND CONTROL WIRING
HIGH VOLTAGE / GROUND WIRES
Any excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring. To facilitate a conduit, a cutout is located in the bottom of the control panel. Connect conduit to the control panel using a proper conduit fitting.
NOTE — Wire tie provides low voltage control wire strain relief and maintains separation of field-installed low and high voltage circuits.
NOTE — For proper voltages, select thermostat wire (control wires) gauge per table above.
NOTE — Do not bundle any excess 24VAC control wires inside control panel.
Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated.
A Run 24VAC control wires through hole with grommet
and secure with provided wire tie.
B Make 24VAC thermostat wire connections. Locate
the two wires from the contactor and make connection using field-provided wire nuts:
S Yellow to Y1 S Black to C (common)
FIELD CONTROL WIRING
THERMOSTAT INDOOR UNIT
R
W1
Y
G
C
WIRE RUN LENGTH AWG# INSULATION TYPE
LESS THAN 100' (30 METERS) 18 TEMPERATURE RATING
MORE THAN 100' (30 METERS) 16 35ºC MINIMUM.
POWER
HEAT
COOLING
INDOOR BLOWER
COMMON
R
W
Y
G
C
YELLOW
BLACK
OUTDOOR UNIT
Y1
C
FIGURE 14
STEP 5 -- UNIT START-UP
IMPORTANT
1. Rotate fan to check for binding.
2. Inspect all factory- and field-installed wiring for loose connections.
3. After evacuation is complete, open the liquid line and suction line service valve stems to release the refrigerant charge (contained in outdoor unit) into the system.
4. Replace the stem caps and tighten to the value listed in table 3.
5. Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit's nameplate. If not, do not start the equipment until you have consulted with the power company and the voltage condition has been corrected.
6. Connect manifold gauge set for testing and charging using figure NO TAG as a guideline.
7. Set the thermostat for a cooling demand. Turn on power to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit.
8. Recheck voltage while the unit is running. Power must be within range shown on the unit nameplate.
9. Check system for sufficient refrigerate using the procedures outlined in under System Refrigerant.
OPERATING MANIFOLD GAUGE SET AND SERVICE VALVES
The liquid and vapor line service valves are used for removing refrigerant, flushing, leak testing, evacuating, checking charge and charging.
Each valve is equipped with a service port which has a factory-installed valve stem. Figure 15 provides information on how to access and operating both angle and ball service valves.
Torque Requirements
When servicing or repairing heating, ventilating, and air conditioning components, ensure the fasteners are appropriately tightened. Table 3 lists torque values for fasteners.
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 3 provides torque values for fasteners.
Page 12
TABLE 3. 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
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.
Using Manifold Gauge Set
When checking the system charge, only use a manifold
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.
SERVICE PORT CAP
SERVICE PORT CORE
TO INDOOR
UNIT
(VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE
(VALVE STEM SHOWN CLOSED) INSERT HEX WRENCH HERE
SERVICE PORT
CORE
TO OUTDOOR UNIT
ANGLE-TYPE SERVICE VALVE
(BACK-SEATED OPENED)
When service valve is OPEN, the service port is open to line set, indoor and outdoor unit.
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°.
TO INDOOR UNIT
TO OPEN ROTATE STEM COUNTERCLOCKWISE 90°.
TO CLOSE ROTATE STEM CLOCKWISE 90°.
SERVICE PORT
SERVICE PORT
SERVICE PORT
CORE
CAP
TO OUTDOOR
UNIT
BALL (SHOWN CLOSED)
VALV E STEM
STEM CAP
STEM CAP
ANGLE-TYPE SERVICE VALVE
(FRONT-SEATED CLOSED)
When service valve is CLOSED, the service port is open to the line set and indoor 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:
S With torque wrench: Finger tighten and
torque cap per table 3.
S Without torque wrench: Finger tighten and
use an appropriately sized wrench to turn an additional 1/6 turn clockwise.
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:
9
10
8
11
12
7
6
S With Torque Wrench: Finger tighten and
then torque cap per table 3.
S Without Torque Wrench: Finger tight
en and use an appropriately sized wrench to turn an additional 1/12 turn clockwise.
10
9
12
11
8
7
6
1/6 TURN
1
2
3
4
5
1/12 TURN
1
2
3
4
5
NOTE — A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
FIGURE 15
Page 13
13ACX SERIES
CHECKING AND ADDING SYSTEM REFRIGERANT
The 13ACX unit is factory-charged with enough HFC-410A refrigerant to accommodate a 15-foot length of refrigerant piping. Charge should be checked and adjusted using the tables provided on the charging procedure sticker located on the unit access panel. Detailed information is provided in the 13ACX Installation and Service Procedures manual (Corp0625-L5), which is available on DaveNet.
Homeowners Information
CAUTION
Before attempting to perform any service or mainte nance, turn the electrical power to unit OFF at discon nect switch.
Cleaning of the outdoor unit's coil should be performed by a licensed professional service technician (or equivalent). Contact your dealer and set up a schedule (preferably twice a year, but at least once a year) to inspect and service your outdoor unit. The following maintenance may be performed by the homeowner.
Outdoor Coil
The outdoor unit must be properly maintained to ensure its proper operation.
S Please contact your dealer to schedule proper inspection
and maintenance for your equipment.
S Make sure no obstructions restrict airflow to the outdoor
unit.
S Grass clippings, leaves, or shrubs crowding the unit can
cause the unit to work harder and use more energy.
S Keep shrubbery trimmed away from the unit and
periodically check for debris which collects around the unit.
S Keep snow level below the louvered panels to ensure
proper performance.
IMPORTANT !
Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to the outdoor unit by treated water. Prolonged exposure of the unit to treated water (i.e., sprinkler systems, soak ers, waste water, etc.) will corrode the surface of steel and aluminum parts, diminish performance and af fect longevity of the unit.
Routine Maintenance
In order to ensure peak performance, your system must be properly maintained. Clogged filters and blocked airflow prevent your unit from operating at its most efficient level.
NOTE — The filter and all access panels must be in place any time the unit is in operation. If you are unsure about the filter required for your system, call your Lennox dealer for assistance.
1. Ask your Lennox dealer to show you where your indoor unit's filter is located. It will be either at the indoor unit (installed internal or external to the cabinet) or behind a return air grille in the wall or ceiling. Check the filter monthly and clean or replace it as needed.
2. Disposable filters should be replaced with a filter of the same type and size.
3. The indoor evaporator coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the inside air. Have your dealer show you the location of the drain line and how to check for obstructions. (This would also apply to an auxiliary drain, if installed.)
Thermostat Operation
See the ComfortSense® 7000 thermostat homeowner manual for instructions on how to operate your thermostat.
Preservice Check
If your system fails to operate, check the following before calling for service:
S Verify room thermostat settings are correct. S Verify that all electrical disconnect switches are ON. S Check for any blown fuses or tripped circuit breakers. S Verify unit access panels are in place. S Verify air filter is clean. S If service is needed, locate and write down the unit
model number and have it handy before calling.
Page 14
13ACX Start-Up and Performance Checklist
Customer Address
Indoor Unit Model Serial
Outdoor Unit Model Serial
Notes:
START UP CHECKS
Refrigerant Type:
Rated Load Amps: Actual Amps Rated Volts
Actual Volts
Condenser Fan Full Load Amps Actual Amps:
COOLING MODE
Suction Pressure: Liquid Pressure:
Supply Air Temperature: Ambient Temperature: Return Air: Temperature:
System Refrigerant Charge (Refer to manufacturer's information on unit or installation instructions for required subcooling and approach temperatures.)
Subcooling:
A — B = SUBCOOLING
Saturated Condensing Temperature (A)
minus Liquid Line Temperature (B)
Approach:
A — B = APPROACH
Liquid Line Temperature (A)
minus Outdoor Air Temperature (B)
Indoor Coil Temperature Drop (18 to 22°F)
A — B = COIL TEMP DROP
Return Air Temperature (A)
minus Supply Air Temperature (B)
Page 15
13ACX SERIES
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