Lennox Merit 13ACD-018, Merit 13ACD-024, Merit 13ACD-030, Merit 13ACD-036, Merit 13ACD-042 Installation Instructions Manual

...
INSTALLATION
,1,_,2008LennoxtndustriesInc,
®
Dallas,Texas,USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
WARNING
INSTRUCTIONS
AIR CONDITIONER UNITS
505,366M 01I08
Supersedes 11/07
Shipping and Packing List ...................... 1
13ACD Outdoor Unit ........................... 1
Unit Dimensions ............................... 2
General Information ........................... 2
Recovering Refrigerant from Existing System ..... 4
Removing Existing Outdoor Unit ................. 5
Positioning New Outdoor Unit ................... 5
New or Replacement Line Set ................... 6
Brazing Connections ........................... 8
Removing Indoor Unit Metering Device ............ 9
Installing New Indoor Unit Metering Device ........ 9
Testing for Leaks .............................. 11
Evacuating the System ......................... 12
Servicing Unit Delivered Void of Charge ........... 13
Electrical Connections ......................... 13
Start-Up and Charging Procedures ............... 14
System Operation ............................. 18
Maintenance .................................. 18
Homeowner Information ........................ 19
Start-Up and Performance Checklist ............. 20
_puTeCh ical
n
blications
Litho U.S.A.
CAUTION
IMPORTANT
01/08
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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)
13ACD Air Conditioners, which will also be referred to in this instruction as the outdoor unit, uses HCFC-22
refrigerant. This outdoor unit must be installed with a matching indoor unit and line set as outlined in the Lennox
13ACD 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
505,366M
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A A
OPTIONAL UNIT STAND-OFF KIT
OUTDOOR COIL FAN tDischarge Air
COMPRESSOR_
SUCTION ANDLIQUIDLINE
CONNECTIONS
(4) (FIELDqNSTALLED)
SIDE VIEW
SIDE VIEW
Model Number A B 13ACD-018 24-1/4 (616) 25-1/4 (641 )
13ACD-024 24-1/4 (616) 25-1/4 (641 ) 13ACD-030 24-1/4 (616) 33-1/4 (845)
13ACD-036 24-1/4 (616) 33-1/4 (845) 13ACD-042 28-1/4 (718) 29-1/4 (743) 13ACD-048 28-1/4 (718) 37-1/4 (946) 13ACD-060 28-1/4 (718) 33-1/4 (845)
WARNING
When servicing or repairing HVAC components, ensure caps and fasteners are appropriately tightened, Table 1
lists torque values for typical service and repair items.
Table 1. Torque Requirements
Part
Service valve cap 8 ft.- lb. Sheet metal screws 16 in.- lb.
Machine screws #10 28 in.- lb.
I
Compressor bolts 90 in.- lb. Gauge port seal cap 8 ft.- lb.
USING MANIFOLD GAUGE SETS
Recommended Torque
11 NM
2NM 3NM
10 NM 11 NM
When checking the system charge, use a manifold gauge set that features low-loss anti-blow back fittings. See figure
1 for a typical manifold gauge connection setup.
OPERATING SERVICE VALVES
IMPORTANT
These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
505366M 01/08
The liquid and suction line service valves are typically used for removing refrigerant, flushing, leak testing, evacuating,
checking charge and charging,
Page 2
OUTDOOR UNIT (Uncased Coil Shown)
LOW HIGH
PRESSURE PRESSURE
LIQUID LINE SUCTION LINE
COMPRESSOR-- I[ -" ..._
Figure 1. Typical Manifold Gauge Connection Setup
Each valve is equipped with a service port which has a
factory-installed valve stem.
t/6 TURN
1/12 TURN
Figure 2. Cap Tightening Distances
,A IMPORTANT
Operating Angle-Type Service Valve
To Access Angle-Type 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 to the service port.
3. When testing is completed, replace service port cap and tighten as follows:
With Torque Wrench: Finger tighten and then tighten per table 1.
Without Torque Wrench: Finger tighten and use an appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 2.
OUTDOOR - ORIFICE
COIL
TXV OR FIXED
To Open and Close Angle-Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak-free seal,
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
suction-line valve sizes) to back the stem out counterclockwise as far as it will go.
3. Replace the stem cap and tighten as follows:
With Torque Wrench: Tighten finger tight and then
tighten per table 1.
Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 2.
NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
NOTE- To prevent stripping of the cap, the wrench should be appropriately sized and fit snugly over the cap before tightening the cap.
SERVICE PORT CAP
STEM CAP
SERVICE PORT
CLOSED) INSERT HEX WRENCH HERE
SERVICE PORT
CLOSED TO BOTH
INDOOR AND
OUTDOOR UNITS
VALVE STEM
FRONT-SEATED
TOINDOOR
UNIT
TO OUTDOOR UNIT
Figure 3. Angle-Type Service Valve
(Font-Seated Closed)
Page 3
13ACD SERIES
SERVICEPORT
SERVICEPORT
OPENTOBOTH
INDOORAND
OUTDOORUNITS
TOINDOOR
UNIT
STEMCAP
TOOUTDOORUNIT
Figure 4. Angle-Type Service Valve
(Back-Seated Opened)
Operating Bali-Type Service Valve
To Access Bali-Type Service Port:
SERVICEPORT
(VALVESTEMSHOWNOPEN)
INSERTHEXWRENCHHERE
To Open and Close Bali-Type Service Valve: A valve stem cap protects the valve stem from
contamination and assures a leak-free seal,
1. Remove stem cap with a wrench.
2. Use an appropriately sized wrench to open. To open valve, rotate stem counterclockwise 90° . To close
rotate stem clockwise 90°,
3. Replace the stem cap and tighten as follows:
With Torque Wrench: Finger tighten and then
tighten per table 1,
Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 2,
NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque,
A service port cap protects the service port core from
contamination and serves as the primary leak seal.
OPEN TO LINE SET WHEN VALVE IS CLOSED, TO BOTH LINE SET AND UNIT WHEN VALVE IS OPEN.
TO OPEN ROTATE STEM COUNTERCLOCKWISE 90 ° . BALL(SHOWN
TO CLOSE ROTATE STEM CLOCKWISE 90 ° .
CORE
SERVlCEPORTCAP
TO INDOOR UNIT
CLOSED)
STEM CAP
VALVE STEM
Figure 5. Bali-Type Service Valve
1. Remove service port cap with an appropriately sized wrench.
2. Connect gauge to the service port,
3. When testing iscompleted, replace service port cap and
tighten as follows:
With Torque Wrench: Finger tighten and then tighten per table table 1,
Without Torque Wrench: Finger tighten and use an appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 2,
Remove existing HCFC-22 refrigerant using one of the
following methods:
METHOD 1: Use this method if the existing outdoor unit is not equipped
with manual shut-off valves, and plan on using existing
HCFC-22 refrigerant to flush the system.
NOTE - Use recovery machine instructions for specific setup requirements.
Perform the following task:
1. Disconnect all power to the existing outdoor unit,
2, Connect to the existing unit a gauge set, clean
recovery cylinder and a recovery machine. Use the instructions provided with the recover machine on how to setup the connections,
3. Remove all HCFC-22 refrigerant from the existing system, Check gauges after shutdown to confirm that the entire system is completely void of refrigerant,
RECOVERY MACHINE
MANIFOLD GAUGES
c p. COVERY
/
OUTDOOR UNIT
Figure 6. Typical Refrigerant Recovery (Method 1)
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Page 4
METHOD2: Usethismethodiftheexistingoutdoorunitis equipped
with manualshut-offvalves,and planon usingnew
HCFC-22refrigeranttoflushthesystem, IMPORTANT:Somesystemconfigurationsmaycontain
higherthannormalrefrigerantchargeduetoeitherlarge internalcoilvolumes,and/orlonglinesets,Thefollowing
conditionsmaycausethecompressortostopfunctioning: Thefollowingdevicescouldpreventfull system charge
recovery into the outdoor unit:
Outdoor unit's high or low-pressure switches if tripped can cycled 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 suction 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:
1, Start the existing HCFC-22 system in the cooling
mode and close the liquid line valve,
2, Pump as much of the existing HCFC-22 refrigerant
with the compressor back into the outdoor unit until you have reached the limitations of the outdoor system, Turn the outdoor unit main power OFF and
use a recovery machine to remove the remaining refrigerant in the system,
NOTE - It may be necessary to bypass the low pressure switches if equipped to ensure complete refrigerant
evacuation.
3, When the low side system pressures reach 0 psig,
close the suction line valve,
4, Check gauges after shutdown to confirm that the
valves are not allowing refrigerant to flow back into the
low side of the system,
* SEE NOTES BELOW THIS FIGURE FOR FURTHER DETAILS.
Figure 7. Installation Clearances
NOTES:
Service clearance of 30 in. (762 mm) must be maintained on one of the sides adjacent to the control
box.
Clearance to one of the other three sides must be 36 in. (914 mm)
Clearance to one of the remaining two sides may be
12 in. (305 mm) and the final side may be 6 in. (152
mm)
48 in. (1219 mm) clearance required on top of unit.
A clearance of 24 in. (610 mm) must be maintained between two units
POSITIONING CONSIDERATIONS
CAUTION
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 8.
INSTALL UNIT AWAY _ _I
FRO W
Perform the following task at the existing outdoor unit:
Disconnect line set at the service valves.
Disconnect electrical service at the disconnect switch.
Remove old outdoor unit.
See Unit Dimensions on page 2 to sizing mounting slab, platforms or supports. Refer to figure 7 for mandatory
installation clearance requirements.
Page 5
TWO 90 ° ELBOWS INSTALLED
IN LINE SET WILL REDUCE _ "_"_
LINE SET VIBRATION.
Figure 8. Outside Unit Placement
13ACD SERIES
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 9,
BUILDING
STRUCTURE
DISCHARGE AIR
MOUNTING
SLAB
GROUND LEVEL
Figure 9. Ground Level Slab Mounting
Slab may be level or have a slope tolerance away from the building of not more than two degrees, or two inches per 5
feet (51 mm per 1524 mm) as illustrated in figure 9,
INSTALLING OUTDOOR UNIT ON ROOF Install the unit a minimum of six inches (152 mm) above the
roof surface to avoid ice build-up around the unit, Locate the unit above a load bearing wall or area of the roof that
can adequately support the unit, Consult local codes for rooftop applications,
This section provides information on new installation or replacement of existing line set. If a new or replacement
line set is not required, then proceed to Brazing Connections on page 8,
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 piping consists of liquid and suction lines
from the outdoor unit (braze connections) to the indoor unit coil (flare or braze connections). Use Lennox L15 (braze, non-flare) series line set, or use field-fabricated refrigerant
lines as listed in table 2,
Table 2. Refrigerant Line Set
Field
Model
-018
-024 (10mm) (19mm)
-030
-036
-042 (10mm) (22mm)
-048
-060 (10mm) (29mm)
Connections
Liquid Suction Line Line
3/8 in. 3/4 in
3/8 in. 7/8 in
3/8 in. 1-1/8 in.
Recommended Line Set
Liquid Suction L15
Line Line Line Sets
3/8 in. 3/4 in L15-41
(10 (19 ram) 15 ft, - 50 ft. mm) (4.6 m - 15 m)
3/8 in. 7/8 in L15-65
(10 (22 mm) 15 ft, - 50 ft. mm) (4.6 m- 15 m)
3/8 in, 1-1/8 in. Field
(10 (29 mm) Fabricated mm)
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 (13ACD) 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 RFCl-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 13ACD 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 13ACD unit, Typically a liquid line used to meter flow is 1/4" in diameter and copper,
505366M 01/08
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