These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
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, HFCs, and HCFCs) as of July 1,
1992. Approved methods of recovery, recycling or
reclaiming must be followed. Fines and/or incarceration
may be levied for noncompliance.
This unit must be matched with an indoor coil as
specified in Lennox’ Engineering Handbook. Coils
previously charged with HCFC−22 must be flushed.
NOTICE TO INSTALLER
UNIT PLACEMENT
It is critical for proper unit operation to place outdoor unit on an
elevated surface as described in Unit Placement section on page 8.
BRAZING LINE SET TO SERVICE VALVES
It is imperative to follow the brazing technique illustrated starting on
page 11 to avoid damaging the service valve’s internal seals.
06/11506648−01
*2P0611**P506648-01*
Shipping and Packing List
Check the unit components for shipping damage. If you
find any damage, immediately contact the last carrier.
1 Assembled outdoor unit
1 Liquid line bi−flow filter drier
General
The T−Class TPA*S4 outdoor units use HFC−410A HFC
refrigerant. This unit must be installed with a matching
indoor blower coil and line set as outlined in the Lennox
Engineering Handbook. TPA*S4 outdoor units are
designed for use in expansion valve systems only. They
are not designed to be used with other refrigerant flow
control devices. An expansion valve approved for use with
HFC−410A must be ordered separately and must be
installed prior to operating the unit.
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
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.
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.
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
When servicing or repairing HVAC components, ensure
the fasteners are appropriately tightened. Table 1 provides
torque values for fasteners.
Table 1. Torque Requirements
PartsRecommended Torque
Service valve cap8 ft.− lb.11 NM
Sheet metal screws16 in.− lb.2 NM
Machine screws #1028 in.− lb.3 NM
Compressor bolts90 in.− lb.10 NM
Gauge port seal cap8 ft.− lb.11 NM
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.
OPERATING 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 2 provides information
on how to access and operating both angle and ball service
valves.
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted
snugly over the cap before tightening.
Page 4
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
(VALVE STEM SHOWN
TO INDOOR
UNIT
(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE
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)
WHENSERVICEVALVE ISCLOSED,THESERVICEPORTISOPEN
TO
THELINE SETANDINDOORUNIT.
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.
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
With Torque Wrench: Finger tighten and
then torque cap per table 1.
Without Torque Wrench: Finger tight-
en and use an appropriately sized
wrench to turn an additional 1/12 turn
clockwise.
9
10
8
11
12
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 2. Angle and Ball Service Valves
Page 5
TPA*S4 SERIES
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.
SERVICE
DISCONNECT
SWITCH
RECOVERING REFRIGERANT
Remove existing 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 to
flush the system.
Remove all 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 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:
AStart the existing system in the cooling mode and close the liquid line valve.
BUse 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.
CWhen the low side system pressures reach 0 psig, close the vapor line valve.
DCheck gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system.
Page 6
CLEARANCE ON ALL SIDES INCHES (MILLIMETERS)
MINIMUM CLEARANCE
ABOVE UNIT
6 (152)
12 (305)
36 (914)
MINIMUM CLEARANCE BETWEEN
DETAIL A
Install unit away
from windows .
DETAIL C
If unit coil cannot be
mounted away from prevailing winter winds, a wind barrier should be constructed.
Size barrier at least the
same height and width as
outdoor unit. Mount barrier
24 inches (610 mm) from the
sides of the unit in the direction of prevailing winds as illustrated.
30 (762)
LINE SET
CONNECTIONS
TWO UNITS
24 (610)
PREVAILING WINTER WINDS
INLET AIR
Figure 4. Placement, Slab Mounting and Wind Barrier
ACCESS PANEL
NOTES:
Clearance to one of the other three
Clearance to one of the remaining
Figure 3. Installation Clearances
Two 90° elbows
installed in line set will
reduce line set vibration.
WIND BARRIER
INLET AIR
INLET AIR
sides must be 36 inches (914mm).
two sides may be 12 inches
(305mm) and the final side may be
6 inches (152mm).
DETAIL B
These units operate under a wide range of weather conditions;
therefore, several factors must be considered when positioning the
outdoor unit. The unit must be positioned to give adequate clearances
for sufficient airflow and servicing.
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.
Install the unit high enough above the ground or roof to allow
adequate drainage of defrost water and prevent ice or snow
build−up.
In heavy snow areas, do not locate the unit where drifting will
occur. The unit base should be elevated above the depth of
average snows. Stand−off kits are available for ordering using
either catalog numbers 94J45 (4 each) or 30K79 (20 each).
When installed in areas where low ambient temperatures exist,
locate unit so winter prevailing winds do not blow directly onto
outdoor unit.
Locate unit away from overhanging roof lines which would allow
water or ice to drop on, or in front of, coil or unto unit.
INLET AIR
MOUNTING SLAB MUST SLOPE
AWAY FROM BUILDING.
STRUCTURE
48 (1219)
DISCHARGE AIR
GROUND LEVEL
Page 7
TPA*S4 SERIES
New Unit Placement
See Unit Dimensions on page 2 for sizing mounting slab,
platforms or supports. Refer to figure 3 for mandatory
installation clearance requirements.
POSITIONING CONSIDERATIONS
CAUTION
NOTICE
Roof Damage!
This system contains both refrigerant and oil. Some
rubber roofing material may absorb oil and cause the
rubber to swell when it comes into contact with oil. The
rubber will then bubble and could cause leaks. Protect
the roof surface to avoid exposure to refrigerant and oil
during service and installation. Failure to follow this
notice could result in damage to roof surface.
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 4.
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.
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. Refer to figure 4,
detail c, for rooftop wind barrier considerations.
Table 2. Refrigerant Line Set Inches (mm)
Model
TPA036S4N4
TPA042S4N4
TPA048S4N4
TPA060S4N43/8 in. (10 mm)1−1/8 in. (29 mm)3/8 in. (10 mm)1−1/8 in. (29 mm)Field Fabricated
NOTE Some applications may required a field provided 7/8" to 1−1/8" adapter
Liquid LineVapor LineLiquid LineVapor LineL15 Line Sets
3/8 in. (10 mm)7/8 in. (22 mm)3/8 in. (10 mm)7/8 in. (22 mm)L15−65 15 ft. − 50 ft. (4.6 m − 15 m)
Field ConnectionsRecommended Line Set
New or Replacement Line Set
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 BrazingConnections on page 11.
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.
IMPORTANT
Mineral oils are not compatible with HFC−410A. If oil
must be added, it must be a Polyol ester oil.
The compressor is charged with sufficient Polyol ester oil
for line set lengths up to 50 feet. Recommend adding oil to
system based on the amount of refrigerant charge in the
system. No need to add oil in system with 20 pounds of
refrigerant or less. For systems over 20 pounds − add one
ounce of every five pounds of refrigerant.
Page 8
Recommended topping−off POE oils are Mobil EAL
ARCTIC 22 CC or ICI EMKARATE RL32CF.
NOTE When installing refrigerant lines longer than 50
feet, see the Lennox Refrigerant Piping Design and
Fabrication Guidelines, CORP. 9351−L9, or contact
Lennox Technical Support Product Applications for
assistance.
To obtain the correct information from Lennox, be sure to
communicate the following points:
Model (TPA*S4) 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 TPA*S4 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 TPA*S4 unit.
Typically a liquid line used to meter flow is 1/4" in diameter
and copper.
IMPORTANT
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.
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 9
TPA*S4 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
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 5. Line Set Installation
Page 10
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