Lennox TPA036H4N4, TPA042H4N4, TPA048H4N4, TPA060H4N4 Installation Instructions Manual

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INSTALLATION

2011 Lennox Industries Inc.

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

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 qualified installer or 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.

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

NOTICE TO INSTALLER

It is critical for proper unit operation to place outdoor unit on an elevated surface as described in Unit Placement section on page 8.

It is critical for proper defrost operation to set the defrost termination pins (P1) on the defrost control prior to starting system. See Defrost System section on page 31 for further details.

BRAZING LINE SET TO SERVICE VALVES

It is imperative to follow the brazing technique illustrated starting on page 10 to avoid damaging the service valve’s internal seals.

UNIT PLACEMENT

DEFROST OPERATION

INSTRUCTIONS

T−CLASSt TPA*H4 Units

G and Y Voltage

HEAT PUMP UNITS

506650−01 02/11 Supersedes 11/10

TABLE OF CONTENTS

Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .

General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Number Identification 2. . . . . . . . . . . . . . . . . . . . . .

Typical Unit Parts Arrangement 3. . . . . . . . . . . . . . . . . . .

Operating Gauge Set and Service Valves 4. . . . . . . . . . .

Recovering Refrigerant from Existing System 6. . . . . . .

New Unit Placement 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

New or Replacement Line Set 8. . . . . . . . . . . . . . . . . . . . .

Brazing Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Line Set and Indoor Coil 13. . . . . . . . . . . . . . . .

Installing Indoor Metering Device 14. . . . . . . . . . . . . . . .

Leak Test Line Set and Indoor Coil 15. . . . . . . . . . . . . . .

Evacuating Line Set and Indoor Coil 16. . . . . . . . . . . . .

Electrical 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Unit Delivered Void of Charge 22. . . . . . . . . . .

Start−Up 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Refrigerant 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defrost System 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checklist 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shipping and Packing List

Check the unit for shipping damage and that all included items listed below are intact. If damaged, or if parts are missing, immediately contact the last carrier.

1  Assembled outdoor unit

1  Liquid line bi−flow filter drier

General

T−Class TPA*H4 Heat Pumps, 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 Engineering Handbook. TPA*H4 Heat Pumps are designed for use in check expansion valve (CTXV) systems.

Litho U.S.A.

02/11 506650−01

*2P0211* *P506650-01*

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Unit Dimensions − inches (mm)

INLET AIR

TOP VIEW

INLET AIR

VAPOR LINE CONNECTION

LIQUID LINE CONNECTION

OPTIONAL UNIT

STAND-OFF KIT (4)

(FIELD−INSTALLED)

COIL DRAIN OUT-

LETS (AROUND PERI-

METER OF BASE)

OUTDOOR COIL

COMPRESSOR

4-3/8 (111)

6-3/8 (162)

FAN

4-3/8 (111)

Compressor

6-3/8 (162)

TOP VIEW BASE SECTION

4-3/8 (111)

DISCHARGE AIR

4-3/8 (111)

Electrical

VAPOR AND LIQUID LINE

CONNECTIONS

2-3/4 (70)

SIDE VIEW

Inlets

2 (51)

3/4 (19)

Model Numbers A B

TPA036H4N4

TPA042H4N4

TPA048H4N4

TPA060H4N4

32−1/4 (819) 29−1/4 (743)

32−1/4 (819) 37 (940)

32-1/4 (819) 37 (940)

32-1/4 (819) 43−1/4 (1099)

Model Number Identification

TPA Y1036 H 44 N

T = T−Class Product Line

P = Heat Pump Outdoor Unit

Brand/Family

Unit Type

Major Design Sequence

A = 1st Generation

B = 2nd Generation

Nominal Cooling Capacity − Tons

036 = 3 Tons

042 = 3.5 Tons

048 = 4 Tons 060 = 5 Tons

Cooling Efficiency

H = High Efficiency

Minor Design Sequence

1 = 1st Revision 2 = 2nd Revision 3 = 3rd Revision

Coil type

4 = Four−sided

Part Load Capability

N = No part load, single stage compressor

Refrigerant Type

4 = HFC−410A

SIDE VIEW

Vol ta ge

Y = 208/230V-3 phase-60hz G = 460V-3 phase-60hz

OPTIONAL UNIT STAND-OFF KIT (4) (FIELD−INSTALLED)

506650−01

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Typical Unit Parts Arrangement

SINGLE

RUN

CAPACITOR

(C12)

GROUND

LUG

CONTACTOR

CUTOUT FOR HIGH

VOLTAGE CONDUIT

(K1)

CONTROL BOX

NOTE  PLUMBING LAYOUT AND COMPRESSOR TYPE MAY VARY SLIGHTLY BETWEEN MODEL SIZES.

FAN RELAY (K10) (G−VOLTAGE UNITS ONLY)

COMPRESSOR

HARNESS

DEFROST CONTROL (A108)

DISTRIBUTOR

CHECK EXPANSION

CONTROL WIRE LOOP

LINE FILTER DRIER

EQUALIZER LINE

CRANKCASE HEATER

LIQUID LINE SERVICE

VALV E

BI−FLOW LIQUID

TRUE SUCTION

HIGH PRESSURE

THERMOSTAT (S40)

PORT

SWITCH (S4)

VALV E

MUFFLER

COMPRESS0R

DISCHARGE LINE

LOW PRESSURE SWITCH (S87)

REVERSING VALVE (R1)

CHECK EXPANSION VALV E SENSING BULB

CRANKCASE HEATER (HR1)

REVERSING VALVE SOLENOID

VAPOR LINE SERVICE VALVE

COIL SENSOR (RT21) IS

LOCATED ON HAIRPIN

SHOWN. SIXTH HAIRPIN

UP ON INSIDE ROW

AMBIENT TEMPERATURE SENSOR (RT13)

Figure 1. Typical Unit Parts Arrangement

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TPA*H4 SERIES

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CAUTION

IMPORTANT

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.

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.

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.

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

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.

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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

CORE

CAP

TO OUTDOOR

UNIT

BALL (SHOWN CLOSED)

VALV E STEM

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:

 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:

 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.

1/6 TURN

1/12 TURN

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

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TPA*H4 SERIES

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Recovering Refrigerant from Existing System

RECOVERING

REFRIGERANT FROM SYSTEM

DISCONNECT POWER

Disconnect all power to the existing outdoor unit at the service

disconnect switch or main fuse box/breaker panel.

SERVICE

DISCONNECT

SWITCH

RECOVERING REFRIGERANT

Remove existing HCFC−22 refrigerant using one of the following procedures:

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

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.

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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

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

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

Figure 4. Placement, Slab Mounting and Wind Barrier

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TPA*H4 SERIES

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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.

CAUTION

In order to avoid injury, take proper precaution when lifting heavy objects.

POSITIONING CONSIDERATIONS

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.

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

 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.

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.

ROOF MOUNTING

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.

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.

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 Brazing Connections on page 10.

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.

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*H4) 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*H4 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*H4 unit. Typically a liquid line used to meter flow is 1/4" in diameter and copper.

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Table 2. Refrigerant Line Set  Inches (mm)

Models

TPA036H4N4 TPA042H4N4 TPA048H4N4

TPA060H4N4 3/8 in. (10 mm) 1−1/8 in. (29 mm) 3/8 in. (10 mm) 1−1/8 in. (29 mm) Field Fabricated

LINE SET

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

Field Connections Recommended Line Set

Liquid Line Vapor Line Liquid Line Vapor Line L15 Line Set

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)

IMPORTANT  Refrigerant lines must not contact structure.

INSTALLATION

NOTE  Similar installation practices should be used if line set is to be installed on exterior of outside wall.

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.

AUTOMOTIVE

MUFFLER-TYPE HANGER

IMPORTANT  Refrigerant lines must not contact wall

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)

FLOOR JOIST OR

ROOF RAFTER

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

OUTSIDE WALL

WOOD BLOCK

BETWEEN STUDS

VAPOR LINE WRAPPED

WITH ARMAFLEX

OUTSIDE

WALL

PVC

PIPE

FIBERGLASS

INSULATION

VAPOR LINE

SLEEVE

CAULK

LIQUID LINE

WIRE TIE

INSIDE WALL

STRAP

NON−CORROSIVE METAL SLEEVE

WIRE TIE

WOOD BLOCK

WIRE TIE

STRAP

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

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TPA*H4 SERIES

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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.

Brazing Connections

Use the procedures outline in figures 6 and 7 for brazing line set connections to service valves.

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

Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve.

IMPORTANT

Allow braze joint to cool before removing the wet rag from the service valve. Temperatures above 250ºF can damage valve seals.

IMPORTANT

WARNING

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.

WARNING

When using a high pressure gas such as dry 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).

Use silver alloy brazing rods with 5% minimum silver alloy for copper−to−copper brazing. Use 45% minimum alloy for copper−to−brass and copper−to−steel brazing.

WARNING

Fire, Explosion and Personal Safety Hazard.

Failure to follow this warning could result in damage, personal injury or death.

Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when exposed to a spark or open flame, can cause fire and/or an explosion, that could result in property damage, personal injury or death.

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CUT AND DEBUR

Cut ends of the refrigerant lines square (free from nicks or dents)

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 both the

vapor and liquid line service ports.

SERVICE PORT

CAP

SERVICE

PORT CORE

LIQUID LINE SERVICE

VALV E

SUCTION / VAPOR LINE

SERVICE VALVE

ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE VALVES

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 Schrader 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

LIQUID LINE SERVICE

SUCTION /

VAPOR LINE

SERVICE

VALV E

WHEN BRAZING LINE SET TO

SERVICE VALVES, POINT FLAME

AWAY FROM SERVICE VALVE.

Figure 6. Brazing Procedures

OUTDOOR

UNIT

NITROGEN

Page 11

TPA*H4 SERIES

Page 12

WRAP SERVICE VALVES

To help protect service valve seals during brazing, wrap a saturated cloth around service valve bodies and copper tube stub. Use another

saturated cloth 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

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 a saturated cloth as illustrated here before brazing to line set.

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 saturated cloths to help cool brazed joint. Do not remove wet rag until piping has cooled. Temperatures above 250ºF will damage valve seals.

LIQUID LINE

SATURATED CLOTH

WARNING

1. FIRE, PERSONAL INJURY, OR PROPERTY DAMAGE will result if you do not wrap a wet cloth

around both liquid and suction line service valve bodies and copper tube stub while brazing in the line set! The braze, when complete, must be quenched with water to absorb any residual heat.

2. Do not open service valves until refrigerant lines and indoor coil have been leak−tested and evacuated. Refer to procedures provided in this supplement.

SUCTION / VAPOR LINE

PREPARATION FOR NEXT STEP

After all connections have been brazed, disconnect manifold gauge set from service ports. Apply saturated rags to both services valves to cool piping. Once piping is cool, remove all wet cloths. Refer to the unit installation instructions for the next step in preparing the unit.

SUCTION / VAPOR LINE

SERVICE VALVE

SATURATED CLOTH

WHEN BRAZING LINE SET TO

SERVICE VALVES, POINT FLAME

AWAY FROM SERVICE VALVE.

Figure 7. Brazing Procedures (continued)

506650−01

Page 12

Page 13

Flushing Line Set and Indoor Coil

Flushing is only required if existing indoor coil and line set are to be used. Otherwise proceed to Installing Indoor Metering Device on page 14.

TYPICAL EXISTING FIXED ORIFICE

DISTRIBUTOR

ASSEMBLY

A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps holding 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 process.

D Remove and discard fixed orifice, valve stem assembly if present and

Teflon® washer as illustrated above.

E Use a field−provided fitting to temporary reconnect the liquid line to the

indoor unit’s liquid line orifice housing.

REMOVAL PROCEDURE (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)

BRASS NUT

TWO PIECE PATCH PLATE

(UNCASED COIL ONLY)

CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE

INVERTED HCFC−22 CYLINDER CONTAINS CLEAN HCFC−22 TO BE USED FOR FLUSHING.

VAPOR LINE

SERVICE VALVE

EXISTING

INDOOR

UNIT

LIQUID LINE SERVICE

VALV E

VAPOR

LIQUID

RECOVERY

CYLINDER

A Inverted HCFC−22 cylinder with clean 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 to the gauge set.

D Connect recovery tank to recovery machines per machine instructions.

OUTDOOR

NEW

UNIT

OPENED

RECOVERY MACHINE

GAUGE

MANIFOLD

LOW HIGH

CLOSED

TANK RETURN

INLET

DISCHARGE

TYPICAL EXISTING EXPANSION VALVE REMOVAL PROCEDURE (UNCASED COIL SHOWN)

LIQUID LINE

DISTRIBUTOR

TUBES

DISTRIBUTOR

ASSEMBLY

MALE EQUALIZER

LINE FITTING

SENSING BULB

A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps holding the liquid line and distributor

assembly.

C Disconnect the equalizer line from the check expansion valve

equalizer line fitting on the vapor line.

D Remove the vapor line sensing bulb. E Disconnect the liquid line from the check expansion valve at the liquid

line assembly.

F Disconnect the check expansion valve from the liquid line orifice

housing. Take care not to twist or damage distributor tubes during this process.

G Remove and discard check expansion valve and the two Teflon® rings. H Use a field−provided fitting to temporary reconnect the liquid line to the

indoor unit’s liquid line orifice housing.

ORIFICE

HOUSING

EQUALIZER LINE

STUB END

TEFLON RING

VAPOR

CHECK

EXPANSION

VALV E

LIQUID LINE

ASSEMBLY WITH

BRASS NUT

LINE

TEFLON

RING

SENSING

LINE

LIQUID

LINE

FLUSHING LINE SET

The line set and indoor unit coil must be flushed with at least the

same 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 set and indoor unit coil.

B Invert the cylinder of clean HCFC−22 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 down to 0 the system.

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.

Figure 8. Removing Metering Device and Flushing

Page 13

TPA*H4 SERIES

Page 14

Installing Indoor Metering Device

This outdoor unit is designed for use in systems that use expansion valve metering device (purchased separately) at the indoor coil.

See the Lennox TPA*H4 Engineering Handbook 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 Leak Test Line Set and Indoor Coil on page 15.

INDOOR EXPANSION VALVE INSTALLATION

TWO PIECE

PATCH PLATE

(UNCASED

COIL ONLY)

DISTRIBUTOR

TUBES

DISTRIBUTOR

ASSEMBLY

MALE EQUALIZER LINE

FITTING (SEE

EQUALIZER LINE INSTALLATION FOR FURTHER DETAILS)

(Uncased Coil Shown)

LIQUID LINE

ORIFICE

HOUSING

STUB

END

TEFLON RING

EQUALIZER LINE

VAPOR

EXPANSION

VALV E

ASSEMBLY WITH

LINE

TEFLON

RING

SENSING

LIQUID LINE

BRASS NUT

LIQUID LINE

Sensing bulb insulation is required if mounted external to the coil casing. sensing bulb installation for bulb positioning.

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 to the right.

B 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 to the right.

LINE

A Remove the field−provided fitting that temporary

reconnected the liquid line to the indoor unit’s distributor assembly.

B Install one of the provided Teflon® rings around the

stubbed end of the expansion valve and lightly lubricate the connector threads and expose surface of the Teflon ring with refrigerant oil.

C Attach the stubbed end of the expansion valve to the

liquid line orifice housing. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above, or 20 ft−lb.

D Place the remaining Teflon® washer around the other

end of the expansion valve. Lightly lubricate connector threads and expose surface of the Teflon® ring with refrigerant oil.

E Attach the liquid line assembly to the expansion valve.

Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or 20 ft−lb.

SENSING BULB INSTALLATION

A Attach the vapor line sensing bulb in the proper

orientation as illustrated to the right using the clamp and screws provided.

NOTE  Confirm proper thermal contact between vapor line and expansion bulb before insulating the sensing bulb once installed.

B Connect the equalizer line from the expansion valve to

the equalizer vapor port on the vapor line. Finger tighten the flare nut plus 1/8 turn (7 ft−lbs) as illustrated below.

VAPOR LINE

BULB

ON LINES SMALLER THAN 7/8", MOUNT SENSING BULB AT EITHER THE 3 OR 9 O’CLOCK POSITION.

BULB

1/2 Turn

1/8 Turn

FLARE SEAL CAP

Figure 9. Installing Indoor Expansion Valve

506650−01

FLARE NUT

COPPER FLARE SEAL BONNET

MALE BRASS EQUALIZER LINE FITTING

VAPOR LINE

Page 14

ON 7/8" AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 4 OR 8 O’CLOCK

BULB

NOTE  NEVER MOUNT ON BOTTOM OF LINE.

POSITION. NEVER MOUNT ON BOTTOM OF LINE.

BULB

Page 15

IMPORTANT

Leak Test Line Set and Indoor Coil

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

CONNECT GAUGE SET

A Connect an HFC−410A manifold gauge set high pressure

hose 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.

IMPORTANT

Leak detector must be capable of sensing HFC refrigerant.

After completing the leak testing the line set and indoor coil as outlined in figure 10, proceed to Evacuating Line Set and Indoor Coil on page 16.

WARNING

When using a high pressure gas such as dry 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).

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.

HIGHLOW

MANIFOLD GAUGE SET

OUTDOOR UNIT

TEST FOR LEAKS

After the line set has been connected to the indoor and outdoor units, check the line set connections and 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 dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set.

D Adjust dry 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.

NITROGEN

HFC−410A

Figure 10. Leak Test

Page 15

TO VAPOR

SERVICE VALVE

TPA*H4 SERIES

Page 16

Evacuating Line Set and Indoor Coil

CONNECT GAUGE SET

NOTE  Remove cores from service valves (if not already done).

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 micron gauge available

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

VACUUM PUMP

OUTDOOR

UNIT

A34000 1/4 SAE TEE WITH SWIVEL COUPLER

500

MICRON

GAUGE

MANIFOLD

GAUGE SET

TO VAPOR

SERVICE VALVE

TO LIQUID LINE SERVICE VALVE

LOW

EVACUATE THE SYSTEM

A Open both manifold valves and start the vacuum pump.

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 within a given volume or system, above the absolute zero of pressure. 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:

 Close manifold gauge valves  Close valve on vacuum pump  Turn off vacuum pump  Disconnect manifold gauge center port hose from vacuum pump  Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose.  Open manifold gauge valves to break the vacuum in the line set and indoor unit.  Close manifold gauge valves.

D Shut off the dry nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the

dry 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 an

upright cylinder of HFC−410A 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:

 Close manifold gauge valves.  Shut off HFC−410A cylinder.  Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core

tool while maintaining a positive system pressure.

 Replace stem caps and secure finger tight, then tighten an additional one−sixth (1/6) of a turn as illustrated.

RECOMMEND

MINIMUM 3/8" HOSE

1/6 TURN

HIGH

506650−01

Figure 11. Evacuating System

Page 16

Page 17

WARNING

Danger of Equipment Damage. Avoid deep vacuum operation. Do not use compressors to evacuate a system. Extremely low vacuums can cause internal arcing and compressor failure. Damage caused by deep vacuum operation will void warranty.

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.

Evacuating the system of non−condensables is critical for proper operation of the unit. Non−condensables are

defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system. Non−condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts.

IMPORTANT

Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns.

Electrical

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)

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.

SERVICE

DISCONNECT

SWITCH

NOTE  Units are approved for use only with copper conductors.

Ground unit at disconnect switch or to an earth ground.

WARNING

Electric Shock Hazard. Can cause injury or death.

Line voltage is present at all components on units with single-pole contactors, even when unit is not in operation!

Unit may have multiple power supplies. Disconnect all remote electric power supplies before opening access panel.

Unit must be grounded in accordance with national and local codes.

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.

Page 17

TPA*H4 SERIES

Page 18

READ WARNING AND NOTE

WARNING! − ELECTRIC SHOCK HAZARD. Can cause INJURY or DEATH. Unit must be grounded in accordance with national and local codes.

NOTE − For use with copper conductors only. Refer to unit rating plate for minimum circuit ampacity and maximum over-current protection size.

GROUND LUG

GROUND

Figure 12. Typical High−Voltage Field Wiring − (Unit Panel)

COMPRESSOR CONTACTOR

L2 L1

GROUND LUG

CAPACITOR

CONTACTOR

CONTROL BOX

OUTDOOR FAN RELAY (460VAC ONLY)

DEFROST CONTROL

(A108)

Figure 13. Typical 208/230 VAC Unit Wiring Diagram

506650−01

Page 18

Page 19

Figure 14. Typical 460 VAC Unit Wiring Diagram

WIRING CONNECTIONS

1. Install line voltage power supply to unit from a properly sized disconnect switch. Any excess high voltage field wiring

should be trimmed or secured away from the low voltage field wiring.

THERMOSTAT

INDOOR UNIT

POWER

COMMON

FIRST STAGE

AUXILIARY. HEAT

INDOOR BLOWER

FIRST STAGE

AUXILIARY. HEAT

REVERSING VALVE

COMPRESSOR

(SOME CONNECTIONS MAY NOT APPLY. REFER TO SPECIFIC THERMOSTAT AND INDOOR UNIT.)

POWER

COMMON

OUTDOOR UNIT

THERMOSTAT INDOOR UNIT

EMERGENCY HEAT

AUXILIARY. HEAT

POWER

COMMON

FIRST STAGE

INDOOR BLOWER

EMERGENCY

HEAT RELAY

REVERSING VALVE

COMPRESSOR

(SOME CONNECTIONS MAY NOT APPLY. REFER TO

SPECIFIC THERMOSTAT AND INDOOR UNIT.)

OUTDOOR T’STAT

FIRST STAGE AUXILIARY.

POWER

COMMON

HEAT

OUTDOOR UNIT

Figure 15. TPA*H4 and Blower Unit Thermostat

Designations

Figure 16. Outdoor Unit and Blower Unit Thermostat

Designations (with Auxiliary Heat)

Page 19

TPA*H4 SERIES

Page 20

Figure 17. Typical Factory Wiring Diagram  Y Voltage (208/230V, 3−PH)

506650−01

Page 20

Page 21

Figure 18. Typical Factory Wiring Diagram  G Voltage (460V, 3−PH)

Page 21

TPA*H4 SERIES

Page 22

Table 3. Wire Run Lengths

Wire run length AWG # Insulation type

Less than 100 feet (30 m) 18

More than 100 feet (30 m) 16

2. Ground unit at unit disconnect switch or to an earth ground.

NOTE − For proper voltages, select thermostat wire gauge per the following table:

3. Connect conduit to the unit using provided conduit bushing.

4. Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and five feet (1.5 m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight, drafts or vibrations.

5. Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated in figures 15 and 16.

6. Do not bundle any excess 24V control wire inside control box. Run control wire through installed wire tie and tighten wire tie to provided low voltage strain relief and to maintain separation of field installed low and high voltage circuits.

THREE-PHASE SCROLL VOLTAGE PHASING

Three-phase scroll compressors must be phased sequentially to ensure correct compressor rotation and operation. Incorrect line voltage phasing may cause compressor damage and abnormal unit operation. Power wires are color-coded as follows: Line 1 − red, line 2 − yellow, line 3 − blue.

To test for proper rotation and operation:

1. Install manifold gauge set on system. Cycle compressor ON and observe that suction pressure decreases and discharge pressure increases.

2. If pressures do not follow the above conditions, disconnect all power to unit. Reverse any two field−installed main power wires to the line side of the compressor contactor. Make sure connections are tight. Repeat pressure test with system.

Color−coded with a minimum temperature rating of 35ºC.

Servicing Units Delivered Void of Charge

If the outdoor unit is void of refrigerant, clean the system using the procedure described below.

1. Leak check system using procedure outlined in this instruction.

2. Evacuate the system using procedure outlined in this instruction.

3. Use nitrogen to break the vacuum and install a new filter drier in the system.

4. Evacuate the system again using procedure outlined in this instruction.

5. Weigh in refrigerant using procedure in figure 21.

Start−Up

IMPORTANT

Crankcase heater (if applicable) should be energized 24 hours before unit start−up to prevent compressor damage as a result of slugging.

1. Check that fan rotates freely.

2. Inspect all factory− and field−installed wiring for loose connections.

3. After evacuation is complete, open both the liquid and vapor line service valves to release the refrigerant charge contained in outdoor unit into the system.

4. Replace the stem caps and tighten as specified in Operating Service Valves on page 4.

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. 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.

7. Recheck voltage while the unit is running. Power must be within range shown on the nameplate.

8. Check system for sufficient refrigerate by using the procedures listed under System Refrigerant.

System Refrigerant

This section outlines procedures for:

1. Connecting gauge set for testing and charging;

2. Checking and adjusting indoor airflow;

3. Adding or removing refrigerant.

506650−01

Page 22

Page 23

GAUGE SET

CONNECTIONS FOR TESTING AND CHARGING

TRUE SUCTION PORT

CONNECTION

REFRIGERANT TANK

MANIFOLD GAUGE SET

LOW

HIGH

OUTDOOR UNIT

AClose manifold gauge set valves and connect the center hose to a cylinder of HFC−410A. Set for

BConnect the manifold gauge set’s low pressure side to the true suction port.

INSIDE OUTDOOR UNIT

CConnect the manifold gauge set’s high pressure side to the liquid line service port.

DPosition temperature sensor on liquid line near liquid line service port.

Figure 19. Manifold Gauge Set Setup and Connections

ADDING OR REMOVING REFRIGERANT

Temp. of air entering indoor coil ºF

Wet−bulb ºF

53º

DRY

BULB

80 24 24 24 23 23 22 22 22 20 19 18 17 16 15 78 23 23 23 22 22 21 21 20 19 18 17 16 15 14 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13 74 21 21 21 20 19 19 18 17 16 16 15 14 13 12

Dry−bulb

72 20 20 19 18 17 17 16 15 15 14 13 12 11 10

70 19 19 18 18 17 17 16 15 15 14 13 12 11 10

57 58 59 60 61 62 63 64 65 66 67 68 69 70

Drop

19º

All temperatures are expressed in ºF

air flowair flow

INDOOR COIL

64º

CHARGE IN

LIQUID PHASE

DIGITAL SCALE

TEMPERATURE

SENSOR

liquid phase charging.

72º

WET

BULB

DRY

BULB

TO LIQUID

LINE SERVICE

VALV E

1. Determine the desired DTMeasure entering air temperature using dry bulb (A) and wet bulb (B). DT is the intersecting value of A and B in the table (see triangle).

2. Find temperature drop across coilMeasure the coil’s dry bulb entering and leaving air temperatures (A and C). Temperature Drop Formula: (T

) = A minus C.

Drop

3. Determine if fan needs adjustmentIf the difference between

the measured T adjustment is needed. See examples: Assume DT = 15 and A temp.

Drop

= 72º, these C temperatures would necessitate stated actions: Cº T

– DT = ºF ACTION

Drop

53º 19 – 15 = 4 Increase the airflow 58º 14 – 15 = −1 (within +3º range) no change 62º 10 – 15 = −5 Decrease the airflow

4. Adjust the fan speedSee indoor unit instructions to increase/

decrease fan speed.

Changing air flow affects all temperatures; recheck temperatures to confirm that the temperature drop and DT are within +3º.

TEMPERATURE SENSOR

(LIQUID LINE)

and the desired DT (T

–DT) is within +3º, no

Drop

LIQUID LINE SERVICE PORT

Figure 20. Checking Indoor Coil Airflow Guide

Page 23

TPA*H4 SERIES

Page 24

Use WEIGH IN method for adding initial refrigerant charge, and then use SUBCOOLING method for verifying refrigerant charge.

WEIGH IN

OUTDOOR UNIT VOID OF CHARGE

If the system is void of refrigerant, first, locate and repair any leaks and then weigh in the refrigerant charge into the unit. To calculate the total refrigerant charge:

CALCULATING SYSTEM CHARGE FOR

Amount specified on nameplate

Adjust amount. for variation in line set

length listed on line set length table below.

Refrigerant Charge per Line Set Length

Liquid Line

Set Diameter

3/8" (9.5 mm)

*If line length is greater than 15 ft. (4.6 m), add this amount. If line length is less than 15 ft. (4.6 m), subtract this amount.

NOTE  The above nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information.

Ounces per 5 feet (g per 1.5 m)

adjust from 15 feet (4.6 m) line set*

3 ounce per 5’ (85 g per 1.5 m)

Additional charge specified per indoor

unit match−ups starting on page 25.

Total charge

SATº LIQº – SCº =

Table 4. Adding Charge per Indoor Unit Match−Up using Subcooling Method

Use cooling mode

60ºF (15ºC) Use heating mode

Figure 21. Weigh In Method

1 Check the airflow using figure 20 to be sure the indoor airflow is as required. (Make any

air flow adjustments before continuing with the following procedure.)

2 Measure outdoor ambient temperature; determine whether to use cooling mode or

heating mode to check charge.

3 Connect gauge set. 4 Check Liquid and Vapor line pressures. Compare pressures with Normal Operating

Pressures table 6, (Table 6 is a general guide. Expect minor pressure variations. Significant differences may mean improper charge or other system problem.)

5 Set thermostat for heat/cool demand, depending on mode being used:

Using cooling modeWhen the outdoor ambient temperature is 60°F (15°C) and above.

Target subcooling values in table below are based on 70 to 80°F (21−27°C) indoor return air temperature; if necessary, operate heating to reach that temperature range; then set thermostat to cooling mode setpoint to 68ºF (20ºC). When pressures have stabilized, continue with step 6.

Using heating modeWhen the outdoor ambient temperature is below 60°F (15°C).

Target subcooling values in table below are based on 65−75°F (18−24°C) indoor return air temperature; if necessary, operate cooling to reach that temperature range; then set thermostat to heating mode setpoint to 77ºF (25ºC). When pressures have stabilized, continue with step 6.

6 Read the liquid line temperature; record in the LIQº space. 7 Read the liquid line pressure; then find its corresponding temperature in the temperature/

pressure table 7) and record it in the SATº space.

8 Subtract LIQº temp. from SATº temp. to determine subcooling; record it in SCº space.

9 Compare SCº results with table below, being sure to note any additional charge for line

set and/or match−up.

10 If subcooling value is greater than shown in table below, remove refrigerant; if less than

shown, add refrigerant.

11 If refrigerant is added or removed, repeat steps 5 through 10 to verify charge.

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Page 25

Table 5. Indoor Unit Match ups and Target Subcooling Values

Target

INDOOR MATCHUPS

TPA*H4−036 lb oz 14HPX/XP14/TPA*H4−042 (Continued) lb oz 14HPX/XP14/TPA*H4−048 (Continued) lb oz

C33−44C 13 6 0 0 CBX32M−048 12 6 0 7 CH33−62D 10 7 1 14

CBX26UH−036 26 5 0 0 CBX32MV−048 12 6 0 8 CR33−50/60C 35 5 0 0

CBX26UH−037 25 4 1 9 CBX40UHV−042, −048 12 6 0 8 CR33−60D 37 6 0 0

CBX27UH−036 13 6 0 3 CH33−43 12 6 0 7 CX34−62C, −62D 10 7 1 7

CBX32M−036 13 6 0 2 CH33−62D 12 6 0 10 CX34−49C 11 8 0 14

CBX32M−042 13 6 0 3 CH33−50/60C 12 6 0 7 CX34−60D 11 8 0 0

CBX32MV−036 13 6 0 3 CH33−60D 12 6 0 4 14HPX/XP14/TPA*H4−060 lb oz

CBX32MV−048 11 8 2 5 CR33−50/60C,−60D 26 6 0 4 CBX26UH−048 12 7 1 0

CBX40UHV−036 13 6 0 3 CX34−62C, −62D 12 6 0 9 CBX26UH−060 14 4 0 0

CBX40UHV−042, −048 11 8 2 5 CX34−49C 12 6 0 7 CBX27UH−060 12 5 0 0

CH33−50/60C 11 8 2 5 CX34−60D 12 6 0 4 CBX32M−048, −060 12 5 0 0

CH33−44B 13 6 1 7 14HPX/XP14/TPA*H4−048 lb oz CBX32MV−048, −060 12 5 0 0

CH33−48B 13 6 1 8 CBX26UH−048 8 7 1 9 CBX40UHV−048, −060 12 5 0 0

CR33−50/60C 25 4 1 15 CBX27UH−048 11 8 1 2 CBX32MV−068 12 7 1 0

CR33−48B/C 25 5 0 9 CBX32M−048, −060 11 8 1 2 CH23−68 12 5 0 0

CX34−49C 13 6 2 4 CBX32MV−048 25 8 0 0 CH33−50/60C 12 5 0 0

CX34−43B/C, −50/60C 13 6 1 8 CBX32MV−060 11 8 1 2 CH33−62D 12 5 0 0

CX34−38A/B S/N# 6007 and

after

CX34−38A/B before S/N#

6007

TPA*H4−042 lb oz CBX32MV−068 10 7 1 12

CH23−68 20 9 0 13 CH23−68 20 9 2 9

CBX26UH−042 27 6 0 0 CH33−50/60C 11 8 1 1

CBX27UH−042 12 6 0 8 CH33−60D 11 8 0 0

Subcooling

HeatingCooling

(+5ºF)(+1ºF)

6 6 0 0 CBX40UHV−048 25 8 0 0 CX34−62C, −62D 12 7 1 0

13 6 0 0 CBX40UHV−060 11 8 1 2

*Add

charge

INDOOR MATCHUPS

Target

Subcooling

HeatingCooling

(+5ºF)(+1ºF)

*Add

charge

Target

INDOOR MATCHUPS

*Add charge = Extra matchup amount required in addition to charge indicated on Heat Pump nameplate (remember to also add any charge required for line set differences from 15 feet).

SN indicates serial number.

Subcooling

HeatingCooling

(+5ºF)(+1ºF)

*Add

charge

Table 6. CTXV Normal Operating Pressures − Liquid +10 and Vapor +5 PSIG*

IMPORTANT

Use table 6 as a general guide when performing maintenance checks. This is not a procedure for charging the unit (Refer to Charging / Checking Charge section). Minor variations in these pressures may be expected due to differences in installations. Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system.

TPA*H4−036 TPA*H4−042 TPA*H4−048 TPA*H4−060

5F (5C)**

HEATING

60 (15) 350 / 134 373 / 139 355 / 130 351 / 117

50 (10) 331 / 117 363 / 117 336 / 113 333 / 105

40 (4) 313 / 97 348 / 97 315 / 88 316 / 88

30 (−1) 298 / 83 336 / 74 296 / 72 308 / 70

20 (−7) 284 / 66 322 / 64 286 / 64 300 / 61

COOLING

65 (18) 220 / 138 223 / 125 231 / 136 243 / 136

70 (21) 236 / 140 241 / 130 248 / 139 263 / 137

75 (24) 256 / 141 261 / 134 271 / 140 282 / 138

80 (27) 276 / 142 282 / 138 291 / 142 306 / 139

85 (29) 298 / 143 302 / 139 312 / 143 327 / 140

90 (32) 321 / 144 326 / 140 335 / 144 351 / 141

95 (35) 344 / 144 349 / 141 359 / 145 376 / 142

100 (38) 369 / 146 374 / 142 384 / 146 401 / 143

105 (41) 394 / 147 399 / 143 411 / 148 426 / 145

110 (38) 421 / 148 428 / 145 439 / 149 452 / 146

115 (45) 449 / 149 455 / 146 468 / 150 484 / 148

*These are most−popular−match−up pressures. Indoor match up, indoor air quality, and indoor load cause pressures to vary.

**Temperature of the air entering the outside coil (outdoor ambient temperature).

Liquid/ Vapor Liquid / Vapor Liquid / Vapor Liquid / Vapor

Page 25

TPA*H4 SERIES

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Table 7. HFC−410A Temp. (°F) − Pressure (Psig)

°F Psig °F Psig °F Psig °F Psig

−40 10.1 21 80.5 56 158.2 91 278.2

−35 13.5 22 82.3 57 161.0 92 282.3

−30 17.2 23 84.1 58 163.9 93 286.5

−25 21.4 24 85.9 59 166.7

−20 25.9 25 87.8 60 169.6 95 295.1

−18 27.8 26 89.7 61 172.6 96 299.4

−16 29.7 27 91.6 62 175.4 97 303.8

−14 31.8 28 93.5

−12 33.9 29 95.5 64 181.6 99 312.7

−10 36.1 30 97.5 65 184.3 100 317.2

−8 38.4 31 99.5 66 187.7 101 321.8

−6 40.7

−4 43.1 33 102.9 68 194.1 103 331.0

−2 45.6 34 105.0 69 197.3 104 335.7 0 48.2 35 107.1 70 200.6 105 340.5 1 49.5 2 50.9 37 111.4 72 207.2 107 350.1 3 52.2 38 113.6 73 210.6 108 355.0 4 53.6 39 115.8 74 214.0 109 360.0 5 55.0 40 118.0 75 217.4 11 0 365.0 6 56.4 41 120.3 76 220.9 111 370.0 7 57.9 42 122.6 77 224.4 11 2 375.1 8 59.3 43 125.0 78 228.0 11 3 380.2 9 60.8 44 127.3 79 231.6 11 4 385.4

10 62.3 45 129.7 80 235.3 115 390.7

11 63.9 46 132.2 81 239.0 11 6 396.0 12 65.4 47 134.6 82 242.7 117 401.3 13 67.0 48 137.1 83 246.5 118 406.7 14 68.6 49 139.6 84 250.3 119 412.2 15 70.2 50 142.2 85 254.1 120 417.7 16 71.9 51 144.8 86 258.0 121 423.2 17 73.5 52 147.4 87 262.0 122 428.8 18 75.2 53 150.1 88 266.0 123 434.5 19 77 54 152.8 89 270.0 124 440.2 20 78.7 55 155.5 90 274.1

32 100.8

36 109.2 71 203.9 106 345.3

63 178.5

67 190.9 102 326.4

94 290.8

98 308.2

125 445.9

System Operation

SECOND−STAGE OPERATION

If the demand defrost control (A108) receives a call for second−stage compressor operation Y2 in heating or cooling mode and the first-stage compressor output is active, the second-stage compressor solenoid output will be energized.

If first-stage compressor output is active in heating mode and the outdoor ambient temperature is below the selected compressor lock−in temperature, the second-stage compressor solenoid output will be energized without the Y2 input. If the jumper is not connected to one of the temperature selection pins on P3 (40, 45, 50, 55°F), the default lock−in temperature of 40°F (4.5°C) will be used.

IMPORTANT

Some scroll compressor have internal vacuum protector that will unload scrolls when suction pressure 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 COMPRESSOR.

UNIT COMPONENTS

High Pressure Switch (S4)

When the high pressure switch trips, the demand defrost control will cycle off the compressor, and the strike counter in the demand defrost control will count one strike. High Pressure (auto reset) − trip at 590 psig, reset at 418.

Low Pressure Switch (S87)

When the low pressure switch trips, the demand defrost control will cycle off the compressor, and the strike counter in the demand defrost control will count one strike. Low pressure switch (auto reset) − trip at 25 psig, reset at 40 psig.

The low pressure switch is ignored under the following conditions:

 During the defrost cycle and 90 seconds after the

termination of defrost

 When the average ambient sensor temperature is

below 15° F (−9°C)

 For 90 seconds following the start up of the

compressor

 During test mode

Ambient Sensor (RT13)

The ambient sensor considers outdoor temperatures below −35°F (−37°C) or above 120°F (48°C) as a fault. If the ambient sensor is detected as being open, shorted or out of the temperature range of the sensor, the demand defrost control will not perform demand defrost operation. The demand defrost control will revert to time/temperature defrost operation and will display the appropriate fault code. Heating and cooling operation will be allowed in this fault condition.

Coil Sensor (RT21)

Coil SensorThe coil temperature sensor considers

outdoor temperatures below −35°F (−37°C) or above 120°F (48°C) as a fault. If the coil temperature sensor is detected as being open, shorted or out of the temperature range of the sensor, the demand defrost control will not perform demand or time/temperature defrost operation and will display the appropriate fault code. Heating and cooling operation will be allowed in this fault condition.

High Discharge Temperature Sensor (RT28)

If the discharge line temperature exceeds a temperature of 285°F (140°C) during compressor operation, the demand defrost control will de−energize the compressor contactor output (and the defrost output, if active). The compressor will remain off until the discharge temperature has dropped below 225°F (107°C) and the 5-minute anti−short cycle delay has been satisfied. This sensor has two fault and lockout codes:

1. If the demand defrost control recognizes five high discharge line temperature faults during a single (Y1) compressor demand, it reverts to a lockout mode and displays the appropriate code. This code detects shorted sensor or high discharge temperatures. Code on demand defrost control is Discharge Line Temperature Fault and Lockout.

2. If the demand defrost control recognizes five temperature sensor range faults during a single (Y1)

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compressor demand, it reverts to a lockout mode and displays the appropriate code. The demand defrost control detects open sensor or out-of-temperature sensor range. This fault is detected by allowing the unit to run for 90 seconds before checking sensor resistance. If the sensor resistance is not within range after 90 seconds, the demand defrost control will count one fault. After five faults, the demand defrost control will lockout. Code on demand defrost control is Discharge Sensor Fault and Lockout.

The discharge line sensor, which covers a range of 150°F (65°C) to 350°F (176°C), is designed to mount on a ½" refrigerant discharge line.

NOTE − Within a single room thermostat demand, if 5−strikes occur, the demand defrost control will lockout the unit. demand defrost control 24 volt power R must be cycled OFF or the TEST pins on demand defrost control must be shorted between 1 to 2 seconds to reset the demand defrost control.

Crankcase Heater (HR1) and Crankcase Thermostat

(S40)

The reference models are equipped with a 70 watt, belly band type crankcase heater. HR1 prevents liquid from accumulating in the compressor. HR1 is controlled by a thermostat located on the liquid line. When liquid line temperature drops below 50° F the thermostat closes energizing HR1. The thermostat will open, de−energizing HR1 once liquid line temperature reaches 70° F .

Internal Solenoid (L34)

The internal unloader solenoid controls the two−stage operation of the compressor by shifting a slide ring mechanism to open two by−pass ports in the first compression pocket of the scrolls in the compressor. The internal solenoid is activated by a 24 volt direct current solenoid coil. The coil power requires 20VAC. The internal wires from the solenoid in the compressor are routed to a 2 pin fusite connection on the side of the compressor shell. The external electrical connection is made to the compressor with a molded plug assembly. This plug contains a full wave rectifier that converts 24 volt AC into 24 volt DC power to power the unloader solenoid. Refer to unit diagram for internal circuitry view of plug).

Outdoor Fan Relay (K10) (G Voltage Only)

Outdoor fan relay K10 is used on all G and voltage units to energize the outdoor fan B4. The relay is located in the control box and is a single−pole double−throw relay. See figure 3. K10 is energized by the indoor thermostat terminal Y1 (24V). When K10 is energized, a set of N.O. contacts closes to energize the outdoor fan.

Liquid Line Bi−Flow Filter Drier

The unit is equipped with a large−capacity biflow filter drier which keeps the system clean and dry. If replacement is necessary, order another of like design and capacity. The replacement filter drier must be suitable for use with HFC−410A refrigerant.

Page 27

TPA*H4 SERIES

Page 28

Demand Defrost Control (A108)

The demand defrost control measures differential temperatures to detect when the system is performing poorly because of ice build−up on the outdoor coil. The controller self−calibrates when the defrost system starts and after each system defrost cycle. The demand defrost control components are shown in figure 22.

TEST PINS

DEFROST TERMINATION PIN

SENSOR PLUG IN (COIL &

REVERSING VALVE

SETTINGS

AMBIENT

SENSORS)

DELAY PINS

LOW AMBIENT THERMOSTAT PINS

DIAGNOSTIC LEDS

24V TERMINAL STRIP CONNECTIONS

PRESSURE

SWITCH

CIRCUIT

CONNECTIONS

Note − Component locations vary by board manufacturer.

Figure 22. Demand Defrost Control (A108)

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Table 8. Demand Defrost Control (A108) Inputs, Outputs and Configurable Settings

Control Location

P1 TEST Test Mode See Test Mode on page 35 for further details.

P1 50, 70, 90, 100

P3 55, 50, 45, 40 Low Ambient Thermostat Pins

P5 DELAY Delay Mode

P6 TST, PS DF, C, R, O, Y1, Y2 Factory Test Connectors No field use.

DS1 RED LED

DS2 GREEN LED

FAN TWO CONNECTORS Condenser Fan Operation These two connections provide power for the condenser fan.

O OUT O OUT 24 VAC output 24 VAC output connection for reversing valve.

Control Label or Description

C 24VAC Common 24VAC common

L Thermostat Service Light Thermostat service light connection.

R 24VAC 24VAC

Y2 Thermostat Input Controls the second stage operation of the unit.

O Thermostat Input Reversing valve solenoid.

Y1 Thermostat Input Controls the operation of the unit.

DIS−YEL Coil Sensor

AMB−BLACK Ambient Sensor

COIL−BROWN Discharge Sensor No discharge sensor is used; replaced by 10K resistor.

Purpose Function

Defrost Temperature Termination Shunt (Jumper) Pins

24VAC Thermostat Input / Output

Diagnostic LED

The demand defrost control has valid selections which are: 50, 70, 90, and 100°F (10, 21, 32 and 38°C). The shunt termination pin is factory set at 50°F (10°C). If the temperature shunt is not installed, the default termination temperature is 90°F (32°C).

24VAC input/output from indoor thermostat to indoor unit.

Provides selection of the Y2 compressor lock−in temperature. Valid options are 40, 45, 50 and 55 degrees Fahrenheit.

(P4−5) Ground connection for outdoor coil temperature sensor. (P4−6) Connection for outdoor coil temperature sensor.

(P4−3) Ground connection for outdoor ambient temperature sensor. (P4−4) Connection for outdoor ambient temperature sensor.

The demand defrost control has a field−selectable function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode. When a jumper is installed on the DELAY pins, the compressor will be cycled off for 30 seconds going in and out of the defrost mode. Units are shipped with jumper installed on DELAY pins.

NOTE − The 30 second off cycle is NOT functional when

jumpering the TEST pins on P1.

Valid states for demand defrost control’s two LEDs are OFF, ON and FLASHING which indicate diagnostics conditions that are described in tables 9 and 10.

When the low pressure switch trips, the demand defrost control will cycle off the compressor, and the strike counter in the demand defrost control will count one strike. The low pressure switch is ignored under the following conditions:

 during the defrost cycle and 90 seconds after the termination

LO−PS LO−PS Low−Pressure Switch

of defrost

 when the average ambient sensor temperature is below 0°F

(−18°C)

 for 90 seconds following the start up of the compressor  during TEST mode

Y2 OUT Y2 OUT 24 VAC Output 24 VAC output for second stage compressor solenoid.

Y1 OUT Y1 OUT 24 VAC Common Output

HS−PS HS−PS High−Pressure Switch

L L Line output 24VAC service light output.

24V 24V 24 Volt output

24 VAC common output, switched for enabling compressor contactor.

When the high pressure switch trips, the demand defrost control will cycle off the compressor, and the strike counter in the demand defrost control will count one strike.

24VAC typically used to supply power to the Lennox System Operation Monitor (LSOM)

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TPA*H4 SERIES

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DEMAND DEFROST CONTROL (A108) DIAGNOSTIC LEDS

The state (Off, On, Flashing) of two LEDs on the demand defrost control (DS1 [Red] and DS2 [Green]) indicate diagnostics conditions that are described as follows.

Table 9. Demand Defrost Control (A108) Diagnostic LEDs

DS2 Green

OFF OFF Power problem No power (24V) to demand defrost

DS1 Red

Condition/Code Possible Cause(s) Solution

Check control transformer power (24V). control terminals R and C or demand defrost control failure.

If power is available to demand defrost control and

LED(s) do not light, replace demand defrost control.

Simultaneous SLOW Flash

Alternating SLOW Flash

Simultaneous FAST Flash

Alternating FAST Flash

ON ON Demand Defrost Control

Normal operation Unit operating normally or in standby

mode.

5−minute anti−short cycle delay Initial power up, safety trip, end of room

thermostat demand.

Ambient Sensor Problem Sensor being detected open or shorted or out of temperature range. Demand defrost control will

revert to time/temperature defrost operation. (System will still heat or cool).

Coil Sensor Problem Sensor being detected open or shorted or out of temperature range. Demand defrost control will

not perform demand or time/temperature defrost operation. (System will still heat or cool).

Indicates that demand defrost control has internal component failure. Cycle 24VAC power to de-

Failure

mand defrost control. If code does not clear, replace demand defrost control.

Table 10. Demand Defrost Control (A108) Diagnostic Fault and Lockout Codes

DS2 Green

(Each fault adds 1 strike to that code’s counter; 5 strikes per code = LOCKOUT)

OFF SLOW

OFF ON Low Pressure Lockout

SLOW Flash

ON OFF High Pressure Lockout

DS1 Red

Condition/Code Possible Cause(s) Solution

Low Pressure Fault

Flash

OFF High Pressure Fault

Restricted air flow over indoor or outdoor coil.

Improper refrigerant charge in system.

Improper metering device installed or incorrect operation of metering device.

Incorrect or improper sensor location or connection to system.

None required.

None required (Jumper TEST pins to override)

Remove any blockages or restrictions from coils and/or fans. Check indoor and outdoor fan motor for proper current draws.

Check system charge using approach and subcooling temperatures.

Check system operating pressures and compare to unit charging charts.

Make sure all pressure switches and sensors have secure connections to system to prevent refrigerant leaks or errors in pressure and temperature measurements.

SLOW

ON Discharge Line Temperature

Flash

FAST

ON Discharge Line Temperature

Flash

OFF Fast

Flash

Fast

OFF Discharge Sensor Lockout

Flash

506650−01

Fault

exceeds a temperature of 285ºF (140ºC) during compressor operation, the demand defrost control will de−energize the compressor contactor output (and the defrost output if active). The compressor will remain off until the discharge temperature has dropped below 225ºF (107ºC).

Lockout

Discharge Sensor Fault The demand defrost control detects open sensor or out of temperature sensor range. This fault is

detected by allowing the unit to run for 90 seconds before checking sensor resistance. If the sensor resistance is not within range after 90 seconds, the demand defrost control will count one fault. After 5 faults, the demand defrost control will lockout.

Page 30

This code detects shorted sensor or high discharge temperatures. If the discharge line temperature

Page 31

Defrost System

EMERGENCY HEAT (AMBER LIGHT)

An emergency heat function is designed into some room thermostats. This feature is applicable when isolation of the outdoor unit is required, or when auxiliary electric heat is staged by outdoor thermostats. When the room thermostat is placed in the emergency heat position, the outdoor unit control circuit is isolated from power and field-provided relays bypass the outdoor thermostats. An amber indicating light simultaneously comes on to remind the homeowner that he is operating in the emergency heat mode.

Emergency heat is usually used during an outdoor unit shutdown, but it should also be used following a power outage if power has been off for over an hour and the outdoor temperature is below 50°F (10°C). System should be left in the emergency heat mode at least six hours to allow the crankcase heater sufficient time to prevent compressor slugging.

The demand defrost control de−energizes the second-stage compressor solenoid output immediately when the Y2 signal is removed or the outdoor ambient temperature is 5°F above the selected compressor lock−in temperature, or the first-stage compressor output is de−energized for any reason.

DEFROST SYSTEM DESCRIPTION

The control monitors ambient temperature, outdoor coil temperature, and total run time to determine when a defrost cycle is required. The coil temperature probe is designed with a spring clip to allow mounting to the outside coil tubing. The location of the coil sensor is important for proper defrost operation.

NOTE − The demand defrost control accurately measures the performance of the system as frost accumulates on the outdoor coil. This typically will translate into longer running time between defrost cycles as more frost accumulates on the outdoor coil before the demand defrost control initiates defrost cycles.

Demand Defrost Control Pressure Switch

Connections

The unit’s automatic reset pressure switches (LO PS − S87 and HI PS − S4) are factory−wired into the demand defrost control on the LO−PS and HI−PS terminals, respectively.

Pressure Switch 5−Strike Lockout

The internal control logic of the demand defrost control counts the pressure switch trips only while the Y1 (Input) line is active. If a pressure switch opens and closes four times during a Y1 (Input), the control logic will reset the pressure switch trip counter to zero at the end of the Y1 (Input). If the pressure switch opens for a fifth time during the current Y1 (Input), the control will enter a lockout condition.

The 5−strike pressure switch lockout condition can be reset by cycling OFF the 24−volt power to the demand defrost control or by shorting the TEST pins between 1 to 2 seconds. All timer functions (run times) will also be reset.

If a pressure switch opens while the Y1 Out line is engaged, a 5−minute short cycle will occur after the switch closes.

Defrost System Sensors

Sensors connect to the demand defrost control through a field-replaceable harness assembly that plugs into the demand defrost control as illustrated in figure 22. Through the sensors, the demand defrost control detects outdoor ambient, coil, and discharge temperature fault conditions. As the detected temperature changes, the resistance across the sensor changes. Sensor resistance values can be checked by ohming across pins shown in table 11.

Table 11. Sensor Temperature /Resistance Range

Temperature

Sensor

Outdoor −35 (−37) to 120 (48) 280,000 to 3750 3 & 4

Coil −35 (−37) to 120 (48) 280,000 to 3750 5 & 6

Discharge (if applicable)

Note: Sensor resistance increases as sensed temperature decreases.

Range °F (°C)

24 (−4) to 350 (176) 41,000 to 103 1 & 2

Resistance values range (ohms)

Pins/W ire Color

(Black)

(Brown)

(Yellow)

Table 12 shows how the resistance varies as the temperature changes for various types of sensors.

NOTE − When checking the ohms across a sensor, be aware that a sensor showing a resistance value that is not within the range shown in table 11, may be performing as designed. However, if a shorted or open circuit is detected, then the sensor may be faulty and the sensor harness will need to be replaced.

Page 31

TPA*H4 SERIES

Page 32

Defrost Temperature Termination Shunt (Jumper)

Pins (P1)

The demand defrost control selections are: 50, 70, 90, and 100°F (10, 21, 32 and 38°C). The shunt termination pin is factory set at 50°F (10°C). If temperature shunt is not installed, default termination temperature is 90°F (32°C).

Compressor Delay Mode (P5)

NOTE − The 30 second off cycle is NOT functional when jumpering the TEST pins.

OPERATIONAL DESCRIPTION

The demand defrost control has three basic operational modes: calibration, normal and defrost.

1. Calibration Mode  The demand defrost control is

considered uncalibrated when power is applied to the demand defrost control, after cool mode operation, or if the coil temperature exceeds the termination temperature when it is in heat mode (see figure 23 for further details).

2. Normal Mode  The demand defrost control monitors the O line, to determine the system operating mode (heat/cool), outdoor ambient temperature, coil temperature (outdoor coil) and compressor run time to determine when a defrost cycle is required.

Calibration of the demand defrost control occurs after a defrost cycle to ensure that there is no ice on the coil. During calibration, the temperature of both the coil and the ambient sensor are measured to establish the temperature differential which is required to allow a defrost cycle.

3. Defrost ModeThe following paragraphs provide a detailed description of the defrost system operation.

TEST MODE Each test pin shorting will result in one test event. For

each TEST the shunt (jumper) must be removed for at least one second and reapplied. Refer to flow chart (figure

24) for TEST operation.

Note: The Y1 input must be active (ON) and the O room thermostat terminal into demand defrost control must be inactive.

DETAILED DEFROST SYSTEM OPERATION

The demand defrost control initiates a defrost cycle based on either frost detection or time.

1. Frost Detection  If the compressor runs longer than

30 minutes and the actual difference between the clear coil and frosted coil temperatures exceeds the maximum difference allowed by the demand defrost control, a defrost cycle will be initiated.

2. Time  If six hours of heating mode compressor run

time has elapsed since the last defrost cycle while the coil temperature remains below 35°F (2°C), the demand defrost control will initiate a defrost cycle.

3. Actuation  When the reversing valve is

de−energized, the Y1 circuit is energized, and the coil temperature is below 35°F (2°C), the demand defrost control logs the compressor run time. If the demand defrost control is not calibrated, a defrost cycle will be initiated after 30 minutes of heating mode compressor run time. The control will attempt to self−calibrate after this (and all other) defrost cycle(s).

Calibration success depends on stable system temperatures during the 20−minute calibration period. If the demand defrost control fails to calibrate, another defrost cycle will be initiated after 45 minutes of heating mode compressor run time. Once the demand defrost control is calibrated, it initiates a demand defrost cycle when the difference between the clear coil and frosted coil temperatures exceeds the maximum difference allowed by the control or after six hours of heating mode compressor run time has been logged since the last defrost cycle.

4. Termination  The defrost cycle ends when the coil

temperature exceeds the termination temperature or after 14 minutes of defrost operation. If the defrost is terminated by the 14−minute timer, another defrost cycle will be initiated after 30 minutes of run time.

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DEFROST CONTROL (A108) CALIBRATION MODE SEQUENCE

Occurs after power up and cooling operation, or if the coil temperature exceeds

Demand defrost control defaults to 30 minute  Time / Temperature Mode

Reset Compressor Runtime / Reset Three / Five Strike Counter

DEMAND MODE

Accumulate compressor runtime of more than 30 minutes while coil temperature is below 35° F (2°C). When the accumulated compressor time exceeds six (6) hours or if the coil sensor indicates frost is present on coil, go to Defrost.

the termination temperature while in Heat Mode.

THIRTY (30) MINUTE TIME /

TEMPERATURE MODE

Accumulate compressor runtime while coil temperature is below 35° F (2°C). When the accumulated compressor time exceeds 30 minutes go to Defrost.

DEFROST

 Outdoor Fan OFF  Reversing Valve ON  W1 line ON

Monitor coil temperature and

time in defrost mode.

TIME/TEMPERATURE MODE

45 MINUTE

Accumulate compressor runtime while coil temperature is below 35° F (2°C). When the accumulated compressor time exceeds 45 minutes go to Defrost.

HOW DID DEFROST TERMINATE?

Coil temperature was above 35°F (2°C) for four (4) minutes. of the 14−minute defrost OR reached defrost termination temperature.

DEFROST TERMINATION

 Compressor runtime counter RESET  Outdoor Fan ON  Reversing Valve OFF  W1 line OFF

Attempt to Calibration  Temperature measurements are not taken for the first few minutes of each heat demand. This is to allow coil temperatures to stabilize. demand defrost control has a maximum of 20 minutes of accumulated compressor runtime in heat mode to calibrate demand defrost control This may involve more than one heating demand.

YES  Calibration occurred

Was stable coil temperature attained within 20 minutes?

Defrosted for 14−minute without the coil temperature going above 35°F (2°C) for four (4) minutes and coil did not reach termination temperature.

DEFROST TERMINATION

 Compressor runtime counter RESET  Outdoor Fan ON  Reversing Valve OFF  W1 line OFF

NO  Demand defrost control reverts to 45 minute time / temperature.

Figure 23. Defrost Calibration

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TPA*H4 SERIES

Page 34

Table 12. Ambient (RT13) and Coil (RT21) Sensors Temperature / Resistance Range

Degrees

Fahrenheit

136.3 2680 56.8 16657 21.6 44154 −11.3 123152

133.1 2859 56.0 16973 21.0 44851 −11.9 125787

130.1 3040 55.3 17293 20.5 45560 −12.6 128508

127.3 3223 54.6 17616 20.0 46281 −13.2 131320

124.7 3407 53.9 17942 19.4 47014 −13.9 134227

122.1 3592 53.2 18273 18.9 47759 −14.5 137234

119.7 3779 52.5 18607 18.4 48517 −15.2 140347

117.5 3968 51.9 18945 17.8 49289 −15.9 143571

115.3 4159 51.2 19287 17.3 50074 −16.5 146913

113.2 4351 50.5 19633 16.8 50873 −17.2 150378

111.2 4544 49.9 19982 16.3 51686 −17.9 153974

109.3 4740 49.2 20336 15.7 52514 −18.6 157708

107.4 4937 48.5 20695 15.2 53356 −19.3 161588

105.6 5136 47.9 21057 14.7 54215 −20.1 165624

103.9 5336 47.3 21424 14.1 55089 −20.8 169824

102.3 5539 46.6 21795 13.6 55979 −21.5 174200

100.6 5743 46.0 22171 13.1 56887 −22.3 178762

99.1 5949 45.4 22551 12.5 57811 −23.0 183522

97.6 6157 44.7 22936 12.0 58754 −23.8 188493

96.1 6367 44.1 23326 11.5 59715 −24.6 193691

94.7 6578 43.5 23720 11.0 60694 −25.4 199130

93.3 6792 42.9 24120 10.4 61693 −26.2 204829

92.0 7007 42.3 24525 9.9 62712 −27.0 210805

90.6 7225 41.7 24934 9.3 63752 −27.8 217080

89.4 7444 41.1 25349 8.8 64812 −28.7 223677

88.1 7666 40.5 25769 8.3 65895 −29.5 230621

86.9 7890 39.9 26195 7.7 67000 −30.4 237941

85.7 8115 39.3 26626 7.2 68128 −31.3 245667

84.5 8343 38.7 27063 6.7 69281 −32.2 253834

83.4 8573 38.1 27505 6.1 70458 −33.2 262482

82.3 8806 37.5 27954 5.6 71661 −34.1 271655

81.2 9040 37.0 28408 5.0 72890 −35.1 281400

80.1 9277 36.4 28868 4.5 74147 −36.1 291774

79.0 9516 35.8 29335 3.9 75431 −37.1 302840

78.0 9757 35.2 29808 3.4 76745 −38.2 314669

77.0 10001 34.7 30288 2.8 78090 −39.2 327343

76.0 10247 34.1 30774 2.3 79465

75.0 10496 33.5 31267 1.7 80873

74.1 10747 33.0 31766 1.2 82314

73.1 11000 32.4 32273 0.6 83790

72.2 11256 31.9 32787 0.0 85302

71.3 11515 31.3 33309 −0.5 86852

70.4 11776 30.7 33837 −1.1 88440

69.5 12040 30.2 34374 −1.7 90068

68.6 12306 29.6 34918 −2.2 91738

67.7 12575 29.1 35471 −2.8 93452

66.9 12847 28.6 36031 −3.4 95211

66.0 13122 28.0 36600 −4.0 97016

65.2 13400 27.5 37177 −4.6 98870

64.4 13681 26.9 37764 −5.2 100775

63.6 13964 26.4 38359 −5.7 102733

62.8 14251 25.8 38963 −6.3 104746

62.0 14540 25.3 39577 −6.9 106817

61.2 14833 24.8 40200 −7.5 108948

60.5 15129 24.2 40833 −8.2 111141

59.7 15428 23.7 41476 −8.8 113400

59.0 15730 23.2 42130 −9.4 115727

58.2 16036 22.6 42794 −10.0 118126

57.5 16345 22.1 43468 −10.6 120600

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

506650−01

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Page 35

TEST

Placing the jumper on the field test pins (P1) allows the technician to:

 Clear short cycle lockout  Clear five−strike fault lockout  Cycle the unit in and out of defrost mode  Place the unit in defrost mode to clear the coil

When Y1 is energized and 24V power is being applied to the Control, a test cycle can be initiated by placing a jumper on the Control’s TEST pins for 2 to 5 seconds. If the jumper remains on the TEST pins for longer than five seconds, the Control will ignore the jumpered TEST pins and revert to normal operation.

The Control will initiate one test event each time a jumper is placed on the TEST pins. For each TEST the jumper must be removed for at least one second and then reapplied.

Y1 Active

Place a jumper on TEST pins for

longer than one second but less than two seconds.

Clears any short cycle lockout and five strike fault lockout function, if applicable. No other functions will be executed and unit will continue in the mode it was operating.

If in COOLING Mode

No further test mode operation will be executed until the jumper is removed from the TEST pins and reapplied.

Place a jumper on TEST pins for

more than two seconds.

Clears any short cycle lockout and five strike fault lockout function, if applicable.

ACTIVE

O Line Status

If in DEFROST Mode

The unit will terminate defrost and enter HEAT MODE uncalibrated with defrost timer set for 45 minute test.

INACTIVE

If in HEATING Mode

If no ambient or coil sensor fault exist, unit will go into DEFROST MODE. If ambient or coil faults exist (open or shorted), unit will remain in HEAT MODE.

NOTE  Placing a jumper on the TEST pins will not bring the unit out of inactive mode. The only way manually activate the heat pump from an inactive mode is to cycle the 24VAC power to the Control.

If jumper on TEST pins remains in place for more than five seconds.

The unit will return to HEAT MODE un−calibrated with defrost timer set for 34 minutes.

Figure 24. Test Mode

Page 35

If jumper on TEST pins is removed before a maximum of five seconds.

The unit will remain in DEFROST MODE until termination on time or temperature.

TPA*H4 SERIES

Page 36

Maintenance

DEALER

Outdoor Unit

1. Clean and inspect outdoor coil (may be flushed with a water hose). Ensure power is off before cleaning.

2. Outdoor unit fan motor is pre−lubricated and sealed. No further lubrication is needed.

3. Visually inspect all connecting lines, joints and coils for evidence of oil leaks.

4. Check all wiring for loose connections.

5. Check for correct voltage at unit (unit operating).

6. Check amp draw on outdoor fan motor. Motor Nameplate:_________ Actual:__________.

7. Inspect drain holes in coil compartment base and clean if necessary.

NOTE - If insufficient heating or cooling occurs, the unit should be gauged and refrigerant charge should be checked.

Outdoor Coil

It may be necessary to flush the outdoor coil more frequently if it is exposed to substances which are corrosive or which block airflow across the coil (e.g., pet urine, cottonwood seeds, fertilizers, fluids that may contain high levels of corrosive chemicals such as salts)

 Outdoor Coil  The outdoor coil may be flushed with

a water hose.

 Outdoor Coil (Sea Coast)  Moist air in ocean

locations can carry salt, which is corrosive to most metal. Units that are located near the ocean require frequent inspections and maintenance. These inspections will determine the necessary need to wash the unit including the outdoor coil. Consult your installing contractor for proper intervals/procedures for your geographic area or service contract.

Indoor Unit

1. Clean or change filters.

2. Lennox blower motors are prelubricated and permanently sealed. No more lubrication is needed.

3. Adjust blower speed for cooling. Measure the pressure drop over the coil to determine the correct blower CFM. Refer to the unit information service manual for pressure drop tables and procedure.

4. Belt Drive Blowers − Check belt for wear and proper tension.

5. Check all wiring for loose connections.

6. Check for correct voltage at unit. (blower operating)

7. Check amp draw on blower motor.

Motor Nameplate:_________ Actual:__________.

Indoor Coil

1. Clean coil if necessary.

2. Check connecting lines, joints and coil for evidence of oil leaks.

3. Check condensate line and clean if necessary.

506650−01

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Page 37

OWNER

Cleaning of the outdoor unit’s coil should be performed by a trained service technician. 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.

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, soakers, waste water, etc.) will corrode the surface of steel and aluminum parts and diminish performance and longevity of the unit.

Outdoor Coil

The outdoor unit must be properly maintained to ensure its proper operation.

 Please contact your dealer to schedule proper

inspection and maintenance for your equipment.

 Make sure no obstructions restrict airflow to the

outdoor unit.

 Grass clippings, leaves, or shrubs crowding the unit

can cause the unit to work harder and use more energy.

 Keep shrubbery trimmed away from the unit and

periodically check for debris which collects around 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.

1. Air Filter  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 Filter  Disposable filters should be

replaced with a filter of the same type and size.

NOTE  If you are unsure about the filter required for your system, call your Lennox dealer for assistance.

3. Reusable Filter  Many indoor units are equipped

with reusable foam filters. Clean foam filters with a mild soap and water solution; rinse thoroughly; allow filter to dry completely before returning it to the unit or grille.

NOTE  The filter and all access panels must be in place any time the unit is in operation.

4. Indoor Unit  The indoor unit’s 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 thermostat homeowner manual for instructions on how to operate your thermostat.

Heat Pump Operation

Your new Lennox heat pump has several characteristics that you should be aware of:

 Heat pumps satisfy heating demand by delivering

large amounts of warm air into the living space. This is quite different from gas- or oil-fired furnaces or an electric furnace which deliver lower volumes of considerably hotter air to heat the space.

 Do not be alarmed if you notice frost on the outdoor coil

in the winter months. Frost develops on the outdoor coil during the heating cycle when temperatures are below 45F (7C). An electronic control activates a defrost cycle lasting 5 to 15 minutes at preset intervals to clear the outdoor coil of the frost.

 During the defrost cycle, you may notice steam rising

from the outdoor unit. This is a normal occurrence. The thermostat may engage auxiliary heat during the defrost cycle to satisfy a heating demand; however, the unit will return to normal operation at the conclusion of the defrost cycle.

Extended Power Outage

The heat pump is equipped with a compressor crankcase heater which protects the compressor from refrigerant slugging during cold weather operation.

If power to your unit has been interrupted for several hours or more, set the room thermostat selector to the EMERGENCY HEAT setting to obtain temporary heat without the risk of serious damage to the heat pump.

In EMERGENCY HEAT mode, all heating demand is satisfied by auxiliary heat; heat pump operation is locked out. After a six-hour compressor crankcase warm-up period, the thermostat can be switched to the HEAT setting and normal heat pump operation may resume.

Preservice Check

If your system fails to operate, check the following before calling for service:

 Verify room thermostat settings are correct.  Verify that all electrical disconnect switches are ON.  Check for any blown fuses or tripped circuit breakers.  Verify unit access panels are in place.  Verify air filter is clean.  If service is needed, locate and write down the unit

model number and have it handy before calling.

Accessories

For update−to−date information, see any of the following publications:

 Lennox TPA*H4 Engineering Handbook  Lennox Product Catalog  Lennox Price Book

Cleaning Outdoor Coil

1. Make sure power is off before cleaning. Clean and inspect outdoor coil. The coil may be flushed with a water hose.

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TPA*H4 SERIES

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2. The outdoor coil is protected by an inner mesh screen and a wire cage (see figure 25). If debris has collected between the mesh screen and the coil and cannot be dislodged by spraying unpressurized water from inside coil surface to the outside, the mesh may be removed by first removing the top of the unit which will allow for removal of the wire cage.

3. Then, using pliers to grip the head of the push pins, pull straight out to extract the push pins along one side of the coil. If necessary, remove the push pins along the back of the unit; it is usually unnecessary to fully remove the inner mesh screen.

4. Drape the mesh screen back and wash the coil. When all the debris has been removed from the coil, reinstall the mesh screen by positioning it in its original position and reinserting the push pin. No tool is required to push the pin back into the same slot in the fins.

5. If the push pin is loose and tends not to stay in place, brush the fins with a fin brush (22 fins/in). Line up the push pin a couple fins to the right or left of the original hole and re−insert the pin.

PUSH PIN

MESH SCREEN

Figure 25. Cleaning Debris from Mesh

9 PINS USED ON −048 AND −060; 6 PINS ALL OTHERS

506650−01

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Page 39

Checklists

Two−Stage Modulation Compressors Field Operational Checklist

Expected results during Y2

Unit Readings Y1 − First-Stage

COMPRESSOR

Voltage Same

Amperage Higher

OUTDOOR UNIT FAN MOTOR

Amperage Same or Higher

TEMPERATURE

demand (Toggle switch On)

Y2 − Second-Stage

Ambient Same

Outdoor Coil Discharge Air Higher

Compressor Discharge Line Higher

Indoor Return Air Same

Indoor Coil Discharge Air Lower

PRESSURES

Suction (Vapor) Lower

Liquid Higher

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TPA*H4 SERIES

Page 40

TPA*H4 Checklist

Job Name Job no. Date

Job Location City State

Installer City State

Unit Model No. Serial No. Service Technician

Nameplate Voltage

Rated Load Ampacity Compressor Outdoor Fan

Maximum Fuse or Circuit Breaker

Electrical Connections Tight?  Indoor Filter clean?  Supply Voltage (Unit Off)

Indoor Blower RPM S.P. Drop Over Indoor (Dry) Outdoor Coil Entering Air Temp.

Discharge Pressure Vapor Pressure Refrigerant Charge Checked? 

Refrigerant Lines: Leak Checked?  Properly Insulated?  Outdoor Fan Checked? 

Service Valves: Fully Opened?  Caps Tight?  Thermostat

Voltage With Compressor Operating Calibrated?  Properly Set?  Level? 

506650−01

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