Lennox TSA024S4N41T, TSA030S4N41M, TSA024S4N41M, TSA030S4N41T, TSA036S4N41M Installation Instructions Manual

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Page 1

INSTALLATION

2010 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 licensed professional installer (or equivalent) or a service agency.

IMPORTANT

The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFCs, HCFCs AND HFCs) as of July 1,

1992. Approved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarceration may be levied for noncompliance.

INSTRUCTIONS

T−Classt TSA*S4 Units

M and T Voltages

AIR CONDITIONER

506663−01 11/10 Supersedes 506418−01

TABLE OF CONTENTS

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

Outdoor Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Typical Unit Parts Arrangement 2. . . . . . . . . . . . . . . . . . .

Model Number Identification 3. . . . . . . . . . . . . . . . . . . . . .

General Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Gauge Set and Service Valves 3. . . . . . . . . . .

Recovering Refrigerant from Existing System 5. . . . . . .

New Outdoor Unit Placement 6. . . . . . . . . . . . . . . . . . . . .

New or Replacement Line Set 7. . . . . . . . . . . . . . . . . . . . .

Brazing Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Line Set and Indoor Coil 12. . . . . . . . . . . . . . . .

Installing Indoor Metering Device 13. . . . . . . . . . . . . . . .

Leak Test Line Set and Indoor Coil 14. . . . . . . . . . . . . . .

Evacuating Line Set and Indoor Coil 15. . . . . . . . . . . . .

Electrical Connections 16. . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Unit Delivered Void of Charge 20. . . . . . . . . . .

Unit Start−Up 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Refrigerant 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up and Performance Checklist 27. . . . . . . . . . . . . .

Litho U.S.A.

IMPORTANT

This unit must be matched with an indoor coil as specified in Lennox Engineering Handbook. Coils previously charged with HCFC−22 must be flushed.

NOTICE TO INSTALLER

UNIT PLACEMENT

It is critical for proper unit operation to place outdoor unit on an elevated surface as described in Unit Placement section on page 6.

BRAZING LINE SET TO SERVICE VALVES

It is imperative to follow the brazing technique illustrated starting on page 9 to avoid damaging the service valve’s internal seals.

11/10 506663−01

*2P1110* *P506663-01*

Shipping and Packing List

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

1  Assembled outdoor unit 1  Liquid line filter drier

Outdoor Unit

This outdoor unit is designed for use with HFC−410A refrigerant only. This unit must be installed with an approved indoor air handler or coil. See the Lennox TSA*S4 Engineering Handbook for approved indoor component matchups.

This outdoor unit is designed for use in thermal expansion valve (TXV) systems only.

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Unit Dimensions − Inches (mm)

OUTDOOR COIL FAN

COMPRESSOR

Discharge Air

SUCTION AND LIQUID LINE

OPTIONAL UNIT STAND-OFF KIT

SIDE VIEW

CONNECTIONS

(4) (FIELD−INSTALLED)

SIDE VIEW

Model Number A B

TSA024S4N41T and M 24−1/4 (616) 25−1/4 (641)

TSA030S4N41T and M 24−1/4 (616) 29−1/4 (743)

TSA036S4N41M 28−1/4 (724) 29−1/4 (743)

TSA036S4N41T 24−1/4 (616) 29−1/4 (743)

TSA048S4N41T and M 28−1/4 (724) 37−1/4 (925)

TSA060S4N41T and M 28−1/4 (724) 33−1/4 (845)

Typical Unit Parts Arrangement

CONTROL

DUAL RUN CAPACITOR

(C12) (T−VOLTAGE)

SINGLE RUN CAPACITOR

(C12) (M−VOLTAGE)

GROUND LUG

CONTACTOR (K1)

LOCATION

TWO−POLE

(M−VOLTAGE)

CUTOUT FOR HIGH VOLTAGE CONDUIT

ONE POLE

(T−VOLTAGE)

NOTE: PLUMBING LAYOUT MAY

VARY SLIGHTLY BETWEEN

MODEL SIZES.

HIGH PRESSURE

SWITCH (S4)

CRANKCASE HEATER

THERMOSTAT (S40)

LIQUID LINE SERVICE VALVE

SUCTION LINE SERVICE VALVE

Figure 1. Typical Unit Parts Arrangement

506663−01 11/10

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Model Number Identification

TSA M1036 S 44 N

T = T−Class Product Line

S = Split−System Air Conditioner

Brand/Family

Unit Type

Major Design Sequence

A = 1st Generation

B = 2nd Generation

024 = 2 Tons 030 = 2.5 Tons 0036 = 3 Tons

048 = 4 Tons

060 = 5Tons

Cooling Efficiency

S = Standard Efficiency

IMPORTANT

This model is designed for use in expansion valve systems only. An indoor expansion valve approved for use with HFC−410A refrigerant must be ordered separately, and installed prior to operating the system.

CAUTION

Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury. Be aware of, and use caution when working near these areas during installation or while servicing this equipment.

Vol ta ge

M = 380/420V−3 phase 50hz T = 220/240V−1 phase 50hz

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 = R−410A

IMPORTANT

Only use Allen wrenches of sufficient hardness (50Rc − Rockwell Harness Scale minimum). Fully insert the wrench into the valve stem recess.

Service valve stems are factory−torqued (from 9 ft−lbs for small valves, to 25 ft−lbs for large valves) to prevent refrigerant loss during shipping and handling. Using an Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench, or stripping the valve stem recess.

See the Lennox Service and Application Notes #C−08−1 for further details and information.

IMPORTANT

General Information

These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation.

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.

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.

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TSA*S4 SERIES

Page 4

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.

Operating Angle Type Service Valve:

1. Remove stem cap with an appropriately sized wrench.

2. Use a service wrench with a hex−head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve sizes) to back the stem out counterclockwise as far as it will go.

SERVICE PORT CAP

SERVICE PORT CORE

TO INDOOR

UNIT

(VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE

(VALVE STEM SHOWN CLOSED) INSERT HEX WRENCH HERE

SERVICE PORT

CORE

TO OUTDOOR UNIT

ANGLE−TYPE SERVICE VALVE

(BACK−SEATED OPENED)

When service valve is OPEN, the service port is open to linE set, indoor and outdoor unit.

Operating Ball Type Service Valve:

1. Remove stem cap with an appropriately sized wrench.

2. Use an appropriately sized wrenched to open. To open valve, rotate stem counterclockwise 90°. To close rotate stem clockwise 90°.

TO INDOOR UNIT

TO OPEN ROTATE STEM COUNTERCLOCKWISE 90°.

TO CLOSE ROTATE STEM CLOCKWISE 90°.

SERVICE PORT

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

506663−01 11/10

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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 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 to flush the system.

Remove all refrigerant from the existing system. Check gauges after shutdown to confirm that the entire system is completely void of refrigerant.

METHOD 2:

Use this method if the existing outdoor unit is equipped with manual shut−off valves, and you plan to use new refrigerant to flush the system.

The following devices could prevent full system charge recovery into the outdoor unit:

 Outdoor unit’s high or low−pressure switches (if applicable) when tripped can cycle the compressor OFF.  Compressor can stop pumping due to tripped internal pressure relief valve.  Compressor has internal vacuum protection that is designed to unload the scrolls (compressor stops pumping) when the pressure ratio meets

a certain value or when the suction pressure is as high as 20 psig. (Compressor suction pressures should never be allowed to go into a vacuum. Prolonged operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips, drive bearings and internal seals.)

Once the compressor can not pump down to a lower pressure due to one of the above system conditions, shut off the vapor valve. Turn OFF the main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set.

Perform the following task:

A Start the existing 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.

Figure 3. Refrigerant Recovery

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TSA*S4 SERIES

Page 6

CLEARANCE ON ALL SIDES  INCHES (MILLIMETERS)

MINIMUM CLEARANCE

ABOVE UNIT

6 (152)

12 (305)

MINIMUM CLEARANCE BETWEEN

DETAIL A

Install unit away from windows .

36 (914)

TWO UNITS

30 (762)

LINE SET CONNECTIONS

24 (610)

ACCESS PANEL

Figure 4. Installation Clearances

NOTES:

 Clearance to one of the other three

sides must be 36 inches (914mm).

 Clearance to one of the remaining

two sides may be 12 inches (305mm) and the final side may be 6 inches (152mm).

DETAIL B

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.

STRUCTURE

48 (1219)

DISCHARGE AIR

Two 90° elbows installed in line set will reduce line set vibration.

Figure 5. Placement, and Slab Mounting

New Outdoor Unit Placement

See Unit Dimensions on page 2 for sizing mounting slab, platforms or supports. Refer to figure 4 for mandatory installation clearance requirements.

POSITIONING CONSIDERATIONS

CAUTION

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

506663−01 11/10

MOUNTING SLAB MUST SLOPE AWAY FROM BUILDING.

GROUND LEVEL

Consider the following when positioning the unit:

 Some localities are adopting sound ordinances based

on the unit’s sound level registered from the adjacent property, not from the installation property. Install the unit as far as possible from the property line.

 When possible, do not install the unit directly outside

a window. Glass has a very high level of sound transmission. For proper placement of unit in relation to a window see the provided illustration in figure 5.

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PLACING OUTDOOR UNIT ON SLAB

When installing a unit at grade level, the top of the slab should be high enough above the grade so that water from higher ground would not collect around the unit as illustrated in figure 5.

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 5.

INSTALLING OUTDOOR UNIT ON ROOF

Install the unit at a minimum of 4 inches (102 mm) above the surface of the roof. Ensure the weight of the unit is properly distributed over roof joists and rafters. Redwood or steel supports are recommended.

New or Replacement Line Set

This section provides information on 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 9.

If refrigerant lines are routed through a wall, seal and isolate the opening so vibration is not transmitted to the building. Pay close attention to line set isolation during installation of any HVAC system. When properly isolated from building structures (walls, ceilings. floors), the refrigerant lines will not create unnecessary vibration and subsequent sounds.

Also, consider the following when placing and installing a high−efficiency air conditioner:

REFRIGERANT LINE SET

Field refrigerant piping consists of liquid and suction lines from the outdoor unit (braze connections) to the indoor unit coil (flare or braze connections). Use Lennox L15 (braze, non−flare) series line set, or use field−fabricated refrigerant lines as listed in table 2.

IMPORTANT

Mineral oils are not compatible with HFC−410A. If oil

must be added, it must be a Polyol ester oil.

The compressor is charged with sufficient Polyol ester oil for line set lengths up to 50 feet. Recommend adding oil to system based on the amount of refrigerant charge in the system. No need to add oil in system with 20 pounds of refrigerant or less. For systems over 20 pounds − add one ounce of every five pounds of refrigerant.

Recommended topping−off POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATE RL32CF.

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 TSA*S4 is being used with either a new or existing indoor coil which is equipped with a liquid line which served as a metering device (RFCI), the liquid line must be replaced prior to the installation of the TSA*S4 unit. Typically a liquid line used to meter flow is 1/4" in diameter and copper.

LIQUID LINE FILTER DRIER INSTALLATION

The filter drier (one is shipped with each TSA*S4 unit) must be field installed in the liquid line between the outdoor unit’s liquid line service valve and the indoor coil’s metering device (fixed orifice or TXV) as illustrated in figure 6. This filter drier must be installed to ensure a clean, moisture−free system. Failure to install the filter drier will void the warranty. A replacement filter drier is available from Lennox. See Brazing Connections on page 9 for special procedures on brazing filter drier connections to the liquid line.

BRAZE CONNECTION POINTS

NOTE − When installing refrigerant lines longer than 50 feet, contact Lennox Technical Support Product Applications for assistance or Lennox piping manual. To obtain the correct information from Lennox, be sure to communicate the following points:

 Model (TSA*S4) and size of unit (e.g. −060).  Line set diameters for the unit being installed as listed

in table 2 and total length of installation.

 Number of elbows and if there is a rise or drop of the

piping.

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LIQUID

LINE

OUTDOOR

UNIT

LIQUID LINE

SERVICE VALVE

LINE

LIQUID LINE

FILTER DRIER

Figure 6. Typical Liquid Line Filter Drier Installation

TSA*S4 SERIES

Page 8

Table 2. Refrigerant Line Set  Inches (mm)

Model

Liquid Line Vapor Line Liquid Line Vapor Line L15 Line Sets

TSA024S4N4 3/8 in. (10 mm) 3/4 in. (19 mm) 3/8 in. (10 mm) 3/4 in. (19 mm) L15−41  15 ft. − 50 ft. (4.6 m − 15 m)

TSA036S4N4

TSA048S4N4

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)

TSA060S4N4 3/8 in. (10 mm) 1−1/8 in. (29 mm) 3/8 in. (10 mm) 1−1/8 in. (29 mm) Field Fabricated

NOTE  Some applications may required a field provided 7/8" to 1−1/8" adapter

Field Connections Recommended Line Set

INSTALLATION

Line Set Isolation  The following illustrations are

examples of proper refrigerant line set isolation:

REFRIGERANT LINE SET  TRANSITION

FROM VERTICAL TO HORIZONTAL

ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE

MUFFLER-TYPE HANGER

WALL

STUD

NON−CORROSIVE

METAL SLEEVE

AUTOMOTIVE

MUFFLER-TYPE HANGER

STRAP LIQUID LINE TO VAPOR LINE

LIQUID LINE

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.

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

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.

WIRE TIE (AROUND VAPOR LINE ONLY)

TAPE OR WIRE TIE

8 FEET (2.43 METERS)

IMPORTANT  Refrigerant lines must not contact structure.

REFRIGERANT LINE SET  INSTALLING

VERTICAL RUNS (NEW CONSTRUCTION SHOWN)

NOTE  Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig.

IMPORTANT  Refrigerant lines must not contact wall

OUTSIDE WALL

WOOD BLOCK

BETWEEN STUDS

VAPOR LINE WRAPPED

WITH ARMAFLEX

OUTSIDE

WALL

PVC

PIPE

FIBERGLASS

INSULATION

VAPOR LINE

SLEEVE

CAULK

LIQUID LINE

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

LIQUID LINE

WIRE TIE

INSIDE WALL

STRAP

NON−CORROSIVE METAL SLEEVE

WIRE TIE

WOOD BLOCK

WIRE TIE

STRAP

506663−01 11/10

Figure 7. Line Set Installation

Page 8

Page 9

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.

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

Brazing Connections

Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves.

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.

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).

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

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.

Page 9

TSA*S4 SERIES

Page 10

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 8. Brazing Procedures

OUTDOOR

UNIT

NITROGEN

506663−01 11/10

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Page 11

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 9. Brazing Procedures (continued)

Page 11

TSA*S4 SERIES

Page 12

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 13.

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 CYLINDER CONTAINS CLEAN TO BE USED FOR FLUSHING.

VAPOR LINE

SERVICE VALVE

EXISTING

INDOOR

UNIT

LIQUID LINE SERVICE

VALV E

VAPOR

LIQUID

RECOVERY

CYLINDER

A Inverted cylinder with clean refrigerant to the vapor service valve. B gauge set (low side) to the liquid line valve. C 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 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 vapor is recovered. Allow the recovery machine to pull down to 0 the system.

D Close the valve on the inverted drum and the gauge set valves.

Pump the remaining refrigerant out of the recovery machine and turn the machine off.

Figure 10. Removing Metering Device and Flushing

506663−01 11/10

Page 12

Page 13

Installing Indoor Metering Device

This outdoor unit is designed for use in systems that use either an fixed orifice (RFC) (included with outdoor unit), or expansion valve metering device (purchased separately) at the indoor coil.

See the Lennox TSA*S4 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 14.

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

LIQUID LINE

ASSEMBLY WITH

LINE

TEFLON

RING

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.

SENSING

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 11. Installing Indoor Expansion Valve

FLARE NUT

COPPER FLARE SEAL BONNET

MALE BRASS EQUALIZER LINE FITTING

VAPOR LINE

Page 13

VAPOR LINE

BULB

NOTE  NEVER MOUNT ON BOTTOM OF LINE.

ON 7/8" AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 4 OR 8 O’CLOCK POSITION. NEVER MOUNT ON BOTTOM OF LINE.

BULB

TSA*S4 SERIES

Page 14

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 12, proceed to Evacuating Line Set and Indoor Coil on page 15.

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.

506663−01 11/10

NITROGEN

HFC−410A

Figure 12. Leak Test

Page 14

TO VAPOR

SERVICE VALVE

Page 15

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

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

HIGHLOW

Figure 13. Evacuating System

Page 15

TSA*S4 SERIES

Page 16

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 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.

MAIN FUSE BOX/

BREAKER PANEL

WARNING

Electric Shock Hazard. Can cause injury or death. Unit must be grounded in accordance with national and local codes.

Line voltage is present at all components when unit is not in operation on units with single-pole contactors. Disconnect all remote electric power supplies before opening access panel. Unit may have multiple power supplies.

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.

506663−01 11/10

Page 16

Page 17

ROUTING HIGH VOLTAGE/ GROUND AND CONTROL WIRING

HIGH VOLTAGE / GROUND WIRES

Any excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring. To facilitate a conduit, a cutout is located in the bottom of the control panel. Connect conduit to the control panel using a proper conduit fitting.

THREE PHASE

CONTROL

WIRING

CONTROL WIRING

Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated.

HIGH VOLTAGE CONNECTIONS

(CONTACTOR)

A Run 24VAC control wires through hole with grommet

and secure with provided wire tie.

B Make 24VAC thermostat wire connections. Locate the

two wires from the contactor and make connection using field provided wire nuts:

 Yellow to Y1

GROUND

GROMMET AND WIRE TIE

 Black to C (common)

NOTE  For proper voltages, select thermostat wire (control wires) gauge per table below.

NOTE  Do not bundle any excess 24VAC control wires inside control panel.

TYPICAL LOW VOLTAGE FIELD

WIRING

THERMOSTAT INDOOR UNIT

POWER

HEAT

COOLING

INDOOR

BLOWER

OUTDOOR

UNIT

HIGH VOLTAGE CONNECTIONS

(CONTACTOR)

GROUND

HIGH VOLTAGE FLEXIBLE

CONDUIT

NOTE  Wire tie provides low voltage control wire strain relief and to maintain separation of field installed low and high voltage circuits.

SINGLE PHASE

CONTROL

WIRING

HIGH VOLTAGE FIELD WIRING

LOW VOLTAGE FIELD WIRING

FACTORY WIRING

COMMON

WIRE RUN LENGTH AWG# INSULATION TYPE

LESS THAN 100’ (30 METERS) 18 TEMPERATURE RATING

MORE THAN 100’ (30 METERS) 16 35ºC MINIMUM.

HIGH VOLTAGE

FLEXIBLE CONDUIT

GROMMET AND WIRE TIE

Page 17

TSA*S4 SERIES

Page 18

Figure 14. Typical Field Wiring Diagram  M Voltage  380/420v (3PH) 50Hz

506663−01 11/10

Page 18

Page 19

Figure 15. Typical Field Wiring Diagram  T Voltage  220/240v (1PH) 50Hz

Page 19

TSA*S4 SERIES

Page 20

Figure 16. Typical Factory Wiring Diagram

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 installation instruction.

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

5. Weigh in refrigerant using procedure outlined in figure

20.

Unit Start−Up

IMPORTANT

If unit is equipped with a crankcase heater, it 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 the liquid line and suction 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 3.

5. Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit’s nameplate. If not, do not start the equipment until you have consulted with the power company and the voltage condition has been corrected.

6. 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 Start−Up and Charging Procedures.

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.

506663−01 11/10

Page 20

Page 21

GAUGE SET

CONNECTIONS FOR TESTING AND CHARGING

SUCTION LINE

SERVICE PORT CONNECTION

AClose manifold gauge set valves and

connect the center hose to a cylinder of HFC−410A. Set for liquid phase charging.

BConnect the manifold gauge set’s low

pressure side to the suction line service port.

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 17. Gauge Set Setup and Connections

CHARGE IN

LIQUID PHASE

TEMPERATURE

SENSOR

REFRIGERANT TANK

DIGITAL SCALE

TO LIQUID

LINE SERVICE

MANIFOLD GAUGE SET

LOW

HIGH

VALV E

TEMPERATURE SENSOR

OUTDOOR UNIT

(LIQUID LINE)

START: Determine how refrigerant is metered

WHEN TO CHARGE?

 Warm weather best  Can charge in colder weather

CHARGE METHOD? Determine by:

 Metering device type  Outdoor ambient temperature

REQUIREMENTS:

 Sufficient heat load in structure  Indoor temperature between 70-80ºF (21−26ºC)  Manifold gauge set connected to unit  Thermometers:

− to measure outdoor ambient temperature

− to measure liquid line temperature

− to measure suction line temperature

Figure 18. Determining Charge Method

OUTDOOR AMBIENT

TEMPERATURE

65ºF (18.3ºC)

AND ABOVE

SUBCOOLING

TXV

64ºF (17.7ºC)

AND BELOW

WEIGH-IN

Page 21

TSA*S4 SERIES

Page 22

CHECKING AIR FLOW AT INDOOR COIL

Check airflow using the Delta−T (

DT) process using the illustration in figure 19.

Temp. of air entering indoor coil ºF

Wet−bulb ºF

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

53º

Drop

19º

All temperatures are expressed in ºF

air flowair flow

INDOOR COIL

64º

Figure 19. Checking Indoor Airflow over Evaporator Coil using Delta−T Chart

START: Measure outdoor ambient temperature

USE SUBCOOLING

METHOD

65ºF

(18.3ºC)

and

ABOVE

72º

DRY

BULB

WET

BULB

ABOVE or

BELOW

1. Determine the desired DTMeasure entering air temper- ature 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

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

the measured T +

3º, no adjustment is needed. See examples: Assume DT =

and the desired DT (T

Drop

) = A minus C.

Drop

–DT) is within

Drop

15 and A temp. = 72º, these C temperatures would necessitate stated actions:

Cº T

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 in-

– DT = ºF ACTION

Drop

crease/decrease fan speed.

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

3º.

64ºF

(17.7ºC) and

BELOW

1. Check Liquid and suction line pressures

2. Compare unit pressures with table 5 or 6.

3. Conduct leak check; evacuate as previously outlined.

4. Weigh in the unit nameplate charge plus any charge required for line set differences over feet.

Refrigerant Charge per Line Set Length

Liquid Line

Set Diameter

9.5 mm

NOTE − *If line length is greater than 4.6 m, add this amount. If line length is less than 4.6 m, subtract this amount.

g per 1.5 m) adjust from 4.6 m line

set*

85 g per 1.5 m)

Figure 20. HFC−410A Weigh In

506663−01 11/10

This nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information.

Page 22

Page 23

START: Measure outdoor ambient temperature

USE WEIGH-IN METHOD

DO NOT CHARGE UNIT

Weigh-in or remove refrigerant

(Results of charging at low

based upon line set length

temperatures not reliable)

64ºF

ABOVE or

BELOW

(18.3ºC)

(17.7ºC) and

BELOW

BLOCK OUTDOOR COIL: [sometimes necessary with lower temperatures] Use cardboard or plastic sheet to restrict the airflow through the outdoor coil to achieve pressures from 325−375 psig (2240−2585 kPa). Higher pressures are needed to check charge. Block equal sections of air intake panels and move coverings sideways until the liquid pressure is in the above noted ranges.

If value is LESS than shown, add refrigerant.

If value is MORE than shown, remove refrigerant.

MORE or

LESS

65ºF

and

ABOVE

1. Confirm proper airflow across coil using figure

19.

2. Compare unit pressures with table 5 or 6.

3. Set thermostat to call for heat (must have a cooling load between 70-80ºF (21−26ºC)

4. Connect gauge set

5. Measure outdoor ambient temperature

6. When heat demand is satisfied, set thermostat to call for cooling

7. Allow temperatures and pressures to stabilize.

NOTE − If necessary, block outdoor coil to maintain 325 − 375 psig.

8. Record liquid line temperature:

LIQº = ______

9. Measure liquid line pressure and use the value to determine saturation temperature (see table 7):

SATº = ______

10. Subtract to determine subcooling (SCº):

SATº_____ − LIQº _____ = SCº _____

11. Compare results with tables 3 or 4 .

Figure 21. HFC−410A Subcooling Charge

Table 3.

Subcooling (SC) Values TXV System − ºF

(ºC) +1ºF (0.5ºC) (1−PHASE)

TSA*S4 50Hz International (1−Phase)

F(5C) −024 −030 −036 −048 −060

65 (18) 10 6 5 2 4

70 (21) 10 6 5 2 4

75 (24) 11 6 6 3 4

80 (27) 11 7 6 3 5

85 (29) 11 7 6 3 5

90 (32) 11 7 7 4 5

95 (35) 11 7 7 4 5

100 (38) 11 7 7 5 5

105 (41) 11 7 7 5 5

110 (43) 11 8 7 5 5

115 (45) 11 8 8 6 5

Table 4. Subcooling (SC) Values  TXV System − ºF

(ºC) +1ºF (0.5ºC) (3−PHASE)

TSA*S4 50Hz International (3−Phase)

F(5C) −036 −048 −060

65 (18) 8 2 2

70 (21) 8 2 3

75 (24) 9 3 3

80 (27) 9 3 3

85 (29) 9 4 4

90 (32) 10 4 4

95 (35) 10 4 4

100 (38) 10 5 4

105 (41) 10 5 4

110 (43) 10 5 4

115 (45) 10 6 4

Page 23

TSA*S4 SERIES

Page 24

Use this table to perform maintenance checks; it is not a procedure for charging the system. Minor variations in these pressures may be due to differences in installations.

IMPORTANT

Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system.

Table 5. HFC−410A Normal Operating Pressures  Liquid +10 and Suction +5 Psig (1−Phase)

TSA*S4 50Hz International (1−Phase)

TSA*S4 −024 −030 −036 −048 −060

F(5C)* Liquid / Suction Liquid / Suction Liquid / Suction Liquid / Suction Liquid / Suction

65 (18) 260 / 137 255 / 132 246 / 133 248 / 133 259 / 143

70 (21) 280 / 138 274 / 134 265 / 134 269 / 134 279 / 144

75 (24) 301 / 139 295 / 135 286 / 136 290 / 136 299 / 146

80 (27) 323 / 141 317 / 136 307 / 137 313 / 137 320 / 147

85 (29) 346 / 142 339 / 137 330 / 138 335 / 138 342 / 148

90 (32) 370 / 144 363 / 139 354 / 140 360 / 140 364 / 150

95 (35) 395 / 145 387 / 140 378 / 141 386 / 142 387 / 151

100 (38) 421 / 147 413 / 142 404 / 143 412 / 143 411 / 153

105 (41) 449 / 149 439 / 143 430 / 145 440 / 145 437 / 154

110 (43) 478 / 151 468 / 145 458 / 146 468 / 147 464 / 156

115 (45) 507 / 152 497 / 147 487 / 148 498 / 149 492 / 157

*Temperature of the air entering the outside coil.

Table 6. HFC−410A Normal Operating Pressures  Liquid +10 and Suction +5 Psig (3−Phase)

TSA*S4 50Hz International (3−Phase)

TSA*S4 −036 −048 −060

5F(5C)* Liquid / Suction Liquid / Suction Liquid / Suction

65 (18) 269 / 135 247 / 132 269 / 136

70 (21) 290 / 136 269 / 134 289 / 137

75 (24) 311 / 137 290 / 136 310 / 139

80 (27) 334 / 138 312 / 138 332 / 140

85 (29) 357 / 139 335 / 139 355 / 142

90 (32) 382 / 141 360 / 140 377 / 143

95 (35) 407 / 142 385 / 142 400 / 144

100 (38) 433 / 143 412 / 144 423 / 146

105 (41) 460 / 145 439 / 145 449 / 148

110 (43) 490 / 146 468 / 147 476 / 149

115 (45) 520 / 148 498 / 149 504 / 151

*Temperature of the air entering the outside coil.

°F °C Psig °F °C Psig

−40 −40.0 11.6 60 15.6 170

−35 −37.2 14.9 65 18.3 185

−30 −34.4 18.5 70 21.1 201

−25 −31.7 22.5 75 23.9 217

−20 −28.9 26.9 80 26.7 235

−15 −26.1 31.7 85 29.4 254

−10 −23.3 36.8 90 32.2 274

10 −12.2 62.3 11 0 43.3 365 15 −9.4 70.0 11 5 46.1 391 20 −6.7 78.3 120 48.9 418 25 −3.9 87.3 30 −1.1 96.8 130 54.4 476 35 1.7 107 135 57.2 507 40 4.4 11 8 140 60.0 539 45 7.2 130 50 10.0 142 55 12.8 155

506663−01 11/10

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

−5 −20.6 42.5 95 35.0 295 0 −17.8 48.6 100 37.8 317 5 −15.0 55.2 105 40.6 340

125 51.7 446

145 62.8 573 150 65.6 608

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System Operation

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.

The outdoor unit and indoor blower cycle on demand from the room thermostat. When the thermostat blower switch is in the ON position, the indoor blower operates continuously.

HIGH PRESSURE SWITCH (S4)

TSA*S4 units are equipped with a high-pressure switch that is located in the liquid line of the compressor as illustrated in figure 1 on page 2.

MANUAL RESET

BUTTON

Maintenance

DEALER

Maintenance and service must be performed by a qualified installer or service agency. At the beginning of each cooling season, the system should be checked as follows:

WARNING

Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause personal injury, loss of life, or damage to property.

Installation and service must be performed by a licensed professional installer (or equivalent) or a service agency.

Outdoor Unit

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

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

3. Check all wiring for loose connections.

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

5. Check amp draw on outdoor fan motor.

Motor Nameplate:_________ Actual:__________.

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

Figure 22. High Pressure Switch (S4) Manual Reset

The switch is a Single Pole, Single Throw (SPST), manual−reset switch which is normally closed and removes power from the compressor when discharge pressure rises above factory setting at 590 + 10 psi. The manual−reset button can be identified by a red cap that is press to preform the reset function.

Crankcase Heater (HR1)

Crankcase heater HR1 prevents liquid from accumulating in the compressor. The heater is always on when the compressor is off. An optional crankcase heater thermostat (S40) is available.

Table 8. Crankcase Heaters

Parts Watts Voltage

M Voltage 40 480

T Voltage 40 240

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

Outdoor Coil

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

NOTE  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)

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.

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TSA*S4 SERIES

Page 26

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.

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.

NOTE − A white residue may appear on the coil guards and grilles on outdoor units. The residue is a non−toxic byproduct of manufacturing the flexible coating. It can be removed by wiping the coil guard with a cloth.

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.

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

CAUTION

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

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

2. The outdoor coil is protected by an inner mesh screen and a wire cage (see figure 23). 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.

506663−01 11/10

PUSH PIN

MESH SCREEN

Figure 23. Cleaning Debris from Mesh

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.

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

4. Lennox Branded Air Filters  are designed to

remove airborne particles from the air passing through the filter.

5. 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.

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.

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

Preservice Check

Accessories

 Lennox TSA*S4 Engineering Handbook  Lennox Commercial Price Book

Start−Up and Performance 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 Suction 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? 

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TSA*S4 SERIES

Page 28

Lennox TSA024S4N41T, TSA030S4N41M, TSA024S4N41M, TSA030S4N41T, TSA036S4N41M Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual