Lennox TSA036H4N41, TSA048H4N41, TSA060H4N41, TSA042H4N41 Installation Instructions Manual

INSTALLATION

2008 Lennox Industries Inc.

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

WARNING

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

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

CAUTION

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.

INSTRUCTIONS

T−Classt TSA*H4 Units

TSA036H4N41, TSA042H4N41,
TSA048H4N41 and TSA060H4N41

AIR CONDITIONER

506083−01
03/08

Table of Contents

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

TSA*H4 Air Conditioners 1. . . . . . . . . . . . . . . . . . . . . . . . .

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

General Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recovering Refrigerant from Existing System 4. . . . . . .

Removing Existing Outdoor Unit 5. . . . . . . . . . . . . . . . .

Positioning New Outdoor Unit 5. . . . . . . . . . . . . . . . . . . . .

New or Replacement Line Set 6. . . . . . . . . . . . . . . . . . . . .

Brazing Connections 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Indoor Unit Metering Device 8. . . . . . . . . . . .

Flushing the System 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing New Indoor Unit Metering Device 10. . . . . . . . .

Testing for Leaks 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evacuating the System 12. . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Unit Delivered Void of Charge 13. . . . . . . . . . .

Electrical Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up and Charging Procedures 15. . . . . . . . . . . . . . . .

System Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Homeowner Information 19. . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up and Performance Checklist 20. . . . . . . . . . . . . .

Shipping and Packing List

Litho U.S.A.

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.

IMPORTANT

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

03/08 506083−01

*2P0308* *P506083-01*

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 filter drier

TSA*H4 Air Conditioners

The TSA*H4 Air Conditioners, 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 TSA*H4
Engineering Handbook. TSA*H4 Air Conditioners are
designed for use in thermal expansion valve (TXV)
systems.

Page 1

Unit Dimensions − Inches (mm)

A

A

B

SIDE VIEW

Model Numbers A B

TSA036H4N41 28−1/4 (718) 37−1/4 (946)

TSA042H4N41 28−1/4 (718) 29−1/4 (743)

TSA048H4N41 28−1/4 (718) 37−1/4 (946)

TSA060H4N41 32−1/4 (819) 33−1/4 (845)

OUTDOOR COIL FAN

COMPRESSOR

SUCTION AND LIQUID LINE

OPTIONAL UNIT STAND-OFF KIT (4)

CONNECTION

(FIELD INSTALLED)

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

DISCHARGE AIR

SIDE VIEW

Table 1. Torque Requirements

WARNING

This product and/or the indoor unit it is matched
with may contain fiberglass wool.

Disturbing the insulation during installation,
maintenance, or repair will expose you to fiberglass
wool dust. Breathing this may cause lung cancer.
(Fiberglass wool is known to the State of California
to cause cancer.)

Fiberglass wool may also cause respiratory, skin,
and eye irritation.

To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact
your supervisor.

Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379−9900

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.

USING MANIFOLD GAUGE SETS

When checking the system charge, only use a manifold
gauge set that features low loss anti−blow back fittings.
See figure 1 for a typical manifold gauge connection setup
for charging.

Manifold gauge sets 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 on the high side and a low side of
30" vacuum to 250 psi with dampened speed to 500 psi.
Gauge hoses must be rated for use at up to 800 psi of
pressure with a 4000 psi burst rating.

OPERATING SERVICE VALVES

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.

When servicing or repairing HVAC components, ensure
the fasteners are appropriately tightened. Table 1 shows
torque values for fasteners.

506083−01 03/08

The liquid and suction line service valves are used for
removing refrigerant, flushing, leak testing, evacuating,
checking charge and charging.

Page 2

OUTDOOR UNIT

(Uncased Coil Shown)

LOW

PRESSURE

GAUGE MANIFOLD

PRESSURE

TO

HFC−410A

DRUM

HIGH

LIQUID LINE

SERVICE VALVE

COMPRESSOR

FILTER DRIER

Figure 1. Typical Manifold Gauge Connection Setup

Each service valve is equipped with a service port which
has a factory−installed valve stem.

1/12 TURN

12

1

2

3

4

7

5

6

9

10

8

11

1/6 TURN

12

1

2

3

4

7

5

6

11

10

9

8

Figure 2. Cap Tightening Distances

IMPORTANT

To prevent stripping of the various caps used, the
appropriately sized wrench should be used and
fitted snugly over the cap before tightening.

Operating Angle−Type Service Valve

To Access Angle−Type Service Port:

A service port cap protects the service port core from
contamination and serves as the primary leak seal.

1. Remove service port cap with an appropriately sized
wrench.

2. Connect gauge to the service port.

3. When testing is completed, replace service port cap and
tighten as follows:

 With Torque Wrench: Finger tighten and then

tighten per table 1.

 Without Torque Wrench: Finger tighten and use an

appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 2.

OUTDOOR

COIL

SUCTION LINE
SERVICE VALVE

TXV

To Open and Close Angle−Type Service Valve:

A valve stem cap protects the valve stem from
contamination and assures a leak−free seal.

1. Remove stem cap with an appropriately sized wrench.

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

3. Replace the stem cap and tighten as follows:

 With Torque Wrench: Finger tighten and then

tighten per table 1.

 Without Torque Wrench: Finger tighten and use an

appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 2.

NOTE − A label with specific torque requirement may be
affixed to the stem cap. If the label is present, use the
specified torque.

NOTE− To prevent stripping of the cap, the appropriately
sized wrench should fit snugly over the cap before
tightening the cap.

SERVICE PORT CAP

SERVICE PORT

CLOSED TO BOTH

INDOOR AND

OUTDOOR UNITS

VALVE STEM

FRONT-SEATED

TO INDOOR

UNIT

TO OUTDOOR UNIT

CORE

VALVE IS FRONT−SEATED

SERVICE PORT

(VALVE STEM SHOWN
CLOSED) INSERT HEX
WRENCH HERE

STEM CAP

(CLOSED)

Figure 3. Angle−Type Service Valve

(Font−Seated Closed)

Page 3

TSA*H4 SERIES

SERVICE PORT CAP

SERVICE PORT

CORE

OPEN TO BOTH

INDOOR AND

OUTDOOR UNITS

TO INDOOR

UNIT

TO OUTDOOR UNIT

STEM CAP

VALVE IS BACK−SEATED

(OPENED)

SERVICE PORT

(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE

Figure 4. Angle−Type Service Valve

(Back−Seated Opened)

Operating Ball−Type Service Valve

To Access Ball−Type Service Port:

A service port cap protects the service port core from
contamination and serves as the primary leak seal.

Open to line set when valve is closed, to
both line set and unit when valve is open.

Use appropriately sized
wrench.

To open rotate stem
counterclockwise 90°.

To close rotate stem clockwise
90°.

TO INDOOR UNIT

BALL (SHOWN
CLOSED)

VALV E
STEM

3. Replace the stem cap and tighten as follows:

 With Torque Wrench: Finger tighten and then

tighten per table 1.

 Without Torque Wrench: Finger tighten and use an

appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 2.

NOTE − A label with specific torque requirements may be
affixed to the stem cap. If the label is present, use the
specified torque.

Recovering Refrigerant from Existing
HCFC−22 System

Remove existing HCFC−22 refrigerant using the following
procedures:

METHOD 1:

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 refrigerant to flush the system, then:

NOTE − Use recovery machine instructions for specific
setup requirements.

1. Disconnect all power to the existing outdoor unit.

2. Connect to the existing unit a gauge set, clean
recovery cylinder and a recovery machine. Use the
instructions provided with the recovery machine on
how to setup the connections.

3. Remove all HCFC−22 refrigerant from the existing
system. Check gauges after shutdown to confirm that
the entire system is completely void of refrigerant.

SERVICE PORT

SERVICE PORT

CORE

SERVICE PORT CAP

TO OUTDOOR UNIT

STEM CAP

Figure 5. Ball−Type Service Valve

1. Remove service port cap with an appropriately sized
wrench.

2. Connect gauge to the service port.

3. When testing is completed, replace service port cap and
tighten as follows:

 With Torque Wrench: Finger tighten and then

tighten per table 1.

 Without Torque Wrench: Finger tighten and use an

appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 2.

To Open and Close Ball−Type Service Valve:

A valve stem cap protects the valve stem from
contamination and assures a leak−free seal.

1. Remove stem cap with an appropriately sized wrench.

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

RECOVERY MACHINE

CLEAN RECOVERY
CYLINDER

MANIFOLD GAUGES

OUTDOOR UNIT

Figure 6. Typical Refrigerant Recovery (Method 1)

NOTE − Use recovery machine instructions for specific
setup requirements.

METHOD 2:

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 then:

1. Start the existing HCFC−22 system in the cooling
mode and close the liquid line valve.

2. Pump all of the existing HCFC−22 refrigerant back into
the outdoor unit.

NOTE − It may be necessary to bypass the low pressure
switches to ensure complete refrigerant evacuation.

506083−01 03/08

Page 4

3. When the low side system pressures reach 0 psig,
close the suction line valve.

4. Check gauges after shutdown to confirm that the
valves are not allowing refrigerant to flow back into the
low side of the system.

Removing Existing Outdoor Unit

Perform the following task at the existing outdoor unit:

 Disconnect line set at the service valves.
 Disconnect electrical service at the disconnect switch.
 Remove existing outdoor unit.

Positioning New Outdoor Unit

CAUTION

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

property, not from the installation property. Install the
unit as far as possible from the property line.

 When possible, do not install the unit directly outside

a window. Glass has a very high level of sound
transmission. For proper placement of unit in relation
to a window see the provided illustration in figure 8.

INSTALL UNIT AWAY

FROM WINDOWS

See Unit Dimensions on page 2 for sizing mounting slab,
platforms or supports. Refer to figure 7 for mandatory
installation clearance requirements.

(SEE NOTES BELOW

FIGURE)

(SEE NOTES

BELOW

FIGURE)

SEE NOTES

BELOW FIGURE)

(SEE NOTES

BELOW

FIGURE)

Figure 7. Installation Clearances

NOTES:

 Service panel access clearance of 30 in. (762 mm)

must be maintained.

 Clearance to one of the other three sides must be 36

in. (914 mm)

.

TWO 90° ELBOWS INSTALLED

IN LINE SET WILL REDUCE

LINE SET VIBRATION.

Figure 8. Outside Unit Placement and Installation

PLACING OUTDOOR UNIT ON SLAB

When installing a unit at grade level, the top of the slab
should be high enough above the grade so that water from
higher ground would not collect around the unit as
illustrated in figure 9.

DISCHARGE AIR

BUILDING

STRUCTURE

MOUNTING
SLAB

GROUND LEVEL

 Clearance on one of the remaining two sides may be

12 in. (305 mm) and the final side may be 6 in. (152

.

mm)

 Clearance required on top of unit is 48 in. (1219 mm).

 A clearance of 24 in. (610 mm) must be maintained

between two units.

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

Figure 9. Typical Slab Mounting at Ground Level

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 9.

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. Either
redwood, steel supports, or roofed in equipment platform is
recommended.

Page 5

TSA*H4 SERIES

New or Replacement Line Set

This section provides information on installation or
replacement of existing line set. If line set is not being
installed or replace then proceed to Brazing Connections
on page 7.

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:

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*H4 unit)
must be field installed in the liquid line between the outdoor
unit’s liquid line service valve and the indoor coil’s
expansion valve. 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
7 for special procedures on brazing.

BRAZE CONNECTION

POINTS

REFRIGERANT LINE SET

Field refrigerant line set 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 below.

Table 2. Refrigerant Line Set

Models

−036

−042

−048

−060

Field
Connections

Liquid
Line

3/8 in.
(10 mm)

3/8 in.
(10 mm)

Suction
Line

7/8 in
(22 mm)

1−1/8 in.
(29 mm)

Recommended Line Set

Liquid
Line

3/8 in.
(10
mm)

3/8 in.
(10
mm)

Suction
Line

7/8 in
(22 mm)

1−1/8 in.
(29 mm)

L15
Line Set

L15−65
15 ft. − 50 ft.
(4.6 m − 15 m)

Field
Fabricated

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*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 TSA*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 TSA*H4 unit.

LIQUID

LINE

OUTDOOR

UNIT

LIQUID LINE

SERVICE VALVE

LINE

LIQUID LINE

FILTER DRIER

Figure 10. Typical Liquid Line Filter Drier

Installation
INSTALLING LINE SET
Line Set IsolationThis reference illustrates

procedures, which ensure proper refrigerant line set
isolation:

 Installation of line set on horizontal runs is

illustrated in figure 11.

 Installation of line set on vertical runs is illustrated in

figure 12.

 Installation of a transition from vertical to

horizontal is illustrated in figure 13.

To hang line set from joist or rafter,
use either metal strapping material
or anchored heavy nylon wire ties.

STRAPPING MATERIAL

(AROUND SUCTION

LINE ONLY)

TAPE OR
WIRE TIE

FLOOR JOIST OR

ROOF RAFTER

8 FEET

FLOOR JOIST OR

ROOF RAFTER

METAL

SLEEVE

Strap the suction line to the
joist or rafter at 8 feet
intervals then strap the
liquid line to the suction line.

8 FEET

Figure 11. Refrigerant Line Set: Installing

Horizontal Runs

WIRE TIE
(AROUND
SUCTION LINE
ONLY)

TAPE OR
WIRE TIE

506083−01 03/08

Page 6