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

IMPORTANT - REFRIGERANT LINES MUST NOT CONTACT WALL.

OUTSIDE WALL

WOOD BLOCK

BETWEEN STUDS

NOTE − SIMILAR INSTALLATION
PRACTICES SHOULD BE USED
IF LINE SET IS TO BE INSTALLED
ON EXTERIOR OF OUTSIDE
WALL.

SLEEVE

SUCTION LINE

WIRE TIE

INSIDE WALL

STRAP

SLEEVE

WIRE TIE

WOOD BLOCK

WIRE TIE

STRAP

LIQUID

LINE

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.

WARNING

Danger of fire. Bleeding the
refrigerant charge from only the high
side may result in the low side shell
and suction tubing being
pressurized. Application of a brazing
torch while pressurized may result in
ignition of the refrigerant and oil
mixture − check the high and low
pressures before unbrazing.

SUCTION LINE WRAPPED WITH

OUTSIDE

WALL

PVC PIPE FIBERGLASS INSULATION

ARMAFLEX

LIQUID LINE

IMPORTANT! REFRIGERANT

LINES MUST NOT CONTACT

CAULK

STRUCTURE.

Figure 12. Refrigerant Line Set: Installing
Vertical Runs (New Construction Shown)

AUTOMOTIVE

STRAP LIQUID LINE
TO SUCTION LINE

LIQUID LINE

SUCTION LINE − WRAPPED
IN ARMAFLEX

ANCHORED HEAVY NYLON
WIRE TIE OR AUTOMOTIVE
MUFFLER-TYPE HANGER

WALL
STUD

METAL SLEEVE

MUFFLER-TYPE HANGER

Figure 13. Refrigerant Line Set: Transition

from Vertical to Horizontal

Brazing Connections

Use the following procedure to braze the line set to the new
outdoor unit. Figure 14 is provided as a general guide for
preparing to braze the line set to the outdoor unit.

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).

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.

1. Cut ends of the refrigerant lines square (free from
nicks or dents). Debur the ends. The pipe must remain
round, do not pinch end of the line.

2. Remove service cap and core from both the suction
and liquid line service ports.

3. Connect gauge low pressure side to liquid line service
valve.

4. To protect components during brazing, wrap a wet
cloth around both the liquid and suction line service
valve body and copper tube stub. Use another wet
cloth underneath the valve body to protect the base
paint.

Page 7

TSA*H4 SERIES

1

2

3

CUT AND DEBUR

7

INSTALL CORE ONLY FOR

BOTH SERVICE PORTS AFTER

THEY HAVE COOLED.

INDOOR UNIT

6

BRAZE LINE SET

REMOVE CAP AND CORE FROM

BOTH LIQUID AND SUCTION

SERVICE PORTS

SERVICE PORT MUST BE

OPEN TO ALLOW EXIT
POINT FOR NITROGEN

SUCTION LINE

LIQUID LINE

Figure 14. Brazing Connections

5. Flow regulated nitrogen (at 1 to 2 psig) through the
refrigeration gauge set into the valve stem port
connection on the liquid line service valve and out of
the valve stem port connection on the suction service
valve.

NOTE − The RFCIV or TXV metering device at the indoor
unit will allow low pressure nitrogen to flow through the
system.)

NOTE − Use silver alloy brazing rods with five or six percent
minimum silver alloy for copper−to−copper brazing or 45
percent silver alloy for copper−to−brass or copper−to−steel
brazing.

6. Braze the liquid line to the liquid line service valve.
Turn off nitrogen flow. Repeat procedure starting at
paragraph 4 for brazing the suction line to service
valve.

7. After all connections have been brazed, disconnect
manifold gauge set from service ports, cool down
piping with wet rag and remove all wrappings. Do not
reinstall cores until after evacuation procedure.
Reinstall service caps if desired to close off refrigerant
ports.

Removing Indoor Unit Metering Device

ATTACH

GAUGES

SERVICE

5

VALVE

SERVICE

VALVE

OUTDOOR

UNIT

FLOW NITROGEN

NITROGEN

4

WRAP

SERVICE

VALV E

REPLACEMENT PARTS

If replacement parts are necessary for the indoor unit,
order kit 69J46. The kit includes the following:

LIQUID LINE ORIFICE HOUSINGS (10)

TEFLON RINGS (20)

LIQUID LINE ASSEMBLIES

(INCLUDES STRAINER) (10)

BRASS NUTS (10)

LIQUID LINE

ASSEMBLY

Figure 15. 69J46 Kit Components

TYPICAL FIXED ORIFICE REMOVAL PROCEDURE

1. On fully cased coils, remove the coil access and
plumbing panels.

2. Remove any shipping clamps holding the liquid line
and distributor assembly.

3. Using two wrenches, disconnect liquid line from liquid
line orifice housing. Take care not to twist or damage
distributor tubes during this process.

PISTON
RETAINER

STRAINER

COPPER
TUBE

Remove the existing HCFC−22 fixed orifice or thermal
expansion valve from the indoor coil. The existing indoor
unit HCFC−22 metering device is not approved for use with
HFC−410A refrigerant and may prevent proper flushing.

506083−01 03/08

4. Remove and discard Teflon ring, orifice, and valve
stem assembly if present as illustrated in figure 16.

5. Use a field−provided fitting to temporary reconnect the
liquid line to the indoor unit’s liquid line orifice housing.

Page 8

DISTRIBUTOR TUBES

LIQUID LINE ORIFICE HOUSING

TEFLON RING

ORIFICE

REMOVE AND DISCARD
VALVE STEM ASSEMBLY
(IF PRESENT)

BRASS NUT

6. Disconnect the TXV from the liquid line orifice housing.
Take care not to twist or damage distributor tubes
during this process.

7. Remove and discard TXV and the two Teflon rings as
illustrated in figure 17.

8. Use a field−provided fitting to temporary reconnect the
liquid line to the indoor unit’s liquid line orifice housing.

DISTRIBUTOR

ASSEMBLY

LIQUID LINE ASSEMBLY

(INCLUDES STRAINER)

VALVE STEM

VALVE STEM CAP

(Uncased Coil Shown)

Figure 16. Typical Fixed Orifice Removal

TYPICAL TXV REMOVAL PROCEDURE

Use following procedure for a typical TXV removal:

(Uncased Coil Shown)

TWO PIECE

PATCH PLATE

(UNCASED COIL

ONLY)

DISTRIBUTOR

TUBES

DISTRIBUTOR

ASSEMBLY

LIQUID LINE

ORIFICE HOUSING

EQUALIZER
LINE

STUB END

TEFLON
RING

TXV

TEFLON

RING

SENSING

LINE

Flushing Existing System

IMPORTANT

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.

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.

IMPORTANT

LIQUID LINE ASSEMBLY

WITH BRASS NUT

MALE EQUALIZER LINE

FITTING

SENSING BULB

SUCTION

LINE

LIQUID

LINE

Figure 17. Typical TXV Removal

1. On fully cased coils, remove the coil access and
plumbing panels.

2. Remove any shipping clamps holding the liquid line
and distributor assembly.

3. Disconnect the equalizer line from the TXV equalizer
line fitting on the suction line.

4. Remove the suction line sensing bulb as illustrated in
figure 17.

5. Disconnect the liquid line from the TXV at the liquid line
assembly.

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.

CAUTION

This procedure should not be performed on
systems which contain contaminants (Example:
compressor burn out).

If the original system used HCFC−22 refrigerant, then the
system must be flushed. If the original system used
HFC−410A refrigerant, then proceed to Installing New
Refrigerant Metering Device on page 10.

REQUIRED EQUIPMENT

Equipment required to flush the existing line set and indoor
unit coil:

 Two clean HCFC−22 recovery bottles,
 Oilless recovery machine with pump-down feature,

Page 9

TSA*H4 SERIES

 Two gauge sets (one for HCFC−22; one for

HFC−410A).

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

SUCTION LINE

SERVICE VALVE

EXISTING

INDOOR

UNIT

LIQUID LINE SERVICE VALVE

RECOVERY

CYLINDER

SUCTION

LIQUID

NOTE − The inverted HCFC−22 cylinder must contain at least the same
amount of refrigerant as was recovered from the existing system.

NEW

OUTDOOR

UNIT

OPENED

RECOVERY MACHINE

GAUGE

MANIFOLD

LOW

PRESSURE

TANK
RETURN

INLET

DISCHARGE

HIGH

PRESSURE

CLOSED

Figure 18. Typical Flushing Connection

FLUSHING PROCEDURE

1. Connect the following:

 HCFC−22 cylinder with clean refrigerant to the

suction service valve,

 HCFC−22 gauge set to the liquid line valve,
 Recovery machine with an empty recovery tank to

the gauge set.

2. 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.

3. Invert the cylinder of clean HCFC−22 and open its
valve to allow liquid refrigerant to flow into the system
through the suction 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.

4. After all of the liquid refrigerant has been recovered,
switch the recovery machine to suction recovery so
that all of the HCFC−22 is recovered. Allow the
recovery machine to pull a vacuum on the system.

5. 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.

6. Use dry nitrogen to break the vacuum on the
refrigerant lines and indoor unit coil before removing
the recovery machine, gauges and HCFC−22
refrigerant drum.

Installing New Indoor Unit Metering
Device

TSA*H4 units are used in thermal expansion valve (TXV)
systems only.

1/8 TURN

12

11

8

7

6

9

10

8

11

12

1

2

3

10

9

4

7

5

6

Figure 19. Tightening Distance

TSA*H4 ENGINEERING HANDBOOK

See the TSA*H4 Engineering Handbook for approved
indoor/outdoor match−ups, applicable TXV kit, and
application information.

Figure 20 illustrates the typical TXV kit parts and
quantities.

TXV (1)

TEFLON
RINGS (2)

COPPER

MOUNTING

STRAP (1)

Figure 20. TXV Kit Components

1/2 TURN

1

2

3

4

5

HEX HEAD BOLTS

AND NUTS (2)

506083−01 03/08

Page 10

TYPICAL TXV INSTALLATION PROCEDURE

The TXV 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 TXV and
provide an access for field servicing of the TXV. Refer to
Figure 21 for reference during installation of TXV unit.

6. Attach the sensing bulb of the TXV in the proper
orientation as illustrated in figure 22 to the suction line
using the clamp and screws provided.

SUCTION LINE

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

TWO PIECE

PATCH PLATE

(UNCASED COIL

ONLY)

DISTRIBUTOR

TUBES

DISTRIBUTOR

ASSEMBLY

MALE EQUALIZER LINE
FITTING (SEE FIGURE 23
FOR FURTHER DETAILS)

SENSING BULB INSULATION IS REQUIRED
IF MOUNTED EXTERNAL TO THE COIL
CASING. SEE FIGURE 22 FOR BULB
POSITIONING.

(Uncased Coil Shown)

LIQUID LINE

ORIFICE

HOUSING

EQUALIZER
LINE

STUB END

TXV

TEFLON
RING

LIQUID LINE ASSEMBLY

WITH BRASS NUT

SUCTION
LINE

TEFLON

RING

SENSING

LINE

LIQUID

LINE

BULB

SUCTION LINE

BULB

12

12

BULB

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

NOTE − NEVER MOUNT ON
BOTTOM OF LINE.

Figure 22. TXV Sensing Bulb Installation

7. Remove and discard either the flare seal cap or flare
nut with copper flare seal bonnet from the equalizer
line port on the suction line.

IMPORTANT

When removing the seal nut, ensure that the copper
flare seal bonnet is removed.

Figure 21. Typical TXV Installation

1. Remove the field−provided fitting that temporary
reconnected the liquid line to the indoor unit’s liquid
line orifice housing.

2. Install one of the provided Teflon rings around the
stubbed end of the TXV and lightly lubricate the
connector threads and expose surface of the Teflon
ring with refrigerant oil.

3. Attach the stubbed end of the kit 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 figure 19, or 20 ft−lb.

4. Place the remaining Teflon washer around the other
end of the TXV. Lightly lubricate connector threads
and expose surface of the Teflon ring with refrigerant
oil.

5. Attach the liquid line assembly to the TXV. Finger
tighten and use an appropriately sized wrench to turn
an additional 1/2 turn clockwise as illustrated in figure
19, or 20 ft−lb.

FLARE SEAL

CAP

OR

MALE BRASS EQUALIZER

FLARE NUT

COPPER

FLARE SEAL

BONNET

LINE FITTING

SUCTION LINE

Figure 23. Copper Flare Seal Bonnet Removal

8. Connect the equalizer line from the TXV to the
equalizer suction port on the suction line. Finger
tighten the flare nut plus 1/8 turn (7 ft−lbs) as illustrated
in figure 19.

NOTE − To prevent any possibility of water damage,
properly insulate all parts of the TXV assembly that may
sweat due to temperature differences between the valve
and its surrounding ambient temperatures.

Page 11

TSA*H4 SERIES

Testing for Leaks

After the line set has been connected to the indoor unit and
outdoor unit, check the line set connections and indoor unit
for leaks. Use the following procedure to test for leaks:

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 damage by fire and/
or an explosion, that could result in
personal injury or death.

6. After a few minutes, open a refrigerant port to ensure
the refrigerant you added is adequate to be detected.

NOTE − Amounts of refrigerant will vary with line lengths.

7. Check all joints for leaks.

8. Purge dry nitrogen and HFC−410A mixture.

9. Correct any leaks and recheck.

10. After leak testing disconnect gauges from service
ports.

Evacuating the System

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.

IMPORTANT

Leak detector must be capable of sensing HFC
refrigerant.

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.

LEAK TEST PROCEDURE

1. Connect an HFC−410A manifold gauge set high
pressure hose to the suction valve service port.

NOTE − Normally, the high pressure hose is connected to
the liquid line port; however, connecting it to the suction
port better protects the manifold gauge set from high
pressure damage.

2. 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 (suction only).

3. 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.

4. Connect a cylinder of dry nitrogen with a pressure
regulating valve to the center port of the manifold
gauge set.

5. 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.

506083−01 03/08

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.

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.

EVACUATING PROCEDURE

NOTE − Remove cores from service valves if not already
done.

1. Connect manifold gauge set to the service valve ports
as follows:

 low pressure gauge to suction line service valve

 high pressure gauge to liquid line service valve

2. Connect micron gauge.

3. Connect the vacuum pump (with vacuum gauge) to
the center port of the manifold gauge set.

4. Open both manifold valves and start the vacuum
pump.

5. 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 to
determine if there is a rapid rise in sure 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.

Page 12

6. When the absolute pressure reaches 23,000 microns
(29.01 inches of mercury), close the manifold gauge
valves, turn off the vacuum pump and disconnect the
manifold gauge center port hose from vacuum pump.
Attach the manifold center port hose to a dry nitrogen
cylinder with pressure regulator set to 150 psig (1034
kPa) and purge the hose. Open the manifold gauge
valves to break the vacuum in the line set and indoor
unit. Close the manifold gauge valves.

7. 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.

8. 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.

9. 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
valves to break the vacuum from 1 to 2 psig positive
pressure in the line set and indoor unit.

10. Perform the following:

A Close manifold gauge valves
B Shut off HFC−410A cylinder
C Reinstall service valve cores by removing

manifold hose from service valve. Quickly install
cores with core tool while maintaining a positive
system pressure.

D Replace the stem caps and secure finger tight,

then tighten an additional one−sixth (1/6) of a turn
as illustrated in figure 2.

In Canada, wiring must conform with current local codes
and the current Canadian Electrical Code (CEC). Refer to
the furnace or blower coil installation instructions for
additional wiring application diagrams and refer to unit
nameplate for minimum circuit ampacity and maximum
overcurrent protection size.

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.

HIGH VOLTAGE
FIELD WIRING

Gnd

WIRE
NUTS

LOW VOLTAGE
FIELD WIRING

FACTORY
WIRING

Serving Unit Delivered Void of Charge

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

1. Use nitrogen to pressurize the system and check for
leaks. Repair all leaks.

2. Evacuate the system to remove as much of the
moisture as possible.

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

4. Evacuate the system again. Then, weigh the
appropriate amount of HFC−410A refrigerant as listed
on unit nameplate into the system.

5. Monitor the system to determine the amount of
moisture remaining in the oil. It may be necessary to
replace the filter drier several times to achieve the
required dryness level. If system dryness is not

verified, the compressor will fail in the future.

Electrical Connections

In the United States, wiring must conform with current local
codes and the current National Electric Code (NEC).

Page 13

GROMMET

GND

L3

L1

L2

Figure 24. Separating High/Low Voltage Field Wiring

(Typical Field Wiring)

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 as illustrated in figures 24 and
figure 25.

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

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 5 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.

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

TSA*H4 SERIES

5. Install low−voltage wiring from outdoor to indoor unit
and from thermostat to indoor unit.

THERMOSTAT

R

POWER

INDOOR UNIT

R

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 as illustrated in figure 25.

NOTE − 24VAC, Class II circuit connections are made in
the low voltage junction box

W1

Y

G

C

HEAT

COOLING

INDOOR BLOWER

COMMON

W

Y

G

C

OUTDOOR UNIT

Y1

C

Figure 25. Low Voltage Wiring Diagram

(Typical Field Wiring)

Table 3. Wire Run Lengths

Wire Run Length AWG # Insulation Type

Less than 100 feet
(30m)

More than 100 feet
(30m)

18

16

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

NOTE − To facilitate conduit, a hole is in the bottom of the
control box. Connect conduit to the control box using a
proper conduit fitting.

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

NOTE − A complete unit wiring diagram is located inside
the unit control box cover.

NOTE − See unit wiring diagram for power supply
connections. If indoor unit is not equipped with blower
relay. It must be field−provided and installed (P−8−3251 or
equivalent)

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.

Note: The thermostat used may be electro−me­chanical or electronic.

COOLING:

1. Cooling demand imitates a 24VAC signal from Y1 in the thermostat.

2. 24VAC from indoor unit Y1 energizes contacts K1−1, K1−2 and K1−3.

3. K1−1, K1−2 and K1−3 N.O. close, energizing compressor B1 and
outdoor fan motor B4.

506083−01 03/08

END OF COOLING DEMAND:

1. Cooling demand is satisfied. Terminal Y1 is de−energized.

2. Compressor contacts K1−1, K1−2 and K1−3 are de−energized.

3. K1−1, K1−2 and K1−3 open and compressor B1 and outdoor fan motor
B4 are de−energized and stop immediately.

Figure 26. Typical Unit Wiring Diagram

Page 14

Start−Up and Charging Procedures

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. Rotate fan to check for binding.

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

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

4. Replace the stem caps and tighten to the value listed
in table 1.

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.

Temp.
of air
entering
indoor
coil ºF

A

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

T

C

Drop

19º

All temperatures are
expressed in ºF

DT

air flowair flow

INDOOR
COIL

B

A

72º

B

64º

WET

BULB

DRY

BULB

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 Testing and Charging
System.

SETTING UP TO CHECK CHARGE

1. Close manifold gauge set valves. Connect the center
manifold hose to an upright cylinder of HFC−410A.

2. Connect the manifold gauge set to the unit’s service
ports as illustrated in figure 1.

 low pressure gauge to suction line service port.
 high pressure gauge to liquid line service port.

INDOOR COIL AIRFLOW CHECK

Check indoor coil airflow using the Delta−T (DT) process

as illustration in figure 27.

DETERMINING CHARGE METHOD

To determine the correct charging method, use the
illustration in figure 27.

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

3. Determine if fan needs adjustmentIf the difference between
the measured T
adjustment is needed. See examples: Assume DT = 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 increase/

decrease fan speed.

Changing air flow affects all temperatures; recheck temperatures to

confirm that the temperature drop and DT are within +3º.

) = A minus C.

Drop

and the desired DT (T

Drop

– DT = ºF ACTION

Drop

–DT) is within +3º, no

Drop

Figure 27. Checking Indoor Coil Airflow Guide

Page 15

TSA*H4 SERIES

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 28. Determining Charge Method

OUTDOOR AMBIENT

TEMPERATURE

65ºF (18.3ºC)

and ABOVE

APPROACH OR

SUBCOOLING

TXV

64ºF (17.7ºC)

and BELOW

WEIGH-IN

START: Measure outdoor ambient temperature

USE EITHER APPROACH

OR SUBCOOLING

METHOD

65ºF

and

ABOVE

WEIGH IN TXV

Refrigerant Charge per Line Set Length

Liquid Line

Set Diameter

3/8" (9.5 mm)

NOTE − *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.

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)

Figure 29. Weigh In Method

ABOVE or

BELOW

64ºF and

BELOW

1. Check Liquid and suction line pressures

2. Compare unit pressures with Table 27,
Normal Operating Pressures.

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.

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

506083−01 03/08

Page 16

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 length

temperatures not reliable)

64ºF and

ABOVE or

BELOW

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 refrigerant is added
or removed, verify
charge using the
Approach Method.

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

27.

2. Compare unit pressures with Table 4, Normal
Operating Pressures.

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 5):

SATº = ______

10. Subtract to determine subcooling (SCº):

SATº_____ − LIQº _____ = SCº _____

11. Compare results with table below.

SCº (Subcooling) Values (F:+/−1.0° [C: +/−0.6°])

ºF (ºC)* −036 −042 −048 −060
65 (18) 13 (7.2) 10 (5.6) 8 (4.4) 8 (4.4)
75 (24) 9 (5.0) 7 (3.9) 8 (4.4) 7 (3.9)
85 (29) 7 (3.9) 7 (3.9) 8 (4.4) 8 (4.4)
95 (35) 8 (4.4) 7 (3.9) 8 (4.4) 7 (3.9)
105 (41) 9 (5.0) 7 (3.9) 8 (4.4) 6 (3.3)
115 (45) 10 (5.6) 7 (3.9) 7 (3.9) 6 (3.3)
*Temperature of air entering outdoor coil

Figure 30. HFC−410A Subcooling TXV Charge

START: Measure outdoor ambient temperature

DO NOT CHARGE UNIT

USE WEIGH-IN METHOD

(Results of charging at low

Weigh-in or remove refrigerant

temperatures not reliable)

based upon line length

64ºF and

BELOW

If refrigerant is added
or removed, verify
charge using the
Subcooling Method.

If value is LESS
than shown, add
refrigerant.

If value is MORE
than shown, remove
refrigerant.

MORE or

LESS

ABOVE or

BELOW

1. Confirm proper airflow across coil using figure

65ºF

and

ABOVE

27.

2. Compare unit pressures with Table 4, Normal
Operating Pressures.

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

4. Connect gauge set.

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

6. Allow temperatures and pressures to stabilize.

7. Record outdoor ambient temperature:

AMBº =_________

8. Record liquid line temperature:

LIQº = __________

9. Subtract to determine approach (APPº):

LIQº_____ − AMBº _____ = APPº_____

10. Compare results with table below.

APPº (Approach) Values(F:+/−1.0° [C: +/−0.6°])

ºF (ºC)* −036 −042 −048 −060
65 (18) 2 (1.1) 6 (3.3) 7 (3.9) 8 (4.4)
75 (24) 5 (2.8) 8 (4.4) 8 (4.4) 9 (5.0)
85 (29) 8 (4.4) 8 (4.4) 8 (4.4) 9 (5.0)
95 (35) 7 (3.9) 8 (4.4) 8 (4.4) 9 (5.0)
105 (41) 6 (3.3) 8 (4.4) 8 (4.4) 9 (5.0)
115 (45) 6 (3.3) 8 (4.4) 9 (5.0) 9 (5.0)
*Temperature of air entering outdoor coil

Figure 31. HFC−410A Approach TXV Charge

Page 17

TSA*H4 SERIES

Table 4. HFC−410A Normal Operating Pressures (Liquid +10 and Suction +5 psig)

IMPORTANT

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

TSA*H4

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

−036 −042 −048 −060

Expansion Valve (TXV)

65 (18) 238 / 132 236 / 138 238 / 136 239 / 133

70 (21) 254 / 135 253 / 140 256 / 138 258 / 135

75 (24) 273 / 138 273 / 141 277 / 139 278 / 136

80 (27) 293 / 140 296 / 142 299 / 140 300 / 137

85 (29) 316 / 142 318 / 143 320 / 139 323 / 138

90 (32) 340 / 143 341 / 144 343 / 140 346 / 139

95 (35) 366 / 144 366 / 146 369 / 141 370 / 140

100 (38) 392 / 145 392 / 147 395 / 142 396 / 142

105 (41) 420 / 147 417 / 148 422 / 144 415 / 143

110 (43) 449 / 148 445 / 149 450 / 146 449 / 145

115 (45) 480 / 149 475 / 151 481 / 148 476 / 147

Table 5. HFC−410A Temperature (°F) − Pressure (Psig)

°F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig

32 100.8 48 137.1 63 178.5 79 231.6 94 290.8 11 0 365.0

33 102.9 49 139.6 64 181.6 80 235.3 95 295.1 111 370.0 126 451.8 142 552.3

34 105.0 50 142.2 65 184.3 81 239.0 96 299.4 11 2 375.1 127 457.6 143 559.1

35 107.1 51 144.8 66 187.7 82 242.7 97 303.8 11 3 380.2 128 463.5 144 565.9

36 109.2 52 147.4 67 190.9 83 246.5 98 308.2 11 4 385.4 129 469.5 145 572.8

37 111.4 53 150.1 68 194.1 84 250.3 99 312.7 115 390.7 130 475.6 146 579.8

38 113.6 54 152.8 69 197.3 85 254.1 100 317.2 11 6 396.0 131 481.6 147 586.8

39 115.8 55 155.5 70 200.6 86 258.0 101 321.8 11 7 401.3 132 487.8 148 593.8

40 118.0 56 158.2 71 203.9 87 262.0 102 326.4 11 8 406.7 133 494.0 149 601.0

41 120.3 57 161.0 72 207.2 88 266.0 103 331.0 119 412.2 134 500.2 150 608.1

42 122.6 58 163.9 73 210.6 89 270.0 104 335.7 120 417.7 135 506.5 151 615.4

43 125.0 59 166.7 74 214.0 90 274.1 105 340.5 121 423.2 136 512.9 152 622.7

44 127.3 60 169.6 75 217.4 91 278.2 106 345.3 122 428.8 137 519.3 153 630.1

45 129.7 61 172.6 76 220.9 92 282.3 107 350.1 123 434.5 138 525.8 154 637.5

46 132.2 62 175.4 77 224.4 93 286.5 108 355.0 124 440.2 139 532.4 155 645.0

47 134.6 78 228.0 109 360.0 140 539.0

125 445.9

141 545.6

INSTALLING SERVICE VALVE CAPS

Disconnect gauge set and install all service valve caps for
both the liquid and suction line valves.

OUTDOOR UNIT

SERVICE VALVES

Figure 32. Installing Service Valve Caps

506083−01 03/08

INSTALL CAPS

System Operation

The outdoor unit and indoor blower will cycle on and off as
dictated by demands from the room thermostat. When the
thermostat’s blower switch is in the ON position, the indoor
blower will operate continuously.

HIGH PRESSURE SWITCH

TSA*H4 units are equipped with a high-pressure switch
that is located in the liquid line of the compressor. The
switch (SPST, manual reset, normally closed) removes
power from the compressor when discharge pressure
rises above factory setting at 590 + 10 psi.

Page 18

LOW PRESSURE SWITCH

TSA*H4 units are equipped with a low pressure switch that
is located in the suction line to the compressor. The switch
is a SPST, auto−reset switch that is normally closed. The
switch opens at 25 psi and closes at 40 psi.

Maintenance

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.

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.

UNIT 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.

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.

INDOOR UNIT

1. Clean or change filters.

2. 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.

UNIT NAMEPLATE: _________ ACTUAL: __________

OPTIONAL ACCESSORIES

Refer to the Engineering Handbook for optional
accessories that may apply to this unit. The following may
or may not apply:

 Timed Off Control
 Sound Cover
 Suction Line Drier
 Stand−Off Kit
 Low Ambient Kit

Homeowner Information

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.

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.

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.

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:

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 33). 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

Page 19

TSA*H4 SERIES

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

PUSH PIN

MESH

SCREEN

Figure 33. Cleaning Debris from Mesh

THERMOSTAT OPERATION

Though your thermostat may vary somewhat from the
description below, its operation will be similar.

Temperature Setting Levers

Most heat pump thermostats have two temperature
selector levers: one for heating and one for cooling. Set the
levers or dials to the desired temperature setpoints for both
heating and cooling. Avoid frequent temperature
adjustment; turning the unit off and back on before
pressures equalize puts stress on the unit compressor.

Fan Switch

In AUTO or INT (intermittent) mode, the blower operates
only when the thermostat calls for heating or cooling. This

mode is generally preferred when humidity control is a
priority. The ON or CONT mode provides continuous
indoor blower operation, regardless of whether the
compressor or auxiliary heat are operating. This mode is
required when constant air circulation or filtering is desired.

System Switch

Set the system switch for heating, cooling or auto
operation. The auto mode allows the heat pump to
automatically switch from heating mode to cooling mode to
maintain predetermined comfort settings. Many heat
pump thermostats are also equipped with an emergency
heat mode which locks out heat pump operation and
provides temporary heat supplied by the auxiliary heat.

Indicating Light

Most heat pump thermostats have an amber light which
indicates when the heat pump is operating in the
emergency heat mode.

Temperature Indicator

Temperature indicator displays actual room temperature.

PROGRAMMABLE THERMOSTATS

Your Lennox system may be controlled by a
programmable thermostat. These thermostats provide the
added feature of programmable time-of-day setpoints for
both heating and cooling. Refer to the user’s information
manual provided with your thermostat for operation
details.

PRESERVICE CHECK

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

 Make sure all electrical disconnect switches are ON.
 Make sure the room thermostat temperature selector

AND the system switch are properly set.

 Replace any blown fuses, or reset circuit breakers.
 Make sure unit access panels are in place.
 Make sure air filter is clean.
 Locate and record unit model number before calling.

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? 

506083−01 03/08

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