Lennox TSA036S4N41, TSA060S4N41, TSA042S4N41, TSA048S4N41 Installation Instructions Manual

INSTALLATION

,1,_2008Lennox tndustries Inc,

Dallas, Texas, USA

0( °s

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

®

WARNING

CAUTION

INSTRUCTIONS

T-ClassTM TSA*S4 Units

TSA036S4N41, TSA042S4N41,
TSA048S4N41 and TSA060S4N41

AIR CONDITIONER

506058-01
02/08

Supersedes 505,300M

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

TSA*S4 Outdoor Unit .......................... 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 .............................. 11

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

Owner Information ............................. 19

Optional Accessories .......................... 20

Start-Up and Performance Checklist ............. 20

TeCh ni cal

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Litho U.S.A.

IMPORTANT

IMPORTANT

02/08

IIIHIIIIIIIIIIIHIIIIIIIIIIIIIIIIII

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

TSA*S4 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 Lennox

TSA*S4 Engineering Handbook.
This outdoor unit is designed for use in thermal expansion

valve (TXV) systems only.

506058-01

Page 1

IIIIIIIIIIIIIIIIlIHIIIIIIIIIIIIIIIIIIIIIIIlllllllllllllll

A

SIDE VIEW

OUTDOOR COILFAN tD schargeA r

COMPRESSOR_

SUCTION ANDLIQUIDLINE

CONNECTIONS

OPTIONAL UNIT STAND-OFF KIT

(4) (FIELDqNSTALLED)

SIDE VIEW

Model Number A B

TSA036S2N41 24-1/4 (616) 29-1/4 (743)
TSA042S2N41 24-1/4 (616) 33-1/4 (845)
TSA048S2N41 28-1/4 (724) 29-1/4 (743)
TSA060S2N41 28-1/4 (724) 37-1/4 (925)

WARNING

Table 1. Torque Requirements

Part 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

I

Gauge port seal cap 8 ft.- lb. 11 NM

USING MANIFOLD GAUGE SETS

When checking the system charge, use a manifold gauge
set that features low-loss anti-blow back fittings. See figure

1 for a typical manifold gauge connection setup,

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
The liquid and suction line service valves are typically used

for removing refrigerant, flushing, leak testing, evacuating,
checking charge and charging.

IMPORTANT

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

who have jurisdiction before installation.

When servicing or repairing HVAC components, ensure
caps and fasteners are appropriately tightened. Table 1

lists torque values for typical service and repair items.

506058-01 02/08

Page 2

OUTDOOR UNIT (Uncased Coil Shown)

LOW HIGH

PRESSURE PRESSURE

SERVICE VALVE

COMPRESSOR

FILTER DRIER

)MPRESSO_ _ I

Figure 1. Typical Manifold Gauge Connection Setup

Each valve is equipped with a service port which has a

factory-installed valve stem.

I/6 TURN

1/12 TURN

Figure 2. Cap Tightening Distances

,A IMPORTANT

OUTDOOR

COIL

SUCTION LINE

• 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 liquidqine 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: Tighten finger tight 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,

NOTE- To prevent stripping of the cap, the wrench should
be appropriately sized and fit snugly over the cap before

tightening the cap,

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.

Page 3

SERVICE PORT

CLOSED TO BOTH

INDOOR AND

OUTDOOR UNITS

VALVE STEM

FRONT-SEATED

TOINDOOR

UNIT

TO OUTDOOR UNIT

Figure 3. Angle-Type Service Valve

SERVICE PORT CAP

(Font-Seated Closed)

STEM CAP

SERVICE PORT

CLOSED) INSERT HEX
WRENCH HERE

TSA*S4 SERIES

SERVICEPORT

SERVICEPORT

OPENTOBOTH

INDOORAND

OUTDOORUNITS

TOINDOOR

UNIT

(VALVESTEMSHOWNOPEN)

INSERTHEXWRENCHHERE

STEMCAP

SERVICEPORT

• 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.

TOOUTDOORUNIT

Figure 4. Angle-Type Service Valve

(Back-Seated Opened)

To Access Bali-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.

TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°. BALL(SHOWN

TO CLOSE ROTATE STEM
CLOCKWISE 90 °.

CORE

SERVlCEPORTCAP

TO INDOOR UNIT

CLOSED)

STEM CAP

VALVE
STEM

Remove existing HCFC-22 refrigerant using one of the

following methods:

METHOD 1:

Use this method if the existing outdoor unit is not equipped

with manual shut-off valves, and plan on using existing

HCFC-22 refrigerant to flush the system,

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 recover 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,

RECOVERY MACHINE

MANIFOLD GAUGES

Figure 5. Bali-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 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 Bali-Type Service Valve:

A valve stem cap protects the valve stem from

contamination and assures a leak-free seal,

1. Remove stem cap with a wrench.

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

rotate stem clockwise 90°,

3. Replace the stem cap and tighten as follows:

506058-01 02/08

CLEAN RECOVERY

/

OUTDOOR UNIT

Figure 6. Typical Refrigerant Recovery

(Method 1)

METHOD 2:

Use this method if the existing outdoor unit is equipped

with manual shut-off valves, and plan on using new

HCFC-22 refrigerant to flush the system,

IMPORTANT: Some system configurations may contain
higher than normal refrigerant charge due to either large

internal coil volumes, and/or long line sets, The following
conditions may cause the compressor to stop functioning:

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

• Outdoor unit's high or low-pressure switches (if
applicable) when tripped can cycled the compressor

OFF,

Page 4

• 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 suction 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:

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

2. Pump as much of the existing HCFC-22 refrigerant
with the compressor back into the outdoor unit until

you have reached the limitations of the outdoor
system. Turn the outdoor unit main power OFF and

use a recovery machine to remove the remaining
refrigerant in the system.

NOTE - It may be necessary to bypass the low pressure
switches if equipped to ensure complete refrigerant

evacuation.

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.

* SEE NOTES BELOW THIS FIGURE FOR FURTHER DETAILS.

Figure 7. Installation Clearances

NOTES:

• Service clearance of 30 in. (762 mm) must be
maintained on one of the sides adjacent to the control

box.

• Clearance to one of the other three sides must be 36
in. (914 mm)

• Clearance to one of the remaining two sides may be

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

mm)

• 48 in. (1219 mm) clearance required on top of unit.

• A clearance of 24 in. (610 mm) must be maintained
between two units

POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:

CAUTION

Perform the following task at the existing outdoor unit:

• Disconnect line set at the service valves.

• Disconnect electrical service at the disconnect switch.

• Remove old outdoor unit.

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

installation clearance requirements.

• 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 8.

Page 5

TSA*S4 SERIES

INSTALLUNITAWAY_/_/_/

FROM_

Figure 8. Outside Unit Placement

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.

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.

BUILDING

STRUCTURE

DISCHARGE AIR

MOUNTING

SLAB

GROUND LEVEL

Figure 9. Ground Level Slab Mounting

Slab may be level or have a slope tolerance away from the
building of not more than two degrees, or two inches per 5

feet (51 mm per 1524 mm) as illustrated in figure 9.

INSTALLING OUTDOOR UNIT ON ROOF
Install the unit a minimum of six inches (152 mm) above the

roof surface to avoid ice build-up around the unit. Locate
the unit above a load bearing wall or area of the roof that

can adequately support the unit, Consult local codes for
rooftop applications.

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 7.

Table 2. Refrigerant Line Set

Field

Model

-036

-042 (10 mm) (22 mm)

-048

-060 (10mm) (29mm)

Connections

Liquid Suction
Line Line

3/8 in, 7/8 in

3/8 in. 1-1/8 in,

Recommended Line Set

Liquid Suction L15
Line Line Line Sets

3/8 in. 7/8 in L15-65

(10 (22 ram) 15 ft. - 50 ft.
mm) (4.6 m - 15 m)

3/8 in. 1-1/8 in, Field

(10 (29 mm) Fabricated
mm)

NOTE - When installing refrigerant lines longer than 50
feet, contact Lennox Technical Support Product
Appfications 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,

MATCHING WITH NEW OR EXISTING INDOOR COIL
AND LINE SET

The RFCl-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 10, This
filter drier must be installed to ensure a clean,
moisture-free system, Failure to install the filter drier will

506058_01 02/08

Page 6