Thermo Pride LX-13 User Manual

INSTALLATION MANUAL

MAC-212
ECN 5287-MA 121005

R-410A
OUTDOOR SPLIT-SYSTEM
AIR CONDITIONING

MODELS: 13 & 14.5 SEER ­TCG(D,F)/GCGD/TCJ(D,F)/YCJ(D,F) SERIES

1.5 TO 6.3 TONS – 1 & 3 PHASE

LIST OF SECTIONS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ORIFICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

TXV INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

LIST OF FIGURES

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation of Vapor Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Orifice Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Outdoor Unit Control Box (Single Phase) . . . . . . . . . . . . . . . . . . . . . . 7

Outdoor Unit Control Box (Three Phase) . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase) . . . 8
Typical Field Wiring (Air Handler / Electrical Heat) (Three-Phase) . . .8

EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . . 9

Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . 10

Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 11

Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 12

Wiring Diagram - Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Wiring Diagram - Three Phase 2.5-5 Tons . . . . . . . . . . . . . . . . . . . . 15

Wiring Diagram - Three Phase 6.3 Ton . . . . . . . . . . . . . . . . . . . . . . 16

24 VAC Connection Wiring for 2-pipe A/C,

6.3 Ton Condensing Unit with 7.5 Ton Air Handler . . . . . . . . . . . . . 16

®

LIST OF TABLES

Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 R-410A Saturation Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION I: GENERAL

The outdoor units are designed to be connected to a matching indoor
coil with sweat connect lines. Sweat connect units are factory charged
with refrigerant for a matching indoor coil plus 15 feet of field-supplied
lines.

The refrigerant charge may need to be changed for some indoor-out­door unit combinations, elevation differences or total line lengths. Refer
to Application Data covering “General Piping Recommendations and
Refrigerant Line Length” (Part Number 247077).

SECTION II: SAFETY

This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.

Understand and pay particular attention to the signal words DANGER,

WAR NIN G, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury

WAR NIN G indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury

CAUTION indicates a potentially hazardous situation, which, if not

avoided may result in minor or moderate injury
alert against unsafe practices and hazards involving only property dam­age.

This product must be installed in strict compliance with the
enclosed installation instructions and any applicable local, state,
and national codes including, but not limited to building, electrical,
and mechanical codes.

.

.

. It is also used to

R-410A systems operate at higher pressures than R-22 systems.
Do not use R-22 service equipment or components on R-410A
equipment. Service equipment

Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.

Improper installation, adjustment, alteration, service or mainte­nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con­tractor, installer or service agency.

Must Be Rated for R-410A.

INSPECTION

As soon as a unit is received, it should be inspected for possible dam­age during transit. If damage is evident, the extent of the damage
should be noted on the carrier’s delivery receipt. A separate request for
inspection by the carrier’s agent should be made in writing. See Local
Distributor for more information.

Requirements For Installing/Servicing R-410A Equipment

• Gauge sets, hoses, refrigerant containers, and recovery system
must be designed to handle the POE type oils, and the higher
pressures of R-410A.

• Manifold sets should be high side and low side with low side
retard.

• All hoses must have a 700 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• Recovery equipment (including refrigerant recovery containers)
must be specifically designed to handle R-410A.

• Do not use an R-22 TXV.

• A liquid-line filter drier is required on every unit.

LIMITATIONS

The unit should be installed in accordance with all National, State and
Local Safety Codes and the limitations listed below:

1. Limitations for the indoor unit, coil, and appropriate accessories
must also be observed.

2. The outdoor unit must not be installed with any duct work in the air
stream. The outdoor fan is the propeller type and is not designed
to operate against any additional external static pressure.

3. The maximum and minimum conditions for operation must be
observed to ensure a system that will give maximum performance
with minimum service.

TABL E 1 :

Application Limitations

Ambient Air Temperature

on Outdoor Coil

Air Temperature on

Indoor Coil

Min. DB Max. DB Min. WB Max. WB

50°F 115°F 57°F 72°F

4. The unit should not be operated at outdoor temperatures below
50°F without an approved low ambient operation accessory kit
installed.

5. The maximum allowable line length for this product is 75 feet.

SECTION III: UNIT INSTALLATION

LOCATION

Before starting the installation, select and check the suitability of the
location for both the indoor and outdoor unit. Observe all limitations and
clearance requirements.

The outdoor unit must have sufficient clearance for air entrance to the
condenser coil, air discharge, and service access. See Figure 1.

NOTICE

For multiple unit installations, units must be spaced a minimum of
18” (46 cm) apart (coil face to coil face).

If the unit is to be installed on a hot sun exposed roof or a black-topped
ground area, the unit should be raised sufficiently above the roof or
ground to avoid taking the accumulated layer of hot air into the outdoor
unit.

Provide an adequate structural support.

ADD-ON REPLACEMENT/RETROFIT

When this unit is being used as a replacement for an R-410A unit, it is
required that the outdoor unit, indoor coil, and metering device all be
replaced. The following steps should be performed in order to insure
proper system operation and performance. Line-set change out is also
recommended.

1. Change-out of the indoor coil to an approved R-410A coil/ con­densing unit combination with the appropriate metering device.

2. Change-out of the line-set when replacing an R-22 unit with an
R410-A unit is highly recommended to reduce cross-contamina­tion of oils and refrigerants.

3. If change-out of the line set is not practical, then the following pre­cautions should be taken.

• Inspect the line set for kinks, sharp bends, or other restrictions,
and for corrosion.

• Determine if there are any low spots which might be serving as oil
traps.

• Flush the line set with a commercially available flush kit to
remove as much of the existing oil and contaminants as possible.

• Install a suction line filter-drier to trap any remaining contami­nants, and remove after 50 hours of operation.

4. If the outdoor unit is being replaced due to a compressor burnout,
then installation of a 100% activated alumina suction-line filter
drier in the suction-line is required, in addition to the factory
installed liquid-line drier. Operate the system for 10 hours. Monitor
the suction drier pressure drop. If the pressure drop exceeds 3
psig, replace both the suction-line and liquid-line driers. After a
total of 10 hours run time where the suction-line pressure drop has
not exceeded 3 psig, replace the liquid line drier, and remove the
suction-line drier. Never leave a suction-line drier in the system
longer than 50 hours of run time.

60” OVERHEAD
CLEARANCE

10” CLEARANCE
AROUND PERIMETER

NOTES:
ALL OUTDOOR WIRING MUST BE WEATHERPROOF.
MINIMUM 24” UNIT TO UNIT CLEARANCE.

FIGURE 1: Typical Installation

MINIMUM 18” SERVICE
ACCESS CLEARANCE
ON ONE SIDE

WEATHERPROOF
DISCONNECT
SWITCH

CONTROL
ACCESS
PANEL

THERMOSTAT

NEC CLASS 1 WIRING

NEC CLASS 2 WIRING

TO FURNACE OR
AIR HANDLER
TERMINAL BLOCK

TO INDOOR COIL

SEAL OPENING(S) WITH
PERMAGUM OR EQUIVALENT

2

GROUND INSTALLATION

The unit should be installed on a solid base that is 2” (5.1 cm) above
grade and will not shift or settle, causing strain on the refrigerant lines
and possible leaks. Maintain the clearances shown in Figure 1 and
install the unit in a level position. The base pad should not come in con­tact with the foundation or side of the structure because sound may be
transmitted to the residence.

The length of the refrigerant tubing between the outdoor unit and indoor
coil should be as short as possible to avoid capacity and efficiency
losses. Excessive spacing of the outdoor unit from the home can result
in the refrigerant lines being restricted by trampling or being punctured
by lawn mowers. Locate the outdoor unit away from bedroom windows
or other rooms where sound might be objectionable.

Adverse effects of snow or sleet accumulating on the outdoor coil can
be eliminated by placing the outdoor unit where the prevailing wind
does not blow across the unit. Trees, shrubs, corners of buildings, and
fences standing off from the coil can reduce capacity loss due to wind
chill effect.

Provide ample clearance from shrubs to allow adequate air to pass
across the outdoor coil without leaves or branches being pulled into the
coil.

ROOF INSTALLATION

When installing units on a roof, the structure must be capable of sup­porting the total weight of the unit, including a pad, lintels, rails, etc.,
which should be used to minimize the transmission of sound or vibra­tion into the conditioned space.

LIQUID LINE FILTER-DRIER

The air conditioning unit’s filter/dryer is located on the liquid line.

NOTICE

Replacements for the liquid line drier must be exactly the same as
marked on the original factory drier. See Source1 for O.E.M.
replacement driers.

Failure to do so or using a substitute drier or a granular type may
result in damage to the equipment.

Filter-Drier

Source 1 Part No.

S1-02922195000 All

PIPING CONNECTIONS

The outdoor condensing unit must be connected to the indoor evapora­tor coil using field supplied refrigerant grade (ACR) copper tubing that is
internally clean and dry. Units should be installed only with the tubing
sizes for approved system combinations as specified in tabular data
sheet. The charge given is applicable for total tubing lengths up to 15
feet (4.6 m). See Application Data Part Number 247077 for installing
tubing of longer lengths and elevation differences.

Apply with Models

This system uses R-410A refrigerant which operates at higher pres­sures than R-22. No other refrigerant may be used in this system.
Gauge sets, hoses, refrigerant containers, and recovery system
must be designed to handle R-410A. If you are unsure, consult the
equipment manufacturer.

Never install a suction-line filter drier in the liquid line of an R-410A
system. Failure to follow this warning can cause a fire, injury or
death.

PRECAUTIONS DURING LINE INSTALLATION

1. Install the lines with as few bends as possible. Care must be taken

not to damage the couplings or kink the tubing. Use clean hard
drawn copper tubing where no appreciable amount of bending
around obstruction is necessary. If soft copper must be used, care
must be taken to avoid sharp bends which may cause a restriction.

2. The lines should be installed so that they will not obstruct service

access to the coil, air handling system, or filter.

3. Care must also be taken to isolate the refrigerant lines to minimize

noise transmission from the equipment to the structure.

4. The vapor line must be insulated with a minimum of 1/2" foam rub-

ber insulation (Armaflex or equivalent). Liquid lines that will be
exposed to direct sunlight, high temperatures, or excessive humid­ity must also be insulated.

5. Tape and suspend the refrigerant lines as shown. DO NOT allow

tube metal-to-metal contact. See Figure 2.

6. Use PVC piping as a conduit for all underground installations as

shown in Figure 3. Buried lines should be kept as short as possible
to minimize the build up of liquid refrigerant in the vapor line during
long periods of shutdown.

7. Pack fiberglass insulation and a sealing material such as perma-

gum around refrigerant lines where they penetrate a wall to reduce
vibration and to retain some flexibility.

8. For systems with total line length exceeding 70 feet (21.3 m), see

APPLICATION DATA and worksheet "General Piping Recommen­dations and Refrigerant Line Length" for vapor and liquid line siz­ing, calibration of liquid line pressure loss or gain, determination of
vapor line velocity, elevation limitations, orifice connections, sys­tem charging, traps, etc.

Sheet Metal Hanger

Liquid
Line

Incorrect

Correct

FIGURE 2: Installation of Vapor Line

Tape

NOTICE

Using a larger than specified line size could result in oil return prob­lems. Using too small a line will result in loss of capacity and other
problems caused by insufficient refrigerant flow. Slope horizontal
vapor lines at least 1" (2.5 cm) every 20 feet (6.1 m) toward the out­door unit to facilitate proper oil return.

TO INDOOR COIL

Liquid Line

PVC
Conduit

FIGURE 3: Underground Installation

Insulated
Vapor Line

TO OUTDOOR UNIT

Cap

3

PRECAUTIONS DURING BRAZING OF LINES

All outdoor unit and evaporator coil connections are copper-to-copper
and should be brazed with a phosphorous-copper alloy material such
as Silfos-5 or equivalent. DO NOT use soft solder. The outdoor units
have reusable service valves on both the liquid and vapor connections.
The total system refrigerant charge is retained within the outdoor unit
during shipping and installation. The reusable service valves are pro­vided to evacuate and charge per this instruction.

Serious service problems can be avoided by taking adequate precau­tions to assure an internally clean and dry system.

Dry nitrogen should always be supplied through the tubing while it
is being brazed, because the temperature required is high enough
to cause oxidation of the copper unless an inert atmosphere is pro­vided. The flow of dry nitrogen should continue until the joint has
cooled. Always use a pressure regulator and safety valve to insure
that only low pressure dry nitrogen is introduced into the tubing.
Only a small flow is necessary to displace air and prevent oxidation.

PRECAUTIONS DURING BRAZING SERVICE VALVE

Precautions should be taken to prevent heat damage to service valve
by wrapping a wet rag around it as shown in Figure 4. Also, protect all
painted surfaces, insulation, and plastic base during brazing. After braz­ing, cool joint with wet rag.

This is not a backseating valve. The service access port has a
valve core. Opening or closing valve does not close service access
port.
If the valve stem is backed out past the chamfered retaining wall,
the O-ring can be damaged causing leakage or system pressure
could force the valve stem out of the valve body possibly causing
personal injury.

Valve can be opened by removing the plunger cap and fully inserting a
hex wrench into the stem and backing out counter-clockwise until valve
stem just touches the chamfered retaining wall.

Connect the refrigerant lines using the following procedure:

1. Remove the cap and Schrader core from both the liquid and vapor
service valve service ports at the outdoor unit. Connect low pres­sure nitrogen to the liquid line service port.

2. Braze the liquid line to the liquid valve at the outdoor unit. Be sure
to wrap the valve body with a wet rag. Allow the nitrogen to con­tinue flowing.

3. Carefully remove the plugs from the evaporator liquid and vapor
connections at the indoor coil.

Do not install any coil in a furnace which is to be operated during
the heating season without attaching the refrigerant lines to the coil.
The coil is under 30 to 35 psig inert gas pressure which must be
released to prevent excessive pressure build-up and possible coil
damage.

4. Braze the liquid line to the evaporator liquid connection. Nitrogen
should be flowing through the evaporator coil.

5. Slide the grommet away from the vapor connection at the indoor
coil. Braze the vapor line to the evaporator vapor connection. After
the connection has cooled, slide the grommet back into original
position.

6. Protect the vapor valve with a wet rag and braze the vapor line
connection to the outdoor unit. The nitrogen flow should be exiting
the system from the vapor service port connection. After this con­nection has cooled, remove the nitrogen source from the liquid fit­ting service port.

7. Replace the Schrader core in the liquid and vapor valves.

8. Go to SECTION IV or SECTION V for orifice or TXV installation
depending on application.

9. Leak test all refrigerant piping connections including the service
port flare caps to be sure they are leak tight. DO NOT OVER­TIGHTEN (between 40 and 60 inch - lbs. maximum).

NOTICE

Line set and indoor coil can be pressurized to 250 psig with dry
nitrogen and leak tested with a bubble type leak detector. Then
release the nitrogen charge.

Do not use the system refrigerant in the outdoor unit to purge or
leak test.

10. Evacuate the vapor line, evaporator, and liquid line to 500 microns
or less.

11. Replace cap on service ports. Do not remove the flare caps from
the service ports except when necessary for servicing the system.

Do not connect manifold gauges unless trouble is suspected.
Approximately 3/4 ounce of refrigerant will be lost each time a stan­dard manifold gauge is connected.

12. Release the refrigerant charge into the system. Open both the liq­uid and vapor valves by removing the plunger cap and with an
allen wrench back out counter-clockwise until valve stem just
touches the chamfered retaining wall. If the service valve is a ball
valve, use a cresent wrench to turn valve stem one-quater turn
counterclockwise to open. Do not overturn or the valve stem may
break or become damaged. See “PRECAUTIONS DURING
BRAZING SERVICE VALVE”.

13. Replace plunger cap finger tight, then tighten an additional 1/12
turn (1/2 hex flat). Cap must be replaced to prevent leaks.

FIGURE 4: Heat Protection

4

Never attempt to repair any brazed connections while the system is
under pressure. Personal injury could result.

See "System Charge” section for checking and recording system
charge.

Supplied with the outdoor unit is a Schrader Valve Core and Orifice for
highest sales volume indoor coil. The valve core must be installed in
equalizer fitting of the indoor coil.