INSTALLATION INSTRUCTIONS

Transkript

1 2010 Lennox Industries Inc. Dallas, Texas, US INSTLLTION INSTRUCTIONS T Class TS*S4 Units M and T Voltages IR CONDITIONER /10 Supersedes Litho U.S.. RETIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation. WRNING 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. The Clean ir ct of 1990 bans the intentional venting of refrigerant (CFCs, HCFCs ND HFCs) as of July 1, pproved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarceration may be levied for noncompliance. This unit must be matched with an indoor coil as specified in Lennox Engineering Handbook. Coils previously charged with HCFC 22 must be flushed. NOTICE TO INSTLLER UNIT PLCEMENT It is critical for proper unit operation to place outdoor unit on an elevated surface as described in Unit Placement section on page 6. RZING LINE SET TO SERVICE VLVES It is imperative to follow the brazing technique illustrated starting on page 9 to avoid damaging the service valve s internal seals. TLE OF CONTENTS Shipping and Packing List Outdoor Unit Unit Dimensions Typical Unit Parts rrangement Model Number Identification General Information Operating Gauge Set and Service Valves Recovering Refrigerant from Existing System New Outdoor Unit Placement New or Replacement Line Set razing Connections Flushing Line Set and Indoor Coil Installing Indoor Metering Device Leak Test Line Set and Indoor Coil Evacuating Line Set and Indoor Coil Electrical Connections Servicing Unit Delivered Void of Charge Unit Start Up System Refrigerant System Operation Maintenance Start Up and Performance Checklist Shipping and Packing List Check the unit for shipping damage and listed times below are intact. If damaged, or if parts are missing, immediately contact the last shipping carrier. 1 ssembled outdoor unit 1 Liquid line filter drier Outdoor Unit This outdoor unit is designed for use with HFC 410 refrigerant only. This unit must be installed with an approved indoor air handler or coil. See the Lennox TS*S4 Engineering Handbook for approved indoor component matchups. This outdoor unit is designed for use in thermal expansion valve (TXV) systems only. 11/ Page 1

2 Unit Dimensions Inches (mm) OUTDOOR COIL FN Discharge ir COMPRESSOR SUCTION ND LIQUID LINE CONNECTIONS SIDE VIEW OPTIONL UNIT STND-OFF KIT (4) (FIELD INSTLLED) SIDE VIEW Model Number TS024S4N41T and M 24 1/4 (616) 25 1/4 (641) TS030S4N41T and M 24 1/4 (616) 29 1/4 (743) TS036S4N41M 28 1/4 (724) 29 1/4 (743) TS036S4N41T 24 1/4 (616) 29 1/4 (743) TS048S4N41T and M 28 1/4 (724) 37 1/4 (925) TS060S4N41T and M 28 1/4 (724) 33 1/4 (845) Typical Unit Parts rrangement CONTROL NOTE: PLUMING LYOUT MY VRY SLIGHTLY ETWEEN MODEL SIZES. DUL RUN CPCITOR (C12) (T VOLTGE) SINGLE RUN CPCITOR (C12) (M VOLTGE) GROUND LUG CONTCTOR (K1) LOCTION OR TWO POLE (M VOLTGE) ONE POLE (T VOLTGE) CUTOUT FOR HIGH VOLTGE CONDUIT HIGH PRESSURE SWITCH (S4) CRNKCSE HETER THERMOSTT (S40) LIQUID LINE SERVICE VLVE SUCTION LINE SERVICE VLVE /10 Figure 1. Typical Unit Parts rrangement Page 2

3 Model Number Identification T S 036 S 4 N 4 1 M rand/family T = T Class Product Line Unit Type S = Split System ir Conditioner Major Design Sequence = 1st Generation = 2nd Generation 024 = 2 Tons 030 = 2.5 Tons 0036 = 3 Tons 048 = 4 Tons 060 = 5Tons Cooling Efficiency S = Standard Efficiency This model is designed for use in expansion valve systems only. n indoor expansion valve approved for use with HFC 410 refrigerant must be ordered separately, and installed prior to operating the system. CUTION Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury. e aware of, and use caution when working near these areas during installation or while servicing this equipment. General Information These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation. Operating Gauge Set and Service Valves These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation. TORQUE REQUIREMENTS When servicing or repairing heating, ventilating, and air conditioning components, ensure the fasteners are appropriately tightened. Table 1 lists torque values for fasteners. Refrigerant Type 4 = R 410 Voltage M = 380/420V 3 phase 50hz T = 220/240V 1 phase 50hz Minor Design Sequence 1 = 1st Revision 2 = 2nd Revision 3 = 3rd Revision Coil Type 4 = Four sided Part Load Capability N = No part load, single stage compressor Only use llen 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 llen wrench rated at less than 50Rc risks rounding or breaking off the wrench, or stripping the valve stem recess. See the Lennox Service and pplication Notes #C 08 1 for further details and information. To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening. When servicing or repairing HVC components, ensure the fasteners are appropriately tightened. Table 1 provides torque values for fasteners. Table 1. Torque Requirements Parts Recommended Torque Service valve cap 8 ft. lb. 11 NM Sheet metal screws 16 in. lb. 2 NM Machine screws #10 28 in. lb. 3 NM Compressor bolts 90 in. lb. 10 NM Gauge port seal cap 8 ft. lb. 11 NM USING MNIFOLD GUGE SET When checking the system charge, only use a manifold gauge set that features low loss anti blow back fittings. Page 3 TS*S4 SERIES

4 Manifold gauge set used with HFC 410 refrigerant systems must be capable of handling the higher system operating pressures. The gauges should be rated for use with pressures of psig on the high side and a low side of 30" vacuum to 250 psig with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psig of pressure with a 4000 psig burst rating. SERVICE PORT CP OPERTING SERVICE VLVES The liquid and vapor line service valves are used for removing refrigerant, flushing, leak testing, evacuating, checking charge and charging. Each valve is equipped with a service port which has a factory installed valve stem. Figure 2 provides information on how to access and operating both angle and ball service valves. Operating ngle Type Service Valve: 1. Remove stem cap with an appropriately sized wrench. 2. Use a service wrench with a hex head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve sizes) to back the stem out counterclockwise as far as it will go. TO INDOOR UNIT SERVICE PORT CORE (VLVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE (VLVE STEM SHOWN CLOSED) INSERT HEX WRENCH HERE SERVICE PORT CORE STEM CP TO OUTDOOR UNIT NGLE TYPE SERVICE VLVE (CK SETED OPENED) When service valve is OPEN, the service port is open to line set, indoor and outdoor unit. Operating all Type Service Valve: 1. Remove stem cap with an appropriately sized wrench. 2. Use an appropriately sized wrenched to open. To open valve, rotate stem counterclockwise 90. To close rotate stem clockwise 90. TO OPEN ROTTE STEM COUNTERCLOCKWISE 90. TO CLOSE ROTTE STEM CLOCKWISE 90. SERVICE PORT SERVICE PORT CORE SERVICE PORT CP TO OUTDOOR UNIT TO INDOOR UNIT LL (SHOWN CLOSED) VLVE STEM STEM CP NGLE TYPE SERVICE VLVE (FRONT SETED CLOSED) WHEN SERVICE VLVE IS CLOSED, THE SERVICE PORT IS OPEN TO THE LINE SET ND INDOOR UNIT. To ccess Service Port: service port cap protects the service port core from contamination and serves as the primary leak seal. 1. Remove service port cap with an appropriately sized wrench. 2. Connect gauge set to service port. 3. When testing is completed, replace service port cap and tighten as follows: With torque wrench: Finger tighten and torque cap per table 1. Without torque wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/6 turn clockwise /6 TURN Reinstall Stem Cap: Stem cap protects the valve stem from damage and serves as the primary seal. Replace the stem cap and tighten as follows: With Torque Wrench: Finger tighten and then torque cap per table 1. Without Torque Wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/12 turn clockwise. 1/12 TURN NOTE label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque. Figure 2. ngle and all Service Valves /10 Page 4

5 Recovering Refrigerant from Existing System RECOVERING REFRIGERNT FROM SYSTEM 1 2 DISCONNECT POWER Disconnect all power to the existing outdoor unit at the service disconnect switch or main fuse box/breaker panel. SERVICE DISCONNECT SWITCH CONNECT MNIFOLD GUGE SET Connect a gauge set, clean recovery cylinder and a recovery machine to the service ports of the existing unit. Use the instructions provided with the recovery machine to make the connections. RECOVERY MCHINE MNIFOLD GUGES LOW HIGH 3 RECOVERING REFRIGERNT Remove existing refrigerant using one of the following procedures: CLEN RECOVERY CYLINDER OUTDOOR UNIT Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes, and/or long line sets. METHOD 1: Us this method if the existing outdoor unit is not equipped with shut off valves, or if the unit is not operational and you plan to use the existing to flush the system. Remove all refrigerant from the existing system. Check gauges after shutdown to confirm that the entire system is completely void of refrigerant. METHOD 2: Use this method if the existing outdoor unit is equipped with manual shut off valves, and you plan to use new refrigerant to flush the system. The following devices could prevent full system charge recovery into the outdoor unit: Outdoor unit s high or low pressure switches (if applicable) when tripped can cycle the compressor OFF. Compressor can stop pumping due to tripped internal pressure relief valve. Compressor has internal vacuum protection that is designed to unload the scrolls (compressor stops pumping) when the pressure ratio meets a certain value or when the suction pressure is as high as 20 psig. (Compressor suction pressures should never be allowed to go into a vacuum. Prolonged operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips, drive bearings and internal seals.) Once the compressor can not pump down to a lower pressure due to one of the above system conditions, shut off the vapor valve. Turn OFF the main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set. Perform the following task: Start the existing system in the cooling mode and close the liquid line valve. Use the compressor to pump as much of the existing HCFC 22 refrigerant into the outdoor unit until the outdoor system is full. Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system. NOTE It may be necessary to bypass the low pressure switches (if equipped) to ensure complete refrigerant evacuation. C When the low side system pressures reach 0 psig, close the vapor line valve. D Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system. Figure 3. Refrigerant Recovery Page 5 TS*S4 SERIES

6 CLERNCE ON LL SIDES INCHES (MILLIMETERS) MINIMUM CLERNCE OVE UNIT 6 (152) CCESS PNEL 12 (305) 36 (914) 30 (762) LINE SET CONNECTIONS NOTES: Clearance to one of the other three sides must be 36 inches (914mm). Clearance to one of the remaining two sides may be 12 inches (305mm) and the final side may be 6 inches (152mm). 48 (1219) MINIMUM CLERNCE ETWEEN TWO UNITS 24 (610) DETIL Install unit away from windows. Figure 4. Installation Clearances DETIL Install unit level or, if on a slope, maintain slope tolerance of 2 degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from building structure. STRUCTURE DISCHRGE IR Two 90 elbows installed in line set will reduce line set vibration. MOUNTING SL MUST SLOPE WY FROM UILDING. GROUND LEVEL Figure 5. Placement, and Slab Mounting New Outdoor Unit Placement Consider the following when positioning the unit: See Unit Dimensions on page 2 for sizing mounting slab, Some localities are adopting sound ordinances based platforms or supports. Refer to figure 4 for mandatory on the unit s sound level registered from the adjacent installation clearance requirements. property, not from the installation property. Install the POSITIONING CONSIDERTIONS unit as far as possible from the property line. CUTION In order to avoid injury, take proper precaution when lifting heavy objects. 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 /10 Page 6

7 PLCING OUTDOOR UNIT ON SL When installing a unit at grade level, the top of the slab should be high enough above the grade so that water from higher ground would not collect around the unit as illustrated in figure 5. Slab may be level or have a slope tolerance away from the building of not more than two degrees, or 2 inches per 5 feet (51 mm per 1524 mm) as illustrated in figure 5. Slab may be level or have a slope tolerance away from the building of not more than two degrees, or 2 inches per 5 feet (51 mm per 1524 mm) as illustrated in figure 5. INSTLLING OUTDOOR UNIT ON ROOF Install the unit at a minimum of 4 inches (102 mm) above the surface of the roof. Ensure the weight of the unit is properly distributed over roof joists and rafters. Redwood or steel supports are recommended. New or Replacement Line Set This section provides information on new installation or replacement of existing line set. If a new or replacement line set is not required, then proceed to razing Connections on page 9. If refrigerant lines are routed through a wall, seal and isolate the opening so vibration is not transmitted to the building. Pay close attention to line set isolation during installation of any HVC system. When properly isolated from building structures (walls, ceilings. floors), the refrigerant lines will not create unnecessary vibration and subsequent sounds. lso, consider the following when placing and installing a high efficiency air conditioner: REFRIGERNT 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. NOTE When installing refrigerant lines longer than 50 feet, contact Lennox Technical Support Product pplications for assistance or Lennox piping manual. To obtain the correct information from Lennox, be sure to communicate the following points: Model (TS*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. Mineral oils are not compatible with HFC 410. If oil must be added, it must be a Polyol ester oil. The compressor is charged with sufficient Polyol ester oil for line set lengths up to 50 feet. Recommend adding oil to system based on the amount of refrigerant charge in the system. No need to add oil in system with 20 pounds of refrigerant or less. For systems over 20 pounds add one ounce of every five pounds of refrigerant. Recommended topping off POE oils are Mobil EL RCTIC 22 CC or ICI EMKRTE RL32CF. MTCHING WITH NEW OR EXISTING INDOOR COIL ND 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 TS*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 TS*S4 unit. Typically a liquid line used to meter flow is 1/4" in diameter and copper. LIQUID LINE FILTER DRIER INSTLLTION The filter drier (one is shipped with each TS*S4 unit) must be field installed in the liquid line between the outdoor unit s liquid line service valve and the indoor coil s metering device (fixed orifice or TXV) as illustrated in figure 6. This filter drier must be installed to ensure a clean, moisture free system. Failure to install the filter drier will void the warranty. replacement filter drier is available from Lennox. See razing Connections on page 9 for special procedures on brazing filter drier connections to the liquid line. OUTDOOR UNIT LIQUID LINE SERVICE VLVE LINE RZE CONNECTION POINTS LIQUID LINE FILTER DRIER LIQUID LINE Figure 6. Typical Liquid Line Filter Drier Installation Page 7 TS*S4 SERIES

8 Table 2. Refrigerant Line Set Inches (mm) Model Field Connections Recommended Line Set Liquid Line Vapor Line Liquid Line Vapor Line L15 Line Sets TS024S4N4 3/8 in. (10 mm) 3/4 in. (19 mm) 3/8 in. (10 mm) 3/4 in. (19 mm) L ft. 50 ft. (4.6 m 15 m) TS036S4N4 TS048S4N4 3/8 in. (10 mm) 7/8 in. (22 mm) 3/8 in. (10 mm) 7/8 in. (22 mm) L ft. 50 ft. (4.6 m 15 m) TS060S4N4 3/8 in. (10 mm) 1 1/8 in. (29 mm) 3/8 in. (10 mm) 1 1/8 in. (29 mm) Field Fabricated NOTE Some applications may required a field provided 7/8" to 1 1/8" adapter INSTLLTION Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation: REFRIGERNT LINE SET TRNSITION FROM VERTICL TO HORIZONTL NCHORED HEVY NYLON WIRE TIE OR UTOMOTIVE MUFFLER-TYPE HNGER UTOMOTIVE MUFFLER-TYPE HNGER Refrigerant lines must not contact structure. REFRIGERNT LINE SET INSTLLING VERTICL RUNS (NEW CONSTRUCTION SHOWN) NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig. Refrigerant lines must not contact wall OUTSIDE WLL VPOR LINE LIQUID LINE WLL STUD NON CORROSIVE METL SLEEVE STRP LIQUID LINE TO VPOR LINE LIQUID LINE VPOR LINE WRPPED IN RMFLEX REFRIGERNT LINE SET INSTLLING HORIZONTL RUNS To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties. WIRE TIE (ROUND VPOR LINE ONLY) WOOD LOCK ETWEEN STUDS WIRE TIE INSIDE WLL STRP NON CORROSIVE METL SLEEVE WIRE TIE WOOD LOCK WIRE TIE STRP STRPPING MTERIL (ROUND VPOR LINE ONLY) 8 FEET (2.43 METERS) FLOOR JOIST OR ROOF RFTER TPE OR WIRE TIE FLOOR JOIST OR ROOF RFTER NON CORROSIVE METL SLEEVE TPE OR WIRE TIE 8 FEET (2.43 METERS) STRP THE VPOR LINE TO THE JOIST OR RFTER T 8 FEET (2.43 METERS) INTERVLS THEN STRP THE LIQUID LINE TO THE VPOR LINE. Figure 7. Line Set Installation PVC PIPE VPOR LINE WRPPED WITH RMFLEX OUTSIDE WLL SLEEVE FIERGLSS INSULTION CULK LIQUID LINE NOTE Similar installation practices should be used if line set is to be installed on exterior of outside wall /10 Page 8

9 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 410 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. razing Connections Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves. Polyol ester (POE) oils used with HFC 410 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. WRNING Danger of fire. leeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing. pplication of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture Check the high and low pressures before applying heat. WRNING 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). CUTION razing alloys and flux contain materials which are hazardous to your health. void 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. Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve. llow braze joint to cool before removing the wet rag from the service valve. Temperatures above 250ºF can damage valve seals. Use silver alloy brazing rods with 5% minimum silver alloy for copper to copper brazing. Use 45% minimum alloy for copper to brass and copper to steel brazing. WRNING Fire, Explosion and Personal Safety Hazard. Failure to follow this warning could result in damage, personal injury or death. Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when exposed to a spark or open flame, can cause fire and/or an explosion, that could result in property damage, personal injury or death. Page 9 TS*S4 SERIES

10 1 2 vapor CUT ND DEUR Cut ends of the refrigerant lines square (free from nicks or dents) and debur the ends. The pipe must remain round. Do not crimp end of the line. CP ND CORE REMOVL Remove service cap and core from both the and liquid line service ports. CUT ND DEUR COPPER TUE STU REDUCER SERVICE VLVE CONNECTION LINE SET SIZE MTCHES SERVICE VLVE CONNECTION SERVICE PORT CP SERVICE PORT CORE LIQUID LINE SERVICE VLVE SERVICE PORT CORE SUCTION / VPOR LINE SERVICE VLVE SERVICE PORT CP 3 TTCH THE MNIFOLD GUGE SET FOR RZING LIQUID ND SUCTION / VPOR LINE SERVICE VLVES Flow regulated nitrogen (at 1 to 2 psig) through the low side refrigeration gauge set into the liquid line service port valve, and out of the suction / vapor line service port valve. C REFRIGERNT LINE LINE SET SIZE IS SMLLER THN CONNECTION Connect gauge set low pressure side to liquid line service valve (service port). Connect gauge set center port to bottle of nitrogen with regulator. Remove Schrader valve in suction / vapor line service port to allow nitrogen to escape. DO NOT CRIMP SERVICE VLVE CONNECTOR WHEN PIPE IS SMLLER THN CONNECTION LOW TTCH GUGES HIGH USE REGULTOR TO FLOW NITROGEN T 1 TO 2 PSIG. SUCTION / VPOR SERVICE PORT MUST E OPEN TO LLOW EXIT POINT FOR NITROGEN VPOR LINE C SUCTION / VPOR LINE SERVICE VLVE INDOOR UNIT OUTDOOR UNIT LIQUID LINE LIQUID LINE SERVICE VLVE WHEN RZING LINE SET TO SERVICE VLVES, POINT FLME WY FROM SERVICE VLVE. NITROGEN Figure 8. razing Procedures Page /10

11 4 saturated WRP SERVICE VLVES To help protect service valve seals during brazing, wrap a saturated cloth around service valve bodies and copper tube stub. Use another cloth underneath the valve body to protect the base paint. 5 FLOW NITROGEN Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and out of the suction / vapor valve stem port. See steps 3, 3 and 3C on manifold gauge set connections 6 RZE LINE SET Wrap both service valves with a saturated cloth as illustrated here before brazing to line set. LIQUID LINE SERVICE VLVE WHEN RZING LINE SET TO SERVICE VLVES, POINT FLME WY FROM SERVICE VLVE. llow braze joint to cool. pply additional saturated cloths to help cool brazed joint. Do not remove wet rag until piping has cooled. Temperatures above 250ºF will damage valve seals. STURTED CLOTH LIQUID LINE WRNING 1. FIRE, PERSONL INJURY, OR PROPERTY DMGE will result if you do not wrap a wet cloth around both liquid and suction line service valve bodies and copper tube stub while brazing in the line set! The braze, when complete, must be quenched with water to absorb any residual heat. 2. Do not open service valves until refrigerant lines and indoor coil have been leak tested and evacuated. Refer to procedures provided in this supplement. SUCTION / VPOR LINE SERVICE VLVE WHEN RZING LINE SET TO SERVICE VLVES, POINT FLME WY FROM SERVICE VLVE. SUCTION / VPOR LINE STURTED CLOTH 7 PREPRTION FOR NEXT STEP fter all connections have been brazed, disconnect manifold gauge set from service ports. pply saturated rags to both services valves to cool piping. Once piping is cool, remove all wet cloths. Refer to the unit installation instructions for the next step in preparing the unit. Figure 9. razing Procedures (continued) Page 11 TS*S4 SERIES

12 Flushing Line Set and Indoor Coil Flushing is only required if existing indoor coil and line set are to be used. Otherwise proceed to Installing Indoor Metering Device on page TYPICL EXISTING FIXED ORIFICE REMOVL PROCEDURE OR (UNCSED COIL SHOWN) DISTRIUTOR TUES LIQUID LINE ORIFICE HOUSING TEFLON RING FIXED ORIFICE 1 TYPICL EXISTING EXPNSION VLVE REMOVL PROCEDURE (UNCSED COIL SHOWN) TWO PIECE PTCH PLTE (UNCSED COIL ONLY) DISTRIUTOR TUES LIQUID LINE ORIFICE HOUSING STU END CHECK EXPNSION VLVE TEFLON RING RSS NUT TEFLON RING SENSING LINE DISTRIUTOR SSEMLY /10 REMOVE ND DISCRD WHITE TEFLON SEL (IF PRESENT) LIQUID LINE SSEMLY (INCLUDES STRINER) Page 12 DISTRIUTOR SSEMLY EQULIZER LINE LIQUID LINE SSEMLY WITH RSS NUT On fully cased coils, remove the coil access and plumbing panels. Remove any shipping clamps holding the liquid line and distributor assembly. MLE EQULIZER LINE FITTING C Using two wrenches, disconnect liquid line from liquid line orifice housing. Take care not to twist or damage distributor tubes during this pro- SENSING UL VPOR LINE LIQUID LINE cess. D Remove and discard fixed orifice, valve stem assembly if present and Teflon washer as illustrated above. On fully cased coils, remove the coil access and plumbing panels. Remove any shipping clamps holding the liquid line and distributor E Use a field provided fitting to temporary reconnect the liquid line to the indoor unit s liquid line orifice housing. C assembly. Disconnect the equalizer line from the check expansion valve equalizer line fitting on the vapor line. 2 CONNECT GUGES ND EQUIPMENT FOR D Remove the vapor line sensing bulb. FLUSHING PROCEDURE E Disconnect the liquid line from the check expansion valve at the liquid line assembly. INVERTED CYLINDER GUGE F Disconnect the check expansion valve from the liquid line orifice CONTINS CLEN TO MNIFOLD E USED FOR housing. Take care not to twist or damage distributor tubes during this FLUSHING. process. G Remove and discard check expansion valve and the two Teflon rings. 1 LOW HIGH H Use a field provided fitting to temporary reconnect the liquid line to the VPOR LINE NEW indoor unit s liquid line orifice housing. SERVICE VLVE OUTDOOR 3 UNIT FLUSHING LINE SET OPENED CLOSED The line set and indoor unit coil must be flushed with at least the EXISTING same amount of clean refrigerant that previously charged the INDOOR system. Check the charge in the flushing cylinder before UNIT proceeding. LIQUID LINE SERVICE VLVE D RECOVERY CYLINDER VPOR LIQUID C TNK RETURN INLET DISCHRGE RECOVERY MCHINE Inverted cylinder with clean refrigerant to the vapor service valve. gauge set (low side) to the liquid line valve. C gauge set center port to inlet on the recovery machine with an empty recovery tank to the gauge set. D Connect recovery tank to recovery machines per machine instructions. Figure 10. Removing Metering Device and Flushing C D 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. Invert the cylinder of clean and open its valve to allow liquid refrigerant to flow into the system through the vapor line valve. llow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine. fter all of the liquid refrigerant has been recovered, switch the recovery machine to vapor recovery so that all of the vapor is recovered. llow the recovery machine to pull down to 0 the system. Close the valve on the inverted drum and the gauge set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off.

13 Installing Indoor Metering Device This outdoor unit is designed for use in systems that use either an fixed orifice (RFC) (included with outdoor unit), or expansion valve metering device (purchased separately) at the indoor coil. See the Lennox TS*S4 Engineering Handbook for approved expansion valve kit match ups. The expansion valve unit can be installed internal or external to the indoor coil. In applications where an uncased coil is being installed in a field provided plenum, install the expansion valve in a manner that will provide access for field servicing of the expansion valve. Refer to below illustration for reference during installation of expansion valve unit.. fter installation of the indoor coil metering device, proceed to Leak Test Line Set and Indoor Coil on page 14. INDOOR EXPNSION VLVE INSTLLTION TWO PIECE PTCH PLTE (UNCSED COIL ONLY) DISTRIUTOR TUES DISTRIUTOR SSEMLY MLE EQULIZER LINE FITTING (SEE EQULIZER LINE INSTLLTION FOR FURTHER DETILS) (Uncased Coil Shown) LIQUID LINE ORIFICE HOUSING STU END TEFLON RING EQULIZER LINE EXPNSION VLVE VPOR LINE Sensing bulb insulation is required if mounted external to the coil casing. sensing bulb installation for bulb positioning. EQULIZER LINE INSTLLTION TEFLON RING LIQUID LINE SSEMLY WITH RSS NUT SENSING LINE Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right. Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right. LIQUID LINE C D E ttach the vapor line sensing bulb in the proper orientation as illustrated to the right using the clamp and screws provided. NOTE Confirm proper thermal contact between vapor line and expansion bulb before insulating the sensing bulb once installed. Remove the field provided fitting that temporary reconnected the liquid line to the indoor unit s distributor assembly. Install one of the provided Teflon rings around the stubbed end of the expansion valve and lightly lubricate the connector threads and expose surface of the Teflon ring with refrigerant oil. ttach the stubbed end of the expansion valve to the liquid line orifice housing. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above, or 20 ft lb. Place the remaining Teflon washer around the other end of the expansion valve. Lightly lubricate connector threads and expose surface of the Teflon ring with refrigerant oil. ttach the liquid line assembly to the expansion valve. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or 20 ft lb. SENSING UL INSTLLTION Connect the equalizer line from the expansion valve to the equalizer vapor port on the vapor line. Finger tighten the flare nut plus 1/8 turn (7 ft lbs) as illustrated below. VPOR LINE UL 12 UL 1/2 Turn ON LINES SMLLER THN 7/8", MOUNT SENSING UL T EITHER THE 3 OR 9 O CLOCK POSITION /8 Turn FLRE SEL CP OR FLRE NUT COPPER FLRE SEL ONNET VPOR LINE 12 ON 7/8" ND LRGER LINES, MOUNT SENSING UL T EITHER THE 4 OR 8 O CLOCK POSITION. NEVER MOUNT ON OTTOM OF LINE. MLE RSS EQULIZER LINE FITTING UL UL VPOR LINE NOTE NEVER MOUNT ON OTTOM OF LINE. Figure 11. Installing Indoor Expansion Valve Page 13 TS*S4 SERIES

14 The Environmental Protection gency (EP) prohibits the intentional venting of HFC refrigerants during maintenance, service, repair and disposal of appliance. pproved methods of recovery, recycling or reclaiming must be followed. 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 410 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. 1CONNECT GUGE SET Connect an HFC 410 manifold gauge set high pressure hose to the vapor valve service port. NOTE Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the vapor port better protects the manifold gauge set from high pressure damage. With both manifold valves closed, connect the cylinder of HFC 410 refrigerant to the center port of the manifold gauge set. NOTE Later in the procedure, the HFC 410 container will be replaced by the nitrogen container. Leak Test Line Set and Indoor Coil Leak detector must be capable of sensing HFC refrigerant. fter completing the leak testing the line set and indoor coil as outlined in figure 12, proceed to Evacuating Line Set and Indoor Coil on page 15. WRNING 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). WRNING 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. LOW HIGH MNIFOLD GUGE SET OUTDOOR UNIT TO VPOR SERVICE VLVE 2 TEST /10 FOR LEKS NITROGEN HFC 410 fter the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the following procedure to test for leaks: With both manifold valves closed, connect the cylinder of HFC 410 refrigerant to the center port of the manifold gauge set. Open the valve on the HFC 410 cylinder (vapor only). Open the high pressure side of the manifold to allow HFC 410 into the line set and indoor unit. Weigh in a trace amount of HFC 410. [ trace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kpa) pressure]. Close the valve on the HFC 410 cylinder and the valve on the high pressure side of the manifold gauge set. Disconnect the HFC 410 cylinder. C Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set. D E F djust 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. fter a few minutes, open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector. fter leak testing disconnect gauges from service ports. Figure 12. Leak Test Page 14

15 Evacuating Line Set and Indoor Coil 1 CONNECT GUGE SET NOTE Remove cores from service valves (if not already done). Connect low side of manifold gauge set with 1/4 SE in line tee to vapor line service valve Connect high side of manifold gauge OUTDOOR set to liquid line service valve UNIT C Connect micron gauge available connector on the 1/4 SE in line tee. D Connect the vacuum pump (with vacuum gauge) to the center port of the manifold gauge set. The center port line will be used later for both the HFC 410 and nitrogen containers. NITROGEN /4 SE TEE WITH SWIVEL COUPLER C 500 MICRON GUGE LOW MNIFOLD GUGE SET TO VPOR SERVICE VLVE HIGH HFC 410 VCUUM PUMP TO LIQUID LINE SERVICE VLVE 2EVCUTE THE SYSTEM RECOMMEND Open both manifold valves and start the vacuum pump. MINIMUM 3/8" HOSE 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. rapid rise in pressure indicates a relatively large leak. If this occurs, repeat the leak testing procedure. NOTE The term absolute pressure means the total actual pressure within a given volume or system, above the absolute zero of pressure. bsolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure. C When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), perform the following: D E F G Close manifold gauge valves Close valve on vacuum pump Turn off vacuum pump Disconnect manifold gauge center port hose from vacuum pump ttach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kpa) and purge the hose. Open manifold gauge valves to break the vacuum in the line set and indoor unit. Close manifold gauge valves. 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. 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. 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 410 refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit. Perform the following: Close manifold gauge valves. 1/6 TURN Shut off HFC 410 cylinder. Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core tool while maintaining a positive system pressure. Replace stem caps and secure finger tight, then tighten an additional one sixth (1/6) of a turn as illustrated. D Figure 13. Evacuating System Page 15 TS*S4 SERIES

16 Electrical In the U.S.., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC). Refer to the furnace or air handler installation instructions SIZE CIRCUIT ND INSTLL DISCONNECT SWITCH Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HCR per NEC). Install power wiring and properly sized disconnect switch. MIN FUSE OX/ REKER PNEL SERVICE DISCONNECT SWITCH for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size. 24VC TRNSFORMER Use the transformer provided with the furnace or air handler for low-voltage control power (24VC 40 V minimum) INSTLL THERMOSTT Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and 5 feet (1.5m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight or drafts. THERMOSTT 5 FEET (1.5M) NOTE Units are approved for use only with copper conductors. Ground unit at disconnect switch or to an earth ground. NOTE 24VC, Class II circuit connections are made in the control panel. WRNING Electric Shock Hazard. Can cause injury or death. Unit must be grounded in accordance with national and local codes. Line voltage is present at all components when unit is not in operation on units with single-pole contactors. Disconnect all remote electric power supplies before opening access panel. Unit may have multiple power supplies. Page /10

17 ROUTING HIGH VOLTGE/ GROUND ND CONTROL WIRING HIGH VOLTGE / GROUND WIRES ny excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring. To facilitate a conduit, a cutout is located in the bottom of the control panel. Connect conduit to the control panel using a proper conduit fitting. CONTROL WIRING Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated. Run 24VC control wires through hole with grommet and secure with provided wire tie. Make 24VC thermostat wire connections. Locate the two wires from the contactor and make connection GROUND using field provided wire nuts: Yellow to Y1 lack to C (common) NOTE For proper voltages, select thermostat wire (control wires) gauge per table below. NOTE Do not bundle any excess 24VC control wires inside control panel. TYPICL LOW VOLTGE FIELD WIRING THERMOSTT INDOOR UNIT HIGH VOLTGE CONNECTIONS (CONTCTOR) THREE PHSE HIGH VOLTGE FLEXILE CONDUIT CONTROL WIRING NOTE Wire tie provides low voltage control wire strain relief and to maintain separation of field installed low and high voltage circuits. GROMMET ND WIRE TIE HIGH VOLTGE FIELD WIRING LOW VOLTGE FIELD WIRING FCTORY WIRING R W1 POWER HET R W OUTDOOR UNIT HIGH VOLTGE CONNECTIONS (CONTCTOR) SINGLE PHSE CONTROL WIRING Y COOLING Y Y1 G C INDOOR LOWER COMMON G C C GROUND GROMMET ND WIRE TIE WIRE RUN LENGTH WG# INSULTION TYPE LESS THN 100 (30 METERS) 18 TEMPERTURE RTING MORE THN 100 (30 METERS) 16 35ºC MINIMUM. HIGH VOLTGE FLEXILE CONDUIT Page 17 TS*S4 SERIES

18 Figure 14. Typical Field Wiring Diagram M Voltage 380/420v (3PH) 50Hz Page /10

19 Figure 15. Typical Field Wiring Diagram T Voltage 220/240v (1PH) 50Hz Page 19 TS*S4 SERIES

20 Figure 16. Typical Factory Wiring Diagram Servicing Units Delivered Void of Charge If the outdoor unit is void of refrigerant, clean the system using the procedure described below. 1. Leak check system using procedure outlined in this installation instruction. 2. Evacuate the system using procedure outlined in this installation instruction. 3. Use nitrogen to break the vacuum and install a new filter drier in the system. 4. Evacuate the system again using procedure outlined in this installation instruction. 5. Weigh in refrigerant using procedure outlined in figure 20. Unit Start Up If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start up to prevent compressor damage as a result of slugging. 1. Check that fan rotates freely. 2. Inspect all factory and field installed wiring for loose connections. 3. fter evacuation is complete, open the liquid line and suction line service valves to release the refrigerant charge (contained in outdoor unit) into the system. 4. Replace the stem caps and tighten as specified in Operating Service Valves on page Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit s nameplate. If not, do not start the equipment until you have consulted with the power company and the voltage condition has been corrected. 6. Set the thermostat for a cooling demand. Turn on power to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit. 7. Recheck voltage while the unit is running. Power must be within range shown on the nameplate. 8. Check system for sufficient refrigerate by using the procedures listed under Start Up and Charging Procedures. System Refrigerant This section outlines procedures for: 1. Connecting gauge set for testing and charging; 2. Checking and adjusting indoor airflow; 3. dding or removing refrigerant. Page /10

21 GUGE SET CONNECTIONS FOR TESTING ND CHRGING MNIFOLD GUGE SET LOW HIGH Close manifold gauge set valves and connect the center hose to a cylinder of HFC 410. Set for liquid phase charging. Connect the manifold gauge set s low pressure side to the suction line service port. CConnect the manifold gauge set s high pressure side to the liquid line service port. DPosition temperature sensor on liquid line near liquid line service port. SUCTION LINE SERVICE PORT CONNECTION D CHRGE IN LIQUID PHSE TEMPERTURE SENSOR REFRIGERNT TNK DIGITL SCLE C TO LIQUID LINE SERVICE VLVE TEMPERTURE SENSOR (LIQUID LINE) OUTDOOR UNIT Figure 17. Gauge Set Setup and Connections STRT: Determine how refrigerant is metered WHEN TO CHRGE? Warm weather best Can charge in colder weather TXV CHRGE METHOD? Determine by: Metering device type Outdoor ambient temperature OUTDOOR MIENT REQUIREMENTS: TEMPERTURE Sufficient heat load in structure 65ºF (18.3ºC) 64ºF (17.7ºC) Indoor temperature between 70-80ºF (21 26ºC) ND OVE ND ELOW Manifold gauge set connected to unit Thermometers: to measure outdoor ambient temperature to measure liquid line temperature to measure suction line temperature SUCOOLING WEIGH-IN Figure 18. Determining Charge Method Page 21 TS*S4 SERIES

22 CHECKING IR FLOW T INDOOR COIL Check airflow using the Delta T (DT) process using the illustration in figure 19. Temp. of air entering indoor coil ºF DT Wet bulb ºF C 53º DRY UL Dry bulb T Drop 19º air flow ll temperatures are expressed in ºF air flow INDOOR COIL 64º WET UL 72º DRY UL 1. Determine the desired DTMeasure entering air temperature using dry bulb () and wet bulb (). DT is the intersecting value of and in the table (see triangle). 2. Find temperature drop across coilmeasure the coil s dry bulb entering and leaving air temperatures ( and C). Temperature Drop Formula: (T Drop ) = minus C. 3. Determine if fan needs adjustmentif the difference between the measured T Drop and the desired DT (T Drop DT) is within +3º, no adjustment is needed. See examples: ssume DT = 15 and temp. = 72º, these C temperatures would necessitate stated actions: Cº T Drop DT = ºF CTION 53º = 4 Increase the airflow 58º = 1 (within +3º range) no change 62º = 5 Decrease the airflow 4. djust the fan speedsee 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. Figure 19. Checking Indoor irflow over Evaporator Coil using Delta T Chart STRT: Measure outdoor ambient temperature 64ºF (17.7ºC) and ELOW USE SUCOOLING METHOD 65ºF (18.3ºC) and OVE OVE or ELOW 1. Check Liquid and suction line pressures 2. Compare unit pressures with table 5 or Conduct leak check; evacuate as previously outlined. 4. Weigh in the unit nameplate charge plus any charge required for line set differences over feet. Refrigerant Charge per Line Set Length Liquid Line g per 1.5 m) adjust from 4.6 m line set* Set Diameter 9.5 mm 85 g per 1.5 m) NOTE *If line length is greater than 4.6 m, add this amount. If line length is less than 4.6 m, subtract this amount. This nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information. Figure 20. HFC 410 Weigh In Page /10

23 STRT: Measure outdoor ambient temperature USE DO WEIGH-IN NOT CHRGE METHOD UNIT Weigh-in (Results or of remove charging refrigerant at low based temperatures upon line set not length reliable) 64ºF (17.7ºC) and ELOW OVE or ELOW LOCK OUTDOOR COIL: [sometimes necessary with lower temperatures] Use cardboard or plastic sheet to restrict the airflow through the outdoor coil to achieve pressures from psig ( kpa). Higher pressures are needed to check charge. lock equal sections of air intake panels and move coverings sideways until the liquid pressure is in the above noted ranges. If value is MORE than shown, remove refrigerant. 65ºF (18.3ºC) and OVE 1. Confirm proper airflow across coil using figure Compare unit pressures with table 5 or 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. llow temperatures and pressures to stabilize. NOTE If necessary, block outdoor coil to maintain psig. 8. Record liquid line temperature: LIQº = 9. Measure liquid line pressure and use the value to determine saturation temperature (see table 7): If value is LESS than shown, add refrigerant. MORE or LESS STº = 10. Subtract to determine subcooling (SCº): STº LIQº = SCº 11. Compare results with tables 3 or 4. Table 3. Subcooling (SC) Values TXV System ºF (ºC) +1ºF (0.5ºC) (1 PHSE) TS*S4 50Hz International (1 Phase) F(C) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43) (45) Figure 21. HFC 410 Subcooling Charge Table 4. Subcooling (SC) Values TXV System ºF (ºC) +1ºF (0.5ºC) (3 PHSE) TS*S4 50Hz International (3 Phase) F(C) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43) (45) Page 23 TS*S4 SERIES