Dallas, Texas, USA T-Class · 2020. 8. 13. · See the Lennox TSA*S4 Engineering Handbook for approved indoor component matchups. This outdoor unit is designed for use in thermal

©2014 Lennox Industries Inc.Dallas, Texas, USA

RETAIN THESE INSTRUCTIONSFOR FUTURE REFERENCE

These instructions are intended as a general guide and donot supersede local codes in any way. Consult authoritieshaving jurisdiction before installation.

WARNINGImproper installation, adjustment, alteration, service ormaintenance can cause personal injury, loss of life, ordamage to property.

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

IMPORTANTThe Clean Air Act of 1990 bans the intentional venting ofrefrigerant (CFCs, HCFCs AND HFCs) as of July 1,1992. Approved methods of recovery, recycling orreclaiming must be followed. Fines and/or incarcerationmay be levied for noncompliance.

IMPORTANTThis 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 INSTALLERUNIT PLACEMENT

It is critical for proper unit operation to place outdoor unit on anelevated surface as described in Unit Placement section on page 6.

BRAZING LINE SET TO SERVICE VALVES

It is imperative to follow the brazing technique illustrated starting onpage 9 to avoid damaging the service valve's internal seals.

INSTALLATIONINSTRUCTIONS

T-Class� TSA*S4 UnitsM and T Voltages

AIR CONDITIONER506663-01 8/2014Supersedes 11/2010

TABLE OF CONTENTS

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

Outdoor Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Typical Unit Parts Arrangement 2. . . . . . . . . . . . . . . . . . .

Model Number Identification 3. . . . . . . . . . . . . . . . . . . . . .

General Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Gauge Set and Service Valves 3. . . . . . . . . . .

Recovering Refrigerant from Existing System 5. . . . . . .

New Outdoor Unit Placement 6. . . . . . . . . . . . . . . . . . . . .

New or Replacement Line Set 7. . . . . . . . . . . . . . . . . . . . .

Brazing Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Line Set and Indoor Coil 12. . . . . . . . . . . . . . . .

Installing Indoor Metering Device 13. . . . . . . . . . . . . . . .

Leak Test Line Set and Indoor Coil 14. . . . . . . . . . . . . . .

Evacuating Line Set and Indoor Coil 15. . . . . . . . . . . . .

Electrical Connections 16. . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Unit Delivered Void of Charge 20. . . . . . . . . . .

Unit Start-Up 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Refrigerant 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-Up and Performance Checklist 27. . . . . . . . . . . . . .

Shipping and Packing List

Check the unit for shipping damage and listed times beloware intact. If damaged, or if parts are missing, immediatelycontact the last shipping carrier.

1 — Assembled outdoor unit

1 — Liquid line filter drier

Outdoor Unit

This outdoor unit is designed for use with HFC-410Arefrigerant only. This unit must be installed with anapproved indoor air handler or coil. See the LennoxTSA*S4 Engineering Handbook for approved indoorcomponent matchups.

This outdoor unit is designed for use in thermal expansionvalve (TXV) systems only.

Litho U.S.A.

506663-01 11/10

Unit Dimensions - Inches (mm)

SUCTION AND LIQUID LINECONNECTIONS

SIDE VIEW

OUTDOOR COIL FAN

A

B

A

OPTIONAL UNIT STAND‐OFF KIT(4) (FIELD-INSTALLED)

Discharge Air

SIDE VIEW

COMPRESSOR

Model Number A B

TSA024S4N41T 24-1/4 (616) 25-1/4 (641)

TSA030S4N41T 24-1/4 (616) 29-1/4 (743)

TSA036S4N41M 24-1/4 (616) 29-1/4 (743)

TSA036S4N41T 28-1/4 (718) 29-1/4 (743)

TSA048S4N41T and M 28-1/4 (718) 37-1/4 (946)

TSA060S4N41T and M 28-1/4 (718) 33-1/4 (845)

Typical Unit Parts Arrangement

GROUND LUG

CONTROL

CUTOUT FOR HIGHVOLTAGE CONDUIT

OR

CONTACTOR (K1)LOCATION

LIQUID LINESERVICE VALVE

SUCTION LINESERVICE VALVE

HIGH PRESSURESWITCH (S4)

NOTE: PLUMBING LAYOUT MAYVARY SLIGHTLY BETWEEN

MODEL SIZES.

CRANKCASE HEATERTHERMOSTAT (S40)

DUAL RUN CAPACITOR(C12) (T-VOLTAGE)

SINGLE RUN CAPACITOR(C12) (M-VOLTAGE)

ONE POLE(T-VOLTAGE)

TWO-POLE(M-VOLTAGE)

Figure 1. Typical Unit Parts Arrangement

TSA*S4 SERIES

Model Number Identification

T S A M1036 S 44 N

Major Design SequenceA = 1st Generation

B = 2nd Generation

Brand/FamilyT = T-Class� Product Line

Unit TypeS = Split-System Air Conditioner

024 = 2 Tons030 = 2.5 Tons0036 = 3 Tons

048 = 4 Tons060 = 5Tons

Cooling EfficiencyS = Standard Efficiency

Minor Design Sequence

1 = 1st Revision2 = 2nd Revision3 = 3rd Revision

VoltageM = 380/420V-3 phase 50hzT = 220/240V-1 phase 50hz

Refrigerant Type4 = R-410A

Part Load CapabilityN = No part load, single stage compressor

Coil Type4 = Four-sided

IMPORTANTThis model is designed for use in expansion valvesystems only. An indoor expansion valve approved foruse with HFC-410A refrigerant must be orderedseparately, and installed prior to operating the system.

CAUTIONPhysical contact with metal edges and corners whileapplying excessive force or rapid motion can result inpersonal injury. Be aware of, and use caution whenworking near these areas during installation or whileservicing this equipment.

General Information

These instructions are intended as a general guide and donot 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 donot supersede local codes in any way. Consult authoritieswho have jurisdiction before installation.

TORQUE REQUIREMENTS

When servicing or repairing heating, ventilating, and airconditioning components, ensure the fasteners areappropriately tightened. Table 1 lists torque values forfasteners.

IMPORTANTOnly use Allen wrenches of sufficient hardness (50Rc -Rockwell Harness Scale minimum). Fully insert thewrench into the valve stem recess.

Service valve stems are factory-torqued (from 9 ft-lbs forsmall valves, to 25 ft-lbs for large valves) to preventrefrigerant loss during shipping and handling. Using anAllen wrench rated at less than 50Rc risks rounding orbreaking off the wrench, or stripping the valve stemrecess.

See the Lennox Service and Application Notes #C-08-1for further details and information.

IMPORTANTTo prevent stripping of the various caps used, theappropriately sized wrench should be used and fittedsnugly over the cap before tightening.

When servicing or repairing HVAC components, ensurethe fasteners are appropriately tightened. Table 1 providestorque 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 MANIFOLD GAUGE SET

When checking the system charge, only use a manifoldgauge set that features low loss anti-blow back fittings.

506663-01 11/10

Manifold gauge set used with HFC-410A refrigerantsystems must be capable of handling the higher systemoperating pressures. The gauges should be rated for usewith pressures of 0 - 800 psig on the high side and a lowside of 30” vacuum to 250 psig with dampened speed to500 psi. Gauge hoses must be rated for use at up to 800psig of pressure with a 4000 psig burst rating.

OPERATING SERVICE VALVESThe liquid and vapor line service valves are used forremoving refrigerant, flushing, leak testing, evacuating,checking charge and charging.

Each valve is equipped with a service port which has afactory-installed valve stem. Figure 2 provides informationon how to access and operating both angle and ball servicevalves.

(VALVE STEM SHOWNCLOSED) INSERT HEXWRENCH HERE

SERVICE PORT CORE

SERVICE PORT CAP

ANGLE-TYPE SERVICE VALVE(FRONT-SEATED CLOSED)

SERVICE PORTCORE

TO OUTDOOR UNIT

STEM CAP

(VALVE STEM SHOWN OPEN)INSERT HEX WRENCH HERE

TO INDOORUNIT

ANGLE-TYPE SERVICE VALVE(BACK-SEATED OPENED)

BALL (SHOWNCLOSED)

SERVICE PORTCORE

TO INDOOR UNIT

TO OUTDOORUNIT

TO OPEN ROTATE STEMCOUNTERCLOCKWISE 90°.

TO CLOSE ROTATE STEMCLOCKWISE 90°.

SERVICE PORT

SERVICE PORTCAP

STEM CAP

VALVESTEM

Operating Angle 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 backthe stem out counterclockwise as far as it will go.

Operating Ball 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 stemclockwise 90°.

123

4567

8910

11 12

1/12 TURN

To Access Service Port:

A service port cap protects the service port core from contamination andserves 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 asfollows:

� With torque wrench: Finger tighten andtorque cap per table 1.

� Without torque wrench: Finger tighten anduse an appropriately sized wrench to turnan additional 1/6 turn clockwise.

123

4567

8910

11 12

1/6 TURN

WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPENTO THE LINE SET AND INDOOR UNIT.

When service valve is OPEN, the service port isopen to linE set, indoor and outdoor unit.

Reinstall Stem Cap:

Stem cap protects the valve stem from damage and serves as theprimary seal. Replace the stem cap and tighten as follows:

� With Torque Wrench: Finger tighten andthen torque cap per table 1.

� Without Torque Wrench: Finger tighten and use an appropriately sizedwrench to turn an additional 1/12 turnclockwise.

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

Figure 2. Angle and Ball Service Valves

TSA*S4 SERIES

Recovering Refrigerant from Existing System

SERVICEDISCONNECT

SWITCH

Disconnect all power to the existing outdoor unit at the servicedisconnect switch or main fuse box/breaker panel.

DISCONNECT POWER CONNECT MANIFOLD GAUGE SET

MANIFOLD GAUGES

RECOVERY MACHINE

CLEAN RECOVERYCYLINDER

OUTDOOR UNIT

HIGHLOW

Connect a gauge set, clean recovery cylinder and a recoverymachine to the service ports of the existing unit. Use theinstructions provided with the recovery machine to make theconnections.

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 toflush 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 meetsa 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 andinternal 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:

A Start the existing system in the cooling mode and close the liquid line valve.

B 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 unitmain 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.

RECOVERINGREFRIGERANT FROM SYSTEM

Remove existing refrigerant using one of the following procedures:

RECOVERING REFRIGERANT

IMPORTANT — Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes,and/or long line sets.

1 2

3

Figure 3. Refrigerant Recovery

506663-01 11/10

6 (152)

36 (914)

12 (305)30 (762)

LINE SETCONNECTIONS

24 (610)

48 (1219)

MINIMUM CLEARANCE BETWEENTWO UNITS

CLEARANCE ON ALL SIDES — INCHES (MILLIMETERS)

ACCESS PANEL

MINIMUM CLEARANCEABOVE UNIT

NOTES:

� Clearance to one of the other threesides must be 36 inches (914mm).

� Clearance to one of the remainingtwo sides may be 12 inches(305mm) and the final side may be6 inches (152mm).

Figure 4. Installation Clearances

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 buildingstructure.

DETAIL A DETAIL B

DISCHARGE AIR

MOUNTING SLAB MUST SLOPEAWAY FROM BUILDING.

GROUND LEVEL

STRUCTUREInstall unit awayfrom windows .

Two 90° elbows installed in line set willreduce line set vibration.

Figure 5. Placement, and Slab Mounting

New Outdoor Unit Placement

See Unit Dimensions on page 2 for sizing mounting slab,platforms or supports. Refer to figure 4 for mandatoryinstallation clearance requirements.

POSITIONING CONSIDERATIONS

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

Consider the following when positioning the unit:

� Some localities are adopting sound ordinances basedon the unit's sound level registered from the adjacent

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

� When possible, do not install the unit directly outsidea window. Glass has a very high level of sound

transmission. For proper placement of unit in relationto a window see the provided illustration in figure 5.

TSA*S4 SERIES

PLACING OUTDOOR UNIT ON SLAB

When installing a unit at grade level, the top of the slabshould be high enough above the grade so that water fromhigher ground would not collect around the unit asillustrated in figure 5.

Slab may be level or have a slope tolerance away from thebuilding of not more than two degrees, or 2 inches per 5feet (51 mm per 1524 mm) as illustrated in figure 5.

Slab may be level or have a slope tolerance away from thebuilding of not more than two degrees, or 2 inches per 5feet (51 mm per 1524 mm) as illustrated in figure 5.

INSTALLING OUTDOOR UNIT ON ROOF

Install the unit at a minimum of 4 inches (102 mm) abovethe surface of the roof. Ensure the weight of the unit isproperly distributed over roof joists and rafters. Redwoodor 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 replacementline set is not required, then proceed to BrazingConnections on page 9.

If refrigerant lines are routed through a wall, seal andisolate the opening so vibration is not transmitted to thebuilding. Pay close attention to line set isolation during

installation of any HVAC system. When properly isolatedfrom building structures (walls, ceilings. floors), therefrigerant lines will not create unnecessary vibration andsubsequent sounds.

Also, consider the following when placing and installing ahigh-efficiency air conditioner:

REFRIGERANT LINE SET

Field refrigerant piping consists of liquid and suction lines

from the outdoor unit (braze connections) to the indoor unitcoil (flare or braze connections). Use Lennox L15 (braze,non-flare) series line set, or use field-fabricated refrigerantlines as listed in table 2.

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*S4) and size of unit (e.g. -060).

� Line set diameters for the unit being installed as listedin table 2 and total length of installation.

� Number of elbows and if there is a rise or drop of thepiping.

IMPORTANTMineral oils are not compatible with HFC-410A. If oilmust be added, it must be a Polyol ester oil.

The compressor is charged with sufficient Polyol ester oilfor line set lengths up to 50 feet. Recommend adding oil tosystem based on the amount of refrigerant charge in thesystem. No need to add oil in system with 20 pounds ofrefrigerant or less. For systems over 20 pounds - add oneounce of every five pounds of refrigerant.

Recommended topping-off POE oils are Mobil EALARCTIC 22 CC or ICI EMKARATE� RL32CF.

MATCHING WITH NEW OR EXISTING INDOOR COILAND LINE SET

The RFC1-metering line consisted of a small bore copperline that ran from condenser to evaporator coil. Refrigerantwas metered into the evaporator by utilizingtemperature/pressure evaporation effects on refrigerant inthe small RFC line. The length and bore of the RFC linecorresponded to the size of cooling unit.

If the TSA*S4 is being used with either a new or existingindoor coil which is equipped with a liquid line which servedas a metering device (RFCI), the liquid line must bereplaced prior to the installation of the TSA*S4 unit.Typically a liquid line used to meter flow is 1/4” in diameterand copper.

LIQUID LINE FILTER DRIER INSTALLATION

The filter drier (one is shipped with each TSA*S4 unit) mustbe field installed in the liquid line between the outdoor unit'sliquid line service valve and the indoor coil's meteringdevice (fixed orifice or TXV) as illustrated in figure 6. Thisfilter drier must be installed to ensure a clean,moisture-free system. Failure to install the filter drier willvoid the warranty. A replacement filter drier is availablefrom Lennox. See Brazing Connections on page 9 forspecial procedures on brazing filter drier connections tothe liquid line.

OUTDOORUNIT

LIQUID LINESERVICE VALVE

LIQUID LINEFILTER DRIER

LINELIQUIDLINE

BRAZE CONNECTION POINTS

Figure 6. Typical Liquid Line Filter Drier Installation

506663-01 11/10

Table 2. Refrigerant Line Set — Inches (mm)

ModelField Connections Recommended Line Set

Liquid Line Vapor Line Liquid Line Vapor Line L15 Line Sets

TSA024S4N4 3/8 in. (10 mm) 3/4 in. (19 mm) 3/8 in. (10 mm) 3/4 in. (19 mm) L15-41 — 15 ft. - 50 ft. (4.6 m - 15 m)

TSA036S4N43/8 in. (10 mm) 7/8 in. (22 mm) 3/8 in. (10 mm) 7/8 in. (22 mm) L15-65 — 15 ft. - 50 ft. (4.6 m - 15 m)

TSA048S4N4

TSA060S4N4 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

ANCHORED HEAVY NYLONWIRE TIE OR AUTOMOTIVE

MUFFLER‐TYPE HANGER

STRAP LIQUID LINE TOVAPOR LINE

WALLSTUD

LIQUID LINE

NON-CORROSIVEMETAL SLEEVE

VAPOR LINE - WRAPPEDIN ARMAFLEX

AUTOMOTIVEMUFFLER‐TYPE HANGER

REFRIGERANT LINE SET — TRANSITIONFROM VERTICAL TO HORIZONTAL

Line Set Isolation — The following illustrations areexamples of proper refrigerant line set isolation:

STRAPPINGMATERIAL (AROUND

VAPOR LINE ONLY)

TAPE ORWIRE TIE

WIRE TIE (AROUNDVAPOR LINE ONLY)

FLOOR JOIST ORROOF RAFTER

TAPE ORWIRE TIE

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

8 FEET (2.43 METERS)

STRAP THE VAPOR LINE TO THE JOISTOR RAFTER AT 8 FEET (2.43 METERS)INTERVALS THEN STRAP THE LIQUIDLINE TO THE VAPOR LINE.

FLOOR JOIST OR

ROOF RAFTER

REFRIGERANT LINE SET — INSTALLING HORIZONTAL RUNS

NOTE — Similar installation practices should be used if line set isto be installed on exterior of outside wall.

PVCPIPE

FIBERGLASSINSULATION

CAULK

OUTSIDEWALL

VAPOR LINE WRAPPEDWITH ARMAFLEX

LIQUIDLINE

OUTSIDE WALL LIQUID LINEVAPOR LINE

WOOD BLOCKBETWEEN STUDS

STRAP

WOOD BLOCK

STRAP

SLEEVE

WIRE TIE

WIRE TIE

WIRE TIE

INSIDE WALL

REFRIGERANT LINE SET — INSTALLINGVERTICAL RUNS (NEW CONSTRUCTION SHOWN)

INSTALLATION

NOTE — Insulate liquid line when it is routed through areas where thesurrounding ambient temperature could become higher than thetemperature of the liquid line or when pressure drop is equal to or greaterthan 20 psig.


IMPORTANT — Refrigerant lines must not contact structure.


8 FEET (2.43 METERS)

IMPORTANT — Refrigerant lines must not contact wall

Figure 7. Line Set Installation

TSA*S4 SERIES

IMPORTANTIf this unit is being matched with an approved line setor indoor unit coil which was previously charged withmineral oil, or if it is being matched with a coil whichwas manufactured before January of 1999, the coiland line set must be flushed prior to installation. Takecare to empty all existing traps. Polyol ester (POE) oilsare used in Lennox units charged with HFC-410Arefrigerant. Residual mineral oil can act as aninsulator, preventing proper heat transfer. It can alsoclog the expansion device, and reduce the systemperformance and capacity.Failure to properly flush the system per theinstructions below will void the warranty.

Brazing Connections

Use the procedures outline in figures 8 and 9 for brazingline set connections to service valves.

IMPORTANTPolyol ester (POE) oils used with HFC-410Arefrigerant absorb moisture very quickly. It is veryimportant that the refrigerant system be kept closedas much as possible. DO NOT remove line set capsor service valve stub caps until you are ready to makeconnections.

WARNINGDanger of fire. Bleeding the refrigerantcharge from only the high side may resultin pressurization of the low side shell andsuction tubing. Application of a brazingtorch to a pressurized system may resultin ignition of the refrigerant and oilmixture - Check the high and lowpressures before applying heat.

WARNINGWhen using a high pressure gas such asdry nitrogen to pressurize a refrigerationor air conditioning system, use aregulator that can control the pressuredown to 1 or 2 psig (6.9 to 13.8 kPa).

CAUTIONBrazing alloys and flux contain materials which arehazardous to your health.

Avoid breathing vapors or fumes from brazingoperations. Perform operations only in well-ventilatedareas.

Wear gloves and protective goggles or face shield toprotect against burns.

Wash hands with soap and water after handling brazingalloys and flux.

IMPORTANTConnect gauge set low pressure side to vapor lineservice valve and repeat procedure starting atparagraph 4 for brazing the liquid line to service portvalve.

IMPORTANTAllow braze joint to cool before removing the wet ragfrom the service valve. Temperatures above 250ºF candamage valve seals.

IMPORTANTUse silver alloy brazing rods with 5% minimum silveralloy for copper-to-copper brazing. Use 45% minimumalloy for copper-to-brass and copper-to-steel brazing.

WARNINGFire, Explosion and Personal SafetyHazard.

Failure to follow this warning couldresult in damage, personal injury ordeath.

Never use oxygen to pressurize orpurge refrigeration lines. Oxygen,when exposed to a spark or openflame, can cause fire and/or an explosion, that could result in propertydamage, personal injury or death.

506663-01 11/10

ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICEVALVES

OUTDOORUNIT

LIQUID LINE

VAPOR LINE

LIQUID LINE SERVICEVALVE

SUCTION /VAPOR LINE

SERVICEVALVE

ATTACHGAUGES

INDOORUNIT

SUCTION / VAPOR SERVICE PORT MUST BEOPEN TO ALLOW EXIT POINT FOR NITROGEN

A Connect gauge set low pressure side toliquid line service valve (service port).

B Connect gauge set center port to bottle ofnitrogen with regulator.

C Remove Schrader valve in suction / vaporline service port to allow nitrogen to escape.

NITROGEN

HIGHLOWUSE REGULATOR TO FLOWNITROGEN AT 1 TO 2 PSIG.

B

A

C

WHEN BRAZING LINE SET TOSERVICE VALVES, POINT FLAME

AWAY FROM SERVICE VALVE.

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.

CUT AND DEBUR CAP AND CORE REMOVAL

Cut ends of the refrigerant lines square (free from nicks or dents)and debur the ends. The pipe must remain round. Do not crimp endof the line.

Remove service cap and core from both thevapor and liquid line service ports.1 2


SERVICEPORTCORE

SERVICE PORTCAP

SERVICEPORTCORE

SERVICEPORT CAP

CUT AND DEBUR

LINE SET SIZE MATCHESSERVICE VALVE CONNECTION

COPPER TUBESTUB

SERVICE VALVECONNECTION

REFRIGERANT LINE

DO NOT CRIMP SERVICE VALVECONNECTOR WHEN PIPE IS

SMALLER THAN CONNECTION

REDUCER

3

SUCTION / VAPOR LINESERVICE VALVE

LINE SET SIZE IS SMALLERTHAN CONNECTION

Figure 8. Brazing Procedures

TSA*S4 SERIES



LIQUID LINE SERVICE VALVE

LIQUID LINE

BRAZE LINE SET

Wrap both service valves with a saturated cloth as illustrated here before brazing to line set.

SATURATED CLOTH

IMPORTANT — Allow braze joint to cool. Applyadditional saturated cloths to help cool brazed joint.Do not remove wet rag until piping has cooled.Temperatures above 250ºF will damage valve seals.

6

SUCTION / VAPOR LINE

SATURATED CLOTH

SUCTION / VAPOR LINESERVICE VALVE

After all connections have been brazed, disconnect manifold gauge set from service ports. Apply saturated rags to both services valves to coolpiping. Once piping is cool, remove all wet cloths. Refer to the unit installation instructions for the next step in preparing the unit.



PREPARATION FOR NEXT STEP7

WARNING

1. FIRE, PERSONAL INJURY, OR PROPERTYDAMAGE will result if you do not wrap a wet clotharound both liquid and suction line service valvebodies and copper tube stub while brazing in the lineset! The braze, when complete, must be quenchedwith water to absorb any residual heat.

2. Do not open service valves until refrigerant lines andindoor coil have been leak-tested and evacuated.Refer to procedures provided in this supplement.

WRAP SERVICE VALVES

To help protect service valve seals during brazing, wrap a saturated cloth around service valve bodies and copper tube stub. Use anothersaturated cloth underneath the valve body to protect the base paint.

4FLOW 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 andout of the suction / vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set connections

5

Figure 9. Brazing Procedures (continued)

506663-01 11/10

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 MeteringDevice on page 13.

SENSINGLINE

TEFLON® RING

FIXED ORIFICE

BRASS NUT

LIQUID LINE ASSEMBLY(INCLUDES STRAINER)

LIQUID LINE ORIFICE HOUSING

DISTRIBUTOR TUBES

DISTRIBUTORASSEMBLY

REMOVE AND DISCARD

WHITE TEFLON® SEAL(IF PRESENT)

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

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

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

D Remove and discard fixed orifice, valve stem assembly if present andTeflon® washer as illustrated above.

E Use a field-provided fitting to temporary reconnect the liquid line to theindoor unit's liquid line orifice housing.

TYPICAL EXISTING FIXED ORIFICEREMOVAL PROCEDURE(UNCASED COIL SHOWN)

TYPICAL EXISTING EXPANSION VALVEREMOVAL PROCEDURE (UNCASED COILSHOWN)

TWO PIECE PATCH PLATE(UNCASED COIL ONLY)

VAPORLINE

DISTRIBUTORASSEMBLY

DISTRIBUTORTUBES

LIQUIDLINE

MALE EQUALIZERLINE FITTING

EQUALIZERLINE

CHECKEXPANSION

VALVE

TEFLON®

RING

STUB END

TEFLON®

RING

SENSING BULB

LIQUID LINEORIFICE

HOUSING

LIQUID LINEASSEMBLY WITH

BRASS NUT

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

B Remove any shipping clamps holding the liquid line and distributorassembly.

C Disconnect the equalizer line from the check expansion valveequalizer line fitting on the vapor line.

D Remove the vapor line sensing bulb.

E Disconnect the liquid line from the check expansion valve at the liquidline assembly.

F Disconnect the check expansion valve from the liquid line orificehousing. Take care not to twist or damage distributor tubes during thisprocess.

G Remove and discard check expansion valve and the two Teflon® rings.

H Use a field-provided fitting to temporary reconnect the liquid line to theindoor unit's liquid line orifice housing.

LOW HIGH

EXISTINGINDOOR

UNIT

GAUGEMANIFOLD

INVERTED CYLINDERCONTAINS CLEAN TOBE USED FORFLUSHING.


INLET

DISCHARGE

TANKRETURN

CLOSEDOPENED

RECOVERYCYLINDER

RECOVERY MACHINE

NEWOUTDOOR

UNIT

VAPOR LINESERVICE VALVE

VA

PO

R

LIQ

UID

1

A Inverted cylinder with clean refrigerant to the vapor service valve.

B gauge set (low side) to the liquid line valve.

C gauge set center port to inlet on the recovery machine with an emptyrecovery tank to the gauge set.

D Connect recovery tank to recovery machines per machine instructions.

CONNECT GAUGES AND EQUIPMENT FORFLUSHING PROCEDURE

A

B

CD

B

OR

FLUSHING LINE SET

A Set the recovery machine for liquid recovery and start therecovery machine. Open the gauge set valves to allow therecovery machine to pull a vacuum on the existing system lineset and indoor unit coil.

B Invert the cylinder of clean and open its valve to allow liquidrefrigerant to flow into the system through the vapor line valve.Allow the refrigerant to pass from the cylinder and through theline set and the indoor unit coil before it enters the recoverymachine.

C After all of the liquid refrigerant has been recovered, switch therecovery machine to vapor recovery so that all of the vapor isrecovered. Allow the recovery machine to pull down to 0 thesystem.

D Close the valve on the inverted drum and the gauge set valves.Pump the remaining refrigerant out of the recovery machine andturn the machine off.

The line set and indoor unit coil must be flushed with at least thesame amount of clean refrigerant that previously charged thesystem. Check the charge in the flushing cylinder beforeproceeding.

1A

2

3

1B

Figure 10. Removing Metering Device and Flushing

TSA*S4 SERIES

Installing Indoor Metering Device

This outdoor unit is designed for use in systems that useeither an fixed orifice (RFC) (included with outdoor unit), orexpansion valve metering device (purchased separately)at the indoor coil.

See the Lennox TSA*S4 Engineering Handbook forapproved expansion valve kit match ups. The expansionvalve unit can be installed internal or external to the indoor

coil. In applications where an uncased coil is beinginstalled in a field-provided plenum, install the expansionvalve in a manner that will provide access for field servicingof the expansion valve. Refer to below illustration forreference during installation of expansion valve unit. .

After installation of the indoor coil metering device,proceed to Leak Test Line Set and Indoor Coil on page 14.

A Attach the vapor line sensing bulb in the properorientation as illustrated to the right using the clamp andscrews provided.

NOTE — Confirm proper thermal contact between vapor lineand expansion bulb before insulating the sensing bulb onceinstalled.

B Connect the equalizer line from the expansion valve tothe equalizer vapor port on the vapor line. Finger tightenthe flare nut plus 1/8 turn (7 ft-lbs) as illustrated below.

TWO PIECEPATCH PLATE

(UNCASEDCOIL ONLY)

VAPORLINE

LIQUID LINEORIFICE

HOUSINGDISTRIBUTOR

TUBES

LIQUID LINE

MALE EQUALIZER LINEFITTING (SEE

EQUALIZER LINEINSTALLATION FORFURTHER DETAILS)

SENSINGLINE

EQUALIZERLINE

EXPANSIONVALVE

TEFLON®

RING

(Uncased Coil Shown)

Sensing bulb insulation is required ifmounted external to the coil casing. sensingbulb installation for bulb positioning.

STUBEND

TEFLON®

RING

LIQUID LINEASSEMBLY WITH

BRASS NUT

DISTRIBUTORASSEMBLY

A Remove the field-provided fitting that temporaryreconnected the liquid line to the indoor unit's distributorassembly.

B Install one of the provided Teflon® rings around thestubbed end of the expansion valve and lightly lubricatethe connector threads and expose surface of the Teflon®

ring with refrigerant oil.

C Attach the stubbed end of the expansion valve to theliquid line orifice housing. Finger tighten and use anappropriately sized wrench to turn an additional 1/2 turnclockwise as illustrated in the figure above, or 20 ft-lb.

D Place the remaining Teflon® washer around the otherend of the expansion valve. Lightly lubricate connectorthreads and expose surface of the Teflon® ring withrefrigerant oil.

E Attach the liquid line assembly to the expansion valve.Finger tighten and use an appropriately sized wrench toturn an additional 1/2 turn clockwise as illustrated in thefigure above or 20 ft-lb.

ON 7/8” AND LARGER LINES,MOUNT SENSING BULB ATEITHER THE 4 OR 8 O'CLOCKPOSITION. NEVER MOUNT ONBOTTOM OF LINE.

12

ON LINES SMALLER THAN7/8”, MOUNT SENSINGBULB AT EITHER THE 3 OR9 O'CLOCK POSITION.

12

BULB

VAPOR LINE

VAPOR LINE

NOTE — NEVER MOUNT ON BOTTOM OF LINE.

BULB

BULBBULB

VAPOR LINE

FLARE NUT

COPPER FLARESEAL BONNET

MALE BRASS EQUALIZERLINE FITTING

FLARE SEAL CAP

OR

123

4567

8910

11 12

1/2 Turn

SENSING BULB INSTALLATION

EQUALIZER LINE INSTALLATION

123

4567

8910

11 12

1/8 Turn

A Remove and discard either the flare seal cap or flare nutwith copper flare seal bonnet from the equalizer line porton the vapor line as illustrated in the figure to the right.

B Remove and discard either the flare seal cap or flare nutwith copper flare seal bonnet from the equalizer line port onthe vapor line as illustrated in the figure to the right.

INDOOR EXPANSION VALVE INSTALLATION

Figure 11. Installing Indoor Expansion Valve

506663-01 11/10

IMPORTANTThe Environmental Protection Agency (EPA) prohibitsthe intentional venting of HFC refrigerants duringmaintenance, service, repair and disposal of appliance.Approved methods of recovery, recycling or reclaimingmust be followed.

IMPORTANTIf this unit is being matched with an approved line setor indoor unit coil which was previously charged withmineral oil, or if it is being matched with a coil whichwas manufactured before January of 1999, the coiland line set must be flushed prior to installation. Takecare to empty all existing traps. Polyol ester (POE) oilsare used in Lennox units charged with HFC-410Arefrigerant. Residual mineral oil can act as aninsulator, preventing proper heat transfer. It can alsoclog the expansion device, and reduce the systemperformance and capacity.Failure to properly flush the system per theinstructions below will void the warranty.

Leak Test Line Set and Indoor Coil

IMPORTANTLeak detector must be capable of sensing HFCrefrigerant.

After completing the leak testing the line set and indoor coilas outlined in figure 12, proceed to Evacuating Line Setand Indoor Coil on page 15.

WARNINGWhen using a high pressure gas such asdry nitrogen to pressurize a refrigerationor air conditioning system, use aregulator that can control the pressuredown to 1 or 2 psig (6.9 to 13.8 kPa).

WARNINGRefrigerant can be harmful if it is inhaled. Refrigerantmust be used and recovered responsibly.

Failure to follow this warning may result in personal injuryor death.

TO VAPORSERVICE VALVE

HFC-410A

MANIFOLD GAUGE SET

OUTDOOR UNIT

HIGHLOW

NITROGEN

A With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. Open the valveon the HFC-410A cylinder (vapor only).

B 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. [Atrace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kPa) pressure]. Close the valve on the HFC-410A cylinderand the valve on the high pressure side of the manifold gauge set. Disconnect the HFC-410A cylinder.

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

D 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 setand the indoor unit.

E After a few minutes, open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leakdetector.

F After leak testing disconnect gauges from service ports.

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

A Connect an HFC-410A manifold gauge set high pressurehose to the vapor valve service port.

NOTE — Normally, the high pressure hose is connected tothe liquid line port. However, connecting it to the vapor portbetter protects the manifold gauge set from high pressuredamage.

B With both manifold valves closed, connect the cylinder ofHFC-410A refrigerant to the center port of the manifold gaugeset.

NOTE — Later in the procedure,the HFC-410A container will bereplaced by the nitrogencontainer.

1CONNECT GAUGESET

2 TEST FOR LEAKS

AB

Figure 12. Leak Test

TSA*S4 SERIES

Evacuating Line Set and Indoor Coil

A Open both manifold valves and start the vacuum pump.

B 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. A 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 ofpressure. Absolute 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:

� Close manifold gauge valves

� Close valve on vacuum pump

� Turn off vacuum pump

� Disconnect manifold gauge center port hose from vacuum pump

� Attach 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.D 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.

E Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and indoor unit until theabsolute pressure does not rise above 500 microns (29.9 inches of mercury) within a 20-minute period after shutting off the vacuum pumpand closing the manifold gauge valves.

F When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to anupright cylinder of HFC-410A refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set andindoor unit.

G Perform the following:

OUTDOOR

UNIT

TO VAPORSERVICE VALVE

TO LIQUID LINESERVICE VALVE

MICRONGAUGE

VACUUM PUMP

A34000 1/4 SAE TEE WITHSWIVEL COUPLER

500

MANIFOLDGAUGE SET

HFC-410A

RECOMMENDMINIMUM 3/8” HOSE

A Connect low side of manifold gauge setwith 1/4 SAE in-line tee to vapor lineservice valve

B Connect high side of manifold gaugeset to liquid line service valve

C Connect micron gauge availableconnector on the 1/4 SAE in-line tee.

D Connect the vacuum pump (withvacuum gauge) to the center port of themanifold gauge set. The center portline will be used later for both theHFC-410A and nitrogen containers.

HIGHLOW

12

34

56

78

910

11 12

1/6 TURN

NITROGEN

1CONNECT GAUGE SET

A

B

C

D

2EVACUATE THE SYSTEM

NOTE — Remove cores from service valves (if not already done).

� Close manifold gauge valves.

� Shut off HFC-410A cylinder.

� Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with coretool 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.

Figure 13. Evacuating System

506663-01 11/10

Electrical

In the U.S.A., wiring must conform with current local codesand the current National Electric Code (NEC). In Canada,wiring must conform with current local codes and the currentCanadian Electrical Code (CEC).

Refer to the furnace or air handler installation instructions

for additional wiring application diagrams and refer to unitnameplate for minimum circuit ampacity and maximumovercurrent protection size.

24VAC TRANSFORMER

Use the transformer provided with the furnace or airhandler for low‐voltage control power (24VAC - 40 VAminimum)

SERVICEDISCONNECT

SWITCH

MAIN FUSE BOX/BREAKER PANEL

Refer to the unit nameplate for minimum circuit ampacity, and maximumfuse or circuit breaker (HACR per NEC). Install power wiring and properlysized disconnect switch.

NOTE — Units are approved for use only with copper conductors.Ground unit at disconnect switch or to an earth ground.

SIZE CIRCUIT AND INSTALL DISCONNECT SWITCH

NOTE — 24VAC, Class II circuit connections are made in the controlpanel.

Install room thermostat (ordered separately) on an inside wallapproximately in the center of the conditioned area and 5 feet (1.5m) fromthe floor. It should not be installed on an outside wall or where it can beaffected by sunlight or drafts.

THERMOSTAT

5 FEET(1.5M)

INSTALL THERMOSTAT

WARNINGElectric Shock Hazard. Can cause injury or death. Unit must be grounded in accordance with national andlocal 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 powersupplies.

TSA*S4 SERIES

Any excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring. To facilitate a conduit, a cutout is locatedin the bottom of the control panel. Connect conduit to the control panel using a proper conduit fitting.

ROUTING HIGH VOLTAGE/ GROUND AND CONTROL WIRING

CONTROL

WIRING

HIGH VOLTAGEFIELD WIRING

LOW VOLTAGEFIELD WIRING

FACTORYWIRING

GROMMET ANDWIRE TIE

WIRE RUN LENGTH AWG# INSULATION TYPE

LESS THAN 100' (30 METERS) 18 TEMPERATURE RATING

MORE THAN 100' (30 METERS) 16 35ºC MINIMUM.

Install low voltage wiring from outdoor to indoor unitand from thermostat to indoor unit as illustrated.

HIGH VOLTAGE / GROUND WIRES

CONTROL WIRING

A Run 24VAC control wires through hole with grommetand secure with provided wire tie.

B Make 24VAC thermostat wire connections. Locate thetwo wires from the contactor and make connectionusing field provided wire nuts:

� Yellow to Y1

� Black to C (common)

NOTE — For proper voltages, select thermostat wire (control wires)gauge per table below.

NOTE — Wire tie provides low voltage control wire strainrelief and to maintain separation of field installed low andhigh voltage circuits.

A

W1

Y

G

C

R

Y

G

C

THERMOSTAT INDOOR UNIT

POWER

HEAT

COOLING

INDOORBLOWER

COMMON

OUTDOORUNIT

Y1

C

W

R

TYPICAL LOW VOLTAGE FIELDWIRING

HIGH VOLTAGE FLEXIBLECONDUIT

THREE PHASE

SINGLE PHASE

NOTE — Do not bundle any excess 24VAC control wiresinside control panel.

CONTROLWIRING

GROUND

HIGH VOLTAGE

CONNECTIONS

(CONTACTOR)

HIGH VOLTAGECONNECTIONS(CONTACTOR)

GROUND

GROMMET ANDWIRE TIE

HIGH VOLTAGEFLEXIBLE CONDUIT

B

A

B

506663-01 11/10

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

TSA*S4 SERIES

Figure 15. Typical Field Wiring Diagram — T Voltage — 220/240v (1PH) 50Hz

506663-01 11/10

Figure 16. Typical Factory Wiring Diagram

Servicing Units Delivered Void of Charge

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

1. Leak check system using procedure outlined in thisinstallation instruction.

2. Evacuate the system using procedure outlined in thisinstallation instruction.

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

4. Evacuate the system again using procedure outlinedin this installation instruction.

5. Weigh in refrigerant using procedure outlined in figure20.

Unit Start-Up

IMPORTANTIf unit is equipped with a crankcase heater, it should beenergized 24 hours before unit start-up to preventcompressor damage as a result of slugging.

1. Check that fan rotates freely.

2. Inspect all factory- and field-installed wiring for looseconnections.

3. After evacuation is complete, open the liquid line andsuction line service valves to release the refrigerantcharge (contained in outdoor unit) into the system.

4. Replace the stem caps and tighten as specified inOperating Service Valves on page 3.

5. Check voltage supply at the disconnect switch. Thevoltage must be within the range listed on the unit'snameplate. If not, do not start the equipment until youhave consulted with the power company and thevoltage condition has been corrected.

6. Set the thermostat for a cooling demand. Turn onpower to the indoor indoor unit and close the outdoorunit disconnect switch to start the unit.

7. Recheck voltage while the unit is running. Power mustbe within range shown on the nameplate.

8. Check system for sufficient refrigerate by using theprocedures listed under Start-Up and ChargingProcedures.

System Refrigerant

This section outlines procedures for:

1. Connecting gauge set for testing and charging;

2. Checking and adjusting indoor airflow;

3. Adding or removing refrigerant.

TSA*S4 SERIES

TO LIQUIDLINE SERVICE

VALVETEMPERATURE

SENSOR

DIGITAL SCALE

REFRIGERANT TANK

TEMPERATURE SENSOR(LIQUID LINE)

MANIFOLD GAUGE SET

AClose manifold gauge set valves andconnect the center hose to a cylinder ofHFC-410A. Set for liquid phasecharging.

BConnect the manifold gauge set's lowpressure side to the suction line serviceport.

CConnect the manifold gauge set's highpressure side to the liquid line serviceport.

DPosition temperature sensor on liquid linenear liquid line service port.

OUTDOOR UNIT

CHARGE INLIQUID PHASE

CONNECTIONS FOR TESTING AND CHARGING

GAUGE SET

A

C

D

LOW HIGH

B SUCTION LINESERVICE PORTCONNECTION

Figure 17. Gauge Set Setup and Connections

WHEN TO CHARGE?

� Warm weather best� Can charge in colder weatherCHARGE METHOD? Determine by:

� Metering device type� Outdoor ambient temperatureREQUIREMENTS:

� 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 SUBCOOLING WEIGH‐IN

64ºF (17.7ºC)AND BELOW

65ºF (18.3ºC)AND ABOVE

START: Determine how refrigerant is metered

TXV

Figure 18. Determining Charge Method

OUTDOOR AMBIENT

TEMPERATURE

506663-01 11/10

CHECKING AIR FLOW AT INDOOR COIL

Check airflow using the Delta-T (DT) process using the illustration in figure 19.

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 drybulb entering and leaving air temperatures (A and C). Temperature Drop Formula: (TDrop) = A minus C.

3. Determine if fan needs adjustment—If the difference betweenthe measured TDrop and the desired DT (TDrop–DT) is within+3º, no adjustment is needed. See examples: Assume DT =15 and A temp. = 72º, these C temperatures would necessitate stated actions:

Cº TDrop – DT = ºF ACTION

53º 19 – 15 = 4 Increase the airflow58º 14 – 15 = -1 (within +3º range) no change62º 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.

DT80 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

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

Temp.of airenteringindoorcoil ºF

INDOORCOIL

DRYBULB

DRYBULB

WETBULB

B

TDrop

19º

A

Dry

-bu

lb

Wet-bulb ºF

A

72º

B

64º

C

53º

air flowair flow

All temperatures areexpressed in ºF

Figure 19. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart

START: Measure outdoor ambient temperature 64ºF

(17.7ºC) and

BELOW

1. Check Liquid and suction line pressures

2. Compare unit pressures with table 5 or 6.

3. Conduct leak check; evacuate aspreviously outlined.

4. Weigh in the unit nameplate charge plusany charge required for line set differencesover feet.

Liquid Line

Set Diameter

g per 1.5 m) adjust from 4.6 m lineset*

9.5 mm 85 g per 1.5 m)

NOTE - *If line length is greater than 4.6 m, add this amount. Ifline length is less than 4.6 m, subtract this amount.

Refrigerant Charge per Line Set Length

USE SUBCOOLINGMETHOD

This nameplate is for illustration purposes

only. Go to actual nameplate on outdoor

unit for charge information.

ABOVE orBELOW

Figure 20. HFC-410A Weigh In

65ºF

(18.3ºC)

and

ABOVE

TSA*S4 SERIES

DO NOT CHARGE UNIT

(Results of charging at lowtemperatures not reliable)

START: Measure outdoor ambient temperature

USE WEIGH‐IN METHOD

Weigh‐in or remove refrigerantbased upon line set length

BLOCK OUTDOOR COIL: [sometimes necessary with lower temperatures]Use cardboard or plastic sheet to restrict the airflow through the outdoor coilto achieve pressures from 325-375 psig (2240-2585 kPa). Higher pressuresare needed to check charge. Block equal sections of air intake panels andmove coverings sideways until the liquid pressure is in the above notedranges.

If value is MORE

than shown, remove

refrigerant.

1. Confirm proper airflow across coil using figure19.

2. Compare unit pressures with table 5 or 6.

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

4. Connect gauge set

5. Measure outdoor ambient temperature

6. When heat demand is satisfied, set thermostat tocall 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 todetermine saturation temperature (see table 7):

SATº = ______

10. Subtract to determine subcooling (SCº):

SATº_____ - LIQº _____ = SCº _____

11. Compare results with tables 3 or 4 .

Figure 21. HFC-410A Subcooling Charge

MORE orLESS

If value is LESS

than shown, add

refrigerant.

ABOVE orBELOW

65ºF

(18.3ºC)

and

ABOVE

64ºF

(17.7ºC) and

BELOW

Table 3. Subcooling (SC) Values —TXV System - ºF(ºC) +1ºF (0.5ºC) (1-PHASE)

TSA*S4 50Hz International (1-Phase)

F(5C) -024 -030 -036 -048 -060

65 (18) 10 6 5 2 4

70 (21) 10 6 5 2 4

75 (24) 11 6 6 3 4

80 (27) 11 7 6 3 5

85 (29) 11 7 6 3 5

90 (32) 11 7 7 4 5

95 (35) 11 7 7 4 5

100 (38) 11 7 7 5 5

105 (41) 11 7 7 5 5

110 (43) 11 8 7 5 5

115 (45) 11 8 8 6 5

Table 4. Subcooling (SC) Values — TXV System - ºF(ºC) +1ºF (0.5ºC) (3-PHASE)


F(5C) -036 -048 -060

65 (18) 8 2 2

70 (21) 8 2 3

75 (24) 9 3 3

80 (27) 9 3 3

85 (29) 9 4 4

90 (32) 10 4 4

95 (35) 10 4 4

100 (38) 10 5 4

105 (41) 10 5 4

110 (43) 10 5 4

115 (45) 10 6 4

506663-01 11/10

IMPORTANTUse this table to perform maintenance checks; it is not a procedure for charging thesystem. 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 aproblem exists with some component in the system.

Table 5. HFC-410A Normal Operating Pressures — Liquid +10 and Suction +5 Psig (1-Phase)TSA*S4 50Hz International (1-Phase)

TSA*S4 -024 -030 -036 -048 -060

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

65 (18) 260 / 137 255 / 132 246 / 133 248 / 133 259 / 143

70 (21) 280 / 138 274 / 134 265 / 134 269 / 134 279 / 144

75 (24) 301 / 139 295 / 135 286 / 136 290 / 136 299 / 146

80 (27) 323 / 141 317 / 136 307 / 137 313 / 137 320 / 147

85 (29) 346 / 142 339 / 137 330 / 138 335 / 138 342 / 148

90 (32) 370 / 144 363 / 139 354 / 140 360 / 140 364 / 150

95 (35) 395 / 145 387 / 140 378 / 141 386 / 142 387 / 151

100 (38) 421 / 147 413 / 142 404 / 143 412 / 143 411 / 153

105 (41) 449 / 149 439 / 143 430 / 145 440 / 145 437 / 154

110 (43) 478 / 151 468 / 145 458 / 146 468 / 147 464 / 156

115 (45) 507 / 152 497 / 147 487 / 148 498 / 149 492 / 157

*Temperature of the air entering the outside coil.

Table 6. HFC-410A Normal Operating Pressures — Liquid +10 and Suction +5 Psig (3-Phase)


TSA*S4 -036 -048 -060

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

65 (18) 269 / 135 247 / 132 269 / 136

70 (21) 290 / 136 269 / 134 289 / 137

75 (24) 311 / 137 290 / 136 310 / 139

80 (27) 334 / 138 312 / 138 332 / 140

85 (29) 357 / 139 335 / 139 355 / 142

90 (32) 382 / 141 360 / 140 377 / 143

95 (35) 407 / 142 385 / 142 400 / 144

100 (38) 433 / 143 412 / 144 423 / 146

105 (41) 460 / 145 439 / 145 449 / 148

110 (43) 490 / 146 468 / 147 476 / 149

115 (45) 520 / 148 498 / 149 504 / 151

*Temperature of the air entering the outside coil.

Table 7. HFC-410A Temperature (°F) - Pressure (Psig)

°F °C Psig °F °C Psig

-40 -40.0 11.6 60 15.6 170

-35 -37.2 14.9 65 18.3 185

-30 -34.4 18.5 70 21.1 201

-25 -31.7 22.5 75 23.9 217

-20 -28.9 26.9 80 26.7 235

-15 -26.1 31.7 85 29.4 254

-10 -23.3 36.8 90 32.2 274

-5 -20.6 42.5 95 35.0 295

0 -17.8 48.6 100 37.8 317

5 -15.0 55.2 105 40.6 340

10 -12.2 62.3 110 43.3 365

15 -9.4 70.0 115 46.1 391

20 -6.7 78.3 120 48.9 418

25 -3.9 87.3 125 51.7 446

30 -1.1 96.8 130 54.4 476

35 1.7 107 135 57.2 507

40 4.4 118 140 60.0 539

45 7.2 130 145 62.8 573

50 10.0 142 150 65.6 608

55 12.8 155

TSA*S4 SERIES

System Operation

IMPORTANTSome scroll compressor have internal vacuum protectorthat will unload scrolls when suction pressure goesbelow 20 psig. A hissing sound will be heard when thecompressor is running unloaded. Protector will resetwhen low pressure in system is raised above 40 psig. DONOT REPLACE COMPRESSOR.

The outdoor unit and indoor blower cycle on demand from

the room thermostat. When the thermostat blower switchis in the ON position, the indoor blower operatescontinuously.

HIGH PRESSURE SWITCH (S4)

TSA*S4 units are equipped with a high‐pressure switchthat is located in the liquid line of the compressor asillustrated in figure 1 on page 2.

MANUAL RESETBUTTON

Figure 22. High Pressure Switch (S4) Manual Reset

The switch is a Single Pole, Single Throw (SPST),manual-reset switch which is normally closed andremoves power from the compressor when dischargepressure rises above factory setting at 590 + 10 psi. The

manual-reset button can be identified by a red cap that ispress to preform the reset function.

Crankcase Heater (HR1)

Crankcase heater HR1 prevents liquid from accumulatingin the compressor. The heater is always on when thecompressor is off. An optional crankcase heaterthermostat (S40) is available.

Table 8. Crankcase Heaters

Parts Watts Voltage

M Voltage 40 480

T Voltage 40 240

Maintenance

DEALER

Maintenance and service must be performed by a qualifiedinstaller or service agency. At the beginning of eachcooling season, the system should be checked as follows:

WARNINGElectric shock hazard. Can cause injuryor death. Before attempting to performany service or maintenance, turn theelectrical power to unit OFF at disconnectswitch(es). Unit may have multiple powersupplies.



Outdoor Unit

1. Outdoor unit fan motor is pre-lubricated and sealed.No further lubrication is needed.

2. Visually inspect all connecting lines, joints and coils forevidence of oil leaks.

3. Check all wiring for loose connections.

4. Check for correct voltage at unit (unit operating).

5. Check amp draw on outdoor fan motor.

Motor Nameplate:_________ Actual:__________.

6. Inspect drain holes in coil compartment base andclean if necessary.

NOTE ‐ If insufficient cooling occurs, the unit should begauged and refrigerant charge should be checked.

Outdoor Coil

Clean and inspect outdoor coil (may be flushed with awater hose). Ensure power is off before cleaning.

NOTE — It may be necessary to flush the outdoor coilmore frequently if it is exposed to substances which arecorrosive or which block airflow across the coil (e.g., peturine, cottonwood seeds, fertilizers, fluids that maycontain high levels of corrosive chemicals such as salts)

Sea Coast — Moist air in ocean locations can carry salt,which is corrosive to most metal. Units that are locatednear the ocean require frequent inspections andmaintenance. These inspections will determine thenecessary need to wash the unit including the outdoor coil.Consult your installing contractor for properintervals/procedures for your geographic area or servicecontract.

Indoor Unit

1. Clean or change filters.

2. Lennox blower motors are prelubricated andpermanently sealed. No more lubrication is needed.

506663-01 11/10

3. Adjust blower speed for cooling. Measure the pressuredrop over the coil to determine the correct blower CFM.Refer to the unit information service manual for pressuredrop tables and procedure.

4. Belt Drive Blowers - Check belt for wear and propertension.

5. Check all wiring for loose connections.

6. Check for correct voltage at unit. (blower operating)

7. Check amp draw on blower motor.

Motor Nameplate:_________ Actual:__________.

Indoor Coil

1. Clean coil if necessary.

2. Check connecting lines, joints and coil for evidence ofoil leaks.

3. Check condensate line and clean if necessary.

OWNER

Cleaning of the outdoor unit's coil should be performed bya trained service technician. Contact your dealer and setup a schedule (preferably twice a year, but at least once ayear) to inspect and service your outdoor unit. Thefollowing maintenance may be performed by thehomeowner.

NOTE - A white residue may appear on the coil guards andgrilles on outdoor units. The residue is a non-toxicbyproduct of manufacturing the flexible coating. It can beremoved by wiping the coil guard with a cloth.


IMPORTANTSprinklers and soaker hoses should not be installedwhere they could cause prolonged exposure to theoutdoor unit by treated water. Prolonged exposure of theunit to treated water (i.e., sprinkler systems, soakers,waste water, etc.) will corrode the surface of steel andaluminum parts and diminish performance and longevityof the unit.

Outdoor Coil

1. Make sure power is off before cleaning. Clean andinspect outdoor coil. The coil may be flushed with awater hose.

2. The outdoor coil is protected by an inner mesh screenand a wire cage (see figure 23). If debris has collectedbetween the mesh screen and the coil and cannot bedislodged by spraying unpressurized water frominside coil surface to the outside, the mesh may beremoved by first removing the top of the unit which willallow for removal of the wire cage.

3. Then, using pliers to grip the head of the push pins, pullstraight out to extract the push pins along one side ofthe coil. If necessary, remove the push pins along theback of the unit; it is usually unnecessary to fullyremove the inner mesh screen.

4. Drape the mesh screen back and wash the coil. Whenall the debris has been removed from the coil, reinstallthe mesh screen by positioning it in its original positionand reinserting the push pin. No tool is required topush 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 thepush pin a couple fins to the right or left of the originalhole and re-insert the pin.

9 PINS USED ON -048AND -060; 6 PINS ALLOTHERS

MESH SCREEN

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Figure 23. Cleaning Debris from Mesh

PUSH PIN

NOTE — It may be necessary to flush the outdoor coil

more frequently if it is exposed to substances which are

corrosive or which block airflow across the coil (e.g., pet

urine, cottonwood seeds, fertilizers, fluids that may

contain high levels of corrosive chemicals such as salts)

Routine Maintenance

In order to ensure peak performance, your system must beproperly maintained. Clogged filters and blocked airflowprevent your unit from operating at its most efficient level.

1. Air Filter — Ask your Lennox dealer to show youwhere your indoor unit's filter is located. It will be eitherat the indoor unit (installed internal or external to thecabinet) or behind a return air grille in the wall orceiling. Check the filter monthly and clean or replaceit as needed.

2. Disposable Filter — Disposable filters should bereplaced with a filter of the same type and size.

NOTE — If you are unsure about the filter required for yoursystem, call your Lennox dealer for assistance.

3. Reusable Filter — Many indoor units are equippedwith reusable foam filters. Clean foam filters with amild soap and water solution; rinse thoroughly; allowfilter to dry completely before returning it to the unit orgrille.

TSA*S4 SERIES

NOTE — The filter and all access panels must be in placeany time the unit is in operation.

4. Lennox Branded Air Filters — are designed toremove airborne particles from the air passing throughthe filter.

5. Indoor Unit — The indoor unit's evaporator coil isequipped with a drain pan to collect condensateformed as your system removes humidity from theinside air. Have your dealer show you the location ofthe drain line and how to check for obstructions. (Thiswould also apply to an auxiliary drain, if installed.)

Thermostat Operation

See the thermostat homeowner manual for instructions onhow to operate your thermostat.

Preservice CheckIf your system fails to operate, check the following beforecalling for service:

� Verify room thermostat settings are correct.

� Verify that all electrical disconnect switches are ON.

� Check for any blown fuses or tripped circuit breakers.

� Verify unit access panels are in place.

� Verify air filter is clean.

� If service is needed, locate and write down the unitmodel number and have it handy before calling.

AccessoriesFor update-to-date information, see any of the followingpublications:

� Lennox TSA*S4 Engineering Handbook

� Lennox Commercial Price Book

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? �

07/11 506294−01

�� Page 1

�2011 Lennox Industries Inc.Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE




IMPORTANTThe Clean Air Act of 1990 bans the intentional venting ofrefrigerant (CFCs, HCFCs and HFCs) as of July 1, 1992.Approved methods of recovery, recycling or reclaimingmust be followed. Fines and/or incarceration may belevied for noncompliance.

INSTALLATIONINSTRUCTIONS

Elite® Series CBX27UHUnits

MULTI−POSITION AIR HANDLERS506294−0107/11Supersedes 05/11

Table of Contents

CBX27UH Up−flow/Down−flow Unit Dimensions 2. . .

CBX27UH Horizontal LH/RH Unit Dimensions 3. . . .

General Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . .

Requirements 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brazing Connections 6. . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Condensate Drain 7. . . . . . . . . . . . . . . . .

Inspecting and Replacing Filters 8. . . . . . . . . . . . . . . . .

Sealing the Unit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring Static Pressure 9. . . . . . . . . . . . . . . . . . . . .

Adjusting the Blower Speed 9. . . . . . . . . . . . . . . . . . . .

Making Electrical Connections 11. . . . . . . . . . . . . . . . . .

Repairing or Replacing Cabinet Insulation 15. . . . . . . . .

TOP CAP SHIPPINGBRACKET (REPLACE

SCREWS IN TOP CAPAFTER REMOVAL)

HORIZONTAL DRAIN PAN (SEE PAGES 4AND 6)

BLOWER HOUSINGSUPPORT PAD

IMPORTANT INFORMATION TO INSTALLERCHECK FOR AND REMOVE THE FOLLOWING ITEMS BEFORE OPERATING UNIT.

REFRIGERANT LINE PLUGS(SEE PAGE 6)

DRIP SHIELD FOR −060 UNITS ONLYHORIZONTAL APPLICATIONS (SEEPAGE 5).

D

D

Litho U.S.A.

506294−01

CBX27UH Up−flow and Down−flow Unit Dimensions − Inches (mm)

OPTIONALELECTRIC HEAT

(FIELD−INSTALLED)

AIRFLOW

LIQUIDLINE

SUCTIONLINE

SUPPLY AIROPENING

RETURN AIRFILTER

LOW VOLTAGEINLETS (TOP AND

RIGHT SIDE)

RETURN AIR

TOP VIEW

FRONT VIEWSIDE VIEW

BLOWER

PIPING PLATE DETAIL(FOR UP−FLOW AND DOWN−FLOW POSITIONS)

A

B C

11-1/16 (281)

D

F E

LIQUID LINE

SUCTION LINE

CONDENSATE DRAINS(2) (HORIZONTAL)

COIL

3/4 (19)

3/4 (19)

5/8 (16)5/8 (16) 1 (25)

5/8 (16)

1-3/4 (44)

2(51)

1-1/8 (29) 4-3/8 (111)

2-3/4(70)

5-3/8(137)

3-1/2 (89)

OPTIONALELECTRIC HEAT

(FIELD−INSTALLED) AIR FLOW

LIQUIDLINE

SUCTIONLINE

ReturnAir Opening

SUPPLYAIR

FILTER

SUPPLY AIR

TOP VIEW

FRONT VIEWSIDE VIEW

BLOWER

A

BC

11-1/16 (281)

F

D

E

COIL

5/8 (16)5/8 (16)

5/8 (16)

5/8 (16)

5/8 (16)

LOW VOLTAGE(RIGHT SIDE)

LINE VOLTAGE(LEFT SIDE)

DOWN−FLOW POSITION

1 (25)

UP−FLOW POSITION

CONDENSATE DRAINS(2) (UP−FLOW ANDDOWN−FLOW)

FILTER ACCESS

FILTER ACCESS

H

G

H

G

LINE VOLTAGEINLETS (TOP

AND LEFT SIDE)

5/8 (16)

5/8 (16)

CBX27UH Common Dimensions − Inches (mm)

Dim. −018/−024 −030/−036 −042/−048 −060

A 49−1/4 (1251) 51 (1295) 58−1/2 (1486) 62-1/2 (1588)

B 21−1/4 (540) 21−1/4 (540) 21-1/4 (540) 21-1/4 (540)

C 20−5/8 (524) 22-5/8 (575) 24−5/8 (625) 24−5/8 (625)

D 19−3/4 (502) 19−3/4 (502) 19-3/4 (502) 19-3/4 (502)

E 19 (483) 21 (533) 23 (584) 23 (584)

F 20 (508) 20 (508) 20 (508) 20 (508)

G 24−5/8 (625) 26-3/8 (670) 27-7/8 (708) 27-7/8 (708)

H 24−5/8 (625) 24−5/8 (625) 30−5/8 (778) 34-5/8 (879)

CBX27UH SERIES

CBX27UH Horizontal Left− and Right−Hand Unit Dimensions − Inches (mm)

LIQUIDLINE

SUCTIONLINE

SupplyAir

Opening

FILTER

LOW VOLTAGEINLETS (BOTTOM

AND RIGHTSIDE)

TOP VIEW

FRONT VIEW

BLOWER

H

B

C

D

LIQUIDLINE

SUCTIONLINE

CONDENSATEDRAINS (2)(UP−FLOW

ANDDOWN−FLOW)

CONDENSATEDRAINS (2)

(HORIZONTAL)

Coil

3/4 (19)

3/4 (19)

1-1/2(38)

1-3/4(44)

5-3/4(46)

2(51)

1-1/8(29)

RETURN AIROPENINGF

E

5/8 (16)

5/8 (16)

5/8 (16)

END VIEW

AIRFLOW

OPTIONAL ELECTRICHEAT (FIELD−INSTALLED)

11-1/16(281)

LINE VOLTAGEINLETS (TOP

AND RIGHTSIDE)

5-3/8(137)

4-3/8(111)

LIQUIDLINE

SUCTIONLINE

SupplyAir Opening

FILTER

LOW VOLTAGEINLETS (TOP AND

LEFT SIDE)

END VIEW

BLOWER

B

C

D

Coil

3/4 (19)

3/4 (19)

3/4 (19)

ReturnAir Opening

F

E

5/8 (16)

5/8 (16)

5/8 (16)

END VIEW

Air Flow

OPTIONAL ELECTRICHEAT (FIELD INSTALLED)

LINE VOLTAGE INLETS(BOTTOM AND LEFT SIDE)

Horizontal Position(Right-Hand Air

Discharge)

FILTER ACCESS

FILTER ACCESS

5-3/4(146)

1-1/2 (38)

1-3/4(44)

CONDENSATE DRAINS (2)(HORIZONTAL)

A5/8 (16)G

H

A5/8 (16)

G

1 (25)

1 (25)

11-1/16(281)

PIPING PLATEDETAIL

LIQUIDLINE

SUCTION LINE

2(51)

1-1/8(29)

5-3/8(137)

4-3/8(111)

PIPING PLATEDETAIL

Horizontal Position(Left-Hand Air

Discharge)

TOP VIEW

FRONT VIEW

3/4 (19)

END VIEW

FOR DIMENSIONS �A" THROUGH�H", SEE CHART ON PAGE 2.

WARNINGThis 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 thismay 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 addressshown below, or contact your supervisor.

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

506294−01

General Information

The Elite® CBX27UH series air handler is designed forinstallation with optional field−installed electric heat and amatching HFC−410A outdoor unit

This instruction is intended as a general guide and doesnot supersede local or national codes in any way. Consultauthorities having jurisdiction before installation. Checkequipment for shipping damage; if found, immediatelyreport damage to the last carrier.

Shipping and Packing List

Package 1 of 1 contains the following:

1�Assembled air handler unit

1�Horizontal drip shield (CBX27UH−60 only)

NOTE − For down−flow applications, order kit number

83M57.

Requirements

IMPORTANTThis unit must be matched with an indoor coil as speci-fied in Lennox Engineering Handbook. Coils previous-ly charged with HCFC−22 must be flushed.

In addition to conforming to manufacturer’s installationinstructions and local municipal building codes, installationof Lennox air handler units (with or without optional electricheat), shall conform with the following National FireProtection Association (NFPA) standards:

� NFPA No. 90A − Standard for Installation of Air

Conditioning and Ventilation Systems

� NFPA No. 90B − Standard for Installation of Residence

Type Warm Air Heating and Air Conditioning Systems

This unit is approved for installation clearance tocombustible material as stated on the unit rating plate.Accessibility and service clearances must takeprecedence over combustible material clearances.

Installing the Unit

These units are factory−configured for up−flow andhorizontal right−hand discharge installation. For down−flowor horizontal left−hand discharge, certain fieldmodifications are required.

DISASSEMBLE/REASSEMBLE AIR HANDLER UNITS

The air handler units consists of two factory-assembledsections. It may be necessary to disassemble the sectionswhen positioning the unit for installation.

To disassemble:

1. Remove access panels.

2. Remove both blower and coil assemblies. This willlighten the cabinet for lifting.

3. Remove one screw from the left and right posts insidethe unit. Remove one screw from each side on theback of the unit. Unit sections will now separate.

To reassemble:

1. Align cabinet sections together.

2. Reinstall screws.

3. Replace blower and coil assemblies.

4. Replace access panel.

UP−FLOW APPLICATIONUse the following procedures to configure the unit forup−flow operations:

1. Remove access panels.

2. Remove and discard the horizontal drip shield (−060model, used only on horizontal applications) and thecorrugated padding between the blower and coilassembly.

3. The horizontal drain pan must be removed when thecoil blower is installed in the up−flow position.Removing horizontal drain pain will allow properairflow and increase efficiency.

4. After removing horizontal drain pan, place the unit indesired location. Set unit so that it is level. Connectreturn and supply air plenums as required using sheetmetal screws as illustrated in figure 1.

5. Install units that have no return air plenum on a standthat is at least 14" from the floor to allow for proper airreturn. Lennox offers an optional up−flow unit stand aslisted in table 1.

HORIZONTAL DRAIN PAN(MUST BE REMOVED)

UP−FLOW/DOWN−FLOWDRAIN PAN

Figure 1. Up−flow Configuration

Table 1. Optional Unit Side Stand (Up−Flow Only)

Model Kit Number

−21, −26, and −31 45K31

−41 through −65. 45K32

HORIZONTAL RIGHT−HAND DISCHARGEAPPLICATION

Use the following procedures to configure the unit forhorizontal right−hand discharge operations:

NOTE − For horizontal applications, a secondary drain pan

is recommended. Refer to local codes.

CBX27UH SERIES

1. Before operating the unit, remove access panels andthe horizontal drip shield (−060 model) and thecorrugated padding between the blower and coilassembly. Discard the corrugated padding.

2. Install the horizontal shield on the front edge of thehorizontal drain pan as illustrated in figure 2.

3. No further adjustment is necessary. Set unit so that it issloped 1/4" towards the drain pan end of the unit.

4. If the unit is suspended, the entire length of the cabinetmust be supported. If you use a chain or strap, use apiece of angle iron or sheet metal attached to the unit(either above or below) to support the length of thecabinet. Use securing screws no longer than 1/2" toavoid damaging the coil or filter as illustrated in figure3. Use sheet metal screws to connect the return andsupply air plenums as required.

No Adjustment Is Necessary

HORIZONTAL DRIP SHIELD (−060 MODELS)

UPLOAD / DOWN−FLOWDRAIN PAN

HORIZONTAL DRAINPAN

DOWN−FLOW RAIL

Figure 2. Right−Hand Discharge Configuration

HORIZONTAL RIGHT−HAND DISCHARGE APPLICATION IN HIGH HUMIDITY AREAS

For horizontal applications in high humidity areas removethe down−flow rail closest to the drain pan.

To remove rail:

1. Remove the screws from the rail at the back of unit andat the cabinet support rail.

2. Remove the down−flow rail then replace screws.

3. Seal around the exiting drain pipe, liquid line, andsuction line to prevent humid air from infiltrating intothe unit.

FRONT VIEW END VIEW

ANGLE IRON ORSHEET METAL

electrical inlet clearance 4 in.(102 mm)

1/2 in. Screws Maximum

Figure 3. Suspending Horizontal Unit

IMPORTANTWhen removing the coil, there is possible danger ofequipment damage and personal injury. Be careful whenremoving the coil assembly from a unit installed in right−or left−hand applications. The coil may tip into the drainpan once it is clear of the cabinet. Support the coil whenremoving it.

HORIZONTAL LEFT−HAND DISCHARGE APPLICATION

NOTE − For horizontal applications, a secondary drain pan

is recommended. Refer to local codes.

90ºBEND

CABINETSUPPORT

Coil shown in upload position for easy conversion

TOP CAP SCREWS

DRAIN PANreinstalled here

DRIPSHIELD

DRAIN PANSHIPPINGLOCATION

TOP CAP ROTATED TOCORRECT POSITION

�� DRAIN plugs ��reinstalled here removed from here

back coil endseal

TOPCAP

90ºBEND

Align holeswith holes in

coil end plate.

Figure 4. Field Modification for Left−Hand Discharge

Use the following procedures to configure the unit forhorizontal left−hand discharge operations:

1. Before operating the unit, remove access panels andthe horizontal drip shield (−060 model) and thecorrugated padding between the blower and coilassembly. Discard the corrugated padding.

2. Pull the coil assembly from unit. Pull off the horizontaldrain pan.

3. Remove the drain plugs from back drain holes onhorizontal drain pan and reinstall them on front holes.

IMPORTANTAfter removal of drain pan plug(s), check drain hole(s) toverify that drain opening is fully open and free of anydebris. Also check to make sure that no debris has falleninto the drain pan during installation that may plug up thedrain opening.

506294−01

4. Rotate drain pan 180º front-to-back and install it on theopposite side of the coil.

5. Remove screws from top cap. Remove horizontal dripshield screw located in the center of the back coil endseal as illustrated in figure 4 on page 5.

6. Rotate horizontal drip shield 180º front to back.

7. Remove plastic plug from left hole on coil front endseal and reinstall plug in back hole. Reinstall horizontaldrip shield screw in front coil end seal. Drip shieldshould drain downward into horizontal drain pan insidecoil.

HORIZONTAL DRIP SHIELD (−060 MODEL)

DOWN−FLOWRAIL

FRONT EDGE OF HORIZONTALDRAIN PAN

Figure 5. Left−Hand Discharge Configuration

8. Rotate top cap 180º front-to-back and align withunused screw holes. Holes must align with front andback coil end plates. The top cap has a 45º bend onone side and a 90º bend on the other. The 90º bendmust be on the same side as the horizontal drainpan as illustrated in figure 4 on page 5.

NOTE − Be very careful when you reinstall the screws into

coil end plate engaging holes. Misaligned screws may

damage the coil.

9. From the up−flow position, flip cabinet 90º to the leftand set into place. Replace blower assembly. Securecoil in place by bending down the tab on the cabinetsupport rail as illustrated in figures 4 and 5.

10. Install the horizontal shield (−060 model) on the frontedge of the horizontal drain pan as illustrated in figure5 on page 6.

NOTE − For horizontal applications in high humidity

areas, remove the down−flow rail closest to the drain pan.

To remove rail, remove screw from rail at back of unit and

at cabinet support rail. Remove down−flow rail then replace

screws. Also, seal around the exiting drain pipe, liquid and

suction lines to prevent infiltration of humid air.

11. Knock out drain seal plate from access door. Secureplate to cabinet front flange with screw provided.

12. Flip access door and replace it on the unit.

13. Set unit so that it is sloped 1/4" toward the drain panend of the unit. Connect return and supply air plenumsas required using sheet metal screws.

14. If suspending the unit, it must be supported along theentire length of the cabinet. If using chain or strap, usea piece of angle iron or sheet metal attached to the unit(either above or below) so that the full length of thecabinet is supported. Use securing screws no longerthan 1/2" to avoid damage to coil or filter. as illustratedin figure 3 on page 5. Connect return and supply airplenums as required using sheet metal screws.

DOWN−FLOW APPLICATION

NOTE − If down−flow application is required, separately

order kit number 83M57 and install per kit’s instructions.

Also use metal or class I supply and return air plenums.

Use the installation instruction provided with the downflowkit.

IMPORTANTIf electric heat section with circuit breakers(ECB29/ECB31) is applied to down−flow and CBX27UHunits, the circuit breakers must be rotated 180° to the UPposition. See ECB29/ECB31 installation instructions formore details.

Brazing Connections

IMPORTANTTo prevent the build up of high levels of nitrogen whenpurging, be sure it is done in a well ventilated area. Purgelow pressure nitrogen (1 to 2 psig) through the refrigerantpiping during brazi

Documents

Dallas, Texas, USA T-Class · 2020. 8. 13. · See the Lennox TSA*S4 Engineering Handbook for approved indoor component matchups. This outdoor unit is designed for use in thermal