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,1,_2008Lennox tndustries Inc,Dallas, Texas, USA

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RETAIN THESE INSTRUCTIONSFOR FUTURE REFERENCE

WARNING

CAUTION

IMPORTANT

INSTALLATIONINSTRUCTIONS

T-ClassTM TSA*S4 UnitsTSA036S4N41, TSA042S4N41,TSA048S4N41 and TSA060S4N41

AIR CONDITIONER506058-0102/08Supersedes 505,300M

TeCh nicalblicationsLitho U.S.A.

Shipping and Packing List ...................... 1TSA*S4 Outdoor Unit .......................... 1Unit Dimensions ............................... 2General Information ........................... 2

Recovering Refrigerant from Existing System ..... 4Removing Existing Outdoor Unit ................. 5Positioning New Outdoor Unit ................... 5New or Replacement Line Set ................... 6Brazing Connections ........................... 7Removing Indoor Unit Metering Device .......... 8Flushing the System ........................... 9Installing New Indoor Unit Metering Device ........ 10Testing for Leaks .............................. 11Evacuating the System ......................... 12Servicing Unit Delivered Void of Charge .......... 13Electrical Connections ......................... 13

Start-Up and Charging Procedures ............... 15System Operation ............................. 18Maintenance .................................. 19Owner Information ............................. 19

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

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

IMPORTANTTSA*S4 Air Conditioners, which will also be referred to inthis instruction as the outdoor unit, uses HFC-410Arefrigerant. This outdoor unit must be installed with amatching indoor unit and line set as outlined in the LennoxTSA*S4 Engineering Handbook.

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

02/08

IIIHIIIIIIIIIIIHIIIIIIIIIIIIIIIIII Page 1506058-01

IIIIIIIIIIIIIIIIlIHIIIIIIIIIIIIIIIIIIIIIIIlllllllllllllll

AOUTDOOR COILFAN tD schargeA r

COMPRESSOR_

SUCTION ANDLIQUIDLINE

CONNECTIONS

SIDE VIEW

Model Number A B

TSA036S2N41 24-1/4 (616) 29-1/4 (743)

TSA042S2N41 24-1/4 (616) 33-1/4 (845)

TSA048S2N41 28-1/4 (724) 29-1/4 (743)

TSA060S2N41 28-1/4 (724) 37-1/4 (925)

WARNING

OPTIONAL UNIT STAND-OFF KIT

(4) (FIELDqNSTALLED)

SIDE VIEW

I

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

When servicing or repairing HVAC components, ensurecaps and fasteners are appropriately tightened. Table 1lists torque values for typical service and repair items.

Table 1. Torque RequirementsPart 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 SETSWhen checking the system charge, use a manifold gaugeset that features low-loss anti-blow back fittings. See figure1 for a typical manifold gauge connection setup,

Manifold gauge sets 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 on the high side and a low side of30" vacuum to 250 psi with dampened speed to 500 psi.Gauge hoses must be rated for use at up to 800 psi ofpressure with a 4000 psi burst rating,OPERATING SERVICE VALVESThe liquid and suction line service valves are typically usedfor removing refrigerant, flushing, leak testing, evacuating,checking charge and charging.

IMPORTANT

506058-01 02/08

Page 2

LOW HIGHPRESSURE PRESSURE

OUTDOOR UNIT (Uncased Coil Shown)

• TXVOUTDOOR

COIL

SUCTION LINE

)MPRESSO_ _ I

SERVICE VALVE

COMPRESSOR

FILTER DRIER

Figure 1. Typical Manifold Gauge Connection Setup

Each valve is equipped with a service port which has afactory-installed valve stem.

I/6 TURN 1/12 TURN

Figure 2. Cap Tightening Distances

,A IMPORTANT

To Open and Close Angle-Type Service Valve:

A valve stem cap protects the valve stem fromcontamination and assures a leak-free seal,

1, Remove stem cap with an appropriately sized wrench.2. Use a service wrench with a hex-head extension

(3/16" for liquidqine valve sizes and 5/16" forsuction-line valve sizes) to back the stem outcounterclockwise as far as it will go,

3. Replace the stem cap and tighten as follows:

• With Torque Wrench: Tighten finger tight and thentighten per table 1.

• Without Torque Wrench: Finger tighten and use anappropriately sized wrench to turn an additional1/12 turn clockwise as illustrated in figure 2.

NOTE -A label with specific torque requirements may beaffixed to the stem cap, If the label is present, use thespecified torque,

NOTE- To prevent stripping of the cap, the wrench shouldbe appropriately sized and fit snugly over the cap beforetightening the cap,

To Access Angle-Type Service Port:

A service port cap protects the service port core fromcontamination and serves as the primary leak seal,

1. Remove service port cap with an appropriately sizedwrench,

2, Connect gauge to the service port,

3. When testing is completed, replace service port cap andtighten as follows:

• With Torque Wrench: Finger tighten and thentighten per table 1,

• Without Torque Wrench: Finger tighten and use anappropriately sized wrench to turn an additional1/6 turn clockwise as illustrated in figure 2.

SERVICE PORT CAP

SERVICE PORT

CLOSED TO BOTHINDOOR AND

OUTDOOR UNITS

VALVE STEMFRONT-SEATED

SERVICE PORT

CLOSED) INSERT HEXWRENCH HERE

TOINDOORUNIT

TO OUTDOOR UNIT

STEM CAP

Figure 3. Angle-Type Service Valve(Font-Seated Closed)

Page 3TSA*S4 SERIES

SERVICEPORT

SERVICEPORTOPENTOBOTHINDOORANDOUTDOORUNITS

SERVICEPORT

(VALVESTEMSHOWNOPEN)INSERTHEXWRENCHHERE

TOINDOORUNIT

STEMCAP

TOOUTDOORUNIT

Figure 4. Angle-Type Service Valve(Back-Seated Opened)

To Access Bali-Type Service Port:

A service port cap protects the service port core fromcontamination and serves as the primary leak seal,

OPEN TO LINE SET WHEN VALVE IS CLOSED,TO BOTH LINE SET AND UNIT WHEN VALVE ISOPEN.

TO INDOOR UNIT

TO OPEN ROTATE STEM

COUNTERCLOCKWISE 90 ° . BALL(SHOWNCLOSED)

TO CLOSE ROTATE STEMCLOCKWISE 90 ° .

VALVESTEM

CORE

SERVlCEPORTCAP

STEM CAP

Figure 5. Bali-Type Service Valve

1. Remove service port cap with an appropriately sizedwrench,

2, Connect gauge to the service port.

3. When testing is completed, replace service port cap andtighten as follows:

• With Torque Wrench: Finger tighten and thentighten per table table 1.

• Without Torque Wrench: Finger tighten and use anappropriately sized wrench to turn an additional1/6 turn clockwise as illustrated in figure 2.

To Open and Close Bali-Type Service Valve:

A valve stem cap protects the valve stem fromcontamination and assures a leak-free seal,

1. Remove stem cap with a wrench.

2. Use an appropriately sized wrench to open. To openvalve, rotate stem counterclockwise 90 °. To closerotate stem clockwise 90 °,

3. Replace the stem cap and tighten as follows:

• With Torque Wrench: Finger tighten and thentighten per table 1.

• Without Torque Wrench: Finger tighten and use anappropriately sized wrench to turn an additional1/12 turn clockwise as illustrated in figure 2.

NOTE - A label with specific torque requirements may beaffixed to the stem cap. If the label is present, use thespecified torque.

Remove existing HCFC-22 refrigerant using one of thefollowing methods:METHOD 1:

Use this method if the existing outdoor unit is not equippedwith manual shut-off valves, and plan on using existingHCFC-22 refrigerant to flush the system,

NOTE - Use recovery machine instructions for specificsetup requirements.

1. Disconnect all power to the existing outdoor unit,2. Connect to the existing unit a gauge set, clean

recovery cylinder and a recovery machine. Use theinstructions provided with the recover machine on howto setup the connections,

3. Remove all HCFC-22 refrigerant from the existingsystem, Check gauges after shutdown to confirm thatthe entire system is completely void of refrigerant,

RECOVERY MACHINE

CLEAN RECOVERY

MANIFOLD GAUGES

/OUTDOOR UNIT

Figure 6. Typical Refrigerant Recovery(Method 1)

METHOD 2:

Use this method if the existing outdoor unit is equippedwith manual shut-off valves, and plan on using newHCFC-22 refrigerant to flush the system,

IMPORTANT: Some system configurations may containhigher than normal refrigerant charge due to either largeinternal coil volumes, and/or long line sets, The followingconditions may cause the compressor to stop functioning:

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

• Outdoor unit's high or low-pressure switches (ifapplicable) when tripped can cycled the compressorOFF,

Page 4506058-01 02/08

• Compressor can stop pumping due to tripped internalpressure relief valve.

• Compressor has internal vacuum protection that isdesigned to unload the scrolls (compressor stopspumping) when the pressure ratio meets a certainvalue or when the suction pressure is as high as 20psig. (Compressor suction pressures should never beallowed to go into a vacuum. Prolonged operation atlow suction pressures will result in overheating of thescrolls and permanent damage to the scroll tips, drivebearings and internal seals).

Once the compressor can not pump down to a lowerpressure due to one of the above system conditions, shutoff the suction valve. Turn OFF the main power to unit anduse a recovery machine to recover any refrigerant left inthe indoor coil and line set.

Perform the following task:

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

2. Pump as much of the existing HCFC-22 refrigerantwith the compressor back into the outdoor unit untilyou have reached the limitations of the outdoorsystem. Turn the outdoor unit main power OFF anduse a recovery machine to remove the remainingrefrigerant in the system.

NOTE - It may be necessary to bypass the low pressureswitches if equipped to ensure complete refrigerantevacuation.

3. When the low side system pressures reach 0 psig,close the suction line valve.

4. Check gauges after shutdown to confirm that thevalves are not allowing refrigerant to flow back into thelow side of the system.

* SEE NOTES BELOW THIS FIGURE FOR FURTHER DETAILS.

Figure 7. Installation Clearances

NOTES:

• Service clearance of 30 in. (762 mm) must bemaintained on one of the sides adjacent to the controlbox.

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

• Clearance to one of the remaining two sides may be12 in. (305 mm) and the final side may be 6 in. (152mm)

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

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

POSITIONING CONSIDERATIONS

Consider the following when positioning the unit:

CAUTION

Perform the following task at the existing outdoor unit:• Disconnect line set at the service valves.

• Disconnect electrical service at the disconnect switch.

• Remove old outdoor unit.

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

• Some localities are adopting sound ordinances basedon the unit's sound level registered from the adjacentproperty, 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 soundtransmission. For proper placement of unit in relationto a window see the provided illustration in figure 8.

Page 5TSA*S4 SERIES

INSTALLUNITAWAY_/_/_/

FROM_

Figure 8. Outside Unit Placement

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 9.

DISCHARGE AIRBUILDING

STRUCTURE

MOUNTINGSLAB

GROUND LEVEL

Figure 9. Ground Level Slab Mounting

Slab may be level or have a slope tolerance away from thebuilding of not more than two degrees, or two inches per 5feet (51 mm per 1524 mm) as illustrated in figure 9.

INSTALLING OUTDOOR UNIT ON ROOF

Install the unit a minimum of six inches (152 mm) above theroof surface to avoid ice build-up around the unit. Locatethe unit above a load bearing wall or area of the roof thatcan adequately support the unit, Consult local codes forrooftop applications.

This section provides information on new installation orreplacement of existing line set. If a new or replacementline set is not required, then proceed to BrazingConnections on page 7.

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 duringinstallation 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 SETField refrigerant piping consists of liquid and suction linesfrom 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.

Model

Table 2. Refrigerant Line Set

FieldConnections

Liquid SuctionLine Line

-036 3/8 in, 7/8 in-042 (10 mm) (22 mm)-048

3/8 in. 1-1/8 in,-060 (10mm) (29mm)

Recommended Line Set

Liquid Suction L15Line Line Line Sets

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

3/8 in. 1-1/8 in, Field(10 (29 mm) Fabricatedmm)

NOTE - When installing refrigerant lines longer than 50feet, contact Lennox Technical Support ProductAppfications for assistance or Lennox piping manual. Toobtain the correct information from Lennox, be sure tocommunicate 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,

MATCHING WITH NEW OR EXISTING INDOOR COILAND LINE SETThe RFCl-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 10, Thisfilter drier must be installed to ensure a clean,moisture-free system, Failure to install the filter drier will

506058_01 02/08

Page 6

voidthewarranty.A replacementfilterdrieris availablefrom Lennox.See Brazing Connections on page 7 forspecial procedures on brazing filter drier connections tothe liquid line,

LIQUID LINESERVICE VALVE

OUTDOORUNIT

LINE

BRAZE CONNECTION POINTS

LIQUID LINEFILTER DRIER

LIQUIDLINE

Figure 10. Typical Liquid Line Filter DrierInstallation

LINE SET ISOLATION

Line set for heat pump applications can not be installedunderground, For more information see the LennoxRefrigerant Piping Design and Fabrication Guidelines, orcontact Lennox Technical Support Product Applicationsfor assistance,

This reference illustrates procedures, which ensure properrefrigerant line set isolation:

• Installation of line set on horizontal runs isillustrated in figure 11.

• Installation of line set on vertical runs is illustrated infigure 12,

• Installation of a transition from horizontal tovertical is illustrated in figure 13,

TO HANG LINE SET FROM JOIST OR

RAFTER, USE EITHER METAL STRAPPING WIRE TIE

MATERIAL OR ANCHORED HEAVY NYLON (AROUNDWIRE TIES. SUCTION LINE

STRAPPING MATERIAL ONLY)

(AROUND SUCTIONLINE ONLY)

TAPE ORWIRE TIE

8 FEET

METALSLEEVE

TAPE OR

WIRE TIE STRAP THE SUCTION LINE TO

THE JOIST OR RAFTER AT 8 FEETINTERVALS THEN STRAP THELIQUID LINE TO THE SUCTIONLINE.

A

FLOOR JOIST OR __>

ROOF RAFTER -- ,b

Figure 11. Refrigerant Line Set: InstallingHorizontal Runs

IMPORTANT - REFRIGERANT LINES MUST NOT CONTACT WALL.LIQUID

OUTSIDE WALL SUCTION LINE LINE

NOTE - SIMILAR INSTALLATION SLEEVEPRACTICES SHOULD BE USEDIF LINE SET IS TO BE INSTALLED WIRE TIEON EXTERIOR OF OUTSIDE --WALL.

WOOD BLOCK

WIRE TIE

STRAP

SUCTION LINE WRAPPED WITH

LIQUID LINE

IMPORTANT! REFRIGERANTLINES MUST NOT CONTACT

STRUCTURE.

................................_ CAULK

PVC PIPE FIBERGLASS INSULATION

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

AUTOMOTIVEMUFFLER-TYPE HANGER

ANCHORED HEAVY NYLONWIRE TIE OR AUTOMOTIVE \

\MUFFLER-TYPE HANGER

WALLSTUD

X STRAP LIQUID LINE

TO SUCTION LINE

LIQUID LINE

SUCTION LINE - WRAPPEDMETAL SLEEVE

IN ARMAFLEX

Figure 13. Refrigerant Line Set: Transitionfrom Vertical to Horizontal

Use the following procedure to braze the line set to the newoutdoor unit. Figure 14 is provided as a general guide forpreparing to braze the line set to the outdoor unit,

Page 7TSA*S4 SERIES

1CUT AND DEBUR

INSTALL CORE ONLY FORBOTH SERVICE PORTS AFTER

THEY HAVE COOLED.

INDOOR UNIT

,,Ibm

REMOVE CAP AND CORE FROMBOTH LIQUID AND SUCTION

SERVICE PORTS

OUTDOORUNIT

SERVICE PORT MUST BEOPEN TO ALLOW EXITPOINT FOR NITROGEN SERVICE

j SUCTION LINE _ /VALVE

LIQUtD LINE SERVICE J

VALVE

RAP /_

SER

VALVE _

Figure 14. Brazing Connections

WARNING

WARNING

I

I

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

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

3. Connect gauge low pressure side to liquid line servicevalve,

4. To protect components during brazing, wrap a wetcloth around the liquid line service valve body andcopper tube stub and use another wet clothunderneath the valve body to protect the base paint.

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

the valve stem port connection on the suction servicevalve, The TXV metering device at the indoor unit coilwill allow low pressure nitrogen to flow through thesystem.)

NOTE - The fixed orifice or TXV metering device at theindoor unit will allow low pressure nitrogen to flow throughthe system,)

NOTE - Use silver alloy brazing rods with five or six percentminimum silver alloy for copper-to-copper brazing or 45percent silver alloy for copper-to-brass or copper-to-steelbrazing,

6. Braze the line to the liquid line service valve. Turn offnitrogen flow.

IMPORTANT

7. After all connections have been brazed, disconnectmanifold gauge set the from service ports and removewrapping. Reinstall the service port core for both of theoutdoor unit's service valves.

Remove the existing HCFC-22 refrigerant flow controlorifice or thermal expansion valve from the indoor coil.REPLACEMENT PARTS

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

• 10 -- Brass nuts for liquid line assemblies

• 20 -- Teflon rings

• 10 -- Liquid line orifice housings

• 10 -- Liquid line assemblies

506058-01 02/08

Page 8

Figure 15.69J46 Kit Components

TYPICAL FIXED ORIFICE REMOVAL PROCEDURE

DISTRIBUTOR TUBES

LIQUID LINE ORIFICE HOUSING

TEFLON RING REMOVE AND DISCARD

FIXED VALVE STEM ASSEMBLY(IF PRESENT)

. . .. J

BRASS NUT

/

O -" / ....VALVE STEM CAP (Uncased Coil Shown)

Figure 16. Typical Fixed Orifice Removal

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

2. Remove any shipping clamps holding the liquid lineand distributor assembly.

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

4. Remove and discard fixed orifice, valve stemassembly if present and Teflon ring as illustrated infigure 16.

TYPICAL TXV REMOVAL PROCEDURE

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

2. Remove any shipping clamps holding the liquid lineand distributor assembly.

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

4. Remove the suction line sensing bulb as illustrated infigure 17.

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

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

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

TWO PIECEPATCH PLATE

JNCASED COIL LIQUID LINEONLY) \ ORIFICE HOUSING

)ISTRIBUTORTUBES

(Uncased Coil Shown)STUB END

TXV

SENSINGLINE

/MALE EQUALIZER LINE /

FITTING J SUCTION

SENSING BULB LINE LIQUIDLINE

Figure 17. Typical TXV Removal

A IMPORTANT

A IMPORTANT

If the original system used:

• HCFC-22 refrigerant, then flush the system using theprocedure provided in this section.

• HFC-410A refrigerant, then proceed to Installing NewRefrigerant Metering Device.

Page 9TSA*S4 SERIES

[_/ INVERTEDHCFC-22CYLINDERCONTAINSCLEANHCFC-22TOBEUSEDFORFLUSHING. GAUGEMANIFOLD

LOW HIGHPRESSUREPRESSURESUCTION

CLOSED

LIQUIDLINESERVICEVALVERECOVERYCYLINDER

RECOVERYMACHINENOTE - The inverted HCFC-22 cylinder must contain at least the sameamount of refrigerant as was recovered from the existing system.

Figure 18. Typical Flushing Connection

CAUTION

REQUIRED EQUIPMENT

Equipment required to flush the existing line set and indoorunit coil:

• Two clean HCFC-22 recovery bottles,

• Oilless recovery machine with pump-down feature,

• Two gauge sets (one for HCFC-22; one forHFC-410A),

PROCEDURE

1, Connect the following:

• HCFC-22 cylinder with clean refrigerant to thesuction service valve,

• HCFC-22 gauge set to the liquid line valve,

• Recovery machine with an empty recovery tank tothe gauge set,

2, Set the recovery machine for liquid recovery and startthe recovery machine. Open the gauge set valves toallow the recovery machine to pull a vacuum on theexisting system line set and indoor unit coil.

3, Invert the cylinder of clean HCFC-22 and open itsvalve to allow liquid refrigerant to flow into the systemthrough the suction line valve. Allow the refrigerant topass from the cylinder and through the line set and theindoor unit coil before it enters the recovery machine.

4, After all of the liquid refrigerant has been recovered,switch the recovery machine to suction recovery sothat all d the HCFC-22 suction is recovered. Allow therecovery machine to pull a vacuum on the system,

5, Close the valve on the inverted HCFC-22 drum andthe gauge set valves. Pump the remaining refrigerantout of the recovery machine and turn the machine off.

6, Use dry nitrogen to break the vacuum on therefrigerant lines and indoor unit coil before removingthe recovery machine, gauges and refrigerant drum,

TSA*S4 units are to be used with a HFC-410A TXVmetering device only. This section provides instructions oninstalling a TXV refrigerant metering device,TSA*S4 ENGINEERING HANDBOOKSee the TSA*S4 Engineering Handbook for approvedindoor/outdoor match-ups, applicable TXV kit andapplication information,The following is the typical contents of a TXV kit:1 -- TXV

2 -- Teflon rings1 -- 1 1/4" wide copper mounting strap for sensing bulb

2 --#10 hex head bolts and nuts for securing sensing bulb

O_TEFLON

RINGS (2) _ I_

STRAP (1)

Figure 19. TXV Kit Components

t/2 TURN

Figure 20. Tightening Distance

TYPICAL TXV INSTALLATION PROCEDUREThe TXV unit can be installed internal or external to theindoor coil. In applications where an uncased coil is beinginstalled in a field-provided plenum, install the TXV in amanner that will provide access for field servicing of theTXV. Refer to Figure 21 for reference during installation ofTXV unit,

506058-01 02/08

Page 10

TWOPIECE (UncasedCoilShown)PATCH PLATEtNCASED COIL

ONLY) LIQUID LINE

. .._ORIFICE STUB END

HOUSING

DISTRIBUTOR TXVTUBES. -

RING

SENSING ILINE

--...j

MALE EQUALIZER LINEFITTING (SEE FIGURE 23 SUCTIONFOR FURTHER DETAILS) LINE

SENSING BULB INSULATION ISREQUIRED IF MOUNTED EXTERNALTO THE COIL CASING. SEE FIGURE 22FOR BULB POSITIONING

LIQUIDLINE

Figure 21. Typical TXV Installation

1, Install one of the provided Teflon rings around thestubbed end of the TXV and lightly lubricate theconnector threads and expose surface of the Teflonring with refrigerant oil.

2. Attach the stubbed end of the kit valve to the liquid lineorifice housing, Finger tighten and use an appropriatelysized wrench to turn an additional 1/2 turn clockwiseas illustrated in figure 20, or 20 ft-lb,

3. Place the remaining Teflon washer around the otherend of the TXV. Lightly lubricate connector threadsand expose surface of the Teflon ring with refrigerantoil,

4. Attach the liquid line assembly to the TXV. Fingertighten and use an appropriately sized wrench to turnan additional 1/2 turn clockwise as illustrated in figure20, or 20 ft-lb.

5. Attach the suction line sensing bulb in the properorientation as illustrated in figure 22 using the clampan screws provided.

NOTE - Insulating the sensing bulb once installed may berequired when the bulb location is external to the coilcasing.

NOTE - To prevent any possibility of water damage,properly insulate all parts of the TXV assembly that maysweat due to temperature differences between the valveand its surrounding ambient temperatures.

SUCTION LINE

/

BULB

\

ON LINES SMALLER THAN7/8", MOUNT SENSING BULBAT EITHER THE 3 OR 9

O'CLOCK POSITION.

SUCTION LINE ON 7/8" AND LARGER LINES,

POSITION. NEVER MOUNT

• . ON BOTTOM OF LINE.

7,

WARNING I

WARNING I

12. Purge dry nitrogen and HFC-410A mixture.13. Correct any leaks and recheck.14. After leak testing disconnect gauges from service

ports.

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

1. Connect an HFC-410A manifold gauge set highpressure hose to the suction valve service port.

NOTE - Normally, the high pressure hose is connected tothe fiquid line port; however, connecting it to the suctionport better protects the manifold gauge set from highpressure damage,

2. With both manifold valves closed, connect the cylinderof HFC-410A refrigerant to the center port of themanifold gauge set. Open the valve on the HFC-410Acylinder (suction only).

3. Open the high pressure side of the manifold to allowHFC-410A into the line set and indoor unit,

4. Weigh in a trace amount of HFC-410A , [A traceamount is a maximum of two ounces (57 g) refrigerantor three pounds (31 kPa) pressure].

5. Close the valve on the HFC-410A cylinder and thevalve on the high pressure side of the manifold gaugeset.

6, Disconnect the HFC-410A cylinder,

7. Connect a cylinder of dry nitrogen with a pressureregulating valve to the center port of the manifoldgauge set.

NOTE - Amounts of refrigerant will vary with line lengths.

8, Adjust dry nitrogen pressure to 150 psig (1034 kPa),

9. Open the valve on the high side of the manifold gaugeset in order to pressurize the line set and the indoor unit,

10. After a few minutes, open one of the service valveports and verify that the refrigerant added to thesystem earlier is measurable with a leak detector.

11. Check all joints for leaks.

Page 12506058-01 02/08

WARNING

IMPORTANT

Evacuating the system of non-condensables is critical forproper operation of the unit. Non-condensables aredefined as any gas that will not condense undertemperatures and pressures present during operation ofan air conditioning system. Non-condensables and watersuction combine with refrigerant to produce substancesthat corrode copper piping and compressor parts,

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

• low pressure gauge to suction line service valve

• high pressure gauge to liquid line service valve2. Connect micron gauge,3. Connect the vacuum pump (with vacuum gauge) to

the center port of the manifold gauge set,4. Open both manifold valves and start the vacuum

pump.5. Evacuate the line set and indoor unit to an absolute

pressure of 23,000 microns (29.01 inches ofmercury).

NOTE - During the early stages of evacuation, it isdesirable to close the manifold gauge valve at least once todetermine if there is a rapid rise in sure indicates arelatively large leak. If this occurs, repeat the leak testingprocedure.

NOTE - The term absolute pressure means the totalactual pressure within a given volume or system, abovethe absolute zero of pressure, Absolute pressure in avacuum is equal to atmospheric pressure minus vacuumpressure.6. When the absolute pressure reaches 23,000 microns

(29.01 inches of mercury), close the manifold gaugevalves, turn off the vacuum pump and disconnect themanifold gauge center port hose from vacuum pump.Attach the manifold center port hose to a dry nitrogencylinder with pressure regulator set to 150 psig (1034kPa) and purge the hose. Open the manifold gaugevalves to break the vacuum in the line set and indoorunit. Close the manifold gauge valves.

7. Shutoff the dry nitrogencylinderand removethemanifoldgaugehosefromthe cylinder.Openthemanifoldgaugevalvestoreleasethedrynitrogenfromthelinesetandindoorunit,

8. Reconnectthemanifoldgaugetothevacuumpump,turnthepumpon,andcontinuetoevacuatethelinesetandindoorunituntiltheabsolutepressuredoesnotriseabove500microns(29.9inchesofmercury)withina 20-minuteperiodaftershuttingoffthevacuumpumpandclosingthemanifoldgaugevalves,

9. Whentheabsolutepressurerequirementabovehasbeenmet, disconnectthe manifoldhosefrom thevacuumpumpandconnectit to anuprightcylinderofHCFC-22refrigerant.Openthemanifoldgaugevalve1to2 psiginordertoreleasethevacuuminthelinesetandindoorunit,

10.Close manifoldgauge valvesand shut off theHCFC-22cylinderand removethe manifoldgaugeset.

If thesystemisvoidofrefrigerant,cleanthesystemusingtheproceduredescribedbelow.

1. Usenitrogentopressurizethesystemandcheckforleaks.Repairallleaks.

2. Evacuatethe systemto removeas muchof themoistureaspossible,

3. Usenitrogento breakthevacuumandinstalla newfilterdrierinthesystem.

4. Evacuatethe system again. Then, weigh theappropriateamountof HCFC-22refrigerantas listedonunitnameplateintothesystem,

5. Monitorthe systemto determinethe amountofmoistureremainingin theoil.Itmaybenecessarytoreplacethefilterdrierseveraltimesto achievetherequireddrynesslevel.If systemdryness is notverified,thecompressorwill fail in thefuture.

Refertotheindoorunitinstallationinstructionforadditionalwiringapplicationdiagramsandrefertounitnameplateforminimumcircuit ampacityand maximumovercurrentprotectionsize.Figures26and25illustratetypicaloutdoorunitwiringdiagramsfortheTSA*S4seriesheatpumps,• In theU.S,A.,wiringmustconformwithcurrentlocal

codesandthecurrentNationalElectricCode(NEC).

• InCanada,wiringmustconformwithcurrentlocalcodesandthecurrentCanadianElectricalCode(CEC).

kWARNING

L3L2 L1

GROUND1 FIELD WIRING

HIGH VOLTAGE1 FIELD WIRING

FIELD WIRING

Figure 24. Separating High/Low VoltageField Wiring (Typical Field Wiring)

WIRING CONNECTIONS1, Install line voltage power supply to unit from a properly

sized disconnect switch. Any excess high voltage fieldwiring should be trimmed or secured away from thelow voltage field wiring.

2, Ground unit at unit disconnect switch or to an earthground.

3, Connect conduit to the unit using provided conduitbushing.

4, Install room thermostat (ordered separately) on aninside wall approximately in the center of theconditioned area and five feet (1,5 m) from the floor.It should not be installed on an outside wall or whereit can be affected by sunlight, drafts or vibrations.

NO TE - For proper voltages, select thermostat wire gaugeper the following table:

Page13TSA*S4 SERIES

Typical Field Wiring Diagram (Y and G Voltages)

B4

PURPLE

_LAC_

A_

RED

_1 C_ESS_IR

HR!CR_£ HEATER

CIOUTgOOR r_fl

CAPACITOR _(

J C_NTROL _

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1 'I' 1

TO 24 VAC POWERSOLK*CEe0VA _N_.U_NEC CLASS 2

_A---Ji

I

D u t575/eo/3 t

L2 I

l ) "_-_GRDUNII ll

It

"PR£SS_R[

A s_Tc. vS_7 DR _4575160/3 K]-I

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L_' _ YE_LDV _ S87

_Pa*AE]_T ]BLACK

- _l TRAN_FOR_ PDV_R gOURC£

_,_2C CLASS _

A

FOR tJ_ WITH CDPP_ CONDUCTORS ONLy,REFER TO L_IT R_TIN_ PLATE FgR _N]NLIMC_RCtJIT AHPACITY /_ _XIleJ_ OV_RCURRENTPRTECT]_ $]]JE

•_ 3L_PE_ IS USE3) VHE_ TOC IS NOT USE])

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NATIONAL AND L_L [_S,

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Typical Field Wiring Diagram (J Voltage)

Note: The thermostat used may be electro-mechanical or electronic

COOLING:

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

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

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

END OF COOLING DEMAND:

4. Cooling demand is satisfied. Terminal Y1 is de-energized.

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

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

Figure 25. Typical Wiring Diagram

Table 3. Wire Run Lengths NOTE - 24VAC, Class II circuit connections are made in

Wire run length AWG # Insulation type the low voltage junction box

Less than 100 feet (30 m) 18 Color-coded with a minimum NOTE - Units are approved for use only with copperMore than 100 feet (30 m) 16 temperature rating of 35°C. conductors.

5, Install low voltage wiring from outdoor to indoor unitand from thermostat to indoor unit as illustrated infigures 26 and 25.

6, Do not bundle any excess 24VAC control wire insidecontrol box. Run control wire through installed wire tieand tighten wire tie to provided low voltage strain reliefand to maintain separation of field installed low andhigh voltage circuits,

NOTE - To facilitate conduit, a hole is in the bottom of thecontrol box. Connect conduit to the control box using aproper conduit fitting.

NOTE - See unit wiring diagram for power supplyconnections. If indoor unit is not equipped with blowerrelay. It must be field-provided and installed (P-8-3251 orequivalent)

506058-01 02/08

Page 14

THERMOSTAT

POWER

CHEAT

@

G COOLING

INDOOR

BLOWER

COMMON

INDOOR UNIT

©1

@

@-@

OUTDOORUNIT

I

I

Figure 26. Typical Field Low Voltage Wiring

4, Replace the stem caps and tighten as specified inOperating Service Valves on page 2.

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 Testing and ChargingSystem,

SETTING UP TO CHECK CHARGE

1, Close manifold gauge set valves. Connect the centermanifold hose to an upright cylinder of HCFC-22,

A IMPORTANT2, Connect the manifold gauge set to the unit's service

ports as illustrated in figure 1,

• low pressure gauge to suction service port

• high pressure gauge to liquid service portINDOOR AIRFLOW CHECK

1. Rotate fan to check for binding.

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.

Check airflow using the Delta-T (DT) process using theillustration in figure 27,

DETERMINING CHARGE METHOD

Use the illustration in figure 28 to determine the correctcharging method.

80

78

76

74

I Wet-bulb °F

Delta-T24 24 24 23 23 22 22 22 20 19 18 17 16 15

23 23 23 22 22 21 21 20 19 18 17 16 15 14

22 22 22 21 21 20 19 19 18 17 16 15 14 13

21 21 21 20 19 19 18 17 16 16 15 14 13 12

20 20 19 18 17 17 16 1L_,_15 14 13 12 11 10

19 19 18 18 17 17 16 15 15 14 13 12 11 10I

57 58 59 60 61 62 63 64 65 66 67 68 69 70 I

DRY

I

BULB

INDOOR i WETCOIL BULB

6

1. Determine the desired DT--Measure entering air temperatureusing dry bulb (A) and wet bulb (B) DT is the intersecting value of Aand B in the table (see triangle),

2. Find temperature drop across coil--Measure the coil's dry bulbentering and leaving air temperatures (A and C). Temperature DropFormula: (TDrop) = A minus C.

3. Determine if fan needs adjustment--If the difference between themeasured TDrop and the desired DT (TDrop-DT) is within +3 °, no ad-justment is needed. See examples: Assume DT = 15 and A temp. =72°, these C temperatures would necessitate stated actions:

C° TDrop- DT = °F ACTION53° 19 - 15 = 4 Increase the airflow

58° 14 - 15 = -1 (within +3° range) nochange62° 10 - 15 = -5 Decrease the airflow

4. Adjust the fan speed--See indoor unit instructions to increase/de-crease fan speed

Changing air flow affects all temperatures; recheck temperatures toconfirm that the temperature drop and DT are within +3 o

Figure 27. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart

Page15TSA*S4 SERIES

WHEN TO CHARGE?

• Warm weather best

• Can charge in colder weather

CHARGE METHOD? Determine by:

• Metering device type

• Outdoor ambient temperature

REQUIREMENTS:

• Sufficient heat load in structure

• Indoor temperature between 70-80°F (21-26°C)

• Manifold gauge set connected to unit

• Thermometers:to measure outdoor ambient temperatureto measure liquid line temperatureto measure suction line temperature

Figure 28. Determining Charge Method

andABOVE

TXVRefrigerant Charge per Line Set Length

Liquid Line Ounces per 5 feet (g per 1.5 m)Set Diameter adjust from 15 feet (4.6 m) line set*

3t8" (9.5 mm) 3 ounce per 5' (85 g per 1.5 m)

NOTE - *If line length is greater than 15 ft. (4.6 m), add thisamount. If line length is less than !5 ft. (4.6 m), subtract thisamount.

64°F andBELOW

1. Check Liquid and suction line pressures

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

3. Conduct leak check; evacuate aspreviously outlined.

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

This nameplate is for illustration purposesonly. Go to actual nameplate on outdoor

unit for charge information.

Figure 29. HCFC-22 Weigh In

506058@1 02/08

Page 16

65°Fand II v

_ ABOVE I ]

USEWEIGH-INMETHODI ..... IINeigh-in or remove refrigeran

based upon line length J64o F and"',_L-'J_• BELOW '"

BLOCK OUTDOOR COIL: [sometimes necessary with lowertemperatures] Use cardboard or plastic sheet to restrict the airflowthrough the outdoor coil to achieve pressures from 325-375 psig(2240-2585 kPa). Higher pressures are needed to check charge.Block equal sections of air intake panels and move coveringssideways until the liquid pressure is in the above noted ranges.

Jiii

1. Confirm proper airflow across coil using figure27.

2. Compare unit pressures with Table 4, NormalOpera ting Pressures.

3. Set thermostat to call for heat (must have acooling load between 70-80°F (21-26°C)

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 tomaintain 325 - 375 psig.

8. Record liquid line temperature:

LIQ o=

9. Measure liquid line pressure and use the value todetermine saturation temperature (see table 5):

SAT o=

I If refrigerant is added Ior removed, verify l_ If value is MOREcharge using the I than shown, remove

Approach Method. I refrigerant,

I If value is LESSthan shown, add

refrigerant.

10. Subtract to determine subcooling (SC°):

SAT ° . LIQ o = SC o

11. Compare results with table below.

SC ° (Subcooling) Values (F:+/-1.0 ° [C: +/-0.6°])

°F (°C) -036 -042 -048 -060

Any 12 (6.7) 8(4.4) 10 (5.6) 7 (3.9)*Temperature of a r enter ng outdoor co

Figure 30. HCFC-22 Subcooling TXV Charge

I If refrigerant is added I

or removed, verify l_charge using the I

Subcooling Method. I

I If value is LESSthan shown, addrefrigerant,

If value is MOREthan shown, removerefrigerant.

1. Confirm proper airflow across coil using figure27.

2. Compare unit pressures with Table 4, NormalOperating Pressures.

3. Set thermostat to call for heat (must have acooling load between 70-80°F (21-26°C).

4. Connect gauge set,

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

6. Allow temperatures and pressures to stabilize.

7. Record outdoor ambient temperature:AMB o =

8. Record liquid line temperature:

LIQo=

9. Subtract to determine approach (APP°):

LIQo . AMB o = App o

10. Compare results with table below.

APP ° (Approach) Values(F:+/-1.0 ° [C: +/-0.6°])

°F (°C)* -036 -042 -048 -060

Any 11 (6.1) 10(5.6) 6(3.3) 9(5.0)

*Temperature of air entering outdoor coil

Figure 31. HCFC-22 Approach TXV Charge

Page17TSA*S4 SERIES

Table 4. HCFC-22 Normal Operating Pressures (Liquid +10 and Suction +5 psig)

A IMPORTANT

TSA*S4 -036

°F (°C)* Liquid / Suction

Expansion Valve (TXV)

65 (18)

70 (21)

75 (24)

80 (27)

85 (29)

90 (32)

95 (35)100 (38)

105 (41)

110 (43)

115 (45)

-042

Liquid / Suction

-048

Liquid / Suction

263 / 135

281 / 138

302 / 140

325 / 142

349 / 142

375 / 143

404 / 144

433 / 145

462 / 147

494 / 149

527 / 150

250 / 135

268 / 137

288 / 138

310/ 139

332 / 140

356 / 140

381 / 141

406 / 143

432 / 143

459 / 145

490 / 145

240 / 130

257 / 131

278 / 132

299 / 133

323 / 134

344 / 135

369 / 136

394 / 137

418 / 139

446 / 140

477 / 141

-060

Liquid / Suction

242 / 130

266 / 131

286 / 132

309 / 133

332 / 134

357 / 135

381 / 136

407 / 137

433 / 138

459 / 140

488 / 141

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

°F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig32 100.8 48 137.1 63 178.5 79 231.6 94 290.8 110 365.0 125 445.9 141 545.6

33 102.9 49 139.6 64 181.6 80 235.3 95 295.1 111 370.0 126 451.8 142 552.334 105.0 50 142.2 65 184.3 81 239.0 96 299.4 112 375.1 127 457.6 143 559.1

35 107.1 51 144.8 66 187.7 82 242.7 97 303.8 113 380.2 128 463.5 144 565.9

36 109.2 52 147.4 67 190.9 83 246.5 98 308.2 114 385.4 129 469.5 145 572.837 111.4 53 150.1 68 194.1 84 250.3 99 312.7 115 390.7 130 475.6 146 579.8

38 113.6 54 152.8 69 197.3 85 254.1 100 317.2 116 396.0 131 481.6 147 586.8

39 115.8 55 155.5 70 200.6 86 258.0 101 321.8 117 401.3 132 487.8 148 593.840 118.0 56 158.2 71 203.9 87 262.0 102 326.4 118 406.7 133 494.0 149 601.0

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

42 122.6 58 163.9 73 210.6 89 270.0 104 335.7 120 417.7 135 506.5 151 615.443 125.0 59 166.7 74 214.0 90 274.1 105 340.5 121 423.2 136 512.9 152 622.7

44 127.3 60 169.6 75 217.4 91 278.2 106 345.3 122 428.8 137 519.3 153 630.145 129.7 61 172.6 76 220.9 92 282.3 107 350.1 123 434.5 138 525.8 154 637.5

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

47 134.6 78 228.0 109 360.0 140 539.0

INSTALLING SERVICE VALVE CAPS

Disconnect gauge set and re-install both the liquid andsuction service valve caps,

INSTALL CAPSOUTDOOR UNIT

SERVICE VALVES _ /

Figure 32. Installing Service Valve Caps

The outdoor unit and indoor blower cycle on demand fromthe room thermostat. When the thermostat blower switchis in the ON position, the indoor blower operatescontinuously.

HIGH PRESSURE SWITCHTSA*S4 units are equipped with a high-pressure switchthat is located in the liquid line of the compressor. Theswitch (SPST, manual reset, normally closed) removespower from the compressor when discharge pressurerises above factory setting at 590 + 10 psi.

506058-01 02/08

Page 18

Maintenanceandservicemustbeperformedbyaqualifiedinstalleror serviceagency,At the beginningof eachcoolingseason,thesystemshouldbecheckedasfollows:

,WARNING

,&WARNING

,&, IMPORTANT

OUTDOOR UNIT

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

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

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

4. Check all wiring for loose connections,

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

6. Check amp draw on outdoor fan motor.

UNIT NAMEPLATE: ACTUAL:

7. Inspect drain holes in coil compartment base andclean if necessary,

NOTE - If insufficient heating or cooling occurs, the unitshould be gauged and refrigerant charge should bechecked,

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.

INDOOR UNIT

1, Clean or change filters.

2. Blower motors are prelubricated and permanentlysealed, No more lubrication is needed,

3. Adjust blower speed for cooling, Measure the pressuredrop over the coil to determine the correct blower CFMRefer 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.

UNIT NAMEPLATE: ACTUAL:

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.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:1. Make sure power is off before cleaning. Clean and

inspect outdoor coil. The coil may be flushed with awater hose.

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

PUSH PIN

MESH SCREEN /

Figure 33. Cleaning Debris from Mesh

2. The outdoor coil is protected by an inner mesh screenand a wire cage (see figure 33). 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 of

Page19TSA*S4 SERIES

the 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,

THERMOSTAT OPERATION

Thermostat operations vary from one thermostat toanother. The following provides general operationprocedures. Refer to the user's information manualprovided with your thermostat for specific operationdetails,

• Temperature Setting Levers -- Set the lever or dialto the desired temperature setpoints for both heatingand cooling. Avoid frequent temperature adjustment;turning the unit off--then back on--before pressurescan equalize will put unusual stress on the unit'scompressor,

• Fan Switch -- In AUTO or INT (intermittent) mode,the blower operates only when the thermostat calls forheating or cooling. This mode is generally preferredwhen humidity control is a priority. The ON or CONTmode provides continuous indoor blower operation,regardless of whether the compressor or furnace isoperating. This mode is required when constant aircirculation or filtering is desired,

• System Switch -- Set the system switch for heating,cooling or auto operation, The auto mode allows thesystem to automatically switch from heating mode to

cooling mode to maintain predetermined comfortsettings,

• Temperature Indicator -- The temperature indicatordisplays the actual room temperature,

PROGRAMMABLE THERMOSTATSYour Lennox system may be controlled by aprogrammable thermostat. These thermostats provide theadded feature of programmable time-of-day setpoints forboth heating and cooling, Refer to the user's informationmanual provided with your thermostat for operationdetails,

PRESERVlCE CHECKIf your system fails to operate, check the following beforecalling for service:• Make sure all electrical disconnect switches are ON,

• Make sure the room thermostat temperature selectorAND the system switch are properly set.

• Replace any blown fuses, or reset circuit breakers,

• Make sure unit access panels are in place,• Make sure air filter is clean.

• Locate and record unit model number before calling,

Refer to the Lennox TSA*S4 Engineering Handbook forthe latest available accessories for this unit. Below is a listof accessories available at the time this instruction waspublish,

• Compressor start kit

• Loss of charge kit• Sound cover

• Replacement liquid line drier• Plastic feet kit

• Crankcase heater- 40W

Job Name

Job Location

Installer

Unit Model No,

Nameplate Voltage

Rated Load Ampacity

Maximum Fuse or Circuit Breaker

Electrical Connections Tight? _1

Indoor Blower RPM

Discharge Pressure __

Serial No.

Job no. Date

City State

City State

Service Technician

Compressor

Indoor Filter clean?

S,P, Drop Over Indoor (Dry)

Suction Pressure

Outdoor Fan

Supply Voltage (Unit Off)

Outdoor Coil Entering Air Temp.

Refrigerant Charge Checked?

Refrigerant Lines: - Leak Checked? _1 Properly Insulated? _1 Outdoor Fan Checked? _1

Service Valves: --- Fully Opened? _1 Caps Tight? _1 Thermostat

Voltage With Compressor Operating Calibrated? _1 Properly Set? _1 Level? _1

Page 20506058-01 02/08