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BLD2021-0650_Manufacturer_Specifications_and_Installation_Instructions_5.10.2021_3.22.30_PM_2188494
LENNOX (D2011 Lennox Industries Inc. Dallas, Texas, USA 1 1 _ �6=— RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation. A IMPORTANT This unit must be matched with an indoor coil as specified in Lennox Engineering Handbook. Coils previously charged with HCFC-22 must be flushed. NOTICE TO INSTALLER UNIT PLACEMENT It is critical for proper unit operation to place outdoor unit on an elevated surface as described in Unit Placement section on page 7. BRAZING LINE SET TO SERVICE VALVES It is imperative to follow the brazing technique illustrated starting on page 11 to avoid damaging the service valve's internal seals. INSTALLATION INSTRUCTIONS Merit® Series 14ACX Units CONDENSING UNITS Technical 506645-01 Publications 07/11 Litho U.S.A. Supersedes 11/10 TABLE OF CONTENTS Shipping and Packing List ........................ 1 General........................................ 1 Unit Dimensions ................................. 2 Typical Unit Parts Arrangement ................... 3 Model Number Identification ...................... 3 Operating Manifold Gauge Set and Service Valves ... 4 Recovering Refrigerant from Existing System ....... 6 New Unit Placement ............................. 7 Removing and Installing Louvers .................. 8 New or Replacement Line Set ..................... 9 Brazing Connections ........................... 11 Flushing Line Set and Indoor Coil ................ 14 Installing Indoor Metering Device ................ 15 Leak Test Line Set and Indoor Coil ............... 16 Evacuating Line Set and Indoor Coil ............. 17 Electrical Connections .......................... 18 Servicing Unit Delivered Void of Charge ........... 22 Unit Start -Up ................................... 22 System Refrigerant ............................. 22 System Operation .............................. 28 Maintenance ................................... 28 Start -Up and Performance Checklist .............. 30 Shipping and Packing List Check the unit for shipping damage and listed times below are intact. If damaged, or if parts are missing, immediately contact the last shipping carrier. 1 — Assembled outdoor unit 1 — Refrigerant flow control kit (fixed orifice) 1 — Liquid line filter drier General 14ACX Air Conditioners, which will also be referred to in this instruction as the outdoor unit, uses HFC-410A refrigerant. This outdoor unit must be installed with a matching indoor unit and line set as outlined in the Lennox 14ACX Engineering Handbook. This outdoor unit is designed for use in systems that use one of the following refrigerant metering devices: • Thermal expansion valve (TXV) • Fixed orifice 1111111III1111111111111111111IN Page 1 111111111III11111111111111111111111111111111111111111111IN Unit Dimensions - Inches (mm) A OUTDOOR COIL FA COMPRESS( SUCTION AND LIQUI[ LINE CONNECTIO OPTIONAL UNIT STANDOFF KIT (4) (FIELD INSTALLED) SIDE VIEW A t DISCHARGE AIR SIDE VIEW Model Numbers A B 14ACX-018-230 24-1/4 (616) 29-1/4 (743) 14ACX-024-230 28-1/4 (724) 33-1/4 (845) 14ACX-030-230 28-1/4 (724) 37-1/4 (946) 14ACX-036-230 28-1/4 (724) 37-1/4 (946) 14ACX-042-230 28-1/4 (724) 29-1/4 (743) 14ACX-041-230 and 14ACX-048-230 28-1/4 (724) 37-1/4 (946) 14ACX-059-230 32-1/4 (819) 37-1/4 (946) 14ACX-047-230 and 14ACX-060-230 132-1/4 (819) 133-1/4 (845) Page 2 506645-01 Typical Unit Parts Arrangement NOTE — Plumbing layout and compressor type may vary between model sizes. CONTROL THERMAL SWITCH COMPRESSOR (131) DUAL RUN (S173) (-036 AND CAPACITOR -060 ONLY) e o (C12) 0 GROUND LUG o 0 o DISCHARGE LINE COMPRESSOR HARNESS CONNECTION CONTACTOR (K1) o OUTDOOR COIL O CUTOUT FOR HIGH VOLTAGE CONDUIT CONTROL WIRE LOOP CRANKCASE HEATER CRANKCASE HEATER THERMOSTAT (S40) SEE NOTE (HR1) SEE NOTE LIQUID LINE SERVICE VALVE / SUCTION LINE SERVICE VALVE HIGH PRESSURE SWITCH (S4) NOTE — -041, -047, -048, -059 and -060 only are equipped with crankcase thermostat (S40) and crankcase heater (HR1). Figure 1. Typical Unit Parts Arrangement Model Number Identification 1144 AC X -024 - 230 -13 Nominal SEER J I- Minor Revision Number LVoltage Unit Type 230 = 208/23OV-1 phase-60hz AC = Air Conditioner Cooling Capacity - Tons Refrigerant X = R-410A 018 = 1.5 024 = 2 030 = 2.5 036 = 3 041 = 3.5 042 = 3.5 047 = 4 048 = 4 059 = 5 060 = 5 Page 3 14ACX SERIES Operating Manifold Gauge Set and Service Valves These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation. TORQUE REQUIREMENTS A IMPORTANT To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening. When servicing or repairing HVAC components, ensure the fasteners are appropriately tightened. Table 1 provides torque values for fasteners. Table 1. Torque Requirements Parts Recommended Torque Service valve cap 8 ft.- lb. 11 NM Sheet metal screws 16 in.- lb. 2 NM Machine screws #10 28 in.- lb. 3 NM Compressor bolts 90 in.- lb. 10 NM Gauge port seal cap 8 ft.- lb. 11 NM When servicing or repairing heating, ventilating, and air USING MANIFOLD GAUGE SET conditioning components, ensure the fasteners are When checking the system charge, only use a manifold appropriately tightened. Table 1 lists torque values for gauge set that features low loss anti -blow back fittings. fasteners. Manifold gauge set used with HFC-410A refrigerant systems must be capable of handling the higher system operating pressures. The gauges should be rated for use with pressures of 0 - 800 psig on the high side and a low side of 30" vacuum to 250 psig with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psig of pressure with a 4000 psig burst rating. OPERATING SERVICE VALVES The liquid and vapor line service valves are used for removing refrigerant, flushing, leak testing, evacuating, checking charge and charging. Each valve is equipped with a service port which has a factory -installed valve stem. Figure 2 provides information on how to access and operating both angle and ball service valves. Page 4 506645-01 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 back the stem out counterclockwise as far as it will go. / SERVICE PORT CAP SERVICE PORT CORE (VALVE STEM SHOWN TO INDOORB CLOSED) INSERT HEX UNIT (VALVE STEM SHOWN OPEN) WRENCH HERE INSERT HEX WRENCH HERE SERVICE PORT STEM CAP Ij CORE TO OUTDOOR UNIT ANGLE -TYPE SERVICE VALVE ANGLE -TYPE SERVICE VALVE (FRONT -SEATED CLOSED) (BACK -SEATED OPENED) When service valve is OPEN, the service port is WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN open to IinE set, Indoor and outdoor unit. TO THE LINE SET AND INDOOR UNIT. Operating Ball Type Service Valve: To Access Service Port: A service port cap protects the service port core from contamination and 1. Remove stem cap with an appropriately sized wrench. serves as the primary leak seal. 2. Use an appropriately sized wrenched to open. To open valve, 1. Remove service port cap with an appropriately sized wrench. rotate stem counterclockwise 90°. To close rotate stem clockwise 90°. 2. Connect gauge set to service port. 3. When testing is completed, replace service port cap and tighten as follows: TO INDOOR UNIT • With torque wrench: Finger tighten and 1/6TURN torque cap per table 1. 11 2 / • Without torque wrench: Finger tighten and 10 TO OPEN ROTATE STEM BALL (SHOWN use an appropriately sized wrench to turn 9 3 COUNTERCLOCKWISE 90°. CLOSED) an additional 1/6 turn clockwise. g 4 S VALVE % 6 TO CLOSE ROTATE STEM STEM Reinstall Stem Cap: CLOCKWISE 90°. \ Stem cap protects the valve stem from damage and serves as the SERVICE PORT primary seal. Replace the stem cap and tighten as follows: 1/12 TURN SERVICE PORT • With Torque Wrench: Finger tighten and -\/ CORE then torque cap per table 1. 11 2 1 SERVICE PORT CAP • Without Torque Wrench: Finger tight- 10 2 en and use an appropriately sized 9 3 TO OUTDOOR STEM CAP wrench to turn an additional 1/12 turn 8 4 UNIT clockwise. % 6 5 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 Page 5 14ACX SERIES Recovering Refrigerant from Existing System Use the following procedure to recover refrigerant from an existing system (indoor coil, line set and outdoor unit). 1DISCONNECT POWER Disconnect all power to the existing outdoor unit at the service disconnect switch or main fuse box/breaker panel. 2CONNECT MANIFOLD GAUGE SET Connect a gauge set, clean recovery cylinder and a recovery machine to the service ports of the existing unit. Use the instructions provided with the recovery machine to make the connections. RECOVE 3RECOVERING REFRIGERANT Remove existing HCFC-22 refrigerant using one of the following procedures: MANIFOLD GAUGES CLEAN RECOVERY OUTDOOR UNIT CYLINDER 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 HCFC-22 to flush the system. Remove all HCFC-22 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 HCFC-22 refrigerant to flush the system. The following devices could prevent full system charge recovery into the outdoor unit: • Outdoor unit's high or low-pressure switches (if applicable) when tripped can cycle the compressor OFF. • Compressor can stop pumping due to tripped internal pressure relief valve. • Compressor has internal vacuum protection that is designed to unload the scrolls (compressor stops pumping) when the pressure ratio meets a certain value or when the suction pressure is as high as 20 psig. (Compressor suction pressures should never be allowed to go into a vacuum. Prolonged operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips, drive bearings and internal seals.) Once the compressor can not pump down to a lower pressure due to one of the above system conditions, shut off the vapor valve. Turn OFF the main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set. Perform the following task: A Start the existing HCFC-22 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 unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system. NOTE — It may be necessary to bypass the low pressure switches (if equipped) to ensure complete refrigerant evacuation. C When the low side system pressures reach 0 psig, close the vapor line valve. D Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system. Figure 3. Refrigerant Recovery Procedure Page 6 506645-01 CLEARANCE ON ALL SIDES — INCHES (MILLIMETERS) 6 (152) ACCESS PANEL ,,,ACCESS NOTES: I 1 • Clearance to one of the other three 12 (305) `— 30 (762) —� sides must be 36 inches (914mm). • Clearance to one of the remaining l two sides may be 12 inches (305mm)and the final side may be 6 inches (152mm). 36 (914) LINE SET CONNECTIONS MINIMUM CLEARANCE BETWEEN TWO UNITS �\ ACCESS PANE <— 24 (610) \ LINE SET CONNECTIONS DETAIL A Figure 4. Installation Clearances INSTALL UNIT AWAY FROM WINDOWS \ I TWO 90' ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION MINIMUM CLEARANCE ABOVE UNIT 48 (1219) DETAIL B Install unit level or, if on a slope, maintain slope tolerance of 2 degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from building structure. DISCHARGE AIR BUILDING 4 STRUCTURE Figure 5. Placement, and Slab Mounting New Unit Placement See Unit Dimensions on page 2 for sizing mounting slab, platforms or supports. Refer to figure 4 for mandatory installation clearance requirements. POSITIONING CONSIDERATIONS MM1111711 In order to avoid injury, take proper precaution when lifting heavy objects. MOUNTING SLAB GROUND LEVEL Consider the following when positioning the unit: • Some localities are adopting sound ordinances based on the unit's sound level registered from the adjacent property, not from the installation property. Install the unit as far as possible from the property line. • When possible, do not install the unit directly outside a window. Glass has a very high level of sound transmission. For proper placement of unit in relation to a window see the provided illustration in figure 5, detail A. Page 7 14ACX SERIES Roof Damage! This system contains both refrigerant and oil. Some rubber roofing material may absorb oil and cause the rubber to swell when it comes into contact with oil. The rubber will then bubble and could cause leaks. Protect the roof surface to avoid exposure to refrigerant and oil during service and installation. Failure to follow this notice could result in damage to roof surface. WARNING To prevent personal injury, or damage to panels, unit or structure, be sure to observe the following: While installing or servicing this unit, carefully stow all removed panels out of the way, so that the panels will not cause injury to personnel, nor cause damage to objects or structures nearby, nor will the panels be subjected to damage (e.g., being bent or scratched). While handling or stowing the panels, consider any weather conditions, especially windy conditions, that may cause panels to be blown around and battered. New or Replacement Line Set This section provides information on new installation or replacement of existing line set. If a new or replacement line set is not required, then proceed to Brazing Connections on page 11. Field refrigerant piping consists of liquid and suction lines from the outdoor unit (braze connections) to the indoor unit coil (flare or braze connections). Use Lennox L15 (braze, non -flare) series line set, or use field -fabricated refrigerant lines as listed in table 2. NOTE - When installing refrigerant lines longer than 50 feet, see the Lennox Refrigerant Piping Design and Fabrication Guidelines, CORP. 9351-L9, or contact Lennox Technical Support Product Applications for assistance. To obtain the correct information from Lennox, be sure to communicate the following points: • Model (14ACX) and size of unit (e.g. -060). • Line set diameters for the unit being installed as listed in table 2 and total length of installation. • Number of elbows and if there is a rise or drop of the piping. If refrigerant lines are routed through a wall, seal and isolate the opening so vibration is not transmitted to the building. Pay close attention to line set isolation during installation of any HVAC system. When properly isolated from building structures (walls, ceilings. floors), the refrigerant lines will not create unnecessary vibration and subsequent sounds. A IMPORTANT Mineral oils are not compatible with HFC-410A If oil must be added, it must be a Polyol ester oil. The compressor is charged with sufficient Polyol ester oil for line set lengths up to 50 feet. Recommend adding oil to system based on the amount of refrigerant charge in the system. No need to add oil in system with 20 pounds of refrigerant or less. For systems over 20 pounds - add one ounce of every five pounds of refrigerant. Recommended topping -off POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATE rM RL32CF. MATCHING WITH NEW OR EXISTING INDOOR COIL AND LINE SET The RFC1-metering line consisted of a small bore copper line that ran from condenser to evaporator coil. Refrigerant was metered into the evaporator by utilizing temperature/pressure evaporation effects on refrigerant in the small RFC line. The length and bore of the RFC line corresponded to the size of cooling unit. If the 14ACX is being used with either a new or existing indoor coil which is equipped with a liquid line which served as a metering device (RFCI), the liquid line must be replaced prior to the installation of the 14ACX unit. Typically a liquid line used to meter flow is 1 /4" in diameter and copper. LIQUID LINE FILTER DRIER INSTALLATION The filter drier (one is shipped with each 14ACX unit) must be field installed in the liquid line between the outdoor unit's liquid line service valve and the indoor coil's metering device (fixed orifice or TXV) as illustrated in figure 7. This filter drier must be installed to ensure a clean, moisture -free system. Failure to install the filter drier will void the warranty. A replacement filter drier is available from Lennox. See Brazing Connections page 11 for special procedures on brazing filter drier connections to the liquid line. BRAZE CONNECTION POINTS LOW bq, LIQUID LINE LINE LIQUID SERVICE VALVE LINE LIQUID LINE FILTER DRIER OUTDOOR UNIT Figure 7. Typical Liquid Line Filter Drier Installation Table 2. Refrigerant Line Set — Inches (mm) Model Number Valve Field Size Connections Recommended Line Set Liquid Line Suction Line Liquid Line Suction Line L15 Series Line Sets 14ACX-018-230 3/8 in. (10 mm) 3/4 in. (19 mm) 3/8 in. (10 mm) 3/4 in. (19 mm) L15-41 — 15 feet to 50 feet (4.6 meters to 15 meters) 14ACX-024-230 14ACX-030-230 14ACX-036-230 3/8 in. (10 mm) 7/8 in. (22 mm) 3/8 in. (10 mm) 7/8 in. (22 mm) L15-65 — 15 feet to 50 feet (4.6 meters to 15 meters) 14ACX-041-230 14ACX-042-230 14ACX-047-230 14ACX-048-230 14ACX-059-230 3/8 in. (10 mm) 1-1/8 in. (29 mm) 3/8 in. (10 mm) 1-1/8 in. (29 mm) Field Fabricated 14ACX-060-230 NOTE — Some applications may required a field provided 7/8" to 1-1/8" adapter Page 9 14ACX SERIES Ll 'SET INSTALLATION Line Set Isolation — The following illustrations are examples of proper refrigerant line set isolation: REFRIGERANT LINE SET — TRANSITION FROM VERTICAL TO HORIZONTAL ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE AUTOMOTIVE MUFFLER -TYPE HANGER MUFFLER -TYPE HANGER WALL STUD NON -CORROSIVE METAL SLEEVE STRAP LIQUID LINE TO VAPOR LINE LIQUID LINE VAPOR LINE - WRAPPED IN ARMAFLEX REFRIGERANT LINE SET — INSTALLING HORIZONTAL RUNS To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties. CTD MATERI/ VAPOR WIRE TIE (AROUND VAPOR LINE ONLY) 8 FEET (2.43 METERS)i O DDIAI (_` PE OR RE TIE rERS) TAPE OR STRAP THE VAPOR LINE TO THE JOIST WIRE TIE OR RAFTER AT 8 FEET (2.43 METERS) INTERVALS THEN STRAP THE LIQUID LINE TO THE VAPOR LINE. FLOOR JOIST OR ROOF RAFTER REFRIGERANT LINE SET — INSTALLING VERTICAL RUNS (NEW CONSTRUCTION SHOWN) NOTE— Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig. OUTSIDE WALL WOOD BLOCK BETWEEN STUDS VAPOR LINE LIQUID LINE WIRE TIE INSIDE WALL STRAP NON -CORROSIVE METAL SLEEVE WIRE TIE WOOD BLOCK WIRE TIE STRAP I SLEEVE VAPOR LINE WRAPPED \ WITH ARMAFLEX OUTSIDE WALL LIQUID I LINE PVC \ CAU7t!77 LK PIPE FIBERGLASS INSULATION i NOTE— Similar installation practices should be used if line set is to be installed on exterior of outside wall. Figure 8. Line Set Installation Guidelines 506645-01 Page 10 Polyol ester (POE) oils used with HFC-410A refrigerant absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as possible. DO NOT remove line set caps or service valve stub caps until you are ready to make connections. Danger of fire. Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing. Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture - Check the high and low pressures before applying heat. When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa). Brazing alloys and flux contain materials which are hazardous to your health. Avoid breathing vapors or fumes from brazing operations. Perform operations only in well -ventilated areas. Wear gloves and protective goggles or face shield to protect against burns. Wash hands with soap and water after handling brazing alloys and flux. Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve. Allow braze joint to cool before removing the wet rag from the service valve. Temperatures above 250OF can damage valve seals. Use silver alloy brazing rods with 5% minimum silver alloy for copper -to -copper brazing. Use 45% minimum alloy for copper -to -brass and copper -to -steel brazing. Fire, Explosion and Personal Safety Hazard. Failure to follow this warning could result in damage, personal injury or death. Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when exposed to a spark or open flame, can cause fire and/or an ex- plosion, that could result in property damage, personal injury or death. 1 CUT AND DEBUR CAP AND CORE REMOVAL Cut ends of the refrigerant lines square (free from nicks or dents) 2 Remove service cap and core from and debur the ends. The pipe must remain round. Do not crimp end both the suction / vapor and liquid line of the line. service ports. CUT AND DEBUR �i LINE SET SIZE MATCHES SERVICE VALVE CONNECTION SERVICE VALVE CONNECTION COPPERTUBE -� STUB \ REDUCER O O O LINE SET SIZE IS SMALLER THAN CONNECTION REFRIGERANT LINE SERVICE PORT CAP ci -�r SERVICE PORT CORE LIQUID LINE SERVICE '��N VALVE DO NOT CRIMP SERVICE VALVE CONNECTOR WHEN PIPE IS SMALLER THAN CONNECTION SUCTION / VAPOR LINE SERVICE VALVE 3 ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE VALVES 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. A Connect gauge set low pressure side to liquid line service valve (service port). / B Connect gauge set center port to bottle of LOW 1 nitrogen with regulator. �\ C Remove core from valve in suction / vapor line service port to allow nitrogen to escape. ATTACH GAUGES SUCTION / VAPOR SERVICE PORT MUST BE OPEN TO ALLOW EXIT POINT FOR NITROGEN C SUCTION / VAPOR LINE SERVICE VAPOR LINE VALVE INDOOR UNIT �� 101 HIGH OUTDOOR UNIT USE REGULATOR TO FLOW NITROGEN AT 1 TO 2 PSIG. \ I I NITROGEN LIQUID LINE LIQUID LINE SERVICE O WHEN BRAZING LINE SET TO VALVE SERVICE VALVES, POINT FLAME AWAY FROM SERVICE VALVE. Figure 9. Brazing Procedures 506645-01 Page 12 4 WRAP SERVICE VALVES To help protect service valve seals during brazing, wrap water saturated cloths around service valve bodies and copper tube stubs. Use additional water saturated cloths underneath the valve body to protect the base paint. 5 FLOW NITROGEN Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and out of the suction / vapor valve stem port. See steps 3A, 36 and 3C on manifold gauge set connections 6 BRAZE LINE SET Wrap both service valves with water saturated cloths as illustrated here and as mentioned in step 4, before brazing to line set. Water saturated cloths must remain water saturated throughout the brazing and cool -down process. LIQUID LINE SERVICE VALVE WHEN BRAZING LINE SET TO SERVICE VALVES, POINT FLAME AWAY FROM SERVICE VALVE. IMPORTANT — Allow braze joint to cool. Apply additional water saturated cloths to help cool brazed joint. Do not remove water saturated cloths until piping has cooled. Temperatures above 250°F will damage valve seals. WATER SATURATED CLOTH LIQUID LINE SUCTION / VAPOR LINE SERVICE VALVE brazing in the line set! The braze, when complete, must be quenched with water to absorb any residual heat. 2. Do not open service valves until refrigerant lines and HEN BRAZING LINE SET TO RVICE .� indoor coil have been leak -tested and evacuated. V OINTFROM SERVICE VALVE. Refer to procedures provided in this supplement. zcjr SUCTION / VAPOR LINE WATER SATURATED CLOTH 7 PREPARATION FOR NEXT STEP After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water saturated cloths to both services valves to cool piping. Once piping is cool, remove all water saturated cloths. Refer to the unit installation instructions for the next step in preparing the unit. Figure 10. Brazing Procedures (continued) Page 13 14ACX SERIES Flushing Line Set and Indoor Coil Flushing is only required if existing indoor coil and line set are to be used. Otherwise proceed to Installing Indoor Metering Device on page 15. TYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL 1 A REMOVAL PROCEDURE (UNCASED OR PROCEDURE (UNCASED COIL SHOWN) COIL SHOWN) 1B DISTRIBUTOR TUBES LIQUID LINE ORIFICE HOUSING /TEFLONE'RING FIXED ORIFICE A&\ BRASS NUT DISTRIBUTOR ASSEMBLY (/ 1 REMOVE AND DISCARD WHITE TEFLON® SEAL (IF PRESENT) LIQUID LINE ASSEMBLY (INCLUDES STRAINER) STUB END TWO PIECE PATCH PLATE LIQUID LINE CHECK (UNCASED COIL ONLY) ORIFICE EXPANSION DISTRIBUTOR \OUSING VALVE TUBES TEFLOP 01 I� RING A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps holding the liquid line and distributor as- sembly. C Using two wrenches, disconnect liquid line from liquid line orifice hous- ing. Take care not to twist or damage distributor tubes during this pro- cess. 0 VJ) • \ TEFLON& \ ® RING SENSING LINE DISTRIBUTOR /I ASSEMBLY/ EQUALIZER LINE LIQUID LINE / ASSEMBLY WITH / BRASS NUT o MALE EQUALIZER / I LINE FITTING VAPOR LINE LIQUID SENSING BULB LINE D Remove and discard fixed orifice, valve stem assembly if present and A On fully cased coils, remove the coil access and plumbing panels. Teflon® washer as illustrated above. B Remove any shipping clamps holding the liquid line and distributor E Use a field -provided fitting to temporary reconnect the liquid line to the assembly. indoor unit's liquid line orifice housing. C 2 CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE INVERTED HCFC-22 GAUGE CYLINDER CONTAINS MANIFOLD CLEAN HCFC-22 TO BE A USED FOR FLUSHING. VAPOR LINE NEW r n SERVICE VALVE OUTDOOR /\ /\ UNIT EXISTING /II p` INDOOR UNIT LIQUID LINE SERVICE VALVE � r D O 2EC0 Y o '0 CYLINDE TANK RETURN D E F G HIGH H CLOSED Disconnect the equalizer line from the check expansion valve equalizer line fitting on the vapor line. Remove the vapor line sensing bulb. Disconnect the liquid line from the check expansion valve at the liquid line assembly. Disconnect the check expansion valve from the liquid line orifice housing. Take care not to twist or damage distributor tubes during this process. Remove and discard check expansion valve and the two Teflon® rings. Use a field -provided fitting to temporary reconnect the liquid line to the indoor unit's liquid line orifice housing. 3 FLUSHING LINE SET The line set and indoor unit coil must be flushed with at least the same amount of clean refrigerant that previously charged the system. Check the charge in the flushing cylinder before proceeding. A Set the recovery machine for liquid recovery and start the recovery machine. Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line set and indoor unit coil. B Invert the cylinder of clean HCFC-22 and open its valve to allow INLET liquid refrigerant to flow into the system through the vapor line DISCHARGE valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery RECOVERY MACHINE machine. A Inverted HCFC-22 cylinder with clean refrigerant to the vapor service valve. B HCFC-22 gauge set (low side) to the liquid line valve. C HCFC-22 gauge set center port to inlet on the recovery machine with an empty recovery tank to the gauge set. D Connect recovery tank to recovery machines per machine instructions. C After all of the liquid refrigerant has been recovered, switch the recovery machine to vapor recovery so that all of the HCFC-22 vapor is recovered. Allow the recovery machine to pull down to 0 the system. D Close the valve on the inverted HCFC-22 drum and the gauge set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off. Figure 11. Removing Metering Device and Flushing 506645-01 Page 14 Installing Indoor Metering Device This outdoor unit is designed for use in systems that use coil. In applications where an uncased coil is being either an fixed orifice (RFC) (included with outdoor unit), or installed in a field -provided plenum, install the expansion expansion valve metering device (purchased separately) valve in a manner that will provide access for field servicing at the indoor coil. of the expansion valve. Refer to below illustration for See the Lennox 14ACX Engineering Handbook for reference during installation of expansion valve unit. . approved expansion valve kit match ups. The expansion After installation of the indoor coil metering device, valve unit can be installed internal or external to the indoor proceed to Leak Test Line Set and Indoor Coil on page 16. INDOOR EXPANSION VALVE INSTALLATION TWO PIECE PATCH PLATE (Uncased Coil Shown) (UNCASED COIL ONLY) LIQUID LINE STUB ORIFICE END EXPANSION HOUSING \ VALVE DISTRIBUTOR TUBES _ I i� 0 I\� RING TEFLONO \ ® RING SENSING \LINE DISTRIBUTOR \ EQUALIZER ASSEMBLYLINE LIQUID LINE / ASSEMBLY WITH n BRASS NUT A Remove the field -provided fitting that temporary 1/2 Turn reconnected the liquid line to the indoor unit's distributor assembly. 11 B Install one of the provided Teflon® rings around the 10 stubbed end of the expansion valve and lightly lubricate 9 the connector threads and expose surface of the Teflon® 8 4 7 5 ring with refrigerant oil. C Attach the stubbed end of the expansion valve to the liquid line orifice housing. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above, or 20 ft-lb. D Place the remaining Teflon® washer around the other end of the expansion valve. Lightly lubricate connector threads and expose surface of the Teflon® ring with refrigerant oil. E Attach the liquid line assembly to the expansion valve. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or 20 ft-lb. SENSING BULB INSTALLATION A Attach the vapor line sensing bulb in the proper orientation as illustrated to the right using the clamp and MALE EQUALIZER LINE VAPOR screws provided. 1/8 Turn FITTING (SEE LINE EQUALIZER LINE NOTE — Confirm proper thermal contact between vapor line 1 INSTALLATION FOR and expansion bulb before insulating the sensing bulb once 10 j FURTHER DETAILS) LIQUID LINE installed. q {� B Connect the equalizer line from the expansion valve to 8 4 Sensing bulb insulation is required if the equalizer vapor port on the vapor line. Finger tighten 6 5 mounted external to the coil casing. sensing the flare nut plus 1/8 turn (7 ft-lbs) as illustrated below. bulb installation for bulb positioning. ON LINES SMALLER THAN EQUALIZER LINE INSTALLATION VAPOR LINE \ 7/8", MOUNT SENSING BULB AT EITHER THE 3 OR A Remove and discard either the flare seal ca p or flare nut ` \ 9 O'CLOCK POSITION. l��u,,. with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right. ( BULB / BULB B Remove and discard either the flare seal cap or flare nut \ with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right. FLARE SEAL CAP I I FLARE NUT VAPOR LINE ON 7/8" AND LARGER LINES, MOUNT SENSING BULB AT OR COPPER FLARE EITHER THE 4 OR 8 O'CLOCK SEAL BONNET c \ POSITION. NEVER MOUNT ON BOTTOM OF LINE. MALE BRASS EQUALIZER ( BULB BULB LINE FITTING VAPOR LINE NOTE— NEVER MOUNT ON BOTTOM OF LINE. Figure 12. Installing Indoor Expansion Valve Page 15 14ACX SERIES 1 CONNECT GAUGE SET A Connect an HFC-410A manifold gauge set high pressure hose to the vapor valve service port. NOTE — Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the vapor port better protects the manifold gauge set from high pressure damage. B With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. NOTE — Later in the procedure, Leak Test Line Set and Indoor Coil A IMPORTANT refrigerant.Leak detector must be capable of sensing HFC After completing the leak testing the line set and indoor coil as outlined in figure 13, proceed to Evacuating Line Set and Indoor Coil on page 17. AWARNING MANIFOLD GAUGE SET the HFC-410A container will be replaced by the nitrogen B container. ~ Elm T TO VAPOR SERVICE VALVE NITROGEN HFC-410A OUTDOOR UNIT F_, 2 TEST FOR LEAKS After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the following procedure to test for leaks: A With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. Open the valve on 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. (A trace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kPa) pressure]. Close the valve on the HFC-410A cylinder and 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 set and 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 leak detector. F After leak testing disconnect gauges from service Figure 13. Leak Test Page 16 506645-01 Evacuating Line Set and Indoor Coil 1 CONNECT GAUGE SET NOTE — Remove cores from service valves (if not already done). A Connect low side of manifold gauge set with 1/4 SAE in -line tee to vapor line service valve B Connect high side of manifold gauge set to liquid line service valve OUTDOOR C Connect micron gauge available UNIT connector on the 1/4 SAE in -line tee. A D Connect the vacuum pump (with vacuum gauge) to the center port of the 1*4000, manifold gauge set. The center port line will be used later for both the HFC-410Aand nitrogen containers. NITROGEN _r_ HFC-410A VACUUM PUMP B A34000 1/4 SAE TEE WITH SWIVEL COUPLER L c 791 LOW MANIFOLD GAUGE SET 500 MICRON GAUGE t TO VAPOR SERVICE VALVE TO LIQUID LINE SERVICE VALVE 1 HIGH 2 EVACUATE THE SYSTEM RECOMMEND A Open both manifold valves and start the vacuum pump. MINIMUM 3/8" HOSE 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 of pressure. 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 the absolute pressure does not rise above 500 microns (29.9 inches of mercury) within a 20-minute period after shutting off the vacuum pump and closing the manifold gauge valves. F When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to an upright cylinder of HFC-410A refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit. G Perform the following: 1/6 TURN • Close manifold gauge valves. • Shut off HFC-410A cylinder. 11 1 1 • Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core 10 2 tool while maintaining a positive system pressure. 9 3 g 4 • Replace stem caps and secure finger tight, then tighten an additional one -sixth (1/6) of a turn as illustrated. 7 5 6 Figure 14. Evacuating System Page 17 14ACX SERIES Evacuating the system of non-condensables is critical for proper operation of the unit. Non-condensables are SIZE CIRCUIT AND INSTALL SERVICE DISCONNECT SWITCH Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR per NEC). Install power wiring and properly sized disconnect switch. MAIN FUSE BOX/ BREAKER PANEL SERVICE DISCONNECT SWITCH NOTE— Units are approved foruse only with copper conductors. Ground unit at disconnect switch or to an earth ground. AWARNING defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system. Non-condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts. A IMPORTANT Use a...-. gauge capable of accurately measuring down to 50 microns. Electrical In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC). Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size. 24VAC TRANSFORMER Use the transformer provided with the furnace or air handler for low -voltage control power (24VAC - 40 VA minimum) INSTALL THERMOSTAT Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and 5 feet (1.5m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight or drafts. THERM NOTE— 24VAC, Class // circuit connections are made in the control panel. 506645-01 Page 18 ROUTING HIGH VOLTAGE/ GROUND AND CONTROL WIRING HIGH VOLTAGE / GROUND WIRES HIGH VOLTAGE CONNECTIONS Any excess high voltage field wiring should be trimmed and (CONTACTOR) secured away from any low voltage field wiring. To facilitate a conduit, a cutout is located in the bottom of the control panel. Connect conduit to the control panel using a proper conduit fitting. LOW VOLTAGE CONTROL WIRING NOTE — Wire tie provides low voltage control wire strain relief and to maintain separation of field installed low and high voltage circuits. HIGH VOLTAGE NOTE — For proper voltages, select thermostat wire (control wires) FIELD WIRING gauge per table above. LOW VOLTAGE FIELD WIRING NOTE— Do not bundle any excess 24VAC control wires inside _ FACTORY control panel. WIRING THERMOSTAT Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated. A Run 24VAC control wires through hole with grommet and secure with provided wire tie. B Make 24VAC thermostat wire connections. Locate the two wires from the contactor and make connection using field provided wire nuts: • Yellow to Y1 • Black to C (common) WIRE RUN LENGTH AWG# INSULATION TYPE LESS THAN 100' (30 METERS) 18 TEMPERATURE RATING MORE THAN 100' (30 METERS) 16 35°C MINIMUM. OUTDOOR RED COMPRESSOR CRANKCASE HEATER Al L1 F 208-230/ 60/ 1 L2 r DESCRIPTION KEY I COMPONENT A4 CONTROL -TIMED OFF B1 COMPRESSOR B4 MOTOR -OUTDOOR FAN C12 CAPACITOR -DUAL HR1 HEATER -COMPRESSOR K1,-1 CONTACTOR -COMPRESSOR S4 SWITCH -HIGH PRESSURE S24 SWITCH -LOSS OF CHARGE S40 TERMOSTAT-CRANKCASE S87 SWITCH -LOW PRESS, COMP 1 5173 SWITCH -THERMAL PROTECTION SINGLE PHASE OUTDOOR YELLOW UNIT DUAL CAPACITOR A4 TO 24 VAC POWER F C H TIMED OFF SOURCE CONTROL 20 VA MINIMUM NEC CLASS 2 2 3 1 C Y1 BLACK COMPRESSOR CONTACTOR I � L2 Ed GROUND L1 LUG I 208-230/ 60/ 1 I I - GROUND L — — 61 l , BLACK — �I C"S4 RED HIGH S173 S24 OR ORANGE PRESSURE S24 SWITCH Q RED 5173 Q S40Z.1,2,BLACK A4 F �Q 64 S4 I I 2 — 3 S87 A GROMMETAND WIRE TIE 0 NOTE- K1 FOR USE WITH COPPER CONDUCTORS ONLY. REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE NOTE- 0 TO 24 VAC IF ANY WIRE IN THIS APPLIANCE IS REPLACED,IT JUMPER IS USED WHEN TOC IS NOT USED POWER SOURCE MUST BE REPLACED WITH WIRE OF LIKE SIZE, © S173 SWITCH USED ONLY IN UNITS EQUIPPED 20 VA MINIMUM RATING, INSULATION THICKNESS, AND TERMINATION. WITH COMPRESSORS WHICH DO NOT INCLUDE NEC CLASS 2 INTERNAL SWITCH LINE VOLTAGE FIELD INSTALLED -------- CLASS II VOLTAGE FIELD WIRING ® S173 TO S87 WHEN A4 IS NOT USED DENOTES OPTIONAL COMPONENTS Figure 15. Typical Field Wiring Diagram Page 19 14ACX SERIES GROUND W (GREEN CRANKCASE HEATER (HR1) 041. -047.-048.-059. -060 ONLY) Figure 16. Typical Factory Wiring Diagram (Copeland Compressor) Page 20 506645-01 THERMAL PROTECTIC SWITCH (S5 OR S17 GROUND WI (GREEN) CRANKCASE HEATER (HR1) (-041. -047.-048.-059. -060 Figure 17. Typical Factory Wiring Diagram (Interlink Compressor) Page 21 14ACX SERIES Servicing Units Delivered Void of Charge If the outdoor unit is void of refrigerant, clean the system using the procedure described below. 1. Leak check system using procedure outlined in this instruction. 2. Evacuate the system using procedure outlined in this instruction. 3. Use nitrogen to break the vacuum and install a new filter drier in the system. 4. Evacuate the system again using procedure outlined in this instruction. 5. Weigh in refrigerant using procedure outlined under Start -Up and Charging Procedures. 6. Monitor the system to determine the amount of moisture remaining in the oil. It may be necessary to replace the filter drier several times to achieve the required dryness level. If system dryness is not verified, the compressor will fail in the future. Start-UpUnit A IMPORTANT If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start-up to prevent compressor damage as a result of slugging. Rotate1. • check forbinding. 2. Inspect all factory- and field -installed wiring for loose connections. 3. After evacuation is complete, open the liquid line and suction line service valve stems (Operating Service Valves on page 4) to release the refrigerant charge (contained in outdoor unit) into the system. 4. Replace the stem caps and tighten to the value listed in table 1. 5. Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit's nameplate. If not, do not start the equipment until you have consulted with the power company and the voltage condition has been corrected. 6. Connect manifold gauge set for testing and charging using figure 18 as a guideline. 7. Set the thermostat for a cooling demand. Turn on power to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit. 8. Recheck voltage while the unit is running. Power must be within range shown on the unit nameplate. 9. Check system for sufficient refrigerate using the procedures outlined in under System Refrigerant. 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. GAUGE SET MANIFOLD GAUGE SET CONNECTIONS FOR TESTING AND CHARGING LOW HIGH B SUCTION LINE / T SERVICE PORT CONNECTION O OUTDOOR UNIT AClose manifold gauge set valves and connect the center hose to a cylinder of HFC-410A. Set for liquid phase charging. REFRIGERANT TANK BConnect the manifold gauge set's low pressure side to the suction line service port. LIQUID PHACHARGE IN SE A CConnect the manifold gauge set's high j pressure side to the liquid line service port. DPosition temperature sensor on liquid line near DIGITAL SCALE liquid line service port. r1 `` y TEMPERATURE SENSOR TO LIQUID (LIQUID LINE) LINE SERVICE VALVE D TEMPERATURE SENSOR Figure 18. Manifold Gauge Set Setup and Connections 506645-01 Page 22 CHECKING AIR FLOW AT INDOOR COIL Check airflow using the Delta-T (DT) process using the illustration in figure 19. Temp. DT of air 80 24 24 24 23 23 22 22 22 20 19 18 17 16 15 entering a 78 23 23 23 22 22 21 21 20 19 18 17 16 15 14 indoor 5 n 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13 coil IF 74 21 21 21 20 19 19 18 17 16 16 15 14 13 12 G 72 20 20 19 18 17 17 16 1 15 14 13 12 11 10 Wet -bulb IF 57 58 59 60 61 62 63 64 65 66 67 68 69 70 T A C D 72° 53, 19° air flow air flow B DRY 640 DRY BULB BULB All temperatures are INDOOR WET expressed in IF o COIL • BULB • 1. Determine the desired DT—Measure entering air temper- ature using dry bulb (A) and wet bulb (B). DT is the intersect- ing value of A and B in the table (see triangle). 2. Find temperature drop across coil —Measure the coil's dry bulb entering and leaving air temperatures (A and C). Tem- perature Drop Formula: (TDrop) = A minus C. 3. Determine if fan needs adjustment —If the difference between the measured TDrop and the desired DT (TDrop DT) is within +31, no adjustment Is needed. See examples: Assume DT = 15 and A temp. = 721, these C temperatures would necessi- tate stated actions: Co TDrop — DT = *FACTION 530 19 — 15 = 4 Increase the airflow 58° 14 — 15 = -1 (within +30 range) no change 62° 10 — 15 = -5 Decrease the airflow 4. Adjust the fan speed —See indoor unit instructions to in- crease/decrease fan speed. Changing air flow affects all temperatures; recheck tempera- tures to confirm that the temperature drop and DT are within +30. Figure 19. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart WHEN TO CHARGE? • Best during warm weather • Can charge in colder weather by determining best charge method? Determine by: A Metering device type B 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 temperature to measure liquid line temperature to measure suction line temperature Which metering device? TXV RFC 65°F 64°F 40°F 39°F (18.3°C) and (17.7°C) and (4.4°0 and (3.8°C) and \ Above Below Above Below , APPROACH OR WEIGH-IN SUPERHEAT WEIGH-IN SUBCOOLING Figure 20. Determining Charge Method Page 23 14ACX SERIES WEIGH IN (RFC AND TXV) CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE If the system is void of refrigerant, first, locate and repair any leaks and then weigh in the refrigerant charge into the unit. To calculate the total refrigerant charge: Adjust amount. for variation Amount specified on in line set length listed on nameplate line set length table below. Total charge Refrigerant 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* 3/8" (9.5 mm) 3 ounce per 5' (85 g per 1.5 m) *If line length is greater than 15 ft. (4.6 m), add this amount. If line length is less than 15 ft. (4.6 m), subtract this amount. NOTE - Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig. NOTE - The above nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information. Figure 21. Using HFC-410A Weigh In Method USE WEIGH-IN METHOD 65°F (18.3°C) 1. Confirm proper airflow across coil using figure 19. and Above 2. Compare unit pressures with table 4, Normal Operating Weigh-in or remove refrigerant Pressures. based upon line length 3. Set thermostat to call for heat (must have a cooling load between 70-80°F (21-260C). 64°F ABOVE or 4. Connect gauge set. (17.7°C) and BELOW 5. When heat demand is satisfied, set thermostat to call for Below cooling. 6. Allow temperatures and pressures to stabilize. If value is greater than shown (high 7. Record outdoor ambient temperature: approach), add refrigerant; if less than shown (liquid temperature too � If refrigerant is added or 8. AMB° _ Record liquid line temperature: close to ambient temperature, low removed, retest to confirm LIQ° = approach), remove refrigerant. that unit is properly charged. 9. Subtract to determine approach (APP° ). LIQ° - AMB° = APP° APP° (Approach) Values(F:+/-1.00 [C: +/-0.60]) 4�= 10. Compare results with table below. OF (°C)* -018 -024 -030 -036 -041 -042 -047 -048 -059/-060 65 (18) 4(2.2) 2(1.1) 2(1.1) 2(1.1) 3(1.7) 6(3.3) 9(5.0) 7(3.9) 8(4.4) 75 (24) 5(2.8) 4(2.2) 4(2.2) 5(2.8) 3(1.7) 6(3.3) 9(5.0) 8(4.4) 9(5.0) 85 (29) 6(3.3) 4(2.2) 6(3.3) 8(4.4) 4(2.2) 8(4.4) 8(4.4) 8(4.4) 9(5.0) 95 (35) 5(2,8) 4(2.2) 5(2.8) 7(3.9) 4(2.2) 8(4.4) 8(4.4) 8(4.4) 9(5.0) 105 (41) 3(1.7) 4(2.2) 5(2.8) 6(3.3) 4 (2.2) 8(4.4) 8(4.4) 8(4.4) 9(5.0) 115 (45) 3(1.7) 3(1.7) 4 (2.2) 6(3.3) 5(2.8) 8(4.4) 8(4.4) 9(5.0) 9(5.0) *Temperature of air entering outdoor coil. Figure 22. HFC-410A Approach TXV Charge Page 24 506645-01 USE WEIGH-IN METHOD476. 1. Confirm proper airflow across coil using figure 19. 2. Compare unit pressures with table 4, Normal Weigh-in or remove refrigerant Operating Pressures. based upon line length 3. Set thermostat to call for heat (must have a cooling load between 70-80°F (21-26°C) 64°F (17.7°C)4. Connect gauge set =_= and below 5. Measure outdoor ambient temperature When heat demand is satisfied, set thermostat to call for BLOCK OUTDOOR COIL: [sometimes necessary with lower cooling temperatures] Use cardboard or plastic sheet to restrict the 7. Allow temperatures and pressures to stabilize. airflow through the outdoor coil to achieve pressures from 325-375 psig (2240-2585 kPa). Higher pressures are needed NOTE - If necessary, block outdoor coil to maintain 325 to check charge. Block equal sections of air intake panels and - 375 psig. CARDBOARD OR move coverings sideways until the liquid pressure is in the 8. Record liquid line temperature: PLASTIC SHEET above noted ranges. LIQ, _ If refrigerant is added orIf value is MORE than shown, 9. Measure liquid line pressure and use the value to removed, verify charge u remove refrigerant. determine saturation temperature (see table 3): the Approach Method. SAT* = 10. Subtract to determine subcooling (SC°): SAT° - LIQ° = SC* If value is LESSMORE than shown, add?LESS or 11. Compare results with table below. refrigerant. SC(Subcooling) Values (F:+/-1.0° [C: +/-0.6°]) OF (°C)* -018 -024 -030 -036 -041 -042 -047 -048 -059/-060 65 (18) 10(5.6) 10(5.6) 11(6.1) 13(7.2) 9(5.0) 10(5.6) 6(3.3) 8(4.4) 8(4.4) 75 (24) 6(3.3) 7(3.9) 8(4.4) 9(5.0) 7(3.9) 7(3.9) 6(3.3) 8(4.4) 7(3.9) 85 (29) 6(3.3) 8(4.4) 6(3.3) 7(3.9) 7(3.9) 8(4.4) 6(3.3) 8(4.4) 8(4.4) 95 (35) 6(3.3) 9(5.0) 6(3.3) 8(4.4) 7(3.9) 8(4.4) 6(3.3) 8(4.4) 7(3.9) 105 (41) 10(5.6) 9(5.0) 7(3.9) 9(5.0) 7(3.9) 8(4.4) 6(3.3) 8(4.4) 6(3.3) 115 (45) 10(5.6) 10(5.6) 8(4.4) 10(5.6) 6(3.3) 7(3.9) 5(2.8) 7(3.9) 6(3.3) *Temperature of air entering outdoor coil. Figure 23. HFC-410A Subcooling TXV Charge Page 25 14ACX SERIES USE WEIGH-IN METHOD Weigh-in or remove refrigerant based upon line length SUPERHEAT RFC If refrigerant is REMOVED, retest to confirm that unit is properly charged. 39°F (3.8°C) and Below ABOVEW or 40°F BELO (4.4°C) and Above SH° (Superheat) Values (+/-5°F) °F* Wet Bulb air enterinq indoor coil 50 52 54 56 58 60 62 64 66 68 70 72 74 76 40 15 18 20 23 26 29 32 34 38 41 43 46 48 51 45 13 16 18 21 24 27 30 33 36 39 41 44 46 49 50 11 14 16 19 22 25 28 31 34 37 39 42 44 47 55 9 12 14 17 20 23 27 30 33 36 38 40 42 44 60 7 10 12 15 18 21 24 27 30133 35 38 40 43 65 - 6 10 13 16 19 21 24 27 30 33 36 38 41 70 - 7 10 13 16 19 21 24 27 30 33 36 39 75 - 6 9 12 15 18 21 24 28 31 34 37 80 - 5 8 12 15 18 21 25 28 31 35 85 - 8 11 15 19 22 26 30 33 90 - 5 9 13 16 20 24.27 31 95 - 6 10 14 18 22 25 29 100 - - 8 12 16 21 24 28 105 - - 5 9 13 17 22 26 110 - - 6 11 15 20 25 115_- - 8 14 18 24 Dry-bulb temperature (°F) of entering outdoor ambient air. If value is LESS than shown, then REMOVE MORI refrigerant. LE£ 1. Confirm proper airflow across coil using figure 19. 2. Compare unit pressures with table 4, Normal Operating Pressures. 3. Use SUPERHEAT to correctly charge unit or to verify the charge is correct. 4. Set thermostat to call for heat (must have a cooling load between 70-80°F (21-26°C) 5. Connect gauge set. 6. When heat demand is satisfied, set thermostat to call for cooling. 7. Allow temperatures and pressures to stabilize. 8. Measure the suction line pressure and use the use value to determine saturation temperature (table 3): SAT' _ 9. Record suction line temperature: VAP° = 10. Subtract to determine superheat (SH°): VAP° - SAT° = SH° 11. Record the wet bulb temperature (air entering indoor coil): WB= 12. Record outdoor ambient temperature. 13. Compare results with table to the left. NOTE - Do not attempt to charge system where a dash appears, system could be overcharged. Superheat is taken at suction line service port. Suction line superheat must never be less than 5°F at the suction line service port. If refrigerant is ADDED, retest to confirm that unit is properly charged. Figure 24. HFC-410A Superheat RFC Method Table 3. HFC-410A Temperature - Pressure (Psig) IF °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 1 80 26.7 235 -15 -26.1 31.7 85 1 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 1 110 43.3 365 15 -9.4 70.0 115 1 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 1 62.8 573 50 10.0 142 150 65.6 608 55 12.8 155 Page 26 506645-01 Table 4. HFC-410A Normal Operating Pressures (Liquid +10 and Suction +5 psig) A IMPORTANT Model -018 -024 -030 -036 -041 -042 -047 -0418-0591-060 **Temp. T (°C) Liquid / Suction Liquid / Suction Liquid / Liquid / Liquid / Liquid / Liquid / Liquid / Liquid / Suction Suction Suction Suction Suction Suction Suction Expansion Valve (TXV)* 65(18) 230/138 225/135 226/129 238/132 233/142 236/138 233/139 238/136 239/133 70(21) 244/139 242/137 241/131 254/135 239/142 253/140 252/140 256/138 258/135 75(24) 265/140 260/138 259/134 273/138 256/143 273/141 272/141 277/139 278/136 80(27) 286/140 282/140 281/138 293/140 278/144 296/142 294/142 299/140 300/137 85(29) 307/142 304/141 301/140 316/142 299/145 318/143 315/142 320/139 323/138 90(32) 330/143 326/142 324/141 340/143 321/145 341/144 338/144 343/140 346/139 95(35) 351/144 351/142 348/142 366/144 343/146 366/146 361/144 369/141 370/140 100(38) 380/144 376/144 372/143 392/145 366/147 392/147 387/144 395/142 396/142 105(41) 407/145 403/145 399/144 420/147 389/148 417/148 413/145 422/144 415/143 110(43) 436/146 433/145 428/145 449/148 421/149 445/149 442/148 450/146 449/145 115(45) 466/147 463/147 456/146 480/149 452/151 475/151 465/148 481/148 476/147 Fixed Orifice (RFC)* 65(18) 232/124 228/125 229/128 241/131 228/131 248/135 232/125 240/126 244/125 70(21) 248/127 244/127 243/129 258/134 245/135 266/138 249/129 260/129 263/128 75(24) 267/131 261/131 261/132 277/136 263/138 285/141 268/133 281/133 281/131 80(27) 286/135 284/134 284/135 298/139 284/141 305/143 286/136 301/135 303/134 85(29) 307/138 303/137 305/138 321/141 306/144 327/145 312/140 324/138 324/136 90(32) 328/141 325/140 327/140 342/143 327/146 349/147 332/142 346/140 347/139 95(35) 351/143 347/142 349/142 366/145 348/148 372/149 357/144 371/142 370/141 100(38) 375/146 370/144 372/144 392/147 372/149 396/150 379/146 395/144 394/143 105(41) 400/148 394/146 396/146 416/149 395/151 421/152 406/149 420/146 418/145 110(43) 426/150 420/148 422/148 446/151 424/153 447/153 430/150 447/148 444/146 115(46) 457/153 447/150 449/150 480/152 453/155 476/154 460/152 473/150 471/147 *Values shown are typical pressures; indoor unit match up, indoor air quality equipment, and indoor load will cause the pressures to vary. **Temperature of the air entering the outside coil. Page 27 14ACX SERIES System Operation UNIT COMPONENTS High Pressure Switch (S4) 14ACX units are equipped with a high-pressure switch that is located in the liquid line of the compressor as illustrated in figure on page 2 and figure 25 for the location of the manual reset button.. MANUALRESET BUTTON 0 Figure 25. High Pressure Switch (S4) Manual Reset The switch is a Single Pole, Single Throw (SPST), manual -reset switch which is normally closed and removes power from the compressor when discharge pressure rises above factory setting at 590 + 10 psi. The manual -reset button can be identified by a red cap that is press to preform the reset function. Thermal Protection Switch (S173) — Compressor Mounted Some units are equipped with a compressor mounted normally closed temperature switch that prevents compressor damage due to overheating caused by internal friction. The switch is located on top of the compressor casing (see figure 1). This switch senses the compressor casing temperature and opens at 239-257°F (115°C-125°C) to shut off compressor operation. The auto -reset switch closes when the compressor casing temperature falls to 151-187°F (66°C-86°C), and the compressor is re -energized. This single -pole, single -throw (SPST) bi-metallic switch is wired in series with the 24V Y input signal to control compressor operation. Crankcase Heater (HR1) and Thermostat Switch (S40) (-041 through -060 models only) These models are equipped with either a 40 or 70 watt belly -band type crankcase heater. HR1 prevents liquid from accumulating in the compressor. HR1 is controlled by a single -pole, single -throw thermostat (SPST) switch (S40) located on the liquid line (see figure 1 for location). When liquid line temperature drops below 50°F the thermostat closes energizing HR1. The thermostat will open, de -energizing HR1 once liquid line temperature reaches 70' F. Maintenance DEALER Maintenance and service must be performed by a qualified installer or service agency. At the beginning of each cooling season, the system should be checked as follows: 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 for evidence 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 and clean if necessary. NOTE - If insufficient cooling occurs, the unit should be gauged and refrigerant charge should be checked. Outdoor Coil Clean and inspect outdoor coil (may be flushed with a water hose). Ensure power is off before cleaning. 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) Sea Coast — Moist air in ocean locations can carry salt, which is corrosive to most metal. Units that are located near the ocean require frequent inspections and maintenance. These inspections will determine the necessary need to wash the unit including the outdoor coil. Consult your installing contractor for proper intervals/procedures for your geographic area or service contract. 506645-01 Page 28 Indoor Unit Clean or change filters. 2. Lennox blower motors are prelubricated and permanently sealed. No more lubrication is needed. 3. Adjust blower speed for cooling. Measure the pressure drop over the coil to determine the correct blower CFM. Refer to the unit information service manual for pressure drop tables and procedure. 4. Belt Drive Blowers - Check belt for wear and proper tension. 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 of oil leaks. 3. Check condensate line and clean if necessary. HOMEOWNER Cleaning of the outdoor unit's coil should be performed by a trained service technician. Contact your dealer and set up a schedule (preferably twice a year, but at least once a year) to inspect and service your outdoor unit. The following maintenance may be performed by the homeowner. Outdoor Coil The outdoor unit must be properly maintained to ensure its proper operation. • Please contact your dealer to schedule proper inspection and maintenance for your equipment. • Make sure no obstructions restrict airflow to the outdoor unit. • Grass clippings, leaves, or shrubs crowding the unit can cause the unit to work harder and use more energy. • Keep shrubbery trimmed away from the unit and periodically check for debris which collects around the unit. Routine Maintenance In order to ensure peak performance, your system must be properly maintained. Clogged filters and blocked airflow prevent your unit from operating at its most efficient level. 1. Air Filter — Ask your Lennox dealer to show you where your indoor unit's filter is located. It will be either at the indoor unit (installed internal or external to the cabinet) or behind a return air grille in the wall or ceiling. Check the filter monthly and clean or replace it as needed. 2. Disposable Filter — Disposable filters should be replaced with a filter of the same type and size. NOTE— If you are unsure about the filter required for your system, call your Lennox dealer for assistance. 3. Reusable Filter — Many indoor units are equipped with reusable foam filters. Clean foam filters with a mild soap and water solution; rinse thoroughly; allow filter to dry completely before returning it to the unit or grille. NOTE — The filter and all access panels must be in place any time the unit is in operation. 4. Indoor Unit — The indoor unit's evaporator coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the inside air. Have your dealer show you the location of the drain line and how to check for obstructions. (This would also apply to an auxiliary drain, if installed.) Thermostat Operation See the thermostat homeowner manual for instructions on how to operate your thermostat. Preservice Check If your system fails to operate, check the following before calling 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 unit model number and have it handy before calling. Accessories For update -to -date information, see any of the following publications: • Lennox 14ACX Engineering Handbook • Lennox Product Catalog • Lennox Price Book Page 29 14ACX SERIES 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? Iff Refrigerant Lines: - Leak Checked? ❑ Properly Insulated? ❑ Outdoor Fan Checked? ❑ Service Valves: --- Fully Opened? ❑ Caps Tight? ❑ Thermostat Voltage With Compressor Operating Calibrated? ❑ Properly Set? ❑ Level? ❑ Page 30 506645-01