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BLD2022-0303_Manufacturer_Specifications_and_Installation_Instructions_3.9.2022_2.53.44_PM_2728124LENNOX (D2008 Lennox Industries Inc. Dallas, Texas, USA C UL N LISTED RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE t � � Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury. Be aware of, and use caution when working near these areas during installation or while servicing this equipment. A IMPORTANT INSTALLATION INSTRUCTIONS Merit® Series 13ACX Units AIR CONDITIONER Technical 506081-01 Publications 09/08 Litho U.S.A. Supersedes 07/08 Table of Contents Shipping and Packing List ........................ 13ACX Air Conditioners .......................... Unit Dimensions ................................. General Information ............................. Recovering Refrigerant from Existing System ....... Removing Existing Outdoor Unit ................... Positioning New Outdoor Unit ..................... New or Replacement Line Set ..................... Brazing Connections ............................ Removing Indoor Unit Metering Device ............ Flushing the System ............................ Installing New Indoor Unit Metering Device ......... Testing for Leaks ............................... Evacuating the System .......................... Servicing Unit Delivered Void of Charge ........... Electrical Connections .......................... Start -Up and Charging Procedures ................ System Operation .............................. Maintenance ................................... Homeowner Information ......................... Optional Accessories ........................... Start -Up and Performance Checklist .............. Shipping and Packing List 1 1 2 2 4 5 5 6 8 9 10 11 13 13 14 14 15 21 22 22 23 24 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) Liquid line filter drier 13ACX Air Conditioners 13ACX 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 13ACX 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 11111111111111111111111111111 IN Page 1 11111111111111111111111111111111111111111111111111111111 IN Unit Dimensions - Inches (mm) A SIDE VIEW OUTDOOR COIL FA COMPRESSI SUCTION AND LIQUID LIN CONNECTIC OPTIONAL UNIT STANDOFF KIT (4) (FIELD INSTALLED) Model Numbers A B 25-1/4 (641) -018 24-1/4 (616) -024 24-1/4 (616) 25-1/4 (641) -030 24-1/4 (616) 29-1/4 (743) -036 24-1/4 (616) 29-1/4 (743) -042 28-1/4 (724) 29-1/4 (743) -048 28-1/4 (724) 37-1/4 (925) -060 28-1/4 (724) 33-1/4 (845) General Information These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation. When servicing or repairing HVAC components, ensure the fasteners are appropriately tightened. Table 1 shows torque values for fasteners. SIDE VIEW Table 1. Torque Requirements Parts Recommended Torque Service valve cap 8 ft.- lb. 11 NM Sheet metal screws 16 in.- lb. 2 NM Machine screws #10 28 in.- lb. 3 NM Compressor bolts 90 in.- lb. 10 NM Gauge port seal cap 8 ft.- lb. 11 NM USING MANIFOLD GAUGE SETS When checking the system charge, only use a manifold gauge set that features low loss anti -blow back fittings. See figure 1 for a typical manifold gauge connection setup. Manifold gauge sets 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 on the high side and a low side of 30" vacuum to 250 psi with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psi of pressure with a 4000 psi burst rating. OPERATING SERVICE VALVES A IMPORTANT Only use Allen wrenches of sufficient hardness (50Rc - Rockwell Harness Scale minimum). Fully insert the wrench into the valve stem recess. Service valve stems are factory -torqued (from 9 ft-Ibs for small valves, to 25 ft-Ibs for large valves) to prevent refrigerant loss during shipping and handling. Using an Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench, or stripping the valve stem recess. The liquid and suction line service valves are used for removing refrigerant, flushing, leak testing, evacuating, checking charge and charging. Page 2 506081-01 09/08 Figure 1. Typical Manif Each service valve is equipped with a service port which has a factory -installed valve stem. 1/6 TURN I 1/12 TURN 11 1 / 10 2 (T) 9 3 g 4 7 6 5 Figure 2. Cap Tightening Distances 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. Operating Angle -Type Service Valve To Access Angle -Type Service Port: A service port cap protects the service port core from contamination and serves as the primary leak seal. 1. Remove service port cap with an appropriately sized wrench. 2. Connect gauge to the service port. 3. When testing is completed, replace service port cap and tighten as follows: • With Torque Wrench: Finger tighten and then tighten per table 1. • Without Torque Wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/6 turn clockwise as illustrated in figure 2. old Gauge Connection Setup To Open and Close Angle -Type Service Valve: A valve stem cap protects the valve stem from contamination 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 liquid -line valve sizes and 5/16" for suction -line valve sizes) to back the stem out counterclockwise as far as it will go. 3. Replace the stem cap and tighten as follows: • With Torque Wrench: Finger tighten and then tighten per table 1. • Without Torque Wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/12 turn clockwise as illustrated in figure 2. NOTE - A label with specific torque requirement may be affixed to the stem cap. If the label is present, use the specified torque. NOTE- To prevent stripping of the cap, the appropriately sized wrench should fit snugly over the cap before tightening the cap. Figure 3. Angle -Type Service Valve (Front -Seated Closed) Page 3 13ACX SERIES To Open and Close Ball -Type Service Valve: SERVICE PORT CAP SERVICE PORT SERVICE PORT CORE / (VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE TO INDOOR UNIT STEM CAP TO OUTDOOR UNIT OPEN TO BOTH INDOOR AND OUTDOOR UNITS Figure 4. Angle -Type Service Valve (Back -Seated Opened) Operating Ball -Type Service Valve To Access Ball -Type Service Port: A service port cap protects the service port core from contamination and serves as the primary leak seal. OPEN TO LINE SET WHEN VALVE IS CLOSED, TO TO INDOOR UNIT BOTH LINE SET AND UNIT WHEN VALVE IS OPEN. TO OPEN ROTATE STEM COUNTERCLOCKWISE 90°. / BALL (SHOWN CLOSED) 0 TO CLOSE ROTATE STEM CLOCKWISE 90°. VALVE STEM SERVICE PORT SERVICE PORT CORE i SERVICE PORT CAP TO OUTDOOR UNIT STEM CAP Figure 5. Ball -Type Service Valve 1. Remove service port cap with an appropriately sized wrench. 2. Connect gauge to the service port. 3. When testing is completed, replace service port cap and tighten as follows: With Torque Wrench: Finger tighten and then tighten per table 1. Without Torque Wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/6 turn clockwise as illustrated in figure 2. A valve stem cap protects the valve stem from contamination and assures a leak -free seal. 1. Remove stem cap with an appropriately sized wrench. 2. Use an appropriately sized wrench to open. To open valve, rotate stem counterclockwise 90°. To close rotate stem clockwise 90°. 3. Replace the stem cap and tighten as follows: With Torque Wrench: Finger tighten and then tighten per table 1. Without Torque Wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/12 turn clockwise as illustrated in figure 2. NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque. Recovering Refrigerant from Existing System Remove existing HCFC-22 refrigerant using one of the following methods: METHOD 1: Use this method if the existing outdoor unit is not equipped with manual shut-off valves, and plan on using existing HCFC-22 refrigerant to flush the system. NOTE - Use recovery machine instructions for specific setup requirements. Perform the following task: 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 the instructions provided with the recovery machine on how to setup the connections. 3. Remove all HCFC-22 refrigerant from the existing system. Check gauges after shutdown to confirm that the entire system is completely void of refrigerant. Figure 6. Typical Refrigerant Recovery (Method 1) 506081-01 09/08 Page 4 METHOD 2: Use this method if the existing outdoor unit is equipped with manual shut-off valves, and plan on using new HCFC-22 refrigerant to flush the system. IMPORTANT. Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes, and/or long line sets. The following conditions may cause the compressor to stop functioning: 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 cycled 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 suction 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: 1. Start the existing HCFC-22 system in the cooling mode and close the liquid line valve. 2. Pump as much of the existing HCFC-22 refrigerant with the compressor back into the outdoor unit until you have reached the limitations of the outdoor system. Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant in the system. NOTE - It may be necessary to bypass the low pressure switches if equipped to ensure complete refrigerant evacuation. 3. When the low side system pressures reach 0 psig, close the suction line valve. 4. Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system. Removing Existing Outdoor Unit 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. Positioning New Outdoor Unit See Unit Dimensions on page 2 for sizing mounting slab, platforms or supports. Refer to figure 7 for mandatory installation clearance requirements. SEE NOTES BELOW THIS FIGURE FOR FURTHER DETAILS. Figure 7. Installation Clearances NOTES: • Service panel access clearance of 30 in. (762 mm) must be maintained. • Clearance to one of the other three sides must be 36 in. (914 mm)- • Clearance on one of the remaining two sides may be 12 in. (305 mm) and the final side may be 6 in. (152 mm). • Clearance required on top of unit is 48 in. (1219 mm). • A clearance of 24 in. (610 mm) must be maintained between two units. POSITIONING CONSIDERATIONS t � � In order to avoid injury, take proper precaution when lifting heavy objects. 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 8. Page 5 13ACX SERIES INSTALL UNIT AWAY FROM WINDOWS TWO 900 ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION. Figure 8. Outside Unit Placement PLACING OUTDOOR UNIT ON SLAB When installing a unit at grade level, the top of the slab should be high enough above the grade so that water from higher ground would not collect around the unit as illustrated in figure 9. DISCHARGE AIR BUILDING STRUCTURE I 1 - JI ' I I MOUNTING SLAB GROUND LEVEL Figure 9. Typical Slab Mounting at Ground Level Slab may be level or have a slope tolerance away from the building of not more than two degrees, or 2 inches per 5 feet (51 mm per 1524 mm) as illustrated in figure 9. INSTALLING OUTDOOR UNIT ON ROOF Install the unit at a minimum of 4 inches (102 mm) above the surface of the roof. Ensure the weight of the unit is properly distributed over roof joists and rafters. Redwood or steel supports are recommended. New or Replacement Line Set This section provides information on installation or replacement of existing line set. If line set is not being installed or replace then proceed to Brazing Connections on page 8. 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. Also, consider the following when placing and installing a high -efficiency air conditioner: REFRIGERANT LINE SET Field refrigerant line set consists of liquid and suction lines from the outdoor unit to the indoor unit coil. Use Lennox L15 (braze, non -flare) series line set, or field -fabricated refrigerant lines that meet the specifications listed below. Table 2. Refrigerant Line Set Valve Field Recommended Line Set Connections Model Liquid Suction Liquid Suction L15 Line Line Line Line Line Set -018 L 15-41 024 3/8 in. 3/4 in. 3/8 in 3/4 in. 15 ft. - 50 ft. -024 (10 mm) (19 mm) (10 mm) (19 mm) (4.6 m - 15 m) 036 L15-65 -036 3/8 in. 7/8 in. 3/8 in. 7/8in. 15 ft. - 50 ft. -048 10 (mm) (mm) 22 10 (mm) 22 (mm) (4.6 m - 15 m) O60 3/8 in. 1-1/8 in. 3/8 in. 1-1/8 in. Field (10 mm) (29 mm) (10 mm) (29 mm) Fabricated NOTE - When installing refrigerant lines longer than 50 feet, contact Lennox Technical Support Product Applications for assistance or Lennox piping manual. To obtain the correct information from Lennox, be sure to communicate the following points: • Model (13ACX) 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. 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 13ACX 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 13ACX 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 13ACX 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 10. This filter drier must be installed to ensure a clean, 506081-01 09/08 Page 6 moisture -free system. Failure to install the filter drier will void the warranty. A replacement filter drier is available from Lennox. See Brazing Connections on page 8 for special procedures on brazing filter drier connections to the liquid line. BRAZE CONNECTION POINTS FLOW LIQUID LINE LINE LIQUID SERVICE VALVE LINE LIQUID LINE FILTER DRIER OUTDOOR UNIT Figure 10. Typical Liquid Line Filter Drier Installation LINE SET ISOLATION This following illustrations provide best practices on ensuring proper refrigerant line set isolation: • Installation of line set on horizontal runs is illustrated in figure 11. • Installation of line set on vertical runs is illustrated in figure 12. • Installation of a transition from vertical to horizontal is illustrated in figure 13. TO HANG LINE SET FROM JOIST OR RAFTER, USE EITHER METAL STRAPPING MATERIAL OR ANCHORED HEAVY NYLON WIRE TIES. WIRE TIE (AROUND SUCTION LINE 8 FE ONLY) / STRAPPING MATERIAL (AROUND SUCTION LINE ONLY) FLOOR JOIST OR \ ROOF RAFTER TAPE OR 8 FEET WIRE TIE l� ° \ STRAP THE SUCTION LINE TO THE JOIST OR RAFTER AT 8 FEET \ METAL INTERVALS THEN STRAP THE SLEEVE LIQUID LINE TO THE SUCTION TAPE OR LINE. WIRE TIE FLOOR JOIST OR - ROOF RAFTER Figure 11. Refrigerant Line Set: Installing Horizontal Runs IMPORTANT - REFRIGERANT LINES MUST NOT CONTACT WALL. LIQUID LINE OUTSIDE WALL \ SUCTION LINE WOOD BLOCK BETWEE STUDS WIRE TIE INSIDE WALL STRAP NOTE - Similar installation SLEEVE practices should be used if line set is to be installed on WIRE TIE exterior of outside wall. WOOD BLOCK WIRE TIE STRAP I SLEEVE SUCTION LINE WRAPPED WITH ARMAFLEX IMPORTANT! LIQUID LINE REFRIGERANT LINES MUST NOT OUTSIDE CONTACT WALL STRUCTURE. \ CAULK PVC PIPE FIBERGLASS INSULATION Figure 12. Refrigerant Line Set: Installing Vertical Runs (New Construction Shown) AUTOMOTIVE ANCHORED HEAVY NYLON MUFFLER -TYPE HANGER WIRE TIE OR AUTOMOTIVE MUFFLER -TYPE HANGER ^ar ,tJ WALL STUD �I STRAP LIQUID LINE TO SUCTION LINE \ LIQUID LINE METAL SLEEVE SUCTION LINE - WRAPPED IN ARMAFLEX Figure 13. Refrigerant Line Set: Transition from Vertical to Horizontal Page 7 13ACX SERIES Figure 14. Brazing Connections Brazing Connections Use the following procedure to braze the line set to the new air conditioner unit. Figure 14 is provided as a general guide for preparing to braze the line set to the air conditioner unit. 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. AWARNING Ad Use the following procedure to braze the line set to the new air conditioner unit. Figure 14 is provided as a general guide for preparing to braze the line set to the air conditioner unit. 1. Cut ends of the refrigerant lines square (free from nicks or dents). Debur the ends. The pipe must remain round, do not pinch end of the line. 2. Remove service cap and core from both the suction and liquid line service ports. 3. Connect gauge low pressure side to liquid line service valve. 4. To protect components during brazing, wrap a wet cloth around the liquid line service valve body and copper tube stub and use another wet cloth underneath the valve body to protect the base paint. 5. Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid line service valve and out of the valve stem port connection on the suction service valve. The TXV metering device at the indoor unit coil will allow low pressure nitrogen to flow through the system.) 506081-01 09/08 Page 8 NOTE - The fixed orifice or TXV metering device at the indoor unit will allow low pressure nitrogen to flow through the system.) NOTE - Use silver alloy brazing rods with five or six percent minimum silver alloy for copper -to -copper brazing or 45 percent silver alloy for copper -to -brass or copper -to -steel brazing. 6. Braze the liquid line to the liquid line service valve. Turn off nitrogen flow. A IMPORTANT Repeat procedure starting at paragraph 4 for brazing the suction line to service port valve. 7. After all connections have been brazed, disconnect manifold gauge set the from service ports and remove wrapping. Reinstall the service port core for both of the outdoor unit's service valves. Removing Indoor Unit Metering Device Remove the existing HCFC-22 fixed orifice or TXV from the indoor coil. The existing indoor unit HCFC-22 metering device is not approved for use with HFC-410A refrigerant and may prevent proper flushing. REPLACEMENT PARTS If replacement parts are necessary for the indoor unit, order catalog number 69J46 (LB-95325A). The kit includes the following: LIQUID LINE ORIFICE HOUSINGS (10) PISTON M / /RETAINER TEFLON RINGS / BRASS NUTS (10) / STRAINER COPPER TUBE LIQUID LINE ASSEMBLIES (INCLUDES STRAINER) (10) LIQUID LINE ASSEMBLY Figure 15. Kit 69J46 Components TYPICAL FIXED ORIFICE REMOVAL PROCEDURE DISTRIBUTOR TUBES LIQUID LINE ORIFICE HOUSING j 17 TEFLON RING REMOVE AND DISCARD FIXED VALVE STEM ASSEMBLY / ORIFICE (IF PRESENT) ® / BRASS NUT LIQUID LINE ASSEMBLY (NCLUDES STRAINER) VALVE STEM VALVE STEM CAP (Uncased Coil Shown; Figure 16. Typical Fixed Orifice Removal 1. On fully cased coils, remove the coil access and plumbing panels. 2. Remove any shipping clamps holding the liquid line and distributor assembly. 3. Using two wrenches, disconnect liquid line from liquid line orifice housing. Take care not to twist or damage distributor tubes during this process. 4. Remove and discard fixed orifice, valve stem assembly if present and Teflon ring as illustrated in figure 16. 5. Use a field -provided fitting to temporary reconnect the liquid line to the indoor unit's liquid line orifice housing. TYPICAL TXV REMOVAL PROCEDURE 1. On fully cased coils, remove the coil access and plumbing panels. 2. Remove any shipping clamps holding the liquid line and distributor assembly. 3. Disconnect the equalizer line from the TXV equalizer line fitting on the suction line. 4. Remove the suction line sensing bulb as illustrated in figure 17. 5. Disconnect the liquid line from the TXV at the liquid line assembly. 6. Disconnect the TXV from the liquid line orifice housing. Take care not to twist or damage distributor tubes during this process. 7. Remove and discard the TXV along with the two Teflon rings. Page 9 13ACX SERIES (Uncased Coil Shown) TWO PIECE PATCH PLATE LIQUID LINE (UNCASED COIL ORIFICE STUB END ONLY) \OUSING TXV \ TEFLON 0 RING o / 0 4p \ TEFLON SENSING ®� RING LINE DISTRIBUTOR EQUALIZER ASSEMBLY LINE LIQUID LINE ASSEMBLY WITH BRASS NUT 0 I MALE EQUALIZER SENSING LINE FITTING BULB LIQUID SUCTION LINE LINE Figure 17. Typical TXV Removal 8. Use a field -provided fitting to temporary reconnect the liquid line to the liquid line orifice housing. Flushing the System A IMPORTANT If this unit is being matched with an approved line set or indoor unit coil which was previously charged with mineral oil, or if it is being matched with a coil which was manufactured before January of 1999, the coil and line set must be flushed prior to installation. Take care to empty all existing traps. Polyol ester (POE) oils are used in Lennox units charged with HFC-410A refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the expansion device, and reduce the system performance and capacity. Failure to properly flush the system per the instructions below will void the warranty. If the original system used: • HCFC-22 refrigerant, then flush the system using the procedure provided in this section. • HFC-410A refrigerant, then proceed to Installing New Refrigerant Metering Device. INVERTED HCFC-22 CYLINDER /CONTAINS CLEAN HCFC-22 TO BE USED FOR FLUSHING. GAUGE MANIFOLD LOW HIGH PRESSURE PRESSURE SUCTIONEW SERVICEOUTDOOR 4LINE UNIT EXISOPENED CLOSED INDUN LIQUID LINE SERVICE VALVE RECOVERY CYLINDER TANK \I RETURN r c pLQ INLET O O DISCHARGE RECOVERY MACHINE NOTE -The inverted HCFC-22 cylinder must contain at least the same amount of refrigerant as was recovered from the existing system. Figure 18. Typical Flushing Connection A CAUTION This procedure should not be performed . compressorsystems which contain contaminants (Example: . REQUIRED EQUIPMENT Equipment required to flush the existing line set and indoor unit coil: • Two clean HCFC-22 recovery bottles, • Oilless recovery machine with pump -down feature, • Two gauge sets (one for HCFC-22; one for HFC-410A). FLUSHING PROCEDURE 1. Connect the following: • HCFC-22 cylinder with clean refrigerant to the suction service valve, • HCFC-22 gauge set to the liquid line valve, • Recovery machine with an empty recovery tank to the gauge set. 2. 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. 3. Invert the cylinder of clean and open its valve to allow liquid refrigerant to flow into the system through the suction line valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor 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 so that all of the suction is recovered. Allow the recovery machine to pull a vacuum on the system. 506081-01 09/08 Page 10 5. Close the valve on the inverted drum and the gauge set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off. 6. Use dry nitrogen to break the vacuum on the refrigerant lines and indoor unit coil before removing the recovery machine, gauges and refrigerant drum. Installing New Indoor Unit Metering Device 13ACX units can be configured for use in with HFC-410A fixed orifice or TXV metering devices. This section provides instructions on installing either a fixed orifice or TXV refrigerant metering device. I 1/8 TURN 1/2 TURN 11 10 12 2 11 10 2 9 3 9 3 8 7 4 6 5 8 7 6 4 5 Figure 19. Tightening Distance 13ACX ENGINEERING HANDBOOK See the 13ACX Engineering Handbook for approved indoor/outdoor match -ups, applicable fixed orifice and TXV kits, and application information. Figures 20 and 21 illustrates the typical RFC and TXV kit parts and quantities. FIXED ORIFICE (1) FIXED ORIFICE EXTRACTOR (1) TEFLON RING (1) FIXED ORIFICE STICKER (1) Figure 20. Fixed Orifice Kit Components a\ TXV (1) HEX HEAD BOLTS AND NUTS (2) 0\TEFLON RINGS (2) COPPER %,00. MOUNTINGSTRAP (1) Figure 21. TXV Kit Components TYPICAL FIXED ORIFICE INSTALLATION PROCEDURE (Uncased Coil Shown) LIQUID LINE ORIFICE HOUSING FIXED ORIFICE TEFLON / RING ®/ LIQUID O / LINE LIQUID LINE ASSEMBLY WITH BRASS NUT Figure 22. Typical Fixed Orifice Installation 1. Remove the field -provided fitting that temporary reconnected the liquid line to the indoor unit's liquid line orifice housing. 2. Ensure that the fixed orifice supplied with the outdoor unit is installed with the nylon seat pointing toward the liquid line orifice housing. 3. Apply a small amount of refrigerant oil on the Teflon ring and insert securely into the liquid line orifice housing. 4. Attached the liquid line assembly 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 figure 19, or 20 ft-lb. 5. Place the supplied fixed orifice sticker on the indoor cabinet after installation. TYPICAL TXV INSTALLATION PROCEDURE The TXV unit can be installed internal or external to the indoor coil. In applications where an uncased coil is being installed in a field -provided plenum, install the TXV in a manner that will provide access for field servicing of the TXV. Refer to Figure 23 for reference during installation of TXV unit. Page 11 13ACX SERIES TWO PIECE PATCH PLATE (Uncased Coil Shown) (UNCASED COIL ONLY) LIQUID LINE ORIFICE STUB END HOUSING DISTRIBUTOR TXV TUBES \ TEFLON 0 I RING 0 TEFLON ®RING , SENSING LINE DISTRIBUTOR EQUALIZER ASSEMBLY LINE LIQUID LINE ASSEMBLY WITH BRASS NUT 0 MALE EQUALIZER LINE FITTING (SEE FIGURE 25 SUCTION \ FOR FURTHER DETAILS) LINE LIQUID LINE SENSING BULB INSULATION IS REQUIRED IF MOUNTED EXTERNAL TO THE COIL CASING. SEE FIGURE 24 FOR BULB POSITIONING. Figure 23. Typical TXV Installation To prevent any possibility of water damage, properly insulate all parts of the TXV assembly that may sweat due to temperature differences between the valve and its surrounding ambient temperatures. 1. Remove the field -provided fitting that temporary reconnected the liquid line to the indoor unit's liquid line orifice housing. 2. Install one of the provided Teflon rings around the stubbed end of the TXV and lightly lubricate the connector threads and expose surface of the Teflon ring with refrigerant oil. 3. Attach the stubbed end of the kit 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 figure 19, or 20 ft-lb. 4. Place the remaining Teflon ring around the other end of the TXV. Lightly lubricate connector threads and expose surface of the Teflon ring with refrigerant oil. 5. Attach the liquid line assembly to the TXV. Finger tighten and use an appropriately sized wrench to turn an additional 1/22 turn clockwise as illustrated in figure 19, or 20 ft-lb. 6. Attach the suction line sensing bulb in the proper orientation as illustrated in figure 24 using the copper mounting strap and fastening hardware provided. NOTE - Insulating the sensing bulb once installed may be required when the bulb location is external to the coil casing. ON LINES SMALLER THAN 7/8", SUCTION LINE MOUNT SENSING BULB AT THE 3 OR 9 O'CLOCK •^ON. I BULB %EITHER SUCTION LINE \ ON 7/8" AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 4 OR 8 O'CLOCK POSITION. NEVER MOUNT ON " - BOTTOM OF LINE. BULB I BULB NOTE - Never mount on bottom of line. Figure 24. TXV Sensing Bulb Installation 7. Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the suction line as illustrated in figure 25. A IMPORTANT FLARE SEAL I I FLARE NUT CAP COPPER i FLARE SEAL R BONNET MALE BRASS EQUALIZER LINE FITTING SUCTION LINE Figure 25. Copper Flare Seal Bonnet Removal 8. Connect the equalizer line from the TXV to the equalizer suction port on the suction line. Finger tighten the flare nut plus 1/8 turn (7 ft-lbs) as illustrated in figure 19. 506081-01 09/08 Page 12 Testing for Leaks After the line set has been connected to both the indoor and outdoor units, check the line set connections at both the indoor and outdoor units for leaks. Use the following procedure to test for leaks: A IMPORTANT Leak detector must be capable of sensing HFC refrigerant. AWARNING Aj 1. Connect an HFC-410A manifold gauge set high pressure hose to the suction valve service port. NOTE - Normally, the high pressure hose is connected to the liquid line port; however, connecting it to the suction port better protects the manifold gauge set from high pressure damage. 2. 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 (suction only). 3. 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. 4. Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set. 5. 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. 6. 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 NOTE - Amounts of refrigerant will vary with line lengths. 7. Check all joints for leaks. 8. Purge dry nitrogen and HFC-410A mixture. 9. Correct any leaks and recheck. 10. After leak testing disconnect gauges from service ports. Evacuating the System A IMPORTANT thermocoupleUse a . capablegauge that is calibrated in microns. Use an instrument down to 50 microns. Evacuating the system of non-condensables is critical for proper operation of the unit. Non-condensables are 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. 1. Connect manifold gauge set to the service valve ports as follows: • low pressure gauge to suction line service valve • high pressure gauge to liquid line service valve 2. 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 of mercury). NOTE - During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once to determine if there is a rapid rise in sure 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. 6. When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), close the manifold gauge valves, turn off the vacuum pump and disconnect the Page 13 13ACX SERIES manifold gauge center port hose from vacuum pump. Attach the manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose. Open the manifold gauge valves to break the vacuum in the line set and indoor unit. Close the manifold gauge valves. 7. 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. 8. 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. 9. 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 valves to break the vacuum from 1 to 2 psig positive pressure in the line set and indoor unit. Close manifold gauge valves and shut off the HFC-410A cylinder and remove the manifold gauge set. Servicing Unit Delivered Void of Charge If the system is void of refrigerant, clean the system using the procedure described below. 1. Use nitrogen to pressurize the system and check for leaks. Repair all leaks. 2. Evacuate the system to remove as much of the moisture as possible. 3. Use nitrogen to break the vacuum and install a new filter drier in the system. 4. Evacuate the system again. Then, weigh the appropriate amount of HFC-410A refrigerant as listed on unit nameplate into the system. 5. Monitor the system to determine the amount of moisture remaining in the oil. It may be necessary to replace the liquid line filter drier several times to achieve the required dryness level. If system dryness is not verified, the compressor will fail in the future. Electrical Connections In the United States, 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 blower coil installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum over -current protection size. HIGH VOLTAGE FIELD WIRING I _ LOW VOLTAGE WIRE TIES FIELD WIRING I - FACTORY WIRING 7-7 GROMMET Figure 26. Separating High/Low Voltage Field Wiring (Typical Field Wiring) WIRING CONNECTIONS 1. Install line voltage power supply to unit from a properly sized disconnect switch. Any excess high voltage field wiring should be trimmed or secured away from the low voltage field wiring as illustrated in figure 28. 2. Ground unit at unit disconnect switch or to an earth ground. 3. Connect conduit to the unit using provided conduit bushing. 4. Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and 5 feet (1.5 m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight, drafts or vibrations. NOTE - For proper voltages, select thermostat wire gauge per the following chart: Table 3. Wire Run Lengths Wire Run Length AWG # Insulation Type less than 100' (30m) 18 Color -coded, temperature rating 35°C minimum. more than 100' (30m) 16 5. Install low -voltage wiring from outdoor to indoor unit and from thermostat to indoor unit. 6. Do not bundle any excess 24V control wire inside control box. Run control wire through installed wire tie and tighten wire tie to provided low voltage strain relief and to maintain separation of field installed low and high voltage circuits. NOTE - 24VAC, Class II circuit connections are made in the low voltage junction box 506081-01 09/08 Page 14 OUTDOOR I DUAL PURPLE CAPACITOR BLACK ORANGE RED BLACK COMPRESSOR COMPRESSOR CONTACTOR CRANKCASE GROUND HEATER O LUG - S40 0 L1 BLACK YELLOW 1 208-23016011 K1.1 L2 RED ORANGE RED_?_[� I BLACK S40 C12 H A4 TO 24 VAC POWER TIMED OFF SOURCE CONTROL 20 VA MINIMUM NEC CLASS 2 2 3 1 C YA1 — I � I L2 I L1 I 208-230I6011 I = GROUNDI I LZ----� L- - - - - --� S R 61 S4 HIGH S87 OR S24 PRESSURE SWITCH _ LI S173 A4 S4 2 3 S87 K1 1 TO 24 VAC POWER SOURCE 20 VA MINIMUM NEC CLASS 2 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 887 1 SWITCH -LOW PRESS, COMP 1 5173 1 SWITCH -THERMAL PROTECTION LINE VOLTAGE FIELD INSTALLED - CLASS II VOLTAGE FIELD WIRING ­*- DENOTES OPTIONAL COMPONENTS NOTE - IF ANY WIRE IN THIS APPLIANCE IS REPLACED,IT MUST BE REPLACED WITH WIRE OF LIKE SIZE, RATING, INSULATION THICKNESS, AND TERMINATION. 0 NOTE - FOR USE WITH COPPER CONDUCTORS ONLY. REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE ® JUMPER IS USED WHEN TOC IS NOT USED © S173 SWITCH USED ONLY IN UNITS EQUIPPED WITH COMPRESSORS WHICH DO NOT INCLUDE INTERNAL SWITCH Figure 27. Typical 13ACX Unit Wiring Diagram Figure 28. 24VAC Control Wiring Diagrams (Field Installed) NOTE - To facilitate conduit, a hole is in the bottom of the control box. Connect conduit to the control box using a proper conduit fitting. NOTE - Units are approved for use only with copper conductors. NOTE - See unit wiring diagram for power supply connections. If indoor unit is not equipped with blower relay. It must be field -provided and installed (P-8-3251 or equivalent) Start -Up and Charging Procedures 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. • • binding. connections.2. Inspect all factory- and field -installed wiring for loo 3. After evacuation is complete, open the liquid line and suction line service valves to release the refrigerant charge (contained in air conditioner) into the system. 4. Replace the stem caps and tighten to the value listed in table 1. Page 15 13ACX SERIES 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. Set the thermostat for a cooling demand. Turn on power to the indoor handler and close the air conditioner disconnect switch to start the unit. 7. Recheck voltage while the unit is running. Power must be within range shown on the nameplate. 8. Check system for sufficient refrigerate by using the procedures listed under Testing and Charging System. Temp. DT of air 80 24 24 24 23 23 22 22 22 20 19 18 17 16 15 entering 78 23 23 23 22 22 21 21 20 19 18 17 16 15 14 indoor 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13 coil IF .9 s' 74 21 21 21 20 19 19 18 17 16 16 15 14 13 12 c 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 TDrop A C 720 53° 19° air flow air flow B DRY 640 DRY BULB BULB All temperatures are INDOOR WEB expressed in IF o COIL BUL• SETTING UP TO CHECK CHARGE 1. Close manifold gauge set valves. Connect the center manifold hose to an upright cylinder of HFC-410A. 2. Connect the manifold gauge set to the unit's service ports as illustrated in figure 1. • low pressure gauge to suction line service port • high pressure gauge to liquid line service port INDOOR AIRFLOW CHECK Check airflow using the Delta-T (DT) process using the illustration in figure 29. DETERMINING CHARGE METHOD Use the illustration in figure 30 to determine the correct charging method. 1. Determine the desired DT—Measure entering air temperature using dry bulb (A) and wet bulb (B). DT is the intersecting value of A and B in the table (see triangle). 2. Find temperature drop across coil —Measure the coil's dry bulb entering and leaving air temperatures (A and C). Temperature 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 ad- justment is needed. See examples: Assume DT = 15 and A temp. _ 72°, these C temperatures would necessitate stated actions: C° TDrop — DT = IF ACTION 530 19 — 15 = 4 Increase the airflow 580 14 — 15 = -1 (within +31 range) no change 620 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 temperatures to confirm that the temperature drop and DT are within +30. Figure 29. Checking Indoor Airflow over Evaporator Coil using Delta-T (DT) Chart 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 temperature to measure liquid line temperature to measure suction line temperature TXV / 65°F 640F (18.3°C) and (17.7°C) and '-, Above Below i APPROACH OR WEIGH-IN SUBCOOLING Which RFC metering device? Figure 30. Determining Charge Method 40°F 390F N (4.4°C) and (3.8°C) and Above Below SUPERHEAT WEIGH-IN 506081-01 09/08 Page 16 USE EITHER APPROACH OR SUBCOOLING METHOD 65°F and ABOVE WEIGH IN TXV Refrigerant Charqe per Line Set Lenqth 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) NOTE - *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. 64°F and BELOW LENNOX DA-, TEXAS MM TSA036H4N41G SIN P-NNNNN µ coos 1. Check Liquid and suction line pressures 2. Compare unit pressures with Table 4, Normal Operating Pressures. 3. Conduct leak check; evacuate as previously outlined. 4. Weigh in the unit nameplate charge plus any charge required for line set differences (�oovvveeerrr feet. V Figure 31. HFC-410A Weigh In TXV Method USE WEIGH-IN METHOD Weigh-in or remove refriger- ant based upon line length 640F and BELOW 650F and ABOVE ABOVE or BELOW APPROACH TXV If refrigerant is added or removed, verify If value MORE charge using the � than shown, remove Subcooling Method. refrigerant. If value is LESS I - /MORE o� hown than s, add C,�\ LESS refrigerant. This nameplate is for illustration do purposes only. Go to actual nameplate on outdoor unit for charge information. 1. Confirm proper airflow across coil using figure 29. 2. Compare unit pressures with Table 4, Normal Operating Pressures. 3. Set thermostat to call for heat (must have a cooling load between 70-80°F (21-261C). 4. Connect gauge set. 5. When heat demand is satisfied, set thermostat to call for cooling. 6. Allow temperatures and pressures to stabilize. 7. Record outdoor ambient temperature: AMB° = 8. Record liquid line temperature: LIQ° = 9. Subtract to determine approach (APP°): LIQ° - AMB° = APP° T::3 10. Compare results with table below. APP° (Approach) Values(F:+/-1.00 [C: +/-0.60]) 'F(°C)* -018 -024 -030 -036 -042 -048 -060 Any 4(2.2) 8(4.4) 8(4.4) 11 (6.1) 9 (5.0) 8(4.4) 9 (5.0L *Temperature of air entering outdoor coil Figure 32. HFC-410A Approach TXV Charge Page 17 13ACX SERIES 650F and ABOVE USE WEIGH-IN METHOD � Weigh-in or remove refrigerant ABOVE or based upon line length o BELOW 64 F and BELOW SUBCOOLING TXV BLOCK OUTDOOR COIL: [sometimes necessary with lower temperatures] Use cardboard or plastic sheet to restrict the airflow through 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 coverings sideways until the liquid pressure is in the above noted ranges. If refrigerant is added If value is MORE or removed, verify <�= than shown, remove charge using the Approach Method. refrigerant. If value is LESS MORE or than shown, add LESS refrigerant. 1. Confirm proper airflow across coil using figure 29. 2. Compare unit pressures with Table 4, Normal Operating Pressures. 3. Set thermostat to call for heat (must have a cooling 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 to call for cooling 7. Allow temperatures and pressures to stabilize. NOTE - If necessary, block outdoor coil to maintain 325 - 375 psig. 8. Record liquid line temperature: LIQ° = 9. Measure liquid line pressure and use the value to determine saturation temperature (see table 5): SAT° = 10. Subtract to determine subcooling (SC°): SAT° - LIQ° = SC* 11. Compare results with table below. SC° (Subcooling) Values (F:+/-1.0° [C: +/-0.6°]) OF('Q) -018 -024 -030 -036 -042 -048 -060 Any 10 (5.6) 10 (5.6) 9 (5.0) 12 (6.7) 9 (5.0) 9(5.0) 7(3.9) 'Temperature of air entering outdoor coil Figure 33. HFC-410A Subcooling TXV Charge USE SUPERHEAT and ABOVE WEIGH IN RFC Refrigerant Charge per Line Set Length Liquid Line Set Diameter Ounces per 5 feet (g per 1.5 m) adjust from 15 feet (4.6 m) line set* 3/8" (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 this amount. If line length is less than 15 ft. (4.6 m), subtract this amount. 39°F and BELOW LENNOX OALU.S, TEXAS MM TSA036H4N41G S N P-NNNNN cULus 1. Check Liquid and suction line pressures 2. Compare unit pressures with Table 4, Normal Operating Pressures. 3. Conduct leak check; evacuate as previously outlined. 4. Weigh in the unit nameplate charge plus any charge required for line set differences over feet. This nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information. Figure 34. HFC-410A Weigh In RFC Method 506081-01 09/08 Page 18 40°F START Measure outdoor ambient •- and USE WEIGH-IN METHOD ABOVE Weigh-in or remove refrigerant ABOVE or based upon line length 39°F and BELOW BELOW SUPERHEAT RFC SH° (Superheat) Values (+/-5°F) If refrigerant is REMOVED, retest to confirm that unit is properly charged. 1. Confirm proper airflow across coil using figure 29. 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 70-80OF (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 5): 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 value is LESS than If refrigerant is shown, then REMOVE If value is MORE ADDED, retest to MORE or than shown, then I=* confirm that unit is refrigerant. LESS ADD refrigerant. properly charged. °F* Wet Bulb air enterinq indoor coil 50 52 54156 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 30.33 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 13116 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 15120 25 115 1 - - 8 14118 24 * Dry-bulb temperature ff) of entering outdoor ambient air. Figure 35. HFC-410A Superheat RFC Method Page 19 13ACX SERIES Table 4. HFC-410A Normal Operating Pressures (Liquid +10 and Suction +5 psig) A IMPORTANT • • • • - • - • . • • • • • • • 13ACX -018 -024 -030 -036 -042 -048 -060 °F (°C)` Liquid / Suction Liquid / Suction Liquid / Suction Liquid / Suction Liquid / Suction Liquid / Suction Liquid / Suction Expansion Valve (TXV) 65 (18) 233 / 132 244 / 137 248 / 127 263 / 135 238 /132 235 / 132 241 / 130 70 (21) 251 / 133 263 / 138 263 / 131 281 / 138 262 / 133 254 / 132 260 / 130 75 (24) 265 / 133 285 / 139 284 / 132 302 / 140 280 / 134 276 / 134 280 / 132 80 (27) 292 / 135 307 / 140 307 / 134 325 / 142 301 / 136 298 / 134 299 / 134 85 (29) 314 / 136 329 / 141 330 / 135 349 / 142 327 / 137 323 / 135 321 / 135 90 (32) 338 / 137 354 / 142 355 / 136 375 / 143 353 / 138 350 / 137 344 / 134 95 (35) 362 / 138 379 / 143 380 / 137 404 / 144 377 / 140 377 / 138 371 / 135 100 (38) 388 / 140 404 / 144 407 / 138 433 / 145 404 / 141 406 / 140 400 / 137 105 (41) 415 / 141 438 / 145 434 / 139 462 / 147 435 / 142 430 / 141 428 / 139 110 (43) 444 / 142 464 / 147 465 / 141 494 / 149 465 / 143 464 / 142 458 / 141 115 (45) 475 / 143 495 / 148 497 / 142 527 / 150 499 / 144 495 / 143 484 / 142 Fixed Orifice (RFC) 65 (18) 233 / 121 246 / 126 245 / 123 261 / 134 246 / 126 247 / 125 248 / 124 70 (21) 250 / 124 265 / 129 265 / 126 281 / 136 263 / 128 266 / 128 266 / 126 75 (24) 270 / 128 286 / 132 286 / 129 301 / 138 284 / 131 286 / 131 288 / 130 80 (27) 291 / 131 307 /135 308 / 132 324 / 140 305 / 133 307 / 133 309 / 133 85 (29) 313 / 134 330 / 137 331 / 135 346 / 142 327 / 135 329 / 135 330 / 135 90 (32) 335 / 136 353 / 140 355 / 138 371 / 144 350 / 138 353 / 138 354 / 138 95 (35) 359 / 138 378 / 142 380 / 140 396 / 146 374 / 140 377 / 140 377 / 140 100 (38) 383 / 140 402 / 143 405 / 142 422 / 148 399 / 142 403 / 142 406 / 142 105 (41) 409 / 142 428 / 145 431 / 144 448 / 150 424 / 144 428 / 144 431 / 144 110 (43) 436 / 145 456 / 147 458 / 146 477 / 151 452 / 146 455 / 146 457 / 146 115 (46) 464 / 147 486 / 149 487 / 148 506 / 153 481 / 148 483 / 147 484 / 148 "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 20 506081-01 09/08 Table 5. HFC-410A Temperature (°F) - Pressure (Psig) -F Psig -F Psig -F Psig -F Psig -F Psig -F Psig -F Psig -F Psig 32 100.8 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 95 295.1 111 370.0 126 451.8 142 552.3 34 105.0 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 98 308.2 114 385.4 129 469.5 145 572.8 37 111.4 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 86 258.0 101 321.8 117 401.3 132 487.8 148 593.8 40 118.0 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 89 270.0 104 335.7 120 417.7 135 506.5 151 615.4 43 125.0 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 91 278.2 106 345.3 122 428.8 137 519.3 153 630.1 45 129.7 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 and suction service valve caps. INSTALL CAPS OUTDOOR UNIT SERVICE VALVES \ Figure 36. Installing Service Valve Caps System Operation The outdoor unit and indoor blower will cycle on and off as dictated by demands from the room thermostat. When the thermostat's blower switch is in the ON position, the indoor blower will operate continuously. HIGH PRESSURE SWITCH 13ACX units are equipped with a high-pressure switch that is located in the liquid line of the compressor as illustrated in figure 37. The switch is a Single Pole, Single Throw (SPST), manual -reset switch with red cap that is normally closed and removes power from the compressor when discharge pressure rises above factory setting at 590 ± 10 psi. Figure 37. High Pressure Switch Location Page 21 13ACX SERIES Maintenance AWARNING At the beginning of each cooling season, the system should be checked as follows: OUTDOOR UNIT 1. Clean and inspect outdoor coil (may be flushed with a water 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 for evidence of oil leaks. 4. Check all wiring for loose connections. 5. Check for correct voltage at unit (unit operating). 6. Check amperage draw on outdoor fan motor. UNIT NAMEPLATE: ACTUAL: 7. Inspect drain holes in coil compartment base and clean if necessary. NOTE - If insufficient heating or cooling occurs, the unit should be gauged and refrigerant charge should be checked. 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. INDOOR UNIT 1. Clean or change filters. 2. Blower motors are pre -lubricated 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 cubic feet per minute (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 amperage draw on blower motor. UNIT NAMEPLATE: ACTUAL: Homeowner Information AWARNING NOTE - A white residue may appear on the coil guards and grilles on outdoor units. The residue is a non -toxic byproduct of manufacturing the flexible coating. It can be removed by wiping the coil guard with a cloth. 9 PINS USED ON -048 AND -060; 6 PINS ALL OTHERS PUSH PIN MESH SCREEN Figure 38. Cleaning debris from mesh 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: 506081-01 09/08 Page 22 1. Make sure power is off before cleaning. Clean and inspect outdoor coil. The coil may be flushed with a water hose. 2. The outdoor coil is protected by an inner mesh screen and a wire cage (see figure 38). If debris has collected between the mesh screen and the coil and cannot be dislodged by spraying un-pressurized water from inside coil surface to the outside, the mesh may be removed by first removing the top of the unit which will allow for removal of the wire cage. 3. Then, using pliers to grip the head of the push pins, pull straight out to extract the push pins along one side of the coil. If necessary, remove the push pins along the back of the unit; it is usually unnecessary to fully remove the inner mesh screen. 4. Drape the mesh screen back and wash the coil. When all the debris has been removed from the coil, reinstall the mesh screen by positioning it in its original position and reinserting the push pin. No tool is required to push 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 the push pin a couple fins to the right or left of the original hole and re-insert the pin. PRESERVICE CHECK If your system fails to operate, check the following before calling for service: • Make sure all electrical disconnect switches are ON. • Make sure the room thermostat temperature selector AND 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. PROGRAMMABLE THERMOSTATS Your Lennox system may be controlled by a programmable thermostat. These thermostats provide the added feature of programmable time -of -day set points for both heating and cooling. Refer to the user's information manual provided with your thermostat for operation details. THERMOSTAT OPERATION Thermostat operations vary from one thermostat to another. The following provides general operation procedures. Refer to the user's information manual provided with your thermostat for specific operation details. Temperature Set the lever or dial to the desired temperature Setting Levers setpoints for both heating and cooling. Avoid frequent temperature adjustment; turning the unit off —then back on —before pressures can equalize will put unusual stress on the unit's compressor. Fan Switch In AUTO or INT (intermittent) mode, the blower operates only when the thermostat calls for heating or cooling. This mode is generally preferred when humidity control is a priority. The ON or CONT mode provides continuous indoor blower operation, regardless of whether the compressor or furnace is operating. This mode is required when constant air circulation or filtering is desired. System Switch Set the system switch for heating, cooling or auto operation. The auto mode allows the system to automatically switch from heating mode to cooling mode to maintain predetermined comfort settings. Temperature The temperature indicator displays the actual room Indicator temperature. Optional Accessories Refer to the Lennox 13ACX Engineering Handbook for the latest available accessories for this unit. Below is a list of accessories available at the time this instruction was publish. • Compressor Start Kit • Loss of Charge Kit • Low Ambient Kit • Timed Off Control • Sound Cover • Replacement Liquid Line Drier • Plastic Feet Kit • Crankcase Heater Page 23 13ACX 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? ❑ Refrigerant Lines: - Leak Checked? ❑ Properly Insulated? ❑ Outdoor Fan Checked? Service Valves: --- Fully Opened? ❑ Caps Tight? ❑ Thermostat Voltage With Compressor Operating Calibrated? ❑ Properly Set? ❑ W Level? ❑ Page 24 506081-01 09/08