Lennox TPAS4 G&Y
Contents
1. TPA S4 Target Add Target Add INDOOR MATCHUPS pie charge INDOOR MATCHUPS mubcooling charge 5 F 1 F Ib 5 F 1 F Ib oz CBX26UH 036 17 10 2 CBX26UH 042 26 5 1 4 CBX27UH 036 230 10 5 2 CBX26UH 048 10 12 4 5 CBX27UH 042 230 10 10 2 CBX27UH 042 230 10 6 4 5 CBX32M 036 042 10 5 2 CBX27UH 048 230 10 6 4 5 CBX32MV 036 230 10 5 2 CBX32M 036 042 15 5 o 0 CBX40UHV 036 10 5 2 CBX32MV 036 15 5 ojo CH33 31A 31B 10 5 2 CBX32MV 048 230 10 6 4 5 CH33 36B 10 5 0 CBX40UHV 036 15 5 o 0 CH33 36C 10 5 0 CBX40UHV 042 048 10 6 4 5 CH33 42 10 5 2 CH33 43C 48C 10 6 1 1 CH33 44 48B 10 5 2 CH33 49C 50 60C 10 6 4 5 CH33 48C 10 5 2 CH33 60D 10 6 2 6 CR33 30 36 25 5 0 CR33 48 32 5 o 5 CR33 48 25 5 2 CR33 50 60 32 9 2 6 CR33 50 60 10 5 2 CR33 60 32 9 2 6 CX34 36B 10 5 0 CX34 43C 10 6 1 4 CX34 38 SN 6007 and after 5 5 2 CX34 49 10 6 3 7 CX34 38 before SN 6007 10 5 2 CX34 50 60C 10 6 1 1 CX34 42B 10 5 0 CX34 44 48B 10 5 2 Page 15 Revised 05 2009 Table 11 TPA048S4N43Y Table 13 HFC 410A Temp F Pressure Psig 59F _ 19F _ Ib oz 40 101 21 80 5 56 158 2 91 278 2 CBX26UH 048 o m 1 7 35 135 22 82 3 57 161 92 2823 CBX2SUF 060 m 1 2 7 CBX27UH 048 230 EE CBX27UH 060 230 m 18 2 7 CBX32M 048 mower 18 278 22. FIGURE 2 TPA S4 Page 4 A DANGER Electric Shock Hazard May cause injury or death Disconnect all remote electrical power supplies before opening unit panel Unit may have multiple power supplies A Control Box Figure 2 TPA S4 units are not equipped with a 24V transformer All 24 VAC controls are powered by the indoor unit Refer to wiring diagram Electrical openings are provided under the control box cover Field thermostat wiring is made to a 24V terminal strip located on the defrost control board located in the control box See figure 3 24V THERMOSTAT TERMINAL STRIP FIGURE 3 1 Compressor Contactor K1 The compressoris energized by a contactor located in the control box See figure 2 Three pole contactors are used in TPA S4 series units K1 is energized through the control board by the indoor thermostat terminal Y1 24V when thermostat demand is present 2 Capacitor C1 All units use single phase PSC outdoor fan motors which require a run capacitor Ratings for capacitor will be on fan motor nameplate C1 aids in the start up of outdoor fan B4 3 Defrost System The TPA03684 defrost system includes two components a defrost thermostat and a defrost control Defrost Thermostat The defrost thermostat is located on the liquid line between the check expansion valve and the distributor When defrost thermostat senses 4
3. lt HIGH PRESSURE SWITCH iE fur 1 U wo e BLACK E A NOTE A FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVER CURRENT PROTECTION SIZE ZX CONNECTION MUST BE JUMPERED WHEN OPTIONAL SWITCH IS NOT USED A 4 TO BE MOUNTED IN CONTROL BOX AND WIRED IN PARALLEL WITH LOW PRESSURE SWITCH DEFROST MODE During heating operation when outdoor coil temperature drops below 35 F 2 C or 42 F 5 5 C defrost switch thermostat S6 closes Defrost control CMC1 begins timing If defrost thermostat S6 remains closed at the end of the 30 60 or 90 minute period defrost relay ener gizes and defrost begins During defrost CMC1 energizes the reversing valve and W1 on the ter minal strip operating indoor unit on the first stage heat mode while de energizing outdoor fan motor B4 Defrost continues 14 1 minutes or until thermostat switch S6 opens When defrost thermostat opens defrost control timer loses power and resets When CMC1 resets the reversing valve and W1 on the terminal strip are de energized while the outdoor fan motor B4 is energized When CMC 1 resets the reversing valve and W1 on the terminal strip are de energized while the outdoor fan motor B4 is energized Revised 05 2009 TPA S4 TPA S4 460 VOLT UNIT DIAGRAM DUTDOOR Oo li PURPLE HRI CRANKCASE HEATER LI 460 60 3 AH D RIP ON CO
4. LENNOX J a e Service Literature UNIT INFORMATION Corp 0632 L6 Revised 05 2009 TPA S4 3 3 5 4 and 5 ton 10 5 12 3 14 and 17 6 kW T CLASS TPA S4 COMMERCIAL SERIES UNITS The TPA S4 is a HFC 410A commercial split system heat pump The series is designed for use with expansion valves TXV All TPA S4 units utilize scroll compressors TPA S4 series units are available in 3 3 5 4 and 5 ton capacities All major components indoor blower and coil must be matched according to Lennox recommendations for the compressor to be covered under warranty Refer to the Engineering Handbook for approved system matchups This manual is divided into sections which discuss the major components refrigerant system charging procedure maintenance and operation sequence Information contained in this manual is intended for use by qualified service technicians only All specifications are subject to change A WARNING Improper installation adjustment alteration service or maintenance can cause personal injury loss of life or damage to property Installation and service must be performed by a licensed professional installer or equivalent or a service agency 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 MODEL NUMBER IDENTIFICATION T PA 036 Brand Family T T Class Product Line
5. Unit Type P Heat Pump Outdoor Unit Major Design Sequence A 1st Generation B 2nd Generation Nominal Cooling Capacity Tons 036 3 Tons 042 3 5 Tons 048 4 Tons 060 5 Tons Cooling Efficiency S Standard Efficiency Table of Contents Specifications Electrical Data Page 2 Optional Accessories Page 3 Unit Components Page 4 Il Refrigerant System Page 8 IIl Charging sees Page 10 IV Maintenance Page 16 V Diagrams 1 1 1 1 22 2 Page 17 4n41Y Voltage Y 208 230V 3 phase 60hz G 460V 3 phase 60hz Minor Design Sequence 1 1st Revision 2 2nd Revision 3 3rd Revision Coil type 4 Four sided Part Load Capability N No part load single stage compressor Refrigerant Type 4 R 410A Technical Publications Page 1 2006 Lennox Industries Inc SPECIFICATIONS General Model No TPA036S4 TPA042S4 TPA048S4 TPA060S4 Data Nominal Tonnage 3 3 5 4 5 Connections Liquid line o d in 3 8 3 8 3 8 3 8 sweat Vapor line o d in 7 8 7 8 7 8 1 1 8 1 Refrigerant HFC 410A charge furnished 8 Ibs 12 oz 10 Ibs 10 oz 13 Ibs 2 oz 15 Ibs 3 oz Outdoor Net face area Outer coil 15 21 18 66 21 11 29 09 Coil sq ft Inner coil 14 50 17 95 20 31 28 16 Tube diameter 5 16 5 16 5 16 5 16 Number of rows 2 2 2 2 Fins
6. 737mm close gauge manifold valves to center port stop vacuum pump and disconnect from gauge manifold Attach an upright nitrogen drum to center port of gauge manifold and open drum valve slightly to purge line at manifold Break vacuum in system with nitrogen pressure by opening manifold high pressure valve Close manifold high pressure valve to center port 4 Close nitrogen drum valve and disconnect from gauge manifold center port Release nitrogen pressure from system 5 Connect vacuum pump to gauge manifold center port Evacuate system through manifold service valves until vacuum in system does not rise above 5mm of mercury absolute pressure or 500 microns within a 20 minute period after stopping vacuum pump 6 After evacuation is complete close manifold center port and connect refrigerant drum Pressurize system slightly with refrigerant to break vacuum Revised 05 2009 D Charging TPA S4N41Y through TPA S4N42Y The outdoor unit should be charged during warm weather However applications arise in which charging must occur in the colder months The method of charging is determined by the unit s refrigerant metering device and the outdoor ambient temperature Measure the liquid line temperature and the outdoor ambient temperature as outlined below 1 Close manifold gauge set valves Connect the manifold gauge set to the service valves e low pressure gauge to vapor valve service port e high pressure gauge
7. 250 psig 1379 1724 kPa range These higher pressures are necessary for checking the charge Block equal sections of air intake panels and move obstructions sideways until the liquid pressure is in the 200 250 psig 1379 1724 kPa range See figure 14 TPA S4 Page 11 Blocking Outdoor Coil Outdoor coil should be blocked one side at a time with cardboard or plastic sheet until proper testing pressures are reached cardboard or plastic sheet Four sided unit shown FIGURE 14 1 With the manifold gauge hose still on the liquid service port and the unit s pressure stabilized use a digital thermometer to record the liquid line temperature 2 At the same time record the liquid line pressure reading 3 Use a temperature pressure chart for HFC 410A to determine the saturation temperature for the liquid line pressure reading 4 Subtract the liquid line temperature from the saturation temperature according to the chart to determine subcooling 5 Compare the subcooling value results with those in table 3 If subcooling is greater than shown recover some refrigerant If subcooling is less than shown add some refrigerant TABLE 3 TPA S4N41Y through TPA S4N42Y TPA036S4 Subcooling Values for Charging Saturation Temperature Liquid Line Temperature z Subcooling Value um e ae 99 Fer F 1 0 C 0 5 Charge using the Approach Method Outdoor Temp
8. CLOCKWISE 90 TO OPEN STEM CAP TO COMPRESSOR SERVICE FIGURE 13 Page 9 Revised 05 2009 Vapor Line Ball Type Service Valve 5 ton unit only A ball type full service valve is used on TPAO60S4N4xY units only Valves are not re buildable If a valve has failed it must be replaced A ball valve is illustrated in figure 13 The ball valve is equipped with a service port A Schrader valve is factory installed A service port cap is supplied to protect the Schrader valve from contamination and assure a leak free seal Ill CHARGING A Pumping Down System A CAUTION Deep vacuum operation operating compressor at 0 psig or lower can cause internal fusite arcing resulting in a damaged or failed compressor This type of damage will result in denial of warranty claim The system may be pumped down when leak checking the line set and indoor coil or making repairs to the line set or indoor coil 1 Attach gauge manifold 2 Front seat close liquid line valve 3 Start outdoor unit 4 Monitor suction gauge Stop unit when O psig is reached 5 Front seat close suction line valve B Leak Testing To Be Done Before Evacuating 1 Attach gauge manifold and connect a drum of dry nitrogen to center port of gauge manifold 2 Open high pressure valve on gauge manifold and pressurize line set and indoor coil to 150 psig 1034 kPa 3 Check lines and connections for leaks NOTE The preferred method i
9. a different accumulated compressor run time period for one defrost cycle This time period must occur before a defrost cycle is initiated The defrost interval can be adjusted to 30 T1 60 T2 or 90 T3 minutes see figure 4 The defrost timing jumper is factory installed to provide a 90 minute defrost interval If the timing selector jumper is not in place the control defaults to a 90 minute defrost interval The maximum defrost period is 14 minutes and cannot be adjusted A TEST option is provided for troubleshooting The TEST mode may be started any time the unit is in the heating mode and the defrost thermostat is closed or jumpered If the jumper is in the TEST position at TPA S4 Page 5 power up the control will ignore the test pins When the jumper is placed across the TEST pins for two seconds the control will enter the defrost mode If the jumper is removed before an additional 5 second period has elapsed 7 seconds total the unit will remain in defrost mode until the defrost thermostat opens or 14 minutes have passed If the jumper is not removed until after the additional 5 second period has elapsed the defrost will terminate and the test option will not function again until the jumper is removed and re applied Compressor Delay The defrost board has a field selectable function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode The compressor will be cycled off fo
10. circuit breaker or fuse 3 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Freezestat is recommended with Low Ambient Kit LOW AMBIENT CONTROL Option Down to 0 F Order one each Speed Control Kit Weatherproof Kit Outdoor Fan Motor and Capacitor Model No TPA036S2 TPA048S2 TPA060S2 Speed Control Kit X5867 Weatherproof Kit 56N41 Outdoor 1 2 HP 230V 69H75 e Fan Motor 460V 69H76 Capacitor with mounting bracket 53H06 A IMPORTANT The Clean Air Act of 1990 bans the intentional venting of refrigerant CFCs HFCs and HCFCs as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration may be levied for noncompliance TPA S4 A CAUTION 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 Page 3 Revised 05 2009 I UNIT COMPONENTS Unit components are illustrated in figure 1 TPA S4 UNIT COMPONENTS condenser fan control box IJ Service valves muffler L M P ae CAPACITOR C1 COMPRESSOR CONTACTOR K1 GROUNDING DEFROST LUG CONTROL CMC1
11. e and for the first 90 seconds each time the reversing valve switches heat cool modes If the TEST pins are jumpered and the 5 minute delay is being bypassed the LO PS terminal signal is not ignored during the 90 second start up period Revised 05 2009 TPA S4 Diagnostic LEDs The defrost board uses two LEDs for diagnostics The LEDs flash a specific sequence according to the condition TABLE 1 Defrost Control Board Diagnostic LED No power to control OFF Normal operation Simultaneous Slow FLASH power to control Anti snort cycle lock Alternating Slow FLASH Low pressure switch fault Optional Low pressure switch OFF ON lockout Optional High pressure switch Slow FLASH OFF fault Optional High pressure switch ON OFF lockout Optional B Compressor All TPA SA units utilize a scrol compressor The scroll compressor design is simple efficient and requires few moving parts A cutaway diagram of the scroll compressor is shown in figure 5 The scrolls are located in the top of the compressor can and the motor is located just below The oil level is immediately below the motor The scroll is a simple compression concept centered around the unique spiral shape of the scroll and its inherent properties Figure 6 shows the basic scroll form Two identical scrolls are mated together forming concentric spiral shapes figure 7 One scroll remains stationary while the other is allowed to orbit figure 8 Not
12. energized and stop immediately FIRST STAGE HEAT Internal thermostat wiring de energizes terminal O by heat ing mode selection de energizing the reversing valve L1 See steps 1 2 and 3 End of FIRST STAGE HEAT See steps 4 5 and 6 Page 18 During heating operation when outdoor coil temperature drops below 35 F 2 C or 42 F 5 5 C defrost switch thermostat S6 closes Defrost control CMC1 begins timing If defrost thermostat S6 remains closed at the end of the 30 60 or 90 minute period defrost relay ener gizes and defrost begins During defrost CMC1 energizes the reversing valve and W1 on the ter minal strip operating indoor unit on the first stage heat mode while de energizing outdoor fan motor B4 Defrost continues 14 1 minutes or until thermostat switch S6 opens When defrost thermostat opens defrost control timer loses power and resets When CMC 1 resets the reversing valve and W1 on the terminal strip are de energized while the outdoor fan motor B4 is energized When CMC 1 resets the reversing valve and W1 on the terminal strip are de energized while the outdoor fan motor B4 is energized Revised 05 2009
13. the amount of HFC 410A refrigerant indicated on the unit rating plate This charge is based on a matching indoor coil and outdoor coil with a 15 foot 4 6 m line set For varying line set lengths and for various indoor unit matchups the refrigerant charge must be adjusted per tables 6 Page 14 and 8 Page 15 A blank space is provided on the unit rating plate to list the actual field charge A IMPORTANT Mineral oils are not compatible with HFC 410A If oil must be added it must be a polyol ester oil Check Indoor Airflow before Charging A IMPORTANT CHECK AIRFLOW BEFORE CHARGING NOTE Be sure that filters and indoor and outdoor coils are clean before testing Revised 05 2009 Temp DT Step 1 Determine the desired DT Measure entering air tempera of air 22 22 22 20 ture using dry bulb A and wet bulb B DT is the intersecting value entering 21 21 20 19 of A and B in the table see triangle indoor coil F 19 19 18 Step 2 Find temperature drop across coil Measure the coil s dry 18 17 16 bulb entering and leaving air temperatures A and C Temperature 16 15 Drop Formula Tprop A minus C 16 15 15 Step 3 Determine if fan needs adjustment If the difference be tween the measured Tprop and the desired DT Tprop DT is within 3 no adjustment is needed See examples Assume DT 15 and A temp 72 these C temperatures would necessitate stated ac tions Drop
14. to iquid valve service port 2 Connect the center manifold hose to an upright cylinder of HFC 410A 3 Set the room thermostat to call for heat This will create the necessary load for properly charging the system in the cooling cycle 4 Use a digital thermometer to record the outdoor ambient temperature 5 When the heating demand has been satisfied switch the thermostat to cooling mode with a set point of 68 F 20 C When pressures have stabilized use a digital thermometer to record the liquid line temperature 6 The outdoor temperature will determine which charging method to use Proceed with the appropriate charging procedure Charge using the Weigh In Method Outdoor Temperature lt 65 F 18 C If the system is void of refrigerant or if the outdoor ambient temperature is cool first locate and repair any leaks and then weigh in the refrigerant charge into the unit 1 Recover the refrigerant from the unit 2 Conduct leak check evacuate as previously outlined 3 Weigh in the unit nameplate charge If weighing facilities are not available or if charging the unit during warm weather use one of the following procedures Charge using the Subcooling Method Outdoor Temperature lt 65 F 18 C When the outdoor ambient temperature is below 65 F 18 C use the subcooling method to charge the unit It may be necessary to restrict the air flow through the outdoor coil to achieve pressures in the 200
15. 2 F 5 5 C or cooler the thermostat contacts close and send a signal to the defrost control board to start the defrost timing It also terminates defrost when the liquid line warms up to 70 F 21 C Revised 05 2009 Defrost Control The defrost control board includes the combined functions of a time temperature defrost control defrost relay diagnostic LEDs and terminal strip for field wiring connections See figure 4 The control provides automatic switching from normal heating operation to defrost mode and back During compressor cycle call for defrost the control accumulates compressor run times at 30 60 or 90 minute field adjustable intervals If the defrost thermostat is closed when the selected compressor run time interval ends the defrost relay is energized and defrost begins TPA036S4 Outdoor Unit Defrost Control Board O 2160 o wo KI RELAY O Test Pins Obs Compressor Quos Delay Pins 4 K2 RELAY v m wi 24v terminal j V strip C Reversin T Valve Low Pressure Switch S87 Defrost Thermostat eleeeee K3 RELAY ele gt e Te TST PS OF C R O YI High Pressure Switch S4 FIGURE 4 Defrost Control Timing Pins Each timing pin selection provides
16. 53 19 15 4 Increase the airflow 58 14 15 14 within 3 range no change 62 10 15 5 Decrease the airflow Step 4 Adjust the fan speed See indoor unit instructions to in All temperatures are a crease decrease fan speed expressed in F Changing air flow affects all temperatures recheck temperatures to confirm that the temperature drop and DT are within 3 DISTRIBUTOR OUTDOOR UNIT NOTE ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW CHECK REVERSING VALVE EXPANSION VALVE FILTER DRIER OUTDOOR COIL LOW HUGH MUFFLE PRESSURE PRESSURE R INDOOR LIQUID SERVICE PORT MANIFOLD LIQUID LINE VALVE COMPRESSOR gt J CHECK EXPANSION VALVE gt NOTE Use gauge ports on vapor line valve and liquid valve for evacuating refrigerant b ng lines and indoor coil Use vapor gauge port to measure vapor pressure during charging Figure 16 TPA S4N43Y Cooling Cycle Showing Gauge Manifold Connections TPA S4 Page 13 Revised 05 2009 TPA S4 Cooling mode indoor airflow check Check airflow using the Delta T DT process figure 15 Heating mode indoor airflow check Blower airflow CFM may be calculated by energizing electric heat and measuring e temperature rise between the return air and supply air temperatures at the indoor coil blower unit e measuring voltage supplied to the unit e measuri
17. 6 897 61 1726 96 299 4 CBX32M 060 n m 313 CBX32MV 048 paps 14 318 28 93 5 63 178 5 98 308 2 CBX32MV 060 230 345 12 339 29 955 64 1816 99 3127 GBXA0UHV 048 RENE a CEX40UHV 060 Tk CH3343C T EP BE SEEDS E CH33 49C 50 60C 11 11 1 3 CHO sa 105 69 104 335 7 c33 62D m n ETT 48 2 70 200 6 105 340 5 CRSEBUBU BE 7 THES 49 5 71 203 9 106 345 3 50 9 72 207 2 107 350 1 m E EUN EU 108 e E LAB EE CERE LL Table 12 TPA060S4N43Y ala _ gt o w w w Tl O O C1 oj o ojo 59 3 43 125 78 2 60 8 44 127 3 79 231 6 8 6 1 2 6_ 18 19 sureng 12 Di INDOOR MATCHUPS Heat Cool 28 113 380 2 5 F 1 F i 114 385 4 CBX26UH 060 1 CBX27UH 060 230 0 116 396 CBX32MV 060 0 CBX32MV 068 0 118 CBX40UHV 060 0 CH33 60D 0 120 CH33 62D 0 75 2 53 150 1 88 266 123 434 5 Amount of charge required in additional to charge shown on unit 19 124 nameplate Remember to consider line set length difference 2 78 7 155 5 90 125 IV MAINTENANCE At the beginning of each heating or cooling season the 2 Check connecting lines and coil for evidence of oil system should be cleaned as follows leaks A Outdoor Unit 3 Check condensate line and clean if necessary 1 Clean and inspect condenser coil Coil may be C Indoor Unit flushed with a water hose 1 Clean
18. Liquid or Vapor Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and hex head extension 5 16 for vapor line and 3 16 for liquid line back the stem out counterclockwise until the valve stem just touches the retaining ring 3 Replace stem cap and tighten finger tight then tighten an additional 1 6 turn A DANGER Do not attempt to backseat this valve Attempts to backseat this valve will cause snap ring to explode from valve body under pressure of refrigerant Personal injury and unit damage will result To Close Liquid or Vapor Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and hex head extension 5 16 for vapor line and 3 16 for liquid line turn stem clockwise to seat the valve Tighten firmly 3 Replace stem cap Tighten finger tight then tighten an additional 1 6 turn TPA S4 LIQUID LINE SERVICE VALVE VALVE OPEN INSERT HEX WRENCH HERE SERVICE PORT SERVICE Nd PORT CAP SCHRADER VALVE LIQUID LINE SERVICE VALVE VALVE CLOSED RETAINING RING STEM CAP SERVICE AR A PORT Gs INSERT HEX O gt M COMPRESSOR WRENCH HERE IN SERVICE PORT CAP SCHRADER VALVE OPEN VALVE FRONT TO LINE SET WHEN VALVE IS SEATED CLOSED FRONT SEATED FIGURE 12 TO INDOOR COIL SUCTION LINE BALL TYPE SERVICE VALVE VALVE OPEN USE ADJUSTABLE WRENCH ROTATE STEM CLOCKWISE 90 TO CLOSE ROTATE STEM COUNTER
19. MPONENT BT COMPRESSOR B4 MOTOR OUTDOOR FAN Cl CAPACITOR OUTDOOR FAN CMC I CONTROL DEFROST HRI HEATER COMPRESSOR IKI L CONTACTOR COMPRESSOR IK10 I RELAY OUTDOOR FAN ILI VALVE REVERSING 54 SWITCH LIMIT HI PRESS ss SWITCH DEFROST 1540 THERMOSTAT CRANKCA 587 SWITCH LOW PRESS N NOTE FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVER CURRENT PROTECTION SIZE ZX CONNECTION MUST BE JUMPERED WHEN OPTIONAL SWITCH IS NOT USED COOLING Internal thermostat wiring energizes terminal O by cooling mode selection energizing the reversing valve L1 1 Demand initiates at Y1 in the thermostat SI THERMOSTAT ORMOND GROUND THERMOSTAT 2060 J pS SS LS SWITCH WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUND IN ACCORDANCE WITH NATIONAL AND LOCAL CODES DENOTES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED CLASS VOLTAGE FIELD INSTALLED Lithe U S A DEFROST MODE 2 Assuming high pressure switch S4 and low pressure switch S87 are closed 24VAC energizes compressor contactor K1 3 K1 1 N O closes energizing compressor B1 and outdoor fan motor B4 END OF COOLING DEMAND 4 Demand is satisfied Terminal Y1 is de energized 5 Compressor contactor K1 is de energized 6 K1 1 opens and compressor B1 and outdoor fan motor B4 are de
20. OR UNIT PRESSURE PRESSURE MUFFLER SUCTION SERVICE LIQUID LINE SERVICE PORT NOTE ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW FIGURE 11 TPA S4 Page 8 Revised 05 2009 A Plumbing Field refrigerant piping consists of liquid and vaporlines from the outdoor unit sweat connections Use Lennox L15 sweat series line sets as shown in table 2 TABLE 2 Refrigerant Line Sets Field Connections Recommended Line Set Model a Liquid Vapor Liquid Vapor L15 Line Line Line Line Line Sets L15 65 036 3 8 in 7 8 in 10 in 7 8in 15 ft 50 ft 048 10 mm 22 mm 22 mm 4 6 m 15 mm m 89 3 8 in 1 1 8 in 10 in 4 4 8 in Field 7 10 mm 29 mm mm 29 mm Fabricated B Service Valves The liquid and vapor line service valves figures 12 and 13 and gauge ports are accessible from outside the unit Each valve is equipped with a service port The service ports are used for leak testing evacuating charging and checking charge A Schrader valve is factory installed A service port cap is supplied to protect the Schrader valve from contamination and serve as the primary leak seal NOTE Always keep valve stem caps clean To Access Schrader Port 1 Remove service port cap with an adjustable wrench 2 Connect gauge to the service port 3 When testing is completed replace service port cap Tighten finger tight then an additional 1 6 turn To Open
21. TER COMPRESSOR CONTROL DEFROST Ft RED CONTACTOR COMPRESSOR VALVE REVERSING SWITCH HIGH PRESSURE EQUIPMENT IS I Q o o z Omro GROUND SWITCH DEFROST THERMOSTAT CRANKCASE THERMOSTAT LOW AMBIENT E SWITCH LOW PRESSURE WARNING ah ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES DENOTES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED CLASS VOLTAGE FIELD INSTALLED COOLING Internal thermostat wiring energizes terminal O by cooling mode selection energizing the reversing valve L1 1 Demand initiates at Y1 in the thermostat 2 Assuming high pressure switch S4 and low pressure Switch S87 are closed 24VAC energizes compressor contactor K1 3 K1 1 N O closes energizing compressor B1 and outdoor fan motor B4 END OF COOLING DEMAND 4 Demand is satisfied Terminal Y1 is de energized 5 Compressor contactor K1 is de energized 6 K1 1 opens and compressor B1 and outdoor fan motor B4 are de energized and stop immediately FIRST STAGE HEAT Internal thermostat wiring de energizes terminal O by heat ing mode selection de energizing the reversing valve L1 See steps 1 2 and 3 End of FIRST STAGE HEAT See steps 4 5 and 6 TPA S4 O B4 PURPLE Cl2 1 Page 17
22. ase PSC fan motors In all units the condenser fan is controlled by the compressor contactor and defrost control during defrost cycles ELECTRICAL DATA tables in this manual show specifications for condenser fans used in TPA S4s Access to the condenser fan motor on all units is gained by removing the seven screws securing the fan assembly See figure 9 The outdoor fan motor is removed from the fan guard by removing the four nuts found on the top panel If outdoor fan motor must be replaced align fan hub flush with motor shaft Drip loops should be used in wiring when servicing motor CONDENSER FAN MOTOR AND COMPRESSOR ACCESS FAN GUARD TT FAN HUB FLUSH WITH MOTOR SHAFT e REMOVE 7 SCREWS SECURING FAN GUARD REMOVE FAN GUARD FAN ASSEMBLY FIGURE 9 Remove 4 nuts TPA S4 Page 7 D Reversing Valve L1 and Solenoid A refrigerant reversing valve with electro mechanical solenoid is used to reverse refrigerant flow during unit operation The reversing valve requires no maintenance The only replaceable part is the solenoid If the reversing valve itself has failed it must be replaced If replacement is necessary access reversing valve by removing the outdoor fan motor Refer to figure 9 E Crankcase Heater HR1 and Optional Thermostat S40 Crankcase heater HR1 prevents liquid from accumulating in the compressor HR1 is controlled by crankcase heater thermostat S40 located on the liqu
23. e that the orbiting scroll does not rotate or tum but merely orbits the stationary scroll SCROLL COMPRESSOR DISCHARGE FIGURE 5 NOTE During operation the head of a scroll compressor may be hot since it is in constant contact with discharge gas Page 6 SCROLL FORM FIGURE 6 CROSS SECTION OF SCROLLS DISCHARGE STATIONARY SCROLL DISCHARGE PRESSURE DD LI a A SG y Sy SASASSAASANM M MAAMMAAASY VLLLLLLLELLU NNNNANAAANYA Che SAAAAAASAAA SASSAAAAS WEFZ Z gZSHP P SAAAAAAASSSY LLL LLL SS N NA N RN ORBITING SCROLL TIPS SEALED BY DISCHARGE PRESSURE FIGURE 7 The counterclockwise orbiting scroll draws gas into the outer crescent shaped gas pocket created by the two scrolls figure 8 1 The centrifugal action of the orbiting scroll seals off the flanks of the scrolls figure 8 2 As the orbiting motion continues the gas is forced toward the center of the scroll and the gas pocket becomes compressed figure 8 3 When the compressed gas reaches the center it is discharged vertically into a chamber and discharge port in the top of the compressor figure 7 The discharge pressure forcing down on the top scroll helps seal off the upper and lower edges tips of the scrolls figure 7 During a single orbit several pockets of gas are compressed simultaneously providing smooth continuous compression The scroll compressor is tolerant to the effects of liquid return If liq
24. epending on mode being used Using cooling mode When the outdoor ambient temperature is 60 F 15 C and above Target subcooling values in table below are based on 70 to 80 F 21 27 C indoor return air temperature if necessary operate heating to reach that temperature range then set thermostat to cooling mode setpoint to 68 F 20 C When pressures have stabilized continue with step 6 Using heating mode When the outdoor ambient temperature is below 60 F 15 C Target subcooling values in table below are based on 65 75 F 18 24 C indoor return air temperature if necessary operate cooling to reach that temperature range then set thermostat to heating mode setpoint to 77 F 25 C When pressures have stabilized continue with step 6 Read the liquid line temperature record in the LIQ space Read the liquid line pressure then find its corresponding temperature in the temperature pressure table 13 and record it in the SAT space Compare SC results with table below being sure to note any additional charge for line set and or matchup If subcooling value is greater than shown in table remove refrigerant if less than shown add refrigerant D Indoor Unit Matchups TPA S4N43Y Table 9 TPA036S4N43Y 11 If refrigerant is added or removed repeat steps 5 through 10 to verify charge Table 10 TPA042S4N43Y
25. erature gt 65 F 18 C The following procedure is intended as a general guide and is for use on expansion valve systems only For best results indoor temperature should be 70 F 21 C to 80 F 26 C Monitor system pressures while charging 1 Record outdoor ambient temperature using a digital thermometer 2 Attach high pressure gauge set and operate unit for several minutes to allow system pressures to stabilize 3 Compare stabilized pressures with those provided in table 4 Normal Operating Pressures Pressures higher than those listed indicate that the system is overcharged Pressures lower than those listed indicate that the system is undercharged Verify adjusted charge using the approach method Revised 05 2009 TPA S4 A IMPORTANT Use table 4 as a general guide when performing maintenance checks This is not a procedure for charging the unit Refer to Charging Checking Charge section Minor variations in these pressures may be expected due to differences in installations Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system 4 Use the same digital thermometer used to check outdoor ambient temperature to check liquid line temperature Verify the unit charge using the approach method 5 The difference between the ambient and liquid temperatures should match the approach values given in table 5 If the values do n
26. id line When liquid line temperature drops below 50 F S40 closes energizing HR1 S40 opens when liquid line temperature reaches 70 F High Pressure Switch S4 S4 is a manual re set switch located on the liquid line When liquid line pressure rises above the factory setting of 590 10 psi the switch opens and shuts off the compressor G Low Pressure Switch S87 S87 is an auto reset low pressure switch located on the suction line The switch shuts of the compressor when suction pressure drops below the factory setting The switch is ignored during the first 90 seconds of compressor start up during defrost operation 90 seconds after defrost operation and during test mode The switch is factory set to open at 25 5 psig and close at 40 5 psig These settings are not adjustable Revised 05 2009 Il REFRIGERANT SYSTEM TPA S4 COOLING CYCLE SHOWING MANIFOLD GAUGE CONNECTIONS OUTDOOR UNIT DEFROST THERMOSTAT REVERSING VALVE EXPANSION CHECK VALVE BI FLOW FILTER DRIER OUTDOOR COIL LOW HIGH PRESSURE PRESSURE INDOOR UNIT MUFFLER POR H H Y GAUGE MANIFOLD J SUCTION I C SERVICE LIQUID LINE SERVICE COMPRESSOR NOTE ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW FIGURE 10 TPA S4 HEATING CYCLE SHOWING MANIFOLD GAUGE CONNECTIONS OUTDOOR UNIT DEFROST THERMOSTAT REVERSING VALVE EXPANSION CHECK VALVE BI FLOW FILTER DRIER OUTDOOR COIL LOW HIGH INDO
27. ng 308 145 367 143 379 140 395 135 105 41 452 148 414 146 432 143 450 138 115 45 512 151 473 148 492 146 512 141 350 131 366 129 348 119 379 127 331 111 348 110 334 105 361 109 314 91 333 91 312 84 341 89 303 74 317 70 300 73 323 71 290 62 298 58 286 60 310 60 These are most popular match up pressures Indoor match up indoor air quality and indoor load cause pressures to vary Temperature of the air entering the outside coil Page 14 Revised 05 2009 Table 8 Use cooling it mode mee od aes b Use heating 7 mode SAT LIQ Sc 60 F 15 C Adding Charge per Indoor Unit Matchup using Subcooling Method N 3 Connect gauge set 4 Check Liquid and Vapor line pressures Compare pressures with Normal Operating Pressures table 4 Table 4 is a general guide Expect minor pressures variations Significant differences may mean 8 Subtract LIQ temp from SAT temp to determine subcooling record it in SC space 10 Measure outdoor ambient temperature determine whether to use cooling mode or heating mode to check charge Check the airflow figure 15 Page 13 to be sure the indoor airflow is as required Make any air flow adjustments before continuing with the following procedure improper charge or other system problem Set thermostat for heat cool demand d
28. ng amperage being drawn by the heat unit s Then apply the measurements taken in following formula to determine CFM Amps x Volts x 3 41 CFM 1 08 x Temperature rise F Setup for Charging Connect the manifold gauge set to the unit s service ports see figure 16 e low pressure gauge to vapor service port e high pressure gauge to liquid service port Close manifold gauge set valves Connect the center manifold hose to an upright cylinder of HFC 410A Calculating 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 Amount Adjust amt for Additional charge specified variation in specified per on line set length indoor unit matchup Total nameplate table 6 table 8 charge Weigh in Charging Method Weigh in 1 Recover the refrigerant from the unit 2 Conduct leak check evacuate as previously outlined 3 Weigh in the unit nameplate charge plus any charge required for line set differences from 15 feet and any extra indoor unit matchup amount per table 8 If weighing facilities are not available use the subcooling method Table 6 Charge per Line Set Lengths Liquid Line Set Diameter 3 8 in 9 5mm 3 ounce per 5 ft 85g per 1 5m 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
29. or change filters NOTE Make sure all power is disconnected before 2 Bearings are pre lubricated and need no further flushing coil with water oiling 2 Visually inspect all connecting lines joints and 3 Check all wiring for loose connections coils for evidence of oil leaks 4 Check for correct voltage at unit NOTE Outdoor fan motors are permanently 5 Check amp draw on blower motor lubricated B Indoor Coil 1 Clean coil if necessary TPA S4 Page 16 Revised 05 2009 V WIRING DIAGRAM AND SEQUENCE OF OPERATION TPA S4 230 VOLT UNIT DIAGRAM OUTDOOR FAN O PURPLE DUAL DEFROST CONTROL CAPACITOR THERMOSTAT BLACK FAN BLACK T T OMMOQ ORANGE BLACK RED I Is 2 ojo YELLOW ojo A F U Uu D COMPRESSOR CRANKCASE HEATER e RU ER o COMPRESSOR CONTACTOR Wo Q S z 2 208 230 60 GROUND LUG THERMOSTAT DEFROST THERMOSTAT DESCRIPTION m COMPCNENT YELLOW LOW AMBIENT LERNO ERESSURE COMPRESSOR 208 230 60 1 MOTOR OQUTDOOR FAN RED i iel V A o 1 U e L2 e CAPACITOR DUAL ORANGE HEA
30. ot agree with the those in table 5 add refrigerant to lower the approach temperature or recover refrigerant from the system to increase the approach temperature TABLE 4 TPA S4N41Y through TPA S4N42Y Normal Operating Pressures TPA036S4N4 TPA042S4N4 TPA048S4N4 TPA060S4N4 1 1 1 1 F C 2 Liquid Vapor Liquid Vapor Liquid Vapor Liquid Vapor Cooling Pressures 331 81 309 62 300 56 314 88 324 91 302 92 290 74 307 73 300 73 283 58 298 61 286 60 These are most popular match up pressures Indoor match up indoor air quality and indoor load cause pressures to vary 2 Temperature of the air entering the outdoor coil 3 Liquid 10 and Vapor 5 psig Page 12 TABLE 5 TPA S4N41Y through TPA S4N42Y TPA036S4 Approach Values for Charging Liquid Line Temperature Outdoor Temperature Approach Temperature LEE E e gE NOTE For best results use the same electronic thermometer to check both outdoor ambient and liquid line temperatures F 1 0 C 0 5 D Charging TPA S4N43Y This system is charged with HFC 410A refrigerant which operates at much higher pressures than HCFC 22 The recommended check expansion valve is approved for use with HFC 410A Do not replace it with a valve that is designed to be used with HCFC 22 This unit is NOT approved for use with coils that include metering orifices or capillary tubes The unit is factory charged with
31. per inch 22 22 22 22 Outdoor Diameter in No of Blades 18 4 22 4 22 4 22 4 Fan Motor hp 208 230V 1 5 1 3 1 3 1 4 460V 1 6 Cfm 2450 3890 3890 3830 Rpm 1100 1080 1085 830 Watts 190 400 375 330 Shipping Data lbs 1 package 180 220 250 255 ELECTRICAL DATA Line voltage data 60 hz 3ph 208 230V 460V 208 230V 460V 208 230V 460V 208 230V 460V Maximum overcurrent protection amps 20 15 30 15 30 15 35 15 3 Minimum circuit ampacity 14 2 7 8 18 6 8 3 18 8 8 6 21 3 10 7 Compressor Rated Load Amps Locked Rotor Amps Power Factor Outdoor Full Load Amps Fan Motor Locked Rotor Amps TPA S4 Page 2 Revised 05 2009 OPTIONAL ACCESSORIES must be ordered extra Model No TPA036S4 TPA042S4 TPA048S4 TPA060S4 Compressor Low Ambient Cut Off 45F08 Compressor Sound Cover 69J03 Freezestat 3 8 in tubing 93G35 f osx de mE nd ECC Low Ambient Control Option down to 30 F See table below See table below See table below See table below Mild Weather Kit 33M07 Monitor Kit Service Light 76F53 Mounting Base 69J06 69J07 Outdoor Thermostat 56A87 Thermostat Kit Mtg Box 31461 Refrigerant L15 65 30 L15 65 40 or L15 65 50 Line Sets Field Fabricate Time Delay Relay Kit 58M51 Unit Stand Off Kit 94J45 NOTE Extremes of operating range are plus 1096 and minus 5 of line voltage 1 Refrigerant charge sufficient for 15 ft length of refrigerant lines 2 HACR type
32. r 30 seconds going in and out of the defrost mode when the compressor delay jumper is removed NOTE The 30 second off cycle is not functional when jumpering the TEST pins Time Delay The timed off delay is five minutes long The delay helps to protect the compressor from short cycling in case the power to the unit is interrupted or a pressure switch opens The delay is bypassed by placing the timer select jumper across the TEST pins for 0 5 seconds Pressure Switch Circuit The defrost control incorporates two pressure switch circuits The optional high pressure switch S4 connects to the board s HI PS terminals The board also includes connections for an optional low pressure or loss of charge pressure switch S87 See figure 4 for switch terminal location During a single demand cycle the defrost control will lock out the unit after the fifth time that the circuit is interrupted by any pressure switch wired to the control board In addition the diagnostic LEDs will indicate a locked out pressure switch after the fifth occurrence of an open pressure switch see Table 1 The unit will remain locked out until power to the board is interrupted then re established or until the jumper is applied to the TEST pins for 0 5 seconds NOTE The defrost control board ignores input from the low pressure switch terminals as follows e during the TEST mode e during the defrost cycle e during the 90 second start up period
33. s to use an electronic leak or Halide detector Add a small amount of HCFC 22 3 to 5 psig 20kPa to 34kPa then pressurize with nitrogen to 150 psig 4 Release nitrogen pressure from the system correct any leaks and recheck TPA S4 Page 10 4 DANGER When using dry nitrogen a pressure reducing regu lator must be used to prevent excessive pressure in gauge manifold connecting hoses and within the system Regulator setting must not exceed 150 psig 1034 kpa Failure to use a regulator can cause equipment failure resulting in injury or death C Evacuating the System 1 Attach gauge manifold Connect vacuum pump with vacuum gauge to center port of gauge manifold With both manifold service valves open start pump and evacuate indoor coil and refrigerant lines A IMPORTANT A temperature vacuum gauge mercury vacuum U tube or thermocouple gauge should be used The usual Bourdon tube gauges are not accurate enough in the vacuum range IMPORTANT The compressor should never be used to evacu ate a refrigeration or air conditioning system 2 Evacuate the system to 29 inches 737mm vacuum During the early stages of evacuation it is desirable to stop the vacuum pump at least once to determine if there is a rapid loss of vacuum A rapid loss of vacuum would indicate a leak in the system and a repeat of the leak testing section would be necessary 3 After system has been evacuated to 29 inches
34. subtract this amount Subcooling Charging Method Requirements these items are required for charging Oz per 5 ft g per 1 5m adjust from 15 ft 4 6m line set e Manifold gauge set connected to unit e Thermometers for measuring outdoor ambient liquid line and vapor line temperatures When to use cooling mode When outdoor temperature is 60 F 15 C and above use cooling mode to adjust charge When to use heating mode When the outdoor temperature is below 60 F 15 C use the heating mode to adjust the charge Adding Charge for Indoor Matchups Table 8 lists all the Lennox recommended indoor unit matchups along with the charge levels for the various sizes of outdoor units Table 7 Normal Operating Pressures Liquid 10 and Vapor 5 PSIG A IMPORTANT Use table 4 as a general guide when performing maintenance checks This is not a procedure for charging the unit Refer to Charging Checking Charge section Minor variations in these pressures may be expected due to differences in installations Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system TPA S4N43Y TPA036S4 TPA036S4 TPA036S4 TPA036S4 F C Liquid Vapor Liquid Vapor Liquid Vapor Liquid Vapor 65 18 260 136 231 135 246 134 256 116 75 24 303 140 267 138 286 136 298 123 348 143 314 140 330 138 345 131 Cooli
35. uid enters the scrolls the orbiting scroll is allowed to separate from the stationary scroll The liquid is worked toward the center of the scroll and is discharged If the compressor is replaced conventional Lennox cleanup practices must be used Due to its efficiency the scroll compressor is capable of drawing a much deeper vacuum than reciprocating compressors Deep vacuum operation can cause internal fusite arcing resulting in damaged internal parts and will result in compressor failure Never use a scroll compressor for evacuating or pumping down the system This type of damage can be detected and will result in denial of warranty claims The scroll compressor is quieter than a reciprocating compressor however the two compressors have much different sound characteristics The sounds made by a scroll compressor do not affect system reliability performance or indicate damage See compressor nameplate and ELECTRICAL DATA table on page 2 for compressor specifications Revised 05 2009 SUCTION N ORBITING SCROLL STATIONARY SCROLL SUCTION POCKET SUCTION SUCTION Y INTERMEDIATE PRESSURE 2 x GAS CRESCENT SHAPED GAS POCKET FLANKS SEALED BY CENTRIFUGAL N FORCE MOVEMENT OF ORBIT HIGH PRESSURE GAS SUCTION V DISCHARGE POCKET FIGURE 8 DANGER Make sure all power is disconnected before beginning electrical service procedures C Outdoor Fan Motor B4 All units use single ph
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