Corp.

0105L2

R410A

Service Literature

Revised 82005

R410A is a near azeotrope refrigerant made of HFC32 (50%) and HFC125 (50%) developed to replace R22 refrigerant. R410A is an ozone friendly refrigerant with expected widespread use. Its characteristics make R410A the replacement for R22. Lennox Industries is committed to R410A. This manual covers components, refrigeration system and charging procedure for condensing units and heat pump units using R410A. Information contained in this manual is intended for use by qualified service technicians only. All specifications are subject to change.

IMPORTANT
Operating pressures in a R410A unit are 50% to 70% higher than pressures in R22 units. Use only service equipment rated for R410A. HS32 SHOWN

WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualified installer or service agency.

WARNING
Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.

WARNING
R410A refrigerant can be harmful if it is inhaled. R410A refrigerant must be used and recovered responsibly. Failure to follow this warning may result in personal injury or death.

WARNING
Avoid Skin and Eye contact with R410A refrigerant. If skin or eyes are exposed to R410A, flush the area with warm water and seek medical attention at once.

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2001 Lennox Industries Inc.

IUNIT COMPONENTS
R410A will not affect all condensing or heat pump unit components. This section covers only components affected by R410A.

ADrier
A filter drier designed for condensing and heat pump units must be installed in the liquid line. Driers installed for units using R22 must be replaced. The factory supplied drier is designed to remove moisture, which can lead to compressor failure.

Arctic 22CC and ICI EMKARATEt RL32CF for use with these compressors. Lennox recommends adding 1 oz. of oil per additional 10 ft. for applications with line sets over 50 ft. Do not add more than 7 oz. of oil. See electrical section in this manual for compressor specifications.

CHigh/Low Pressure Switch

IMPORTANT
Pressure switch settings for R410A refrigerant will be significantly higher than units with R22. Heat pump and condensing units will have a high pressure switch is located in the liquid line. This switch shuts off the compressor when liquid line pressure rises above the factory setting. The switch is normally closed and is permanently adjusted to open on a pressure rise. Condensing units will have a low pressure switch located in the suction line. This switch shuts off the compressor when suction pressure drops below the factory setting. The switch is closed during normal operating pressure conditions and is permanently adjusted to open on a pressure drop.

IMPORTANT
Any time unit is exposed to open air due to service, drier must be replaced. All replacement driers must be approved for R410A refrigerant.

BScroll Compressor
The scroll compressors in all condensing and heat pump units are designed for use with R410A refrigerant and operation at high pressures. Compressors are shipped from the factory with 3MA (32MMMA) P.O.E. oil. If oil must be added for service, Copeland has approved Mobil EALt

CONDENSER FAN (NOT SHOWN) TOP OF CABINET RUN CAPACITOR

R410A CONDENSING UNIT PARTS ARRANGEMENT TIME DELAY HS32 SHOWN

GROUND LUG

CONTACTOR

TERMINAL BOX THERMOMETER WELL (early manufactured units only)

SUCTION VALVE AND GAUGE PORT

LIQUID LINE SERVICE VALVE AND GAUGE PORT

COMPRESSOR LOW PRESSURE SWITCH HIGH PRESSURE SWITCH

FIGURE 1

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IIPlumbing Service Valves

The liquid line and suction line service valves and gauge ports are accessible by removing the compressor access cover. Full service liquid and suction line valves are used. The service ports are used for leak testing, evacuating, charging and checking charge. Service valves have a factoryinstalled schrader valve. A service port cap is supplied to protect the schrader valve from contamination and assure a leak free seal. Valves are not rebuildable. If a valve has failed it must be replaced. The pressure tap fitting has a LIGHT MAROON tag to remind service technicians that the unit contains R410A.

IIIRefrigerant System Flushing Existing Line Set and Indoor Coil

IMPORTANT
If this unit is being matched with an approved line set or indoor coil which was previously charged with R22 refrigerant, 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 R410A refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the thermal expansion valve, reducing system performance and capacity. Failure to properly flush the system per the instructions below will void the warranty.

ing to the instructions provided with the recovery machine. Remove all R22 refrigerant from the existing system. Refer to gauges after shutdown to confirm that the entire system is completely void of refrigerant. Disconnect the liquid and vapor lines from the existing outdoor unit. If the existing outdoor unit is equipped with manual shutoff valves AND you plan to use NEW R22 refrigerant to flush the system Start the existing R22 system in the cooling mode and close the liquid line valve. Pump all of the existing R22 refrigerant back into the oudoor unit. (It may be necessary to bypass the low pressure switches to ensure complete refrigerant evacuation.) When the low side system pressures reach 0 psig, close the suction line valve. Disconnect all power to the existing outdoor unit. Refer to gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system. Disconnect the liquid and vapor lines from the existing outdoor unit. NOTE Before making linset connections, use dry nitrogen to purge refrigerant piping. This will help prevent oxidation and introduction of moisture into the system.

WARNING
Danger of explosion: Can cause equipment damage, injury or death. When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioned systm, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa). 2 Remove the existing outdoor unit. Set the new R410A unit and make line set connections. DO NOT install provided R410A check/expansion valve at this time. Make low voltage and line voltage connections to the new outdoor unit. DO NOT turn on power to the unit or open the outdoor unit service valves at this time. 3 Remove the existing refrigerant flow control orifice or thermal expansion/check valve before continuing with flushing procedures. The existing devices are not approved for use with R410A refrigerant and may prevent proper flushing. Use a fieldprovided fitting to reconnect the lines.

CAUTION
This procedure should not be performed on systems which contain contaminants (Example: compressor burn out).

Required Equipment
You will need the following equipment in order to flush the existing line set and indoor coil: two clean R22 recovery bottles, an oilless recovery machine with a pump down feature, and two sets of gauges (one for use with R22 and one for use with the R410A).

Flushing Procedure
1 Remove existing R22 refrigerant using the appropriate procedure below. If the existing outdoor unit is not equipped with shutoff valves, or if the unit is not operational AND you plan to use the existing R22 refrigerant to flush the system Disconnect all power to the existing outdoor unit. Connect to the existing unit, a clean recovery cylinder and the recovery machine accordPage 3

IMPORTANT
The line set and indoor coil must be flushed with at least the same amount of clean refrigerant that previously charged the system. Check the charge in the flushing cylinder before proceeding.

FLUSHING CONNECTIONS
INVERTED R22 CYLINDER (Contains clean R22 to be used for flushing) HP32 UNIT
EXISTING SUCTION LINE SUCTION LINE SERVICE VALVE GAUGE MANIFOLD LIQUID LINE SERVICE VALVE OPENED CLOSED LOW HIGH PRESSURE PRESSURE

EXISTING INDOOR COIL

EXISTING LIQUID LINE

TANK RETURN

INLET DISCHARGE RECOVERY CYLINDER

NOTE The inverted R22 cylinder must contain at least the same amount of refrigerant as was recovered from the existing system.

RECOVERY MACHINE

FIGURE 2 4 Remove the pressure tap valve cores from the units service valves. Connect an R22 cylinder with clean refrigerant to the suction service valve. Connect the R22 gauge set to the liquid line valve and connect a recovery machine with an empty recovery tank to the gauge set. 5 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 coil. 6 Invert the cylinder of clean R22 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 coil before it enters the recovery machine. 7 After all of the liquid refrigerant has been recovered, switch the recovery machine to vapor recovery so that all of the R22 vapor is recovered. Allow the recovery machine to pull a vacuum on the system. NOTE A single system flush should remove all of the mineral oil from the existing refrigerant lines and indoor coil. A second flushing may be done (using clean refrigerant) if insufficient amounts of mineral oil were removed during the first flush. Each time the system is flushed, you must allow the recovery machine to pull a vacuum on the system at the end of the procedure. 8 Close the valve on the inverted R22 drum and the gauge set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off. 9 Use nitrogen to break the vacuum on the refrigerant lines and indoor coil before removing the recovery machine, gauges and R22 refrigerant drum. Reinstall pressure tap valve cores into the units service valves. 10 Install the provided check/expansion valve (approved for use with R410A refrigerant) in the liquid line at the indoor coil.

Manifold Gauge Set

Manifold gauge sets used with systems charged with R410A refrigerant 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.

Leak Testing
After the line set and check/expansion valve have been connected to the indoor and outdoor units, the line set connections and indoor unit must be checked for leaks.

WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly. Page 4

WARNING
Never use oxygen or air to pressurize refrigeration or air conditioning systems. Oxygen or air will explode on contact with oil and could cause personal injury. When using high pressure gas such as nitrogen for this purpose, be sure to use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).

WARNING
Danger of Equipment Damage. Avoid deep vacuum operation. Do not use compressors to evacuate a system. Extremely low vacuums can cause internal arcing and compressor failure. Damage caused by deep vacuum operation will void warranty. 1 Connect manifold gauge set to the service valve ports as follows: low pressure gauge to vapor line service valve; high pressure gauge to liquid line service valve. 2 Connect the vacuum pump (with vacuum gauge) to the center port of the manifold gauge set. 3 Open both manifold valves and start vacuum pump. 4 Evacuate the line set and indoor unit to an absolute pressure of 23mm (23,000 microns) of mercury or approximately 1 inch of mercury. 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 absolute pressure. A rapid rise in pressure indicates a relatively large leak. If this occurs, the leak testing procedure must be repeated. 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. 5 When the absolute pressure reaches 23mm (23,000 microns) of mercury, close the manifold gauge valves, turn off the vacuum pump and disconnect the manifold gauge center port hose from vacuum pump. Attach the manifold center port hose to a 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. 6 Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the nitrogen from the line set and indoor unit. 7 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 .5mm (500 microns) of mercury within a 20 minute period after shutting off the vacuum pump and closing the manifold gauge valves. 8 When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to a bottle of R410A refrigerant that has been positioned to dispense liquid refrigerant. Open the manifold gauge valves to break the vacuum in the line set and indoor unit. Close manifold gauge valves and shut off R410A bottle and remove manifold gauge set.

Using an Electronic Leak Detector

1 Connect the high pressure hose of the manifold gauge set to the service port of the vapor valve. (Normally, the high pressure hose is connected to the liquid line port; however, connecting it to the vapor port better protects the manifold gauge set from high pressure damage.) 2 Connect a cylinder of R410A in the UPRIGHT position to the center port of the manifold gauge set. 3 With both manifold valves closed, open the valve on the R410A bottle (vapor only). 4 Open the high pressure side of the manifold to allow R410A into the line set and indoor unit. Weigh in a trace amount of R410A. [A trace amount is a maximum of 2 ounces (57g) refrigerant or 3 pounds (31 kPa) pressure]. Close the valve on the R410A bottle and the valve on the high pressure side of the manifold gauge set. Disconnect R410A bottle. 5 Connect a cylinder of nitrogen with a pressure regulator valve to the center port of the manifold gauge set. 6 Adjust nitrogen pressure to 150 psig (1034 kPa). Open the valve on the high side of the manifold gauge set which will pressurize line set and indoor unit. 7 After a short period of time, open a refrigerant port to make sure the refrigerant added is adequate to be detected. (Amounts of refrigerant will vary with line lengths.) Check all joints for leaks. Purge nitrogen and R410A mixture. Correct any leaks and recheck.

IMPORTANT
Leak detector must be capable of sensing HFC refrigerant.

Evacuation and Dehydration

Evacuating the system of noncondensables is critical for proper operation of the unit. Noncondensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system. Noncondensables and water vapor combine with refrigerant to produce substances that corrode copper piping and compressor parts. Page 5

Charging

IMPORTANT
When charging unit, R410A must be in the liquid state. This system is charged with R410A refrigerant which operates at much higher pressures than R22. The check/expansion valve provided with the unit is approved for use with R410A. Do not replace it with a valve designed for use with R22. This unit is NOT approved for use with coils which include metering orifices or capillary tubes. Processing Procedure The unit is factorycharged with the amount of R410A refrigerant indicated on the unit rating plate. This charge is based on a matching indoor coil and outdoor coil with a 20 foot (6.1m) line set. For varying lengths of line set, refer to table 2 for refrigerant charge adjustment. A blank space is provided on the unit rating plate to list actual field charge. TABLE 2
Liquid Line Set Diameter 3/8 in. (10mm) Ozs. per 5 ft. (grams per 1.5m) adjust from 20 ft. (6.1m) line set* 3 ounces per 5 feet (85g per 1.5m)

If weighing facilities are not available or if unit is just low on charge, use the following procedure: 1 Connect gauge manifold. Connect an R410A drum to center port of gauge manifold. 2 Record outdoor ambient temperature using a digital thermometer. 3 Set room thermostat to 74_F (23_C) in Emergency Heat" or Heat" position and allow unit to run until heating demand is satisfied. This will create the necessary load for proper charging of system in cooling cycle. Change thermostat setting to 68_F (20_C) in Cool" position. Allow unit to run until system pressures stabilize. 4 Use the same digital thermometer used to check outdoor ambient temperature to check liquid line temperature. 5 If outdoor temperature is 60_F (15_C) or above, use the approach method to check the refrigerant charge. The difference between ambient and liquid line temperatures should match Approach Values given on unit charging sticker. Refrigerant must be added to lower approach temperature. Remove refrigerant from system to increase approach temperature. 6 If ambient temperature is less than 60_F (15_C), air flow might need to be restricted to achieve pressures in the 300350 psig (20682413 kPa) range. See figure 3. These higher pressures are necessary for checking charge. Block equal sections of air intake panels, moving obstructions sideways as shown until liquid pressure is in the 300350 psig (20682413 kPa) range.
BLOCKING OUTDOOR COIL
OUTDOOR COIL SHOULD BE BLOCKED ONE SIDE AT A TIME WITH CARD BOARD OR PLASTIC SHEET UNTIL PROPER TESTING PRESSURES ARE REACHED.

*If line length is greater than 20 ft. (6.1m), add this amount. If line length is less than 20 ft. (6.1m), subtract this amount.

IMPORTANT
Mineral oils are not compatible with R410A. If oil must be added, it must be a polyol ester oil. The compressor is charged with sufficient polyol ester oil for line set lengths up to 50 ft. If line set lengths longer than 50 ft. will be required, add 1 ounce of oil for every additional 10 ft. of line set. Do not add any more than 7 oz. of oil. Copeland has approved Mobil EALt Arctic 22CC and ICI EMKARATEt RL32CF for use with these compressors when oil must be added in the field. It is desirable to charge the system in the cooling cycle if weather conditions permit. However, if the unit must be charged in the heating season, one of the following procedures must be followed to ensure proper system charge. If the system is completely void of refrigerant, the recommended and most accurate method of charging is to weigh the refrigerant into the unit according to the total amount shown on the unit nameplate. Refer to the Lennox Unit Information Service manual for proper procedure.

CARDBOARD OR PLASTIC SHEET

FIGURE 3

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refrigerant from the bottom of the cylinder with7 Read liquid line temperature. Read liquid line pressure from gauge and convert to temperature using out turning the cylinder upsidedown. The cylthe temperature/pressure chart for R410A refrigerant inder will be marked if it is equipped with a dip provided in table 6. The difference between the liquid tube. line temperature and the conversion temperature is 8 Use Normal Operating Pressures on charging sticker the subcooling temperature (subcooling = converas a general guide when performing maintenance sion temperature minus liquid temperature). Subchecks. This is not a procedure for charging unit (see cooling should approximate values given in SubcoolCharging/Checking Charge section). Minor variations ing values on charging sticker. Add refrigerant to inin these pressures may be expected due to differcrease subcooling and remove refrigerant to reduce ences in installations. Significant differences could subcooling. Be aware of the R410A refrigerant cylmean that the system is not properly charged or that a inder. It will be light marooncolored. Refrigerant problem exists with some component in the system. should be added through the vapor line valve in the Used carefully, this table could serve as a useful serliquid state. Some R410A cylinders are equipped with a dip tube which allows you to draw liquid vice guide. TABLE 6 R410A Temperature/Pressure Chart
Temperature F 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 Pressure Psig 100.8 102.9 105.0 107.1 109.2 111.4 113.6 115.8 118.0 120.3 122.6 125.0 127.3 129.7 132.2 134.6 137.1 139.6 142.2 144.8 147.4 150.1 152.8 155.5 158.2 161.0 163.9 166.7 169.6 172.6 195.5 Temperature F 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 Pressure Psig 178.5 181.6 184.3 187.7 190.9 194.1 197.3 200.6 203.9 207.2 210.6 214.0 217.4 220.9 224.4 228.0 231.6 235.3 239.0 242.7 246.5 250.3 254.1 258.0 262.0 266.0 270.0 274.1 278.2 282.3 286.5 Temperature F 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 Pressure Psig 290.8 295.1 299.4 303.8 308.2 312.7 317.2 321.8 326.4 331.0 335.7 340.5 345.3 350.1 355.0 360.0 365.0 370.0 375.1 380.2 385.4 390.7 396.0 401.3 406.7 412.2 417.7 423.2 428.8 434.5 440.2 Temperature F 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 Pressure Psig 445.9 451.8 457.6 463.5 469.5 475.6 481.6 487.8 494.0 500.2 506.5 512.9 519.3 525.8 532.4 539.0 545.6 552.3 559.1 565.9 572.8 579.8 586.8 593.8 601.0 608.1 615.4 622.7 630.1 637.5 645.0

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IVSERVICE AND RECOVERY

4 Evacuate the system to remove any moisture and other noncondensables. Any time the condensing unit or heat pump sealed system is opened, the drier must be replaced and the system must be evacuated. Any moisture not absorbed by the polyol ester oil can be removed by triple evacuation. Moisture that has been absorbed by the compressor oil can be removed by replacing the drier.

WARNING
Polyol ester (POE) oils used with R410A 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.

IMPORTANT
Evacuation of system only will not remove moisture from oil. Drier must be replaced to eliminate moisture from POE oil.

IMPORTANT
USE RECOVERY MACHINE RATED FOR R410A REFRIGERANT. If the R410A charged system must be opened for any kind of service, such as compressor or drier replacement, you must take extra precautions to prevent moisture from entering the system. The following steps will help to minimize the amount of moisture that enters the system during recovery of R410A. 1 Use a regulatorequipped nitrogen cylinder to break the system vacuum. Do not exceed 5 psi. The dry nitrogen will fill the system, purging any moisture. 2 Remove the faulty component and quickly seal the system (using electrical tape or some other means) to prevent additional moisture from entering the system. 3 Do not remove the tape until you are ready to install new component. Quickly install the replacement component.

VSTORAGE
When storing R410A, cylinders must have a minimum pressure requirement of 400 psig. All cylinders must be clearly marked with type refrigerant (R410A) and with type color (light maroon). The light maroon caps must stay in place until cylinder is to be used. Remember, R410A is under higher pressure than other refrigerants so cylinders must be secured to prevent from falling or knocking into one an other. DO NOT store cylinders in temperatures exceeding 125F (52C).

WARNING
Broken or damaged cylinder valve will release high pressure. Cylinder may propel at a high rate which may cause personal injury or death.

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