Lennox air conditioners

The reports, as CPSC published them

1. No one hurt

   Made Aug 28, 2024 · , sent to the company Sep 3, 2024 · , published by CPSC Sep 17, 2024

   The product, in the report: The product is a Lennox outdoor air conditioner unit, model XC25-048-230-01, grey color, featuring a black fiberglass cover. It measures approximately 35” x 36” with a height of approximately 47”. The unit is used for residential cooling.

   What happened that made you want to report? I experienced severe skin irritation upon touching the black cover of our outdoor air conditioner unit. A similar incident occurred with one of my children, indicating a recurring problem with this product.

   What type of product(s) were being used? The product in question is an outdoor air conditioner unit, specifically the Lennox model XC25-048-230-01, installed in 2018.

   Who was using the product(s)? The product is installed at my residence and is used by household members for indoor climate control.

   How were the product(s) being used? The air conditioner unit is used as intended for home cooling purposes. The irritation occurred when the external fiberglass cover of the unit was touched.

   Were there any injuries that happened or may have happened while using the product? Yes, both I and one of my children suffered skin irritations from contact with the deteriorating cover of the unit. The irritation was significant, causing discomfort and concern due to the difficulty in removing the fiberglass particles embedded in the skin.

   How did any injuries occur? The injuries occurred due to direct skin contact with the fiberglass cover of the air conditioner unit, which has deteriorated to the point where it sheds thin, sharp fibers upon touch.

   Additional Information: The severity of the irritation highlights a significant hazard posed by the deteriorating material of the unit’s cover. Despite reporting this issue to Lennox, reference number [REDACTED} and case number [REDACTED], their response was that this part is not covered under warranty, and they refused to replace the cover. Given the potential for harm, especially to children, I believe this matter warrants urgent attention.

   Model

   XC25-048-230-01

   Serial number

   5818B00664

   Bought from

   Burgeson’s

   Bought

   Sep 5, 2018

   Where

   Yucaipa, California: Home/Apartment/Condominium

   Who was involved

   Unspecified

   The reporter’s relation to them

   My Child

   As this report names them

   Brand Lennox, made or sold by LENNOX INDUSTRIES, INC.

   How badly, in CPSC’s words

   Incident, No Injury

2. First aid

   Made Jan 30, 2023 · , sent to the company Feb 2, 2023 · , published by CPSC Feb 16, 2023

   The product, in the report: Lennox Merit Series 13ACX, Model No.: 13ACXN024-230A28, Serial No.: 1921J66881, air conditioner

   The sharp edge of the discharge air louver of a Lennox Merit Series 13ACX, Model No.: 13ACXN024-230A28, Serial No.: 1921J66881, air conditioner posed a hazard resulting in bodily injury of skin laceration and avulsion. On October 27, 2022, the unit was being readied for winter by clearing the discharge air opening of leaves with a cordless, battery-operated leaf blower. One leaf clung to the louver and clearing it was with the swiping action of the free hand. The sharp edge of the louver sliced the tip of the thumb and the hook of the formed end of the louver gouged the end of the laceration with an avulsion. The maintenance was among the items the installation instructions state may be performed by the homeowner. The instructions, Lennox 506945-01, 7/2018, Homeowners Information cautions only to turn off the electrical power at disconnect before attempting to perform any service or maintenance. The maintenance operation followed the cautionary statement – electrical power was not involved.

   UPDATED ON 6/13/2023: [The sharp edge of the discharge air louver of a Lennox Merit Series 13ACX, Model No.: 13ACXN024-230A28, Serial No.: 1921J66881, air conditioner posed a hazard resulting in bodily injury of skin laceration and avulsion. Refer to attachments:

   “Outdoor Condensing Coil Placement Front View” “Outdoor Condensing Coil Lennox Nameplate” “Lennox 13ACX Air Conditioner Discharge Louver Sharp Metal Edges Revision A” “Thumb Injury – Lennox 13ACX Air Conditioner Air Louver” “Lennox 13ACX Instruction Excerpt p 14” “Lennox 13ACX Instruction Excerpts p 1 v 14” “Lennox 13ACX Air Conditioner Outdoor Coil Warning Label”

   On October 27, 2022, the unit was being readied for winter by clearing the discharge air opening of leaves with a cordless, battery-operated leaf blower. One leaf clung to the louver and clearing it was with the swiping action of the free hand. The sharp edge of the louver sliced the top of the thumb and the hook of the formed end of the louver gouged the end of the laceration with an avulsion (see attachment “Thumb Injury – Lennox 13ACX Air Conditioner Air Louver”). The maintenance was among the items the installation instructions state may be performed by the homeowner. The activity was maintenance performed according to Homeowner Information in the installation instructions (see attachment “Lennox 13ACX Instruction Excerpt p 14”). The instructions, Lennox 506945-01, 7/2018, Homeowners Information cautions only to turn off the electrical power at disconnect before attempting to perform any service or maintenance. The maintenance operation followed the cautionary statement – electrical power was not involved. Whether the Lennox air conditioners are safe is quite at the point of the consumer’s Incident Report. An industry periodical, ‘The Fabricator’, cites International Standards Organization (ISO) Standard 12100:2010 (reviewed and confirmed in 2022) Safety of machinery – General principles for design – Risk assessment and risk reduction, saying when sharpness is not desirable for safety reasons, follow a hierarchy for making safe products:

   1. Design out hazards. 2. If that can’t be done, protect against them. 3. If that isn’t possible, warn against them. a. In any hazard safety analysis, the risk includes assessment of exposure. i. In the case of the discharge air louver, there are 100 six-inch long metal fins projecting their sharp edges upward in a 20-inch diameter circular array (see revised attachment “Lennox 13ACX Air Conditioner Discharge Air Louver Sharp Metal Edges Revision A”). 600 inches is 300 times the 2-inch test sample described in UL 1439. This is equivalent to 50 feet of sharp metal edge concentrated in an area of 314 square inches (1.9 inches per square inch). This amount of metal edge, likely to be sharp, presents an unreasonable risk of personal injury. ii. The CPSC has previously (April 24, 1978) warned of sharp edges on heat register louvers. Note there too, contact with sharp edges of a louver is incidental to homeowner activity, not limited to heating system maintenance by service personnel. iii. From an abridged excerpt of FEDERAL HAZARDOUS SUBSTANCES ACT (FHSA) (Codified at 15 U.S.C. §§1261-1278), SEC. 2. [15 U.S.C. § 1261] - Definitions(s) An article may be determined to present a mechanical hazard if, in normal use or when subjected to reasonably foreseeable damage or abuse, its design or manufacture presents an unreasonable risk of personal injury or illness . . . (3) from points or other protrusions, surfaces, edges, openings, or closures, . . . b. The louver acts as a guard from moving mechanical parts of the fan but poses its own stationary hazard. Contact with the stationary sharp edges are not prevented with a guard or warned against. c. Hazard communication is to inform and remind those who install, operate, and maintain the air conditioner about potential hazards and how to avoid them. Operation and maintenance manuals communicate hazards with signal words such as Danger or Warning. Labels are part of a system of such communication, providing visual alert. The labels must be suited to the safety communication needs, take into account the characteristics of the people to whom they are communicating, and comply with the latest safety standards for the product. Hazard communication deficiencies may result in increased risk of accidents. Absence or deficiencies may be ‘failure to warn’ or ‘inadequate to warn’. Basic elements to communicate hazard: i. Signal word: Danger or Warning ii. Pictogram iii. Hazard statements iv. Precautionary statements: Unlike the ‘Caution! Before attempting to perform any service or maintenance turn off the electrical power at disconnect switch’ also on page 1, the CAUTION sharp sheet metal - is not repeated in the Homeowners Information (see attachment “Lennox 13ACX Instruction Excerpts p 1 v 14”). The instructions do not explain the different types of labels used, including IMPORTANT!, NOTICE!, !CAUTION, and !WARNING, or the hierarchy of the seriousness of the condition. Not all include a pictogram, the nature of the issue and the action to be taken. The action to wear gloves is without the cut-resistance rating. The equipment labeling has warnings (see attachment “Lennox 13ACX Air Conditioner Outdoor Coil Warning Label”), but particularly for accessing a service panel, not for homeowner maintenance or at the location of sharp sheet metal.

   Whether the Lennox Merit Series 13ACX air conditioner’s discharge air louver meets applicable standard, namely UL 1439 Tests for Sharpness of Edges on Equipment, is not independently determined. Referring to ANSI/UL 1439-2021 Edition 5, dated April 21, 2015, revision dated May 4, 2021:

   1. Scope 1.1 These requirements cover a test procedure to be used to determine the potential personal injury related to the sharpness of edges that are part of or associated with appliances or equipment. 4. General 4.1 The edge of an enclosure opening, frame, guard, knob, handle or the like of an appliance or equipment shall be smooth and rounded so as not to cause a cut-type injury when contacted during normal use or user maintenance. Exception: A sharp edge that must be exposed to enable the product to perform its intended function need not comply with the requirement in 4.1

   Whether the Lennox Merit Series 13ACX air conditioner was manufactured with processes to comply with UL 1439 Tests for Sharpness of Edges on Equipment is not stated on the nameplate (Ref. Incident Report Attachment “Outdoor Condensing Coil Lennox Nameplate”) identifying the National Recognized Testing Laboratory (NRTL) and the standards to which that third party tested and listed the product. Neither of these standards reference UL 1439; as such, it is concluded that Lennox asserts conformity by self-declaration of its manufacturing processes. According to UL LLC, “a ‘self-certification’ claim that has not been verified by an independent third party such as UL, [] the product would not be considered [] ‘Listed’ as defined in NFPA or ICC model codes.” A NRTL Field Evaluation may be able to determine if the specific air conditioner complies with the applicable requirements and if it does, a Field Evaluation Product Label would be applied, otherwise, the NRTL would provide a detailed ‘preliminary findings report’. The manufacturer was requested to request a NRTL Field Evaluation but has not responded to that request. ]

   Model

   Merit Series 13ACX, Model No.: 13ACXN024-230A28

   Serial number

   Serial No.: 1921J66881

   Bought from

   Four Seasons Heating & Air Conditioning, Inc.

   Bought

   Dec 6, 2021

   Where

   Merrillville, Indiana: Home/Apartment/Condominium

   Who was involved

   Age 68, Male

   The reporter’s relation to them

   Self

   As this report names them

   Brand Lennox Merit Series, made or sold by LENNOX INDUSTRIES, INC.

   How badly, in CPSC’s words

   Injury, First Aid Received by Non-Medical Professional

3. No one hurt

   Made Oct 24, 2013 · , sent to the company Nov 1, 2013 · , published by CPSC Nov 18, 2013

   The product, in the report: Lennox home air conditioner

   About three years ago I had a local contractor install a completely new air conditioning system. This past week I noticed a “shower” of tiny particles (later determined to be fiberglass) coming out of the ducts throughout the home. This was followed by small (1/16-1/4”) particles of aluminum foil, paper and a black substance.

   When the service technician arrived he determined that the fiberglass batts that lined the air handler had separated from the inner walls and had fallen into the fan - which in turn, chopped the fiberglass into little particles than then blew throughout the home.

   I spoke to the manufacturer, Lennox, who denied that there was any sort of manufacturing defect. The technician commented that this was a not-uncommon occurence. He re lined the air handler with solid fiberglass “duct board”.

   I am not sure what the consequences of inhaling fiberglass dust, but I am sure it’s not good for us (and our pets) to be breathing this material

   Serial number

   5811D08822

   Bought from

   A/C Designs

   Bought

   May 9, 2011

   Where

   Palm Coast, Florida: Home/Apartment/Condominium

   Who was involved

   Age 71, Male

   The reporter’s relation to them

   My Spouse

   As this report names them

   Brand Lennox “Elite”, made or sold by LENNOX INDUSTRIES, INC.

   How badly, in CPSC’s words

   Incident, No Injury

4. No one hurt

   Made Jun 6, 2011 · , published by CPSC Jul 27, 2011

   The product, in the report: air conditioning

   An air conditioining unit was involved in a fire at a residential community. Field reports indicate during suction line brazing at the time of installation, valves on some of the units overheated and cracked, which caused refrigerant to disperse under pressure. In a few cases, the oil in the refrigerant ignited and caught fire.

   Where

   Charlotte, North Carolina: Home/Apartment/Condominium

   Who was involved

   Unspecified

   The reporter’s relation to them

   Unspecified

   As this report names them

   Brand Lennox, made or sold by LENNOX INDUSTRIES, INC.

   How badly, in CPSC’s words

   Incident, No Injury

CPSC’s disclaimer

Sources