LENNOX Air Conditioner/heat Pump(outside Unit) Manual L0805500
User Manual: LENNOX LENNOX Air conditioner/heat pump(outside unit) Manual LENNOX Air conditioner/heat pump(outside unit) Owner's Manual, LENNOX Air conditioner/heat pump(outside unit) installation guides
Open the PDF directly: View PDF 
.
Page Count: 19
| Download | |
| Open PDF In Browser | View PDF |
LENNOX INSTALLATION INSTRUCTIONS ¢_2002 Lennox Industries Inc. Dallas, Texas HSXA12 Series Units CONDENSING UNITS 504,540M 04/04 Supersedes 12/03 HSXA12 outdoor units use R410A which is an ozone friendly HFC refrigerant. This unit must be installed with a matching indoor coil and line set as outlined in the Lennox Engineering Handbook. HSXA12 outdoor units are designed for use in expansion valve (TXV) and fixed orifice systems. Refer to the Lennox Engineering Handbook for expansion valve kits which must be ordered separately, A filter dryer approved for use with R410A has been shipped with the unit. This component must be installed prior to operating the unit. Failure to install the provided filter dryer will void the warranty. 1 - Assembled HSXA12 outdoor unit 1 - Liquid line filter drier (approved for use with R410A systems) 1 - Fixed orifice refrigerant metering device Check equipment for shipping damage. If you find any damage, immediately contact the last carrier. FT_ Technical .LLL[ Publications Lithe U.S.A. HSXA12 Outdoor Unit ........................... Shipping And Packing List ....................... General Information ............................. Unit Dimensions ................................ Setting the Unit ................................. Electrical ...................................... Refrigerant Piping .............................. Flushing Existing Line Set & Indoor Coil ........... Refrigerant Metering Device .................... Manifold Gauge Set ............................ Service Valves ................................ Leak Testing .................................. Evacuation ................................... Start-up ...................................... Charging ..................................... System Operation ............................. Maintenance .................................. Optional Accessories .......................... HSXA12 Check Points ......................... 1 1 1 2 3 3 5 5 11 11 12 13 13 14 14 18 18 18 19 RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions are intended as a general guide and do not supersede national or local codes in any way. Consult authorities having jurisdiction before installation. WARNING AWARNING ,IMPORTANT 04/04 IIIHllllllllliillllillllillllillllill 504,540M Page 1 IIIHllllllllliillliillllllll IN LET._ AIR 4-3/8 (111) INLET OPTIONAL STAND-OFF INLET © © (Field 4-3/8 (111) UNIT KIT Installed) AIR AIR (Around perimeter of base) VAPOR LINE CONNECTION INLET'_ 6-3/8 (162) 4-3/8 (111) LIQUID LINE CONNECTION AIR Top View Top View _- C Base C DISCHARGEr _-_ Section AIR OUTDOOR COIL FAN COMPRESSOR_ A VAPOR & LIQUID LINE CONNECTION ELECTRICAL INLETS 2-3/4 (70) Side View 3/4 (19) OPTIONAL STAND-OFF (Field UNIT KIT Model No. HSXA12-018 HSXA12-024 HSXA12-030 HSXA12-036 HSXA12-042 HSXA12-048 Side View Installed) A B C in, 25 24-1/4 24-1/4 mm 635 616 616 in. 33 32-1/4 24-1/4 mm 838 819 616 29 28-1/4 28-1/4 737 718 718 in, HSXA12-060 mm Page 2 Roof Mounting Install unit at a minimum of 4 inches above the surface of the roof. Care must be taken to ensure weight of unit is properly distributed over roof joists and rafters, Either redwood or steel supports are recommended, &CAUTION kCAUTION In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Refer to unit dimensions for sizing mounting slab, platforms or supports, Refer to figure 1 for installation clearances, Installation Clearances 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 overcurrent protection size. A WARNING 1 - Install line voltage power supply to unit from a properly sized disconnect switch, 2 - Ground unit at unit disconnect switch or to an earth (914 ram) ground, NOTE - To facilitate conduit, a hole is in the bottom of the control box. Connect conduit to the control box us *NO TE - A service clearance of 30" (762 mm) must be maintained on one of the sides adjacent to the control box. Clear- ing a proper conduit fitting. ance to one of the other three sides must be 36" (914 mm). Clearance to one of the remaining two sides may be 12" (304 mm) and the final side may be 6" (152 mm). NO TE - Units are approved for use only with copper conductors. NOTE - A clearance of 24" (610 mm) must be maintained between two units. NOTE - 48" (1219 mm) clearance required on top of unit. Maximum soffit overhang is 36" (914 mm). Figure 24V, Class II circuit connections are made in the low voltage junction box, Refer to figure 4 for field wiring diagram, 1 Slab Mounting 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 will not collect around the unit. See figure 2. Slab should have a slope tolerance away from the building of 2 degrees or 2 inches per 5 feet (51 mm per 1524 mm), Refer to roof mounting section for barrier construction if unit must face prevailing winter winds, Slab Mounting At Ground structure 'i_ Level discharge air NOTE - A complete unit wiring diagram is located in side the unit control box coven 3 - 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 effected by sunlight, drafts or vibrations, 4 - Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit, See figure 3, J, 12 Mounting slab must slope away from building, Figure ground level 2 Page 3 Thermostat Thermostat Designations Indoor Unit NOTE - see unit wiring diagram for power supply connections. ® power Outdoor Unit [Wl; t -® heat E_ cooling V_ -(_- v indoor blower @ © NOTE - If the @ [_ common indoor unit is not ..... equipped with blower relay It must Figure Typical _0_ TDOOR FAN __ RED YELLOW BLACK RELAY* CI2 DUAL CAPACITOR TIMED *A4 OFF field-provided and installed (P-8-3251 or equivalent). A CONTROL KI COMPRESSOR CONTACTOR NOTEFOR USE WITH COPPER CONDUCTORS ONLY.REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE WARNINGELECTRIC SHOCK HAZARD, CAN CAUSE INJURY OR DEATH. UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES 50 COMPRESSOR \ ..... Diagram © K3 I POTENTIAL C Outdoor Unit / 3 Field Wiring CAPACITOR START * be PURPLE LACK ANGE Y1 Outdoor Unit l,' 208-230/60/I A " D 1 GROUND *May be optional Figure 4 Page 4 Installing Refrigerant Line If theHSXA12 unitisbeinginstalled withanindoorcoiland lineset,maketherefrigerant connections asoutlined inthis section.If anexistinglinesetand/orindoorcoilis goingto beusedtocomplete theHSXA12 system,refertothissection,aswellas theflushingsectionwhichfollows, Fieldrefrigerantpipingconsistsof liquidandvaporlines fromtheoutdoorunit(sweatconnections) totheindoorcoil (flareor sweatconnections). UseLennoxL15(sweat,nonflare)serieslinesetsasshownintable1or usefield-fabricatedrefrigerant lines.Referto Refrigerant PipingGuide (Corp,9351-L9)for propersize,type,andapplicationof field-fabricated lines.Valvesizesarealsolistedintable1. Refrigerant Line Connections HSXA12 Matched with New Indoor Coil and Line Set If the HSXA12 is being used with an existing indoor coil which was equipped with a liquid line which served as a metering device (RFCI), the liquid line must be replaced prior to the installation of the HSXA12 unit. If refrigerant lines are routed through a wall, seal and isolate the opening so vibration is not transmitted to the building, Table 1 Refrigerant Line Sets Valve Field Size Connections Recommended Model Line Set L15 Line Sets Liquid Line Vapor Line Liquid Line Vapor Line -018 3/8 in. (10 mm) 5/8 in. (16 mm) 3/8 in, (10 mm) 5/8 in, (19 mm) L15-26 15 if, - 50 ft. (4.6 m- 15 m) 024 -030 -036 3/8 in, (10mm) 3/4 in, (19mm) 3/8 in, (10mm) 3/4 in, (19mm) L15-41 15 ft. - 50 ft. (4.6m-15m) -042 -048 3/8 in. (10 mm) 7/8 in. (22 mm) 3/8 in, (10 mm) 7/8 in, (22 mm) 3/8 in, 1-1/8 in, 3/8 in, 1-1/8 in. Field (10 mm) (29 mm) (10 mm) (29 mm) Fabricated -060 During the installation of any heat pump or a/c system, it is important to properly isolate the refrigerant lines to prevent unnecessary vibration, Line set contact with the structure (wall, ceiling or floor) causes some objectionable noise when vibration is translated into sound, As a result, more energy or vibration can be expected. Closer attention to line set isolation must be observed, Following are some points to consider when placing and installing a high-efficiency outdoor unit: 1-Placement - Be aware some localities are adopting sound ordinances based on how noisy the unit is from the adjacent property not at the original installation. 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. 2- Line Set Isolation - The following illustrations demonstrate procedures which ensure proper refrigerant line set isolation. Figure 5 shows how to install line sets on vertical runs. Figure 6 shows how to install line sets on horizontal runs. Figure 7 shows how to make a transition from horizontal to vertical. Finally, figure 8 shows how to place the outdoor unit and line set. L15-65 15 ft, - 50 ft. (4.6 m - 15 m) NOTE - Units are designed for line sets of up to fifty feet (15 m). For applications longer than fifty feet, consult the Lennox Refrigerant Piping Guide (Corp. 9351-L9). Select line set diameters from table 1 to ensure that oil returns to the compressor. Page 5 Refrigerant Line Sets How To Install Vertical Runs (new construction shown) NOTE - Similar installation practices should be used if line set is to be installed on exterior of outside wall. Outside Wall \ r IMPORTANT- Refrigerant lines must not contact wall. Vapor Line Liquid Line Wood Block _, Between Studs Wire Tie E J \ Strap Sleeve Liquid Line Vapor Line (wrapped Inside Wall Wire Tie m m Wall Wood Block m Wire Tie Strap r -,tit L_ PVC Pipe Caulk Fiberglass Insulation Sleeve IMPORTANT- Refrigerant lines must not contact structure. Figure 5 Page 6 Refrigerant Line Sets: Installing Horizontal Runs To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties. Wire Tie (around vapor line only) 8 feet Floor Joist or Roof Rafter j / / Tape or Wire Tie / 8 feet Strapping Material (around vapor line only) Metal Sleeve \ Tape or Wire Tie _) h r / Floor Joist or Roof Rafter jf Strap the vapor line to the joist or rafter at 8 ft. intervals then strap the liquid line to the vapor line. Figure 6 Page 7 ) Refrigerant Line Sets: Transition From Vertical To Horizontal Automotive Muffler-Type Hanger Anchored Heavy Nylon Wire Tie ) I Wall Stud Wall Stud i/ Strap Liquid Line To Vapor Line Strap Liquid Line To Vapor Line Liquid Line Metal / Sleeve Va )or Line Wrapped in Armaflex Metal Sleeve Liquid Line Figure Vapor Line Wrapped in Armaflex 7 Outside Unit Placement and Installation Install unit away from windows. Two 90 ° elbows installed in line set will reduce line set vibration. Figure Page 8 8 AWARNING ,WARNING Brazing Connection Procedure 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. ,IMPORTANT 2 - Before making line set connections, use dry nitrogen to purge the refrigerant piping. This will help to prevent oxidation and the introduction of moisture into the system. 3 - Use silver alloy brazing rods (5 or 6 percent minimum silver alloy for copper-to-copper brazing or 45 percent silver alloy for copper-to-brass or copper-to-steel brazing) which are rated for use with R410A refrigerant. Wrap a wet cloth around the valve body and the copper tube stub. Remove light maroon washers from service valves and shield light maroon stickers in order to protect them during brazing. Braze the line set to the service valve. 4 - Wrap a wet cloth around the valve body and copper tube stub to protect it from heat damage during brazing. Wrap another wet cloth underneath the valve body to protect the base paint. -&CAUTION Quench the joints with a wet cloth to prevent possible heat damage to the valve core and opening port. NOTE - The tube end must stay bottomed in the fitting during final assembly to ensure proper seating, sealing and rigidity. 5 - Install the provided fixed orifice (or thermal expansion valve which is sold separately and approved for use with R410A refrigerant) in the liquid line at the indoor coil. 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 that has a pump down feature, and two sets of gauges (one for use with R22 and one for use with the R410A). 6 - Install the provided filter drier (approved for use with R410A refrigerant) in the liquid line as close as possible to the expansion device. Do not leave the filter drier uncapped for more than 10 to 15 minutes prior to brazing, evacuation, and leak testing. Polyol ester oils used in this system absorb moisture quickly. Failure to install the filter drier will void the warranty. Flushing Procedure 1 - Remove existing R22 refrigerant using the appropriate procedure below. If the existing outdoor unit is not equipped with shut-off valves, or if the unit is not operational AND you plan to use the existing R22 refrigerant to flush the system - Disconnect all power to the existing outdoor unit. Connect to the existing unit, a Page 9 clean recoverycylinderandthe recoverymachine according totheinstructions provided withtherecoverymachine.RemoveallR22refrigerant fromtheexistingsystem,Refertogaugesaftershutdown toconfirmthattheentiresystemiscompletely voidofrefrigerant,Disconnect theliquidandvaporlinesfromthe existingoutdoorunit, If the existing outdoor unit is equipped with manual shut-off 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 outdoor 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 vapor 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, 2 - Remove the existing outdoor unit. Set the new R410A unit and follow the brazing connection procedure which begins on the previous page to make line set connections. DO NOT install the provided fixed orifice yet. 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 valve before continuing with flushing procedures, The existing devices are not approved for use with R410A refrigerant and may prevent proper flushing, Use a field-provided fitting to reconnect the lines, &IMPORTANT Flushing Connections Inverted R22 Cylinder (Contains clean R22 to be used for flushing) Low Pressure High Pressure HSXA12 Service Valve Indoor Coil Existing Liquid Line Liquid Line Service Valve Tank Return Inlet Discharge RECOVERY CYLINDER RECOVERY MACHINE Figure 9 Page 10 Unit GAUGE MANIFOLD Closed NOTE- The inverted R22 cylinder must contain at least the same amount of refrigerant as was recovered from the existing system. 4- Removethe pressuretap valve cores from the HSXA12unit'sservicevalves,ConnectanR22cylinderwithcleanrefrigeranttothevaporservicevalve. ConnecttheR22gaugesettotheliquidlinevalveand connecta recoverymachinewithanemptyrecovery tanktothegaugeset, 5 - Settherecovery machineforliquidrecovery andstart therecoverymachine,Openthegaugesetvalvesto allowtherecovery machine topulla vacuum ontheexistingsystemlinesetandindoorcoil, 6 - InvertthecylinderofcleanR22andopenitsvalveto allowliquidrefrigerant toflowintothesystemthrough thevaporlinevalve.Allowtherefrigerant to passfrom thecylinderandthroughthelinesetandtheindoorcoil beforeitenterstherecoverymachine. 7 - Afterallofthe liquidrefrigeranthasbeenrecovered, switchtherecovery machine tovaporrecovery sothat alloftheR22vaporis recovered. Allowtherecovery machinetopulla vacuumonthesystem. may not be appropriately sized. Refer to the Engineering Handbook for specific orifice information. Table 2 Fixed Orifice Drill Sizes Fixed Orifice Part # Drill Size HSXA12-018 Unit 29M88 .05 HSXA12-024 42J43 .063 HSXA12-030 42J43 .063 HSXA12-036 42J47 .071 HSXA12-042 42J51 .078 HSXA12-048 29M93 .081 HSXA12-060 42J57 .090 Install the fixed orifice as shown in figure 10. Do not twist the cap tubes when loosening the seal nut from the orifice housing. Use a wrench to back up the distributor, Metering Device Installation 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. distributor I_ ..._.j(fa _valve OR orifice J // expansion valve (opt.) e o-ring strainer liquid line stub gauge set valves, Pump the remaining refrigerant out of the recovery machine and turn the machine off, 10 -Install the provided fixed orifice in the liquid line at the indoor coil. o-ring O 8- Close the valve on the inverted R22 drum and the 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 HSXA12 service valves, c torC;i.[inCst a iie d ) Figure Expansion 10 Valve Systems Expansion valves equipped with Chatleff type fittings are available from Lennox, Refer to the Engineering Handbook for expansion valves for use with specific match-ups. If you install an expansion valve with an indoor coil that includes a fixed orifice, remove the orifice before the expansion valve is installed. • , IMPORTANT HSXA12 units are applicable to either fixed orifice or an expansion valve system. See the indoor coil installation instructions and the Lennox Engineering Handbook for approved TXV and fixed orifice match-ups and application information, Table 1 lists the unit liquid and vapor line sizes and corresponding line sets, Fixed Orifice Systems HSXA12 units are shipped with a fixed orifice refrigerant metering device. Replace the existing indoor unit fixed orifice with the orifice supplied with the outdoor unit, Place the supplied fixed orifice sticker on the indoor cabinet after installation. See table 2 for the fixed orifice size for each unit, In nonstandard applications, the provided fixed orifice 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, Page 11 Theliquidlineandvaporlineservicevalves(figures11and 12)andgaugeportsareusedforleaktesting,evacuating, chargingandcheckingcharge,Seetable3 fortorquerequirements, Eachvalveis equipped witha serviceportwhichhasafactory-installed Schradervalve.A serviceportcapprotects theSchradervalvefromcontamination andservesasthe primaryleakseal. Table3 Torque Requirements Part Recommended Service Valve (Valve Closed) serviCeport _,_m cap insert hex wrench here to outdoor coil service port cap Schrader to line Torque indoor coil valve open set when valve is closed (front seated) (valve front seated) Service valve cap 8 ft,-lb. 11 NM Sheet metal screws 16 in.- lb. 2 NM Machine screws #10 28 in.- lb. 3 NM 90 in.-lb. 10 NM 8 ft.- lb. 11 NM Compressor bolts Gauge port seal cap To Access Schrader Service Valve (Valve Open) insert hex wrench here service port Port: stem cap © \ to outdoor coil 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 tighten an additional 1/6 turn. To Open Service Valve: service port 1 - Remove stem cap with an adjustable wrench. 2 - Use a service wrench with a hex-head extension to back the stem out counterclockwise as far as it will go. cap to indoor coil Schrader valve Figure 11 NOTE - Use a 3/16" hex head extension for liquid line sizes or a 5/16" extension for vapor line sizes. 3 - Replace the stem cap. Tighten finger tight, then tighten an additional 1/6 turn, To Close Service Valve: Vapor 1 - Remove the stem cap with an adjustable wrench. 2 - Use a service wrench with a hex-head extension to turn the stem clockwise to seat the valve, Tighten it firmly. er valves; the difference NOTE - Use a 3/16" hex head extension for liquid line sizes or a 5/16" extension for vapor line sizes. 3 - Replace the stem cap, Tighten finger tight, then tighten an additional 1/6 turn. Line (Ball Type) Service Valve Vapor line service valves function the same way as the othis in the construction, These valves are not rebuildable, If a valve has failed, you must replace it. A ball valve is illustrated in figure 12, The ball valve is equipped with a service port with a factoryinstalled Schrader valve, A service port cap protects the Schrader valve from contamination free seal. Page 12 and assures a leak- 2 - With both manifold valves closed, connect the cylinder of R410A refrigerant. Open the valve on the R410A cyl- Ball Valve (Valve Open) Use Adjustable Wrench To open: rotate Stem Counter-clockwise 90 °. To close: rotate Stem Clockwise 90 °. inder (vapor only). 3 - Open the high pressure side of the manifold to allow to outdoor coil stem cap _.,i-----"q__J/ R410A into the line set and indoor unit. Weigh in a trace amount of R410A. [A trace amount is a maximum of 2 stem ounces (57 g) refrigerant or 3 pounds (31 kPa) pressure]. Close the valve on the R410A cylinder and the valve on the high pressure side of the manifold gauge ball (shown open) set. Disconnect R410A cylinder. to indoor coil 4 - Connect a cylinder of nitrogen with a pressure regulating valve to the center port of the manifold gauge set. 5 - Connect the manifold gauge set high pressure hose to the vapor valve service port. (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.) service port cap service port Schrader valve Figure 6 - Adjust nitrogen pressure to 150 psig (1034 kPa). Open the valve on the high side of the manifold gauge set in or- 12 der to pressurize the line set and the indoor unit. After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. 7 - After a few minutes, open a refrigerant port to ensure the refrigerant you 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. WARNING XklMPORTANT ,WARNING 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. WARNING XkIMPORTANT 1 - Connect manifold gauge set to the service valve ports as follows: Using an Electronic Leak Detector 1 - Connect a cylinder of R410A to the center port of the manifold gauge set. • low pressure gauge to vapor line service valve • high pressure gauge to liquid line service valve 2 - Connect micron gauge. Page 13 3 - Connectthevacuumpump(withvacuumgauge)tothe centerportofthemanifoldgaugeset. 4- Openbothmanifoldvalvesand startthe vacuum pump. 5 - Evacuate the linesetandindoorunittoan absolute pressureof23,000microns(29.01inchesof mercury).Duringtheearlystagesof evacuation, it is desirabletoclosethemanifold gaugevalveatleastonceto determine ifthereisa rapidriseinabsolutepressure. A rapidriseinpressure indicates a relatively largeleak. If thisoccurs,repeattheleaktestingprocedure. 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 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, IMPORTANT 1 - Rotate fan to check for frozen bearings or binding. 2 - Inspect all factory- and field-installed wiring for loose connections. 3 - After evacuation is complete, open the liquid line and vapor line service valves to release the refrigerant charge (contained in outdoor unit) into the system, 4 - Replace the stem caps and secure finger tight, then tighten an additional one-sixth (1/6) of a turn, 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 the power company and the voltage condition has been corrected. 6 - Set the thermostat for a cooling demand. Turn on power to the indoor blower and close the outdoor unit disconnect switch to start the unit. _ A, WARNING Recheck voltage while the unit is running, Power must be within range shown on the nameplate, This system is charged with R410A refrigerant which operates at much higher pressures than R22, The provided liquid line filter drier is approved for use with R410A, Do not replace it with components designed for use with R22, This unit is NOT approved for use with coils which use capillary tubes as a refrigerant metering device, 7 - 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. 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 R410A 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 R410A cylinder and remove the manifold gauge set. Factory Charge Units are factory charged 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 15 ft. (4.6 m) line set. For varying lengths of line set, refer to table 4 for refrigerant charge adjustment. Table 4 Liquid Line Set Diameter Oz. per 5 ft. (grams per 1.5 m) adjust from 15 ft. (4.6 m) line set* 3/8 in, (10 ram) 3 ounces per 5 feet (85g per 1.5 m) *If line length length Page 14 is greater is less than than 15 ft. (4.6 m), add this amounL 15 ft. (4.6 m), subtract this amounL klMPORTANT If line The compressor is charged with sufficient polyol ester oil for line set lengths up to 50 feet (15.2 m). If oil must be added to the compressor in the field, Copeland has approved Mobil EAL'" Arctic 22CC and ICI EMKARATE "_ RL32CF. Units Delivered Void of Charge If the system is void of refrigerant, clean the system using the procedure described below. 4 - 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, 5 - The outdoor temperature will determine which charging method to use, Proceed with the appropriate charging procedure, 1 - Use nitrogen to pressurize the system and check for leaks. Repair leaks, if possible, 2 - Evacuate the system to remove as much of the moisture as possible, 3 - Use nitrogen to break the vacuum and install the provided filter drier in the system, 4 - Evacuate the system again. Then, weigh the appropriate amount of R410A refrigerant (listed on unit nameplate) into the system, 5 - Monitor the system to determine the amount of moisture remaining in the oil. Use test kit 10N46 to verify that the moisture content is within the kit's dry color range. It may be necessary to replace the filter drier several times to achieve the required dryness level, If system dryness is not verified, the compressor will fail in the future. Checking Weighing in the Charge TXV Systems - Outdoor Fixed Orifice or Temp. < 65°F (18°C) If the system is void of refrigerant, or if the outdoor ambient temperature is cool, the refrigerant charge should be weighed into the unit, Do this after any leaks have been repaired. 1 - Recover the refrigerant from the unit, 2 - Conduct a leak check, then evacuate as previously outlined, 3 - Weigh in the unit nameplate charge, If weighing facilities are not available or if you are charging the unit during warm weather, follow one of the other procedures outlined below. Charging Using the Subcooling Fixed Orifice Outdoor Charge Method Systems Temp. _>65°F (18°C)) The outdoor unit should be charged during warm weather, If you charge a fixed orifice system when the outdoor ambi- 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 ent is 65<_F(18<_C)or above, use the subcooling method to charge the unit. outdoor ambient temperature. Measure the liquid line temperature and the outdoor ambient temperature as outlined below: 1 - Connect the manifold gauge set to the service valves: • low pressure gauge to vapor valve service port • high pressure gauge to liquid valve service port Close manifold gauge set valves. Connect the center manifold hose to an upright cylinder of R410A, 1 - With the manifold gauge hose still on the liquid service port and the unit operating stably, 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 R410A to determine the saturation temperature for the liquid line pressure reading, See table 5, 4 - Subtract the liquid line temperature from the saturation temperature (according to the chart) to determine subcooling. (Saturation temperature - Liquid line tem- 2 - Set the room thermostat to call for heat. This will create the necessary load for properly charging the system in the cooling cycle. 3 - Use a digital thermometer to record the outdoor ambient temperature, perature = Subcooling) 5 - Compare the subcooling value with those in table 6, If subcooling is greater than shown, recover some refrigerant. If subcooling is less than shown, add some refrigerant, Page 15 Table 5 R410A Temperature/Pressure Temperature oF Pressure Psig Temperature oF Pressure Psig Chart Temperature oF Pressure Psig Temperature oF Pressure Psig 32 1O018 63 178.5 94 290.8 125 445.9 33 102.9 64 181.6 95 295.1 126 451.8 34 105.0 65 184.3 96 299.4 127 457.6 35 107.1 66 187.7 97 303.8 128 463.5 36 109.2 67 190.9 98 308.2 129 469.5 37 111.4 68 194.1 99 312.7 130 475.6 38 113.6 69 197.3 IO0 317.2 131 481.6 39 115.8 7O 200.6 101 321.8 132 487.8 4O 118.0 71 203.9 102 326.4 133 494.0 41 120.3 72 207.2 103 331.0 134 500.2 42 122.6 73 210.6 104 335.7 135 506.5 43 125.0 74 214.0 105 340.5 136 512.9 44 127.3 75 217.4 106 345.3 137 519.3 45 129.7 76 220.9 107 350.1 138 525.8 46 132.2 77 224.4 108 355.0 139 532.4 47 134.6 78 228.0 109 360.0 140 539.0 48 137.1 79 231.6 110 365.0 141 545.6 49 139.6 8O 235.3 111 370.0 142 552.3 5O 142.2 81 239.0 112 375.1 143 559.1 51 144.8 82 242.7 113 380.2 144 565.9 52 147.4 83 246.5 114 385.4 145 572.8 53 150.1 84 250.3 115 390.7 146 579.8 54 152.8 85 254.1 116 396.0 147 586.8 55 155.5 86 258.0 117 401.3 148 593.8 56 158.2 87 262.0 118 406.7 149 601.0 57 161.0 88 266.0 119 412.2 150 608.1 58 163.9 89 270.0 120 417.7 151 615.4 59 166.7 9O 274.1 121 423.2 152 622.7 6O 169.6 91 278.2 122 428.8 153 630.1 61 172.6 92 282.3 123 434.5 154 637.5 62 195.5 93 286.5 124 440.2 155 645.0 Table 6 Subcooling Outdoor Temp. °F (°C) 65 70 75 80 85 90 (18) (21) (24) (27) (29) (32) Values for Fixed Orifice Systems Liquid -018 13 (7.2) 12 (6.7) 11 (6.1) 9 (5) -024 13 (7.2) 11 (6.1) 10 (5.6) 8 (4.5) 7 (3.9) 6 (3.3) 6 (3.3) 95 (35) 100 (38) 5 (2.8) 5 (2.8) 105 (41) 110 (43) 115 (45t 4 (2.2) 3 (1.7) 2 (1.1t 9(5) 5 (2.8) 4 4 3 3 (2.2) (2.2) (1.7) (1.7t Subcoolin -030 16 (8.9) 9 [+ l°F (.6°C)] -042 11 (6.4) 10 (5.6) 9 (5) 8 (4.5) 7 (3.9) 6 (3.3) 6 (3.3) -048 14 (7.8) 13 (7.2) 12 (6.7) 11 (6.1) 10 (5.6) 9 (5) -060 13 (7.2) 12 (6.7) (7.8) (7.2) (6.7) (5.6) (5) -036 12 (6.7) 11 (6.1) 10 (5.6) 9 (5) 8 (4.5) 7 (3.9) 6 (3.3) 8 (4.5) 8 (4.5) 8 (4.5) 5 (2.8) 5 (2.8) 7 (3.9) 6 (3.3) 5 (2.8t 4 (2.2) 4 (2.2) 3 (1.7t 4 (2.2) 3 (1.7) 3 (1.7t 7 7 6 6 7 6 6 5 15 (8.3) 14 13 12 10 9 Page 16 (3.9) (3.9) (3.3) (3.3t 11 (6.1) 10 (5.6) 10 (5.6) 9 (5) (3.9) (3.3) (3.3) (2.8t Approach Normal TXV Systems Method Operating - Outdoor frigerant from the system to increase the approach temperature. Be aware of the R410A refrigerant cylinder. It will be rose-colored. Refrigerant should be added through the vapor valve in the liquid state. Some R410A cylinders are equipped with a dip tube which allows you to draw liquid refrigerant from the bottom of the cylinder without turning the cylinder upside-down. The cylinder will be marked if it is equipped with a dip tube. and Pressures Temp. >_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 thermometer. using a digital Table 7 2 - Attach high pressure gauge set and operate unit for several minutes to allow system pressures to stabilize. HSXA12 3 - Compare stabilized pressures with those provided in table 8, "Normal Operating Pressures." 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. 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. Approach Values -018 -024 -030 Approach Temperature Liquid Line Outdoor Ambient °F (°C) 10 (5.6) 12 (6,7) 13 (7.2) -036 -042 -048 -060 12 (6.7) 11 (6.1) 13 (7,2) 14 (7,8) Model No. Approach Method A IMPORTANT 4 - Use the same digital thermometer you used to check the outdoor ambient temperature to check the liquid line temperature. 5 - The difference between the ambient and liquid temperatures should match values given in table 7. If the values don't agree with the those in table 7, add refrigerant to lower the approach temperature, or recover re- Normal Mode fixed orifice TXV Operating Out. Coil Entering Air Temp. -018 Pressures Table 8 In psig (liquid +/- 10 and vapor -030 -024 -036 +/- 5 PSIG)* -042 -048 -060 OF(oc) LIQ SUC LIQ SUC LIQ SUC LIQ SUC LIQ SUC LIQ SUC LIQ SUC 65 (18.3) 238 123 261 131 261 128 268 130 254 121 270 124 280 121 75 (23.9) 275 131 300 135 300 133 308 134 296 128 311 130 332 126 85 (29.4) 317 136 343 139 343 138 351 138 340 133 356 134 379 130 95 (35.o) 362 141 391 143 387 141 398 142 389 138 404 139 427 135 105 (40.6) 410 144 441 147 434 145 447 146 440 142 456 143 479 140 65 234 133 256 134 256 137 264 135 256 124 269 131 262 121 75 (23.9) 270 135 298 137 296 139 305 138 296 127 312 133 304 127 85 (29.4) 312 137 344 140 339 141 349 139 341 133 357 135 349 132 95 (35.0) 361 138 394 142 384 144 396 140 389 136 406 137 397 136 (18.3) 409 141 448 143 432 146 446 143 440 140 460 140 449 140 105 (40.6) *These are typical pressures only. Indoor indoor match up, indoor air quality, and indoor load will cause the pressures to vary. Page 17 Theoutdoorunitandindoorblowercycleondemandfrom theroomthermostat. Whenthethermostat blowerswitchis intheONposition, theindoorbloweroperates continuously. Compressor Time Belay (TB1) A compressor timedelayis usedto preventcompressor shortcyclingandto preventthecompressor fromrunning backwards. Whenthereisdemandfora coolingcycle,the controldelayscompressor operation forabout5 minutes (+ 2 minutes).Donotbypassthecontrol. High Pressure 3 - Visually inspect connecting lines and coils for evidence of oil leaks. 4 - Check wiring for loose connections. 5 - Check for correct voltage at unit (unit operating). 6 - Check amp-draw outdoor fan motor. Unit nameplate Actual NQ TE - If owner complains of insufficient cooling, the unit should be gauged and refrigerant charge checked. Refer to section on refrigerant charging in this instruction. Indoor Coil 1 - Clean coil, if necessary. 2 - Check connecting lines and coils for evidence of oil leaks. Switch HSXA12 units are also equipped with a low pressure switch that is located in the vapor line of the compressor. The switch (SPST, auto-reset, normally closed) removes power from the compressor when vapor line pressure drops below factory setting at 40 + 5 psi. Filter 2 - Outdoor fan motor is prelubricated and sealed. No further lubrication is needed. Switch HSXA12 units are equipped with a high pressure switch that is located in the liquid line of the compressor. The switch (SPST, manual reset, normally closed) removes power from the compressor when discharge pressure rises above factory setting at 640 + 10 psi. Low Pressure 1 - Clean and inspect the outdoor coil. The coil may be flushed with a water hose. Ensure the power is turned off before you clean the coil. Brier A filter drier is shipped with each HSXA12 unit. The filter drier must be field installed in the liquid line between the liquid line service valve and the expansion valve. This filter drier must be installed to ensure a clean, moisturefree system. Failure to install the filter drier will void the warranty. A replacement filter drier is available as from Lennox. AWARNING 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: 3 - Check condensate line and clean, if necessary. Indoor Unit 1 - Clean or change filters. 2 - Adjust blower speed for cooling. Measure the pressure drop over the coil to determine the correct blower CFM Refer to the unit information service manual for pressure drop tables and procedure. 3 - Belt Drive Blowers - Check belt for wear and proper tension. 4 - Check all wiring for loose connections 5 - Check for correct voltage at unit (blower operating). 6 - Check amp-draw on blower motor Unit nameplate Actual Refer to the Engineering Handbook for optional accessories that may apply to this unit. The following may or may not apply: • Loss of Charge Kit • High Pressure Switch Kit • Compressor Monitor • Compressor Crankcase Heater • Hail Guards • Mounting Bases • Timed Off Control • Stand-off Kit • Sound Cover • LowAmbient Kit Page 18 Start-up Job Name Job Location Installer Unit Model No, and Performance Job No, Check List Date City City Serial No, State State Service Technician Nameplate Voltage Rated Load Ampacity Maximum Fuse or Circuit Breaker Compressor Electrical Connections Tight? [] Indoor Blower RPM Indoor Filter Clean? [] S,R Drop Over Indoor (Dry) Discharge Pressure Refrigerant Lines: Outdoor Fan Supply Voltage (Unit Off) __ -- Vapor Pressure Leak Checked? [] Service Valves Fully Opened? [] Voltage With Compressor Operating Properly Insulated? [] Outdoor Coil Entering Air Temp, Refrigerant Charge Checked? Outdoor Fan Checked? Service Valve Caps Tight? [] -- Calibrated? [] Page 19 [] [] Thermostat Properly Set? [] Level? []
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.2 Linearized : No Page Count : 19 Page Layout : SinglePage Page Mode : UseNone Producer : Goby Monitor Application version 4, 0, 0, 13 Create Date : Mon Jun 30 04:27:18 2008 Author : Title : Subject :EXIF Metadata provided by EXIF.tools