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

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Page Count: 19

LENNOX

¢_2002 Lennox Industries Inc.

Dallas, Texas

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 de-

signed 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 op-

erating 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.

INSTALLATION

INSTRUCTIONS

HSXA12 Series Units

CONDENSING UNITS FT_ Technical

504,540M .LLL[ Publications

04/04

Supersedes 12/03 Lithe U.S.A.

HSXA12 Outdoor Unit ........................... 1

Shipping And Packing List ....................... 1

General Information ............................. 1

Unit Dimensions ................................ 2

Setting the Unit ................................. 3

Electrical ...................................... 3

Refrigerant Piping .............................. 5

Flushing Existing Line Set & Indoor Coil ........... 5

Refrigerant Metering Device .................... 11

Manifold Gauge Set ............................ 11

Service Valves ................................ 12

Leak Testing .................................. 13

Evacuation ................................... 13

Start-up ...................................... 14

Charging ..................................... 14

System Operation ............................. 18

Maintenance .................................. 18

Optional Accessories .......................... 18

HSXA12 Check Points ......................... 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 Page 1

504,540M

IIIHllllllllliillliilllllllllillllilllllill

IN LET._ AIR

4-3/8

(111)

4-3/8

(111)

INLET

AIR

INLET'_ AIR

Top View

C _-_

INLET

AIR

OPTIONAL UNIT

STAND-OFF KIT

(Field Installed)

(Around perimeter of base)

VAPOR LINE

CONNECTION

LIQUID LINE

CONNECTION

6-3/8

(162)

OUTDOOR

COIL FAN

Top View Base Section

_- C

DISCHARGEr AIR

4-3/8

(111)

COMPRESSOR_

ELECTRICAL

INLETS

VAPOR &

LIQUID LINE

CONNECTION

2-3/4 (70)

Side View 3/4

(19) OPTIONAL UNIT

STAND-OFF KIT

(Field Installed)

Side View

HSXA12-018

HSXA12-024

HSXA12-030

HSXA12-036

HSXA12-042

HSXA12-048

HSXA12-060

Model No.

in,

in.

in,

635

838

737

24-1/4

616

32-1/4

819

28-1/4

718

24-1/4

616

24-1/4

616

28-1/4

718

Page 2

&CAUTION

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 red-

wood or steel supports are recommended,

kCAUTION

Refer to unit dimensions for sizing mounting slab, plat-

forms or supports, Refer to figure 1 for installation clear-

ances,

Installation Clearances

(914 ram)

*NO TE -A service clearance of 30" (762 mm) must be main-

tained on one of the sides adjacent to the control box. Clear-

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).

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 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 Level

structure 'i_ discharge air

Mounting slab must slope

away from building,

Figure 2

ground level

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

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

ground,

NOTE -To facilitate conduit, a hole is in the bottom of

the control box. Connect conduit to the control box us

ing a proper conduit fitting.

NO TE -Units are approved for use only with copper

conductors.

24V, Class II circuit connections are made in the low

voltage junction box, Refer to figure 4 for field wiring

diagram,

NOTE -A complete unit wiring diagram is located in

side the unit control box coven

3 - Install room thermostat (ordered separately) on an in-

side 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,

Page 3

Thermostat

[Wl;

tV_

NOTE

power

heat

cooling

indoor blower

common

Thermostat Designations

Indoor Unit

-®

-(_-

NOTE -see unit wiring diagram for

power supply connections.

Outdoor Unit

E_ Y1 Outdoor Unit

[_ C Outdoor Unit

..... /\ .....

-If the indoor unit is not equipped with blower relay It must be field-provided and installed (P-8-3251 or equivalent).

Figure 3

Typical Field Wiring Diagram

_0_ TDOOR

FAN

PURPLE

LACK

ANGE

RED

NOTE-

FOR USE WITH COPPER CONDUCTORS

ONLY.REFER TO UNIT RATING

PLATE FOR MINIMUM CIRCUIT

AMPACITY AND MAXIMUM OVER-

YELLOW

COMPRESSOR

START *

CAPACITOR CI2

DUAL

CAPACITOR

__ ©

K3 I*A4

POTENTIAL RELAY* TIMED OFF CONTROL

BLACK COMPRESSOR

CONTACTOR

l,'

CURRENT PROTECTION SIZE

WARNING-

ELECTRIC SHOCK HAZARD, CAN CAUSE

INJURY OR DEATH. UNIT MUST BE

GROUNDED IN ACCORDANCE WITH

NATIONAL AND LOCAL CODES

208-230/60/I

GROUND

*May be optional

Figure 4

Page 4

IftheHSXA12unitisbeinginstalledwithanindoorcoiland

lineset,maketherefrigerantconnectionsasoutlinedinthis

section.Ifanexistinglinesetand/orindoorcoilisgoingto

beusedtocompletetheHSXA12system,refertothissec-

tion,aswellastheflushingsectionwhichfollows,

Fieldrefrigerantpipingconsistsof liquidandvaporlines

fromtheoutdoorunit(sweatconnections)totheindoorcoil

(flareorsweatconnections).UseLennoxL15(sweat,non-

flare)serieslinesetsasshownintable1orusefield-fabri-

catedrefrigerantlines.Referto RefrigerantPipingGuide

(Corp,9351-L9)for propersize,type,andapplicationof

field-fabricatedlines.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 re-

placed 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 Recommended Line Set

Connections

Model L15

Liquid Vapor Liquid Vapor Line Sets

Line Line Line Line

L15-26

3/8 in. 5/8 in. 3/8 in, 5/8 in, 15 if, - 50 ft.

-018 (10 mm) (16 mm) (10 mm) (19 mm) (4.6 m- 15 m)

024 L15-41

-030 3/8 in, 3/4 in, 3/8 in, 3/4 in, 15 ft. - 50 ft.

-036 (10mm) (19mm) (10mm) (19mm) (4.6m-15m)

-042 3/8 in. 7/8 in. 3/8 in, 7/8 in, L15-65

-048 (10 mm) (22 mm) (10 mm) (22 mm) 15 ft, - 50 ft.

(4.6 m - 15 m)

-060 3/8 in, 1-1/8 in, 3/8 in, 1-1/8 in. Field

(10 mm) (29 mm) (10 mm) (29 mm) Fabricated

NOTE -Units are designed for line sets of up to fifty feet (15

m). For applications longer than fifty feet, consult the Len-

nox Refrigerant Piping Guide (Corp. 9351-L9). Select line

set diameters from table 1 to ensure that oil returns to the

compressor.

Installing Refrigerant Line

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 transmis-

sion.

2- Line Set Isolation -The following illustrations demon-

strate 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.

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

rWood Block _,

Between Studs

Liquid Line

Vapor Line

(wrapped

Wall

L_ Caulk

PVC Pipe Fiberglass

Insulation

IMPORTANT- Refrigerant

lines must not contact

structure.

IMPORTANT- Refrigerant

lines must not contact wall.

r-,tit

Vapor Line Liquid Line

Wire Tie

Inside Wall

Strap

Sleeve

Wire Tie

Wood Block

Wire Tie

Strap

Sleeve

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.

8 feet

Floor Joist or

Roof Rafter

j /

8 feet

Wire Tie

(around vapor line only)

Tape or Wire Tie

Strapping Material (around vapor line only)

Tape or Wire Tie

Metal Sleeve

r/jf

_) Floor Joist or Roof Rafter )

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

Anchored Heavy

Nylon Wire Tie

Wall

Stud

Metal /

Sleeve

Va )or Line

Wrapped in

Armaflex

Strap Liquid Line

To Vapor Line

Liquid Line

Automotive

Muffler-Type

Hanger

Wall

Stud

Metal

Sleeve

)

Strap Liquid Line

To Vapor Line

Liquid Line

Vapor Line

Wrapped in

Armaflex

Figure 7

Outside Unit Placement and Installation

Install unit away from windows.

Two 90° elbows

installed in line set

will reduce line set

vibration.

Figure 8

Page 8

AWARNING

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.

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 sys-

tem.

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 braz-

ing) 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 pro-

tect them during brazing. Braze the line set to the ser-

vice valve.

4 - Wrap a wet cloth around the valve body and copper

tube stub to protect it from heat damage during braz-

ing. Wrap another wet cloth underneath the valve body

to protect the base paint.

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 expan-

sion valve which is sold separately and approved

for use with R410A refrigerant) in the liquid line at the

indoor coil.

6 - Install the provided filter drier (approved for use with

R410A refrigerant) in the liquid line as close as pos-

sible 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 mois-

ture quickly. Failure to install the filter drier will

void the warranty.

,WARNING

,IMPORTANT

-&CAUTION

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).

Flushing Procedure

1 - Remove existing R22 refrigerant using the appropri-

ate 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 ex-

isting outdoor unit. Connect to the existing unit, a

Page 9

cleanrecoverycylinderandthe recoverymachine

accordingtotheinstructionsprovidedwiththerecov-

erymachine.RemoveallR22refrigerantfromtheex-

istingsystem,Refertogaugesaftershutdowntocon-

firmthattheentiresystemiscompletelyvoidofrefrig-

erant,Disconnecttheliquidandvaporlinesfromthe

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 exist-

ing R22 system in the cooling mode and close the liq-

uid line valve. Pump all of the existing R22 refrigerant

back into the outdoor unit. (It may be necessary to by-

pass 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, Re-

fer 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 ori-

fice 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 flush-

ing procedures, The existing devices are not ap-

proved for use with R410A refrigerant and may pre-

vent proper flushing, Use a field-provided fitting to re-

connect the lines,

&IMPORTANT

Inverted R22 Cylinder

(Contains clean R22 to

be used for flushing)

Flushing Connections

Low High

Pressure Pressure

Service Valve

HSXA12

Unit

GAUGE MANIFOLD

Indoor Coil Existing Liquid Line Liquid Line

Service Valve

Closed

RECOVERY CYLINDER

Tank Return

Inlet

Discharge

RECOVERY MACHINE

NOTE- The inverted R22 cylin-

der must contain at least the

same amount of refrigerant as

was recovered from the existing

system.

Figure 9

Page 10

4- Removethe pressuretap valve cores from the

HSXA12unit'sservicevalves,ConnectanR22cylin-

derwithcleanrefrigeranttothevaporservicevalve.

ConnecttheR22gaugesettotheliquidlinevalveand

connectarecoverymachinewithanemptyrecovery

tanktothegaugeset,

5- Settherecoverymachineforliquidrecoveryandstart

therecoverymachine,Openthegaugesetvalvesto

allowtherecoverymachinetopullavacuumontheex-

istingsystemlinesetandindoorcoil,

6 - InvertthecylinderofcleanR22andopenitsvalveto

allowliquidrefrigeranttoflowintothesystemthrough

thevaporlinevalve.Allowtherefrigerantto passfrom

thecylinderandthroughthelinesetandtheindoorcoil

beforeitenterstherecoverymachine.

7- Afteralloftheliquidrefrigeranthasbeenrecovered,

switchtherecoverymachinetovaporrecoverysothat

alloftheR22vaporisrecovered.Allowtherecovery

machinetopulla vacuumonthesystem.

NOTE -A single system flush should remove all of the

mineral oil from the existing refrigerant lines and in-

door 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 ma-

chine, gauges and R22 refrigerant drum, Reinstall

pressure tap valve cores into HSXA12 service valves,

10 -Install the provided fixed orifice in the liquid line at the

indoor coil.

may not be appropriately sized. Refer to the Engineering

Handbook for specific orifice information.

Table 2

Fixed Orifice Drill Sizes

Unit Fixed Orifice Part # Drill Size

HSXA12-018 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

I_ ..._.j(fa ctorC;i.[inCsta iie d )

distributor _valve OR orifice

o-ring

expansion

valve (opt.)

// e

o-ring

strainer

liquidline

stub

Figure 10

Expansion 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.

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 ori-

fice 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

• , IMPORTANT

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,Seetable3fortorquere-

quirements,

Eachvalveisequippedwithaserviceportwhichhasafac-

tory-installedSchradervalve.A serviceportcapprotects

theSchradervalvefromcontaminationandservesasthe

primaryleakseal. Table3

Torque Requirements

Part Recommended Torque

Service valve cap 8 ft,-lb. 11 NM

Sheet metal screws 16 in.- lb. 2 NM

Machine screws #10 28 in.- lb. 3 NM

Compressor bolts 90 in.-lb. 10 NM

Gauge port seal cap 8 ft.- lb. 11 NM

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 tighten an additional 1/6 turn.

To Open Service Valve:

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.

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:

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.

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.

Service Valve

(Valve Closed)

serviCeport _,_m cap

to outdoor coil

insert hex

wrench here

service

port cap

Schrader valve open

to line set when valve is

closed (front seated)

indoor coil

(valve front seated)

insert hex

wrench here

Service Valve

(Valve Open)

service

port \

to outdoor coil

stem cap

service port to indoor coil

cap Schrader

valve

Figure 11

Vapor Line (Ball Type) Service Valve

Vapor line service valves function the same way as the oth-

er valves; the difference is 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 factory-

installed Schrader valve, A service port cap protects the

Schrader valve from contamination and assures a leak-

free seal.

Page 12

Ball Valve (Valve Open)

Use Adjustable Wrench

To open: rotate Stem Counter-clockwise 90 °.

To close: rotate Stem Clockwise 90 °.

to outdoor coil _.,i------ stem cap

"q__J/ stem

ball

(shown open)

service port

cap

service port

Schrader valve

to indoor coil

Figure 12

After the line set has been connected to the indoor and

outdoor units, check the line set connections and indoor

unit for leaks.

WARNING

2 - With both manifold valves closed, connect the cylinder

of R410A refrigerant. Open the valve on the R410A cyl-

inder (vapor only).

3 - 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 (57 g) refrigerant or 3 pounds (31 kPa) pres-

sure]. Close the valve on the R410A cylinder and the

valve on the high pressure side of the manifold gauge

set. Disconnect R410A cylinder.

4 - Connect a cylinder of nitrogen with a pressure regulat-

ing 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 pres-

sure hose is connected to the liquid line port; however,

connecting it to the vapor port better protects the man-

ifold gauge set from high pressure damage.)

6 - Adjust nitrogen pressure to 150 psig (1034 kPa). Open

the valve on the high side of the manifold gauge set in or-

der to pressurize the line set and the indoor unit.

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.

XklMPORTANT

,WARNING

WARNING

Using an Electronic Leak Detector

1 - Connect a cylinder of R410A to the center port of the

manifold gauge set.

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 pip-

ing and compressor parts.

XkIMPORTANT

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 micron gauge.

Page 13

3- Connectthevacuumpump(withvacuumgauge)tothe

centerportofthemanifoldgaugeset.

4- Openbothmanifoldvalvesand startthe vacuum

pump.

5- Evacuatethelinesetandindoorunittoan absolute

pressureof23,000microns(29.01inchesof mercu-

ry).Duringtheearlystagesof evacuation,it isdesir-

abletoclosethemanifoldgaugevalveatleastonceto

determineifthereisa rapidriseinabsolutepressure.

A rapidriseinpressureindicatesa relativelylargeleak.

Ifthisoccurs,repeattheleaktestingprocedure.

NOTE -The term absolute pressure means the total

actual pressure within a given volume or system,

above the absolute zero of pressure. Absolute pres-

sure in a vacuum is equal to atmospheric pressure mi-

nus 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 cylin-

der 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,

A,WARNING

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 pow-

er to the indoor blower and close the outdoor unit dis-

connect switch to start the unit.

_Recheck voltage while the unit is running, Power must

be within range shown on the nameplate,

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 vacu-

um 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.

This system is charged with R410A refrigerant which oper-

ates at much higher pressures than R22, The provided liq-

uid 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,

Factory Charge

Units are factory charged with the amount of R410A refrig-

erant 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 Oz. per 5 ft. (grams per 1.5 m) adjust

Diameter from 15 ft. (4.6 m) line set*

3/8 in, 3 ounces per 5 feet

(10 ram) (85g per 1.5 m)

*If line length is greater than 15 ft. (4.6 m), add this amounL If line

length is less than 15 ft. (4.6 m), subtract this amounL

klMPORTANT

Page 14

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 EMKA-

RATE "_ RL32CF.

Units Delivered Void of Charge

If the system is void of refrigerant, clean the system us-

ing the procedure described below.

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 mois-

ture as possible,

3 - Use nitrogen to break the vacuum and install the pro-

vided filter drier in the system,

4 - Evacuate the system again. Then, weigh the appropri-

ate amount of R410A refrigerant (listed on unit name-

plate) into the system,

5 - Monitor the system to determine the amount of mois-

ture 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 Charge

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 deter-

mined by the unit's refrigerant metering device and the

outdoor ambient temperature.

Measure the liquid line temperature and the outdoor ambi-

ent 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,

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 ambi-

ent temperature,

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 charg-

ing method to use, Proceed with the appropriate charg-

ing procedure,

Weighing in the Charge Fixed Orifice or

TXV Systems - Outdoor 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 re-

paired.

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 proce-

dures outlined below.

Charging Using the Subcooling Method

Fixed Orifice Systems

Outdoor Temp. _>65°F (18°C))

If you charge a fixed orifice system when the outdoor ambi-

ent is 65<_F(18<_C)or above, use the subcooling method to

charge the unit.

1 - With the manifold gauge hose still on the liquid service

port and the unit operating stably, use a digital ther-

mometer 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 deter-

mine the saturation temperature for the liquid line pres-

sure reading, See table 5,

4 - Subtract the liquid line temperature from the saturation

temperature (according to the chart) to determine sub-

cooling. (Saturation temperature - Liquid line tem-

perature = Subcooling)

5 - Compare the subcooling value with those in table 6, If

subcooling is greater than shown, recover some refrig-

erant. If subcooling is less than shown, add some re-

frigerant,

Page 15

Temperature

Outdoor

Temp. °F (°C)

65 (18)

70 (21)

75 (24)

80 (27)

85 (29)

90 (32)

95 (35)

100(38)

105 (41)

110 (43)

115 (45t

Pressure

Psig

1O018

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

Table 5

R410A Temperature/Pressure Chart

Temperature

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

IO0

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

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

-018

13 (7.2)

12 (6.7)

11 (6.1)

9 (5)

8 (4.5)

6 (3.3)

5 (2.8)

4 (2.2)

3 (1.7)

2 (1.1t

Table 6

Subcooling Values for Fixed Orifice Systems

-024

13 (7.2)

11 (6.1)

10 (5.6)

9(5)

7 (3.9)

6 (3.3)

5 (2.8)

4 (2.2)

3 (1.7)

3(1.7t

Liquid Subcoolin 9 [+ l°F (.6°C)]

-030

16 (8.9)

15 (8.3)

14 (7.8)

13 (7.2)

12 (6.7)

10 (5.6)

9 (5)

8 (4.5)

7 (3.9)

6 (3.3)

5(2.8t

-036 -042

12 (6.7) 11 (6.4)

11 (6.1) 10 (5.6)

10 (5.6) 9 (5)

9 (5) 8 (4.5)

8 (4.5) 7 (3.9)

7 (3.9) 6 (3.3)

6 (3.3) 6 (3.3)

5 (2.8) 5 (2.8)

4 (2.2) 4 (2.2)

4 (2.2) 3 (1.7)

3(1.7t 3 (1.7t

-048

14 (7.8)

13 (7.2)

12 (6.7)

11(6.1)

10 (5.6)

9 (5)

8 (4.5)

7 (3.9)

6 (3.3)

6(3.3t

-060

13 (7.2)

12 (6.7)

11(6.1)

10 (5.6)

9 (5)

8 (4.5)

7 (3.9)

6 (3.3)

5 (2.8t

Page 16

Approach Method and

Normal Operating Pressures

TXV Systems - Outdoor 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 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 8, "Normal Operating Pressures." Minor varia-

tions in these pressures may be expected due to differ-

ences 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 Method

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 temper-

atures should match values given in table 7. If the val-

ues don't agree with the those in table 7, add refriger-

ant to lower the approach temperature, or recover re-

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 cylin-

der without turning the cylinder upside-down. The

cylinder will be marked if it is equipped with a dip

tube.

Table 7

HSXA12 Approach Values

Approach Temperature

Model No. Liquid Line -

Outdoor Ambient °F (°C)

-018 10 (5.6)

-024 12 (6,7)

-030 13 (7.2)

-036 12 (6.7)

-042 11 (6.1)

-048 13 (7,2)

-060 14 (7,8)

AIMPORTANT

Table 8

Normal Operating Pressures In psig (liquid +/- 10 and vapor +/- 5 PSIG)*

Out. Coil

Mode Entering Air

Temp.

OF(oc)

65 (18.3)

75 (23.9)

fixed 85 (29.4)

orifice 95 (35.o)

105 (40.6)

65 (18.3)

75 (23.9)

TXV 85 (29.4)

95 (35.0)

105 (40.6)

*These are

to vary.

-018

LIQ SUC

238 123

275 131

317 136

362 141

410 144

234 133

270 135

312 137

361 138

409 141

-024

LIQ SUC LIQ

261 131 261

300 135 300

343 139 343

391 143 387

441 147 434

256 134 256

298 137 296

344 140 339

394 142 384

448 143 432

-030

SUC

128

133

138

141

145

137

139

141

144

146

typical pressures only. Indoor indoor match up, indoor

-036

LIQ SUC

268 130

308 134

351 138

398 142

447 146

264 135

305 138

349 139

396 140

446 143

-042

LIQ SUC

254 121

296 128

340 133

389 138

440 142

256 124

296 127

341 133

389 136

440 140

-048

LIQ SUC

270 124

311 130

356 134

404 139

456 143

269 131

312 133

357 135

406 137

460 140

-060

LIQ SUC

280 121

332 126

379 130

427 135

479 140

262 121

304 127

349 132

397 136

449 140

air quality, and indoor load will cause the pressures

Page 17

Theoutdoorunitandindoorblowercycleondemandfrom

theroomthermostat.Whenthethermostatblowerswitchis

intheONposition,theindoorbloweroperatescontinuously.

Compressor Time Belay (TB1)

A compressortimedelayisusedto preventcompressor

shortcyclingandto preventthecompressorfromrunning

backwards.Whenthereisdemandforacoolingcycle,the

controldelayscompressoroperationforabout5minutes(+

2minutes).Donotbypassthecontrol.

High Pressure 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 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 be-

low factory setting at 40 + 5 psi.

Filter 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 fil-

ter drier must be installed to ensure a clean, moisture-

free system. Failure to install the filter drier will void

the warranty. A replacement filter drier is available as

from Lennox.

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.

2 - Outdoor fan motor is prelubricated and sealed. No fur-

ther lubrication is needed.

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.

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

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:

Refer to the Engineering Handbook for optional accesso-

ries 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 and Performance Check List

Job Name Job No, Date

Job Location City State

Installer City State

Unit Model No, Serial No, Service Technician

Nameplate Voltage

Rated Load Ampacity Compressor Outdoor Fan

Maximum Fuse or Circuit Breaker

Electrical Connections Tight? [] Indoor Filter Clean? []

Indoor Blower RPM S,R Drop Over Indoor (Dry)

Discharge Pressure Vapor Pressure

Refrigerant Lines: Leak Checked? [] Properly Insulated? []

Service Valves Fully Opened? [] Service Valve Caps Tight? []

Voltage With Compressor Operating -- Calibrated? []

Supply Voltage (Unit Off) __

-- Outdoor Coil Entering Air Temp,

Refrigerant Charge Checked? []

Outdoor Fan Checked? []

Thermostat

Properly Set? [] Level? []

Page 19

LENNOX Air Conditioner/heat Pump(outside Unit) Manual L0805500

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