LENNOX Controls And HVAC Accessories Manual L0806301

User Manual: LENNOX LENNOX Controls and HVAC Accessories Manual LENNOX Controls and HVAC Accessories Owner's Manual, LENNOX Controls and HVAC Accessories installation guides

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q _ _ Technical

J .J L Publications

Lithe U.S.A.

_;)2007

HEAT PUMP UNITS

KITS AND ACCESSORIES

503,802M

11/2007

Supersedes 2/98 DEFROST CONTROL KIT

INSTALLATION INSTRUCTIONS FOR DEFROST CONTROL KIT (23L00 - LB-93614)

USED WITH HP14 t16 t18 t20 tCHP16 t20 t24 tAND CHP15-261 TO 461 UNITS

Package 1 of I contains:

1--Defrost control assembly (CMC1 & K4)

2- Wiring diagrams stickers

1--Bag assembly containing:

1- Defrost thermostat switch ($6)

1- Defrost (refrigerant-type) pressure switch

($46) assembly (HP14, HP16 and HP18)

1- 1/2" snap-hole plug (HP16 units only)

8- Wire nuts

1- Wire tie

2- Insulating sleeves

2- #8 - 32 X 1/2" Screws

1- Saddle valve (HP14 and HP18)

This defrost control kit replaces the existing defrost

control systems in HP14, HP16, HP18, HP20, CHP16,

CHP20, CHP24 and CHP15-261 to 461 units.

This kit is used to upgrade units to a temperature initiated /

pressure terminated defrost system, Various defrost

components are used in each unit, Once updated, all

units will contain these four defrost components:

CMC1 Defrost Control

S6 Defrost Thermostat Switch

S46 Defrost Pressure Switch (refrigerant type)

K4 Defrost Relay

The replacement defrost control system checks every 90

minutes (factory-set) to determine if defrost is necessary.

If the defrost thermostat senses a temperature below

35°F (1,6°C), the thermostat contacts close to initiate

defrost. When the pressure level sensed by defrost

pressure switch rises to 275 psi, switch contacts open and

defrost terminates.

1 - Turn off electrical power to unit at disconnect switch,

2- Remove access panels and remove defrost pressure

switch cover.

3- Remove existing S9 defrost (air-type) pressure switch

and install replacement S46 (refrigerant-type) pressure

switch as shown in figure 1, Replace switch cover.

4- Install S6 defrost thermostat on the liquid line as

shown in figure 1,

5-Single-Phase Units Only -- Start capacitor and

mounting bracket must be relocated to a position

outside of the control box, Remove the start C3

capacitor and mounting bracket and discard the wires

connected to the capacitor.

Position capacitor mounting bracket below control

box, Use mounting bracket as a template to drill two

.218" diameter mounting holes. Use existing screws

to install bracket and capacitor,

6- Position the CMCl defrost control in the control box,

See figure 2, Use the mounting bracket as a template

to drill two 3/16" diameter holes. Use two #8 - 32 X

1/2" screws provided to secure bracket,

7- Wire defrost components as shown in figures 4 and

6, Wires are identified in figure 7, Figure 8 shows

terminal designations for older model Essex

cube-style relays versus standard relays,

8- Affix appropriate wiring diagram adjacent to existing

unit diagram.

HP14 UNIT DEFROST SYSTEM

Install S46 replacement defrost pressure switch with saddle

valve/depressor tee (provided) on liquid line. See saddle valve

installation procedure in these instructions.

AIRFLOW $6

DIRECTION DEFROST

;TAT

EXISTING $8 DEFROST

PRESSURE SWITCH

FIGURE 1

Page 1

INSTALL CMC1 DEFROST CONTROL ASSEMBLY

DEFROST

RELAY

BRACKET

SIDE OF

CONTROL BOX

FIGURE 2

9- Turn on electrical power to unit,

10- Run defrost system through several cycles, Check for

proper function,

11- Reinstall access panels,

1 - Turn off electrical power to unit at disconnect switch,

2 - Remove access panels and remove defrost pressure

switch cover,

3 - Remove existing defrost pressure switch and sensor.

Install snaphole plug (provided) into panel hole, If

electronic defrost pressure switch has been

previously used, remove and discard the two

pressure switch wires. Install replacement $46

(refrigerant-type) pressure switch with valve

depressor tee on service port of liquid line service

valve,

4- Install $6 defrost thermostat on the liquid line

between the drier and the distributor.

5 - Route brown defrost thermostat wires through hole in

bottom or back of control box,

6- Position the CMC1 defrost control in control box and

use the mounting bracket as a template to drill two

3/16" diameter holes, Use two #8-32 X 1/2" screws

provided to secure bracket,

7- Wire defrost components as shown in figure 5 and 6,

Wires are identified in figure 7, Figure 8 shows

terminal designations for older model Essex

cube-style relays versus standard relays,

8- Affix appropriate wiring diagram adjacent to existing

unit diagram,

9- Turn on electrical power to unit,

10- Run defrost system through several cycles, Check for

proper function,

11- Reinstall access panels,

1- Turn off electrical power to unit at disconnect switch,

2- Remove access panels.

3- HP18 units - Install saddle valve on liquid line, Install

defrost refrigerant-type pressure switch/depressor

tee to saddle valve (early model units),

CHP16, 20, 24, and CHP15-261/461 units - Install

(refrigerant-type) pressure switch on existing liquid

line pressure tap fitting.

4- Position the CMC1 defrost control in control box and

use the mounting bracket as a template to drill two

3/16" diameter holes. Use two #8-32 X 1/2" screws

provided to secure bracket,

5-Wire defrost components as shown in figure 5

through 8. Wires are identified in figure 9. Figure 10

shows terminal designations for older model Essex

cube-style relays versus standard relays.

6- Affix appropriate wiring diagram adjacent to existing

unit diagram,

7- Turn on electrical power to unit,

8- Run defrost system through several cycles, Check for

proper function,

9- Reinstall access panels,

1 - Braze saddle valve (provided) onto 3/8" O.D. process

tube between unit distributor and drier for leakproof

joint, Cool with wet rag and clean joint. Apply process

hose to pressurize and check for leaks as shown in

figure 3,

IMPORTANT -Do not install saddle valve near an

existing fitting or solder joint.

2 - After cooling, place teflon seal on pin as shown and

insert steel pin (core side down) into valve body.

3 - Screw cap down on valve body, forcing steel pin to

pierce line. Use two wrenches to avoid breaking

brazed joint, Continue to tighten cap until valve body

is smoothly crimped over steel pin,

A - Defrost Timer

The defrost control will not allow a defrost to last more

than 14 minutes, The defrost timer can be field adjusted

from a 90-minute to a 30- or 60-minute defrost interval if

warranted by climatic conditions,

Page 2

BRAZE SADDLE

VALVE BODY ONTO TUBE

CHECK FOR LEAKS

AT BRAZE

COOL WITH

WET CLOTH

CHECK VALVE CORE

TO MAKE SURE

iT IS TIGHT

_ TEFLON SEAL

STEEL PIN

._, INSERT STEEL

PIN INTO BODY.

SCREW CAP ON

BODY TO

I_1 P,EROE TUBE

USE TWO WRENCHES

TO AVOID TWiSTiNG

FIGURE 3

B - Defrost Thermostat

The thermostat closes at 35°F + 4°F initiating the defrost

cycle. It is mounted on the liquid line between the drier

and the distributor.

C - Defrost Pressure Switch

The defrost cycle is terminated by the defrost pressure

switch when the switch senses a rise in pressure to a level

of 275 psi. If the coil pressure does not rise to this value

within the time override period of the defrost timer

(approximately 14 minutes), the defrost cycle is

terminated by the defrost timer. The pressure switch is

located as follows for the various units covered by this

instruction:

HP14/HP18 liquid line with saddle valve/valve

depressor tee.

HPf6 - service port of liquid line service valve with valve

depressor tee.

CHPf6, 20, 24 and CHP15-261/461 - existing liquid line

pressure tap fitting.

NOTE -Termination of the defrost cycle, by rising

refrigerant pressure or by defrost timer override, begins

another 90-minute (30- or @-minute) period before the

system checks for defrost again.

IMPORTANT -Inspect both sides of the outdoor coil

periodically and remove any grass, leaves, or other

obstructions.

DEFROST KIT WIRING FOR HP14 UNITS

COMPRESSOR

PRO1 EC1 i ON

MOD[ LE

LO SPEED

(IN

UNIT)t

DESCRIPIION

KEY COMPONENT

* CMCI IlMER=DEFROSI

*K4,-I,2,5 RELAY-DEPROSI]

KS,-_ RELAY@EFROSI 2(LO SPD)

K6 RELAY-LATCH(IN UNIT)

"86 SWITCH-DEFROST

"$46 SWI[CH-DEFROS1,TERMINAfION

T] 1RANS[:ORMER CONqROL

* DENOTES NEW COMPONENTS,OTHERS

SHOWN ARE EXTSTTNG,

= =

HEAT PUMP OUTDOOR UNITS

DEFROST CONTROL KIT

FOR HPI4 SERIES UNITS

208 230/60/I

Supersedes or_ No. New orm N_.

.552,7 I IW

(_ 1998 Lenno× [_dus!r e_ 1_¢ h i _ h 0 _U , S A .

LOW

SPEED

FIGURE 4

Page 3

DEFROST KIT WIRING FOR

HP16, HP18, HP20 AND CliP15 UNITS

K4-3

DEFROST

RELAY

(K4 ON CHPL5)

K4 2

REMOVE EXSIST!NG WIRES FROM TERMINALS

1,2,& 3 OF EXISTING DEFROST RELAY.

LEAVE REST OF WIRES ON POLES

2 & 5 AS IS.

L.eNNDX_,o_,_. WlRN@OIAGRAMJl9s....................

HEArPuMPou soo uNi -s

DEFROST CONTROL KIT

FOR HP 6,HPI8,HP20 & CHPI5

SERIES UNITS

208-250/60/I

Supersedes Form No. New Form No.

552,7lOW

(_199B Lennox Indusl_ies Inc. L fho U.S.A.

TBI-

CHP}5 ONLY

) s4

D- PRESSURE

{SWITCII

COMPRESSOR

CONTACTOR

124v tOM

* DENO]ES NEW COMPONENIS,O1HERS

SHOWN ARE EXISTING,

DESCRIPTION

KEY COMPONENT

BI COMPRESSOR

B4 MOTOR-FAN

..........t_M_! ...............................................................................................................................................................................................

HR}

....................._.L -I

*K4,-I,2,3

K31

' $6

. SS6

HEATER COMPRESOR

CONIACTOR-COMPRESSOR

RELAY DEFROST

RE1AY HARD START KIT

iSWITCH-PRESSURE,HIGH

SWITCH DEFROST

iSWlTCH-DEFROST,TERMINATION

FIGURE 5

Page 4

'-rl

on m

24 VOLTS

HOT

S[RIR

DEFROST KIT FIELD WIRING

$46 TERMINAL (E)

DEFROST

PRESSURE SWITCH

BLUE (}2")

EG/

EXISTING

CMC}

..jREO(16")

KI COIL (YI)

OR (M)

ORANGE(5") \

©/

THI

["_

STRIP

BROWN_" /\

ORANGE(4")

.YELLOW (iS"}

$6 TERMINAL (})

DEFROST

T-STAT

EXISTING

PIGTAIL

EXISTING

=IGTAIL

_$46 TERMINAL (2)

DEFROST

PRESSURE SWI]CH

(6")

ORANGE(6")

-_24V COMMON

KI COIL

DEFROST

T-STAT

$6 TERMINAL (2)

B4 FAN _#_

COIL (A) k..___ @_J

EXISTING

DE ROST RELAY STING

K I °IGTAIL

(I)

DEFROST KIT WIRING FOR

CHP16, CHP20, CHP24 UNITS

KEY

_CMCI

KI,-I

• K4,-I,2,3

K26,-I,2

_$6

$46

24V HOT

DESCRIPTION

COMPONENT

TIMER-DEFROST

CDNTACTOR-CONPRESSOR

RELAY-DEFROST

RELAY-EMERGENCY HEAT

SWITCH-PRESSURE,HIGH

SWITCH-DEFROST

SWITCH-DEFROST,TERMINATION

K4-1

0 OUT

PRESSURE

SWITCH

_) K1

L COMPRESSOR

( _ CDNTACTOR

24V CON

DENOTES NEW COMPONENTS,OTHERS

SHOWN ARE EXISTING.

WIRING DIAGRAH ii/07

HEAT PUHP-DUTDDDR UNITS

DEFROST CONTROL KIT

FOR CHPI6,CHP20 AND CHP24

SERIES UNITS

Supersedes Form No, New Form No.

537021-01

C) 2007 Litho U,S,A.

FIGURE 7

Page 6

DEFROST KIT WIRING FOR

CHP24D UNITS 24V POWER

J35 •

< -6

-8

-3

TD2

_EOUIPMEN_ 27 575V

GROUND

460VK3-2: ._

NOTE_USE COPPER

CONBL_TORSONLY

GROUND P43

DIRECT DRIVE

2.N

J43 5 _X6 43/_

• z • z i _:

C4 208/230V

DISCONNECT ALL POWER BEFORE SERVICINO

IF ANY WIRE IN THIS APPLIANCE IS REPLACED,

IT MUST BE REPLACED WITH VIRE OF LIKE SIZE,

RATING AND INSULATION THICKNESS

K3-1

(_ ECONOMIZER

BLOWER(O)

_._6 HEAT l(Wl)

-t HEAT 2(W2)

P66

DENOTES OPTIONAL COMPONENTS

DOB-230V,

460v HOOKUP

WARNING-ELECTRIC SHOCK HAZARD_AN

CAUSE INJURY OR DEATH, UNIT

_MCI MUST DE GROUNDED IN ACCORD-

ANCE WITH NATIONAL ANO LOCAL

CODES

//\CONNECTIONS FOR FACTORY

INSTALLED SMOKE DETECTOR

AI7.MAX LOAD O.IVA 24VAC

CLASS II

LETTER !

IDESIGNATIONI VOLTAGE

IY1208-230/60/3

57516013

24V COMMON

/_ MEO SPEED(BLACK TO J43-3 & BLUE TO J43-2)

LOW SPEED(BLACK TO J43-4 & BLUE TO J43-0)

NOTE-FOR USE WITH COPPER CONDUCTORS

ONLY, REFER TO UNIT RATING PLATE FOR

MINIMUM CIRCUIT AMPACITY AND MAXIMUM

OVERCURRENT PROTECTION SIZE

FACTORY INSTALLED OPTION

$3 NOT USED V/HEN LOW AMBIENT KIT

IS FACTORY INSTALLED

/6_ INSTALL JUMPER WHEN LOW AMBIENT KIT

FIELD INSTALLED

DESCRIPTION

(EY COMPONENT

'35 PLUO-TES T

43 PLUG-BLOWER MOTOR

47 PLUG-OUTDOOR PAN

PLU_-UNIT TO _MOK_ I)ET_CTOR

178 PLUG-SMOKE DETECTOR

SWITCH-LIMIT.LOW COMP 1

/COMPRESSOR MONITOR

;4 SWITCH-LIMIT HI PRESS COMP I

;6 SWITCH-DEFROST COMP I

;11 SWITCH-LOW PRESS.LOW AMD KIT

;04 SWITCH-LOSS OF CHARGE,CORP I

;4G SWITCH-DEFROST TERMINATION

;48 SWITCH-DISCONNECT

;75 SWITCH-FIR_STAT O

I TRANSFORMER-CONTROL

4 TRANSFORNER-BLOVOR MOTOR

'D_ TERMINAL STR_P-UNIT

"D13TERMINAL STRIP-POVOR DISTRID

LINE VOLTAGE FIELD INSTALLED

WIRINGDIAGRAMII/O7

HEAT PUMP-PACKAGED

CHP24D-G53-I-Y,G,JI I

HEAT PUMP SECTIrIN B4

SL_per_edes FoPr_ NO, I New FOP_ NO,

537020-01

_) _007 Lltho U.&A,

FIGURE 8

Page 7

K4-6 D

K4-9 D

K4-3 D

CMC1 "24v" D

Red 6"

Red 12"

Red 6"

Blue 12"

Existing Wire

WIRE IDENTIFICATION

Existing Wire

Brown 6"

K4-7 D

Brown 4"

K44 D

Existing Wire

K4-4 I::C)Orange 6"

K4-B E:::) Orange 4"

K4-8 D Orange 5"

Yellow 4"

K4-2 D

Yellow 13"

CMC1 "COM" D

Red 16"

CMC1 "HLD" D

a Defrost Relay Coil "A"

a K1 Contactor"Tl"

a B4 Outdoor Fan Motor

<:::3 24V Hot, $46-1, K5-4 (HP14)

a s46-2, s6-1

<::3 K4-A

C:] S6-2, K6-A (HP14)

a CMC1 "OUT"

CMCl "RST"

a CMCl "COM"

4::3 K1-B, COM, K5 (HP14)

<::3 K1-A, K5 (HP14)

Existing Wire - HP14

FIGURE 9

RELAY TERMINAL IDENTIFICATION

EXISTING DEFROST

RELAY

C:::223

................ i

-[333333

-_ 3

.................... i

REPLACEMENT DEFROST

RELAY

---4

.................

FIGURE 10

Page 8

LENNOX Controls And HVAC Accessories Manual L0806301

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