LENNOX Air Conditioner/heat Pump(outside Unit) Manual L0806490
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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LENNOX _2003 INSTALLATION INSTRUCTIONS Lennox industries inc. Dallas, Texas, USA HP29 Heat Pump Units HEAT PUMP UNITS 1-1/2 through 5 tons 504,829M 06/04 Supersedes Lennox Elite® Series HP29 outdoor units are approved and warranted only for installation with specially matched indoor coils, line sets, and refrigerant control devices as designated by Lennox. Refer to Lennox engineering hand book for expansion valve kits which must be ordered separately. q [_ _ Technical J L [ Publications Litho U.S.A. 02/04 HP29 Outdoor Units ............................ Shipping & Packing List ......................... General Information ............................ Unit Dimensions ............................... Setting the Unit ................................ Electrical ...................................... Refrigerant Piping .............................. Refrigerant Metering Device ..................... Manifold Gauge Set ............................ Service Valves ................................ Leak Testing .................................. Evacuation ................................... Start-Up ...................................... Charging ..................................... System Operation ............................. Defrost System ............................... Optional Units ................................ Maintenance .................................. Optional Accessories .......................... Start-Up and Performance Check List ............ 1 1 1 2 3 4 5 9 9 10 11 12 13 13 15 15 17 17 17 18 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. Authorities having jurisdiction should be consulted before installation. 1 - Assembled HP29 outdoor unit 1 - Coupling, 5/16 x 3/8" (018, 024, 030) Check equipment for shipping damage. If you find any damage, immediately contact the last carrier. A WARNING a,WARNING IMPORTANT 06/04 IIIHIIIIIIIIIIIHIIII]IIII]IIIIIIII 504,829M Page 1 IIIllllll]lllllllllllll]llll]llll]lllll inlet,_air 4-3/8 (111) optional unit inlet inlet © © air _ stand-off kit (4) (field-installed) coil drain outlets _lm (around perimeter of base) • air 6-3/8 (162) vapor line connection liquid line connection inlet"_air Top View ql -m Top View Base Section °i C AIR T' B outdoor coil fan c compressor A vapor & liquidline connecti I electrical inlets 2-3/4 (70) Side View optional unit J stand-off kit (4) (field-installed) (19) Model No. HP29-018 HP29-024 HP29-030 HP29-036 HP29-042 HP29-048 Side View 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 in. 37-1/4 36-1/2 28-1/4 mm 946 921 718 HP29-060 Page 2 ; 4 - When installed in areas where low ambient temperatures exist, locate unit so winter prevailing winds do not blow directly into outdoor coil. -&CAUTION 5 - Locate unit away from overhanging roof lines which would allow water or ice to drop on, or in front of, coil or into unit. ACAUTION Slab Mounting These units operate under a wide range of weather conditions; therefore, several factors must be considered when positioning the outdoor unit. The unit must be positioned to give adequate clearances for sufficient airflow and servicing. A minimum clearance of 36 in. (914 mm) between multiple units must be maintained. Refer to figure 1 for installation clearances. - Figure 2 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). This will prevent ice build-up under the unit during a defrost cycle. Refer to roof mounting section for barrier construction if unit must face prevailing winter winds. Slab Mounting structure Installation At Ground Level d isch_g e air Clearances L.L_ L] Mounting slab must slope away from building, Figure *NOTE - A service clearance of 30" (762 mm) must be maintained on one of the sides adjacent to the control box. Clear- Roof Mounting 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 - 48" (1219 mm) clearance required on top of unit. Maximum soffit overhang is 36" (914 mm). _ _ _ 2 - Figure 3 Install the unit a minimum d 6 inches (152 mm) above the roof surface to avoid ice build-up around the unit. Locate the unit above a load bearing wall or area of the roof that can adequately support the unit. Consult local codes for rooftop applications. NO TE - A clearance of 24" (610 mm) must be maintained between two units. Figure ground level 1 Rooftop Application Wind Barrier Construction Place a sound-absorbing material, such as Isomode, under the unit if it will be installed in a location or position that will transmit sound or vibration to the living area or adjacent buildings. Install the unit high enough above the ground or roof to allow adequate drainage of defrost water and prevent ice build-up. In heavy snow areas, do not locate the unit where drifting will occur. The unit base should be elevated above the depth of average snows. NOTE- Elevation of the unit may be accomplished by constructing a frame using suitable materials. Ira support frame is constructed, it must not block drain holes in unit base. Page 3 I prevailing_ter winds wind barrier inlet air inlet air I inlet air 0 0 inlet air Figure 3 If unitcoilcannotbemountedawayfromprevailing winter winds,awindbarriershouldbeconstructed. Sizebarrierat leastthesameheightandwidthasoutdoorunit.Mountbarrier24inches(610mm)fromthesidesoftheunitinthedirectionof prevailing winds. IntheU.S.A., wiringmustconform withcurrentlocalcodes andthe currentNational ElectricCode(NEC).In Canada, wiringmustconform withcurrentlocalcodesandthecurrent Canadian Electrical Code(CEC). Refertothefurnaceor blowercoilinstallation instructions foradditional wiringapplication diagramsandrefertounit nameplatefor minimumcircuitampacityand maximum overcurrent protectionsize. 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 condu# to the control box us ing a proper conduit fitting. NO TE - Units are approved conductors. for use only with copper 24V, Class It circuit connections are made in the low voltage junction box, Refer to figure 4 for field wiring diagram, NQ TE - A complete unit wiring diagram is located in side the unit control box cover. 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 A WARNING by sunlight, drafts or vibrations, 4 - Install voltage wiring from outdoor to indoor unit and from thermostat to indoor unit, See figures 5 and 6, Typical Wiring 0U]OOOR Field Wiring START CAPACITOR Diagram DUAL CAPACITOR DEFROST CONTROL FAN P( RPLE BLACK ORANGE RED C BLACK YI OUT C_ PS2 _ COMPRESSOR RC>_._ W} 0 I0. PSI ........ OF CRANKCASE HEATER _0 OUT A DEFROS1 THERMOSTAT' REVERSING VALVE 208-250/60/} EOUIPMENT GROUND 7 Figure 4 Page 4 Table 1 Outdoor Unit and Blower Unit Thermostat Designations (Some connections Refrigerant may not apply. Valve Refer to specific thermostat and indoor unit.) Model Thermostat Indoor Unit Outdoor Unit f_ F_ power ®4 common common 1st. staqe aux. ileal 1st. stage aux. heat Recommended 4_ Line Set Connections Liquid Line Vapor Line Liquid Line Vapor Line L15 Line Sets 3/8 in (10 mm) 5/8 in (16 mm) 5/16 in (8mm) 5/8 in (16 mm) L15-21 15 ft.- 50 ft. (4.6 m- 15 m) L15-31 15ft.- 50 ft. (4.6 m- 15 m) -®1 power cCcC -018 Field Size Line Sets -024 3/8 in 3/4 in 5/16 in 3/4 in -030 (10 mm) (19 mm) (8 ram) (19 ram) 3/8 in 3/4 in 3/8 in 3/4 in -036 (10 ram) (19 ram) (10 ram) (19 ram) -042 -048 3/8 in (10ram) 7/8 in (22ram) 3/8 in (10ram) 7/8 in (22ram) -060 3/8 in (10 mm) 1-1/8 in (29 mm) 3/8 in (10 mm) 1-1/8 in (29 mm) L15-41 15ff.- 50ff (4.6 m- 15 m) indoor blower reversing valve @÷ _.J compressor @1 _J (4.6 m- 15 m) Field Fabricated NOTE - Units are designed for line sets of up to 50 feet (15 m). For appfications longer than 50 feet consult the Len- Figure 5 nox Refrigerant Piping Guide (Corp. 9351-L9). Select line set diameters from table 1 to ensure that oil returns to the Outdoor Unit and Blower Unit Thermostat Designations (with auxiliary heat) (Some connections L15-65 15ft.-50ft compressor. Installing Refrigerant Line may not apply. Refer to specific thermostat and indoor unit.) During the installation of any heat pump or a/c system, it is Indoor Unit Thermostat (_ (_ power _ : __ I_ common power_ 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. he emergency I I 1st. stage Outdoor Unit @1 '22 stat "_-si%t_ _. _t aux. TTeaq- - Following are some points to consider when placing and installing a high-efficiency outdoor unit: @1 ®1 indoor blower 1-Placement reversinq_vatve @1 compressor @l Figure - 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 6 window, Glass has a very high level of sound transmission. 2- Line Set Isolation Field refrigerant piping consists of liquid and vapor lines from the outdoor unit (sweat connections) to the indoor coil (flare or sweat connections). Use Lennox L15 (sweat, nonflare) series line sets as shown in table 1 or use field-fabricated refrigerant lines. Refer to Refrigerant Piping Guide (Corp. 9351-L9) for proper size, type, and application of field-fabricated lines. Valve sizes are also listed in table 1. Page 5 - The following illustrations demon- strate procedures which ensure proper refrigerant line set isolation. Figure 7 shows how to install line sets on vertical runs. Figure 8 shows how to install line sets on horizontal runs, Figure 9 shows how to make a transition from horizontal to vertical, Finally, figure 10 shows how to place the outdoor unit and line set, Refrigerant Line Sets How To Install Vertical Runs (new construction shown) NOTE - Similar installation practices should be used if fine set is to be installed on exterior of outside wall. IMPORTANT- Refrigerant lines must not contact wall. Outside Wall \ i r Vapor Line Liquid Line Wood Block Between Studs Wire Tie "_ Inside Wall '- Strap _ Liquid Lin_ Vapor Line (wrapped with Sleeve f m \ Wire Tie m 2------- Outside Wall _ Wood Block Wire Tie Strap Caulk PVC Pipe L \ _ Fiberglass Insulation IMPORTANT - Refrigerant lines must not contact structure, i j Figure 7 Page 6 Sleeve 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 I I .J ,f Floor Joist or Roof Rafter p --, / Tape or Wire Tie / 8 feet Strapping Material (around vapor line only) Metal Sleeve \ Tape or Wire Tie _, Floor Joist or Roof Rafter / jr Strap the vapor line to the joist or rafter at 8 ft. intervals then strap the liquid line to the vapor line. Figure 8 Page 7 ) Refrigerant Line Sets: Transition From Vertical To Horizontal Automotive Muffler-Type Hanger AnchoredHeavy NylonWireTie Wall Stud Wall Stud Strap Liquid Line To Vapor Line Strap Liquid Line To Vapor Line Liquid Line Metal Sleeve Vapor Line Wrapped in Armaflex Liquid Line Figure 9 Outside Unit Placement and Installation Install unit away from windows, Figure 10 Page 8 Metal Sleeve Vapor Line Wrapped in Armaflex 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 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 HCFC22 refrigerant, Wrap a wet cloth around the valve body and the copper tube stub, 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, NQ TE - The tube end must stay bottomed in the fitting during final assembly to ensure proper seating, sealing and rigidity. 5- Install a field-provided thermal expansion valve (approved for use with HCFC22 refrigerant) in the liquid line at the indoor coil, These units are used in check expansion valve systems only, See the Lennox Engineering Handbook for approved TXV match-ups and application information, Check expansion valves equipped with either Chatleff or flare-type fittings are available from Lennox, Refer to the Page 9 Engineering Handbook for applicable expansion valves for use with specific match-ups, IMPORTANT See figure 11 for installation of the check expansion valve. Metering Device Installation distributor o\ o-ring expansmn valve o-ring strainer liquid line stub Figure 11 When checking the unit charge, use a manifold gauge set that is equipped with "low loss" hoses. Do not use a manifold gauge set with anything other than a "low loss" hose, See figure 12 for manifold gauge connections, HP29 Manifold Gauge Connections (Cooling Cycle) Outdoor Unit defrost thermostat "--_._ I I expansion/check _1 bif, ow valve _€/ high pressure coil / mu._ 0:[t ga ,ge_anifold compressor limit J_ l E|[ _i % -" j,_ -r_L_ 'fI I'J= 0, a_ II ;" I1_ ._\ outdoor interna, r filter/drier low pressure reversing valve h,_l Indoor Unit _1 'vaor II %or service port line "-1 _ I t _ _ valve H Ci2_-_2t/ 'iqsid'rl _ I--"_ compressor k _ _ v expansion/check NO TE - Arrows indicate direction of refrigerant valve flow. Figure Table 2 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 I L coil I J 12 A IMPORTANT The liquid line and vapor line service valves (figures 13 and 14) and gauge ports are used for leak testing, evacuating, charging and checking charge. See table 2 for torque requirements. Each valve is equipped with a service port which has a factory-installed Schrader valve. A service port cap protects the Schrader valve from contamination and serves as the primary leak seal. Y 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 an additional 1/6 turn, To Open Liquid or Vapor Line 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 stem cap. Tighten finger tight, then tighten an additional 1/6 turn, Page 10 The ball valve is equipped with a service port with a factory- Liquid Service Valve (Valve Closed) installed Schrader valve. A service port cap protects the m cap SepV_te and assures a leak- free seal. Vapor Line (Ball Type) Service Valve (Valve Open) insert hex wrench here to outdoor coil Schrader valve from contamination service To open: rotate stem counter-clockwise 90% To close: use adjustable wrench and rotate stem clockwise 90% port cap ervice port Lo indoor coil Schrader valve open to line set when valve is closed (front seated) insert hex wrench here service port stem cap ste m service port \ field side to outdoor coil ball (shown open) Figure service port cap unit side SCharlavde r/_ (valve front seated) Liquid Service Valve (Valve Open) cap to indoor coil stem cap 14 After the line set has been connected to the indoor and Schrader valve outdoor units, check the line set connections and indoor Figure unit for leaks, 13 -&WARNING ,WARNING To Close Liquid or Vapor Line Service Valve: 1 - Remove 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 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. Vapor Line (Bali-Type) Service Valve - 5-Ton Units Vapor line service valves function the same way as the other valves, the difference is in the construction. These valves are not rebuildable. If a valve has failed, you must replace it. A ball valve valve is illustrated in figure 14. Page 11 AWARNING -&WARNING IMPORTANT 1 - Connect the 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. ,WARNING 3 - Connect the vacuum pump (with vacuum gauge) to the center port of the manifold gauge set, Using an Electronic Leak Detector or Halide 1 - Connect a cylinder of HCFC-22 to the center port of the manifold gauge set. 2 - With both manifold valves closed, open the valve on the HCFC-22 cylinder (vapor only). 3 - Open the high pressure side of the manifold to allow the HCFC-22 into the line set and indoor unit, Weigh in a trace amount of HCFC-22, [A trace amount is a maximum of 2 ounces (57 g) or 3 pounds (31 kPa) pressure,] Close the valve on the HCFC-22 cylinder and the valve on the high pressure side of the manifold gauge set. Disconnect the HCFC-22 cylinder, 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.) 4-Open both manifold valves and start the vacuum pump. 5 - Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29,01 inches of mercury). During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once to determine if there is a rapid rise in absolute pressure. A rapid rise in pressure indicates a relatively large leak, If this occurs, repeat the leak testing procedure. 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. A CAUTION 6 - Adjust the nitrogen pressure to 150 psig (1034 kPa), Open the valve on the high side of the manifold gauge set which will pressurize line set and indoor unit, 7 - After a 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 HCFC-22 mixture, Correct any leaks and recheck, Evacuating the system of noncondensables is critical for proper operation of the unit. Noncondensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system. Noncondensables and water vapor combine with refrigerant to produce substances that corrode copper piping and compressor parts. Page 12 _ 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. _ 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- Whenthe absolutepressurerequirement abovehas beenmet,disconnect themanifold hosefromthevacuum pumpand connectit to an uprightcylinderof HCFC-22 refrigerant. Openthemanifold gaugevalves tobreakthevacuum from1to2psigpositive pressure in the line set and indoorunit, Closemanifoldgauge valvesandshutoffthe HCFC-22 cylinderandremove themanifoldgaugeset, backward operation will cause the compressor to cycle on internal protector. The unit is factory charged with the amount of HCFC-22 refrigerant indicated on the unit rating plate, This charge is based on a matching indoor coil and outdoor coil with a 15 foot (4,6 m) line set. For varying lengths of line set, refer to table 3 for refrigerant charge adjustment, Table IMPORTANT 3 Liquid Line Set Diameter Oz. per 5 ft. (g per 1.5 m) adjust from 15 ft. (4.6 m) line set* 5/16 in, (8 mm) 2 ounce per 5 ft, (57 g per 1,5 m) 3/8 in, (9,5mm) 3 ounce per S ft, (85 g per1,S m) *If line length is greater than 15 ft. (4.6 m), add this amount. If line length is less than 15 ft. (4.6 m), subtract this amount. Cooling Start-Up 1 - Rotate fan to check for frozen bearings or binding. 2 - Inspect all factory- and field-installed connections. wiring for loose 3 - After evacuation is complete, open the liquid line and vapor line service valves (counterclockwise) to release refrigerant charge (contained in outdoor unit) into the system, 4 - Replace stem caps and secure finger tight, then tighten an additional (1/6) one-sixth of a turn, 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 determined by the unit's refrigerant metering device and the 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 fiquid valve service port 5 - Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit nameplate. If not, do not start the equipment until the power company has been consulted and the voltage condition has been corrected. Close manifold gauge set valves. Connect the center manifold hose to an upright cylinder of HCFC-22. 2 - Set the room thermostat to call for heat. This will create 6 - Set the thermostat for a cooling demand, turn on power to indoor blower unit and close the outdoor unit disconnect to start the unit. 3 - Use a digital thermometer to record the outdoor ambient temperature, 7 - Recheck voltage while the unit is running. Power must be within range shown on the nameplate, Three-Phase Compressor Rotation Three-phase scroll compressors must be phased sequentially to ensure correct compressor rotation and operation. At compressor start-up, a rise in discharge and drop in vapor pressures indicates proper compressor phasing and operation, If discharge and vapor pressures do not perform normally, follow the steps below to correctly phase the unit, the necessary load for properly charging the system in the cooling cycle. 4 - When the heating demand has been satisfied, switch the thermostat to cooling mode with a set point of 68 ° F (20_%). 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, Weighing in the Charge Outdoor TXV Systems - Temp < 65°F (18°C) 1 - Disconnect power to the unit, If the system is void of refrigerant, or if the outdoor ambient 2 - Reverse any two field power leads to the unit, temperature is cool, the refrigerant charge should be weighed into the unit, Do this after any leaks have been repaired. 3 - Reapply power to the unit. Discharge and vapor pressures should operate within their normal start-up ranges, NOTE - Compressor noise level may be significantly higher when phasing is incorrect and the unit will not provide cooling when compressor is operating backwards. Continued Page 13 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 facilitiesarenotavailable or ifyouarecharging theunitduringwarmweather, followoneoftheotherproceduresoutlinedbelow. Subcooling Outdoor Method Temp. < 65°F (18°C) When the outdoor ambient temperature is below 65°F (18°C), use the subcooling method to charge the unit, It may be necessary to restrict the air flow through the outdoor coil to achieve pressures in the 200-250 psig (1379-1724 kPa) range, These higher pressures are necessary for checking the charge. Block equal sections of air intake panels and move obstructions sideways until the liquid pressure is in the 200-250 psig (1379-1724 kPa) range. See figure 15. Blocking Outdoor Coil Outdoor coil should be blocked one side at a time with cardboard or plastic sheet until proper testing pressures Using Normal 15 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, Outdoor Temp. _>65°F (18°C) 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 6, "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. Method 4 - Use the same digital thermometer used to check outdoor ambient temperature to check liquid line temperature. Verify the unit charge using the approach method. 5 - The difference between the ambient and liquid temperatures should match values given in table 5. If the values don't agree with the those in table 5, add refrigerant to lower the approach temperature or recover refrigerant from the system to increase the approach temperature. Table Approach Model 4 - Subtract the liquid line temperature from the saturation 5 Values Liquid Temp. Minus Ambient Temp. _F (_C) temperature (according to the chart) to determine sub- HP29-018 HP29-024 cooling. (Saturation temperature perature = Subcooling) HP29-030 8 (4.5) HP29-036 13 (7.2) 5 - Compare the subcooling value with those in table 4. If HP29-042 13 (7.2) subcooling is greater than shown, recover some refrig- HP29-048 15 (8.3) HP29-060 8 (4.5) - Liquid line tem- erant, If subcooling is less than shown, add some refrigerant, 10 (5,6) 13 (7,2) NOTE - For best results, the same thermometer should be used to check both outdoor ambient and liquid temperatures. Table 4 Subcooling Model No. Pressures Method 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, 3 - Use a temperature/pressure chart for HCFC-22 to determine the saturation temperature for the liquid line pressure reading. Operating and the Approach Approach are reached. cardboard or plastic sheet Figure Charging Values Subcooling A IMPORTANT Temperature HP29-018 8 (4.5) HP29-024 HP29-030 HP29-036 4 (2.2) 11 (6.1) 10 (5.6) HP29-042 HP29-048 HP29-060 12 (6.7) 7 (3.9) 10 (5.6) Page 14 Table 6 Normal Operating Pressures Outdoor Coil Air Entering Te m p. " F (°C) liq. +10 psig suc. +5 psig liq. +10 psig suc. +5 psig liq. +10 psig suc. +5 psig liq. +10 psig suc. +5 psig liq. +10 psig suc. +5 psig liq. +10 psig suc. +5 psig liq. +10 psig suc. +5 psig Cooling 75 (24) 85 (29) 95 (35) 171 200 230 74 76 78 182 210 241 72 74 75 184 214 246 71 72 74 184 215 249 74 75 76 180 205 245 71 74 75 180 210 240 70 70 71 183 214 248 72 73 75 Heating 105 20 30 40 (41) (-7) (-1) (4) 263 166 177 188 81 33 42 51 275 170 184 194 78 28 36 42 282 186 198 210 45 28 36 43 285 170 180 230 76 27 38 50 280 180 190 195 76 30 40 47 280 175 185 195 72 25 35 43 285 186 200 212 77 25 32 42 50 (10) 200 61 212 56 218 53 240 55 205 54 206 52 224 50 Mode HP29-018 HP29-024 HP29-030 HP29-036 HP29-042 HP29-048 HP29_060 The unit is equipped with a bifiow filter drier. See figure 12. If replacement is necessary, order another of like design. shutdown, but it should also be used following a power outage if power h_ h_ e,_ ....... an h...... ,4 _h.... _,4_, temperature is below 50°F (10°C). System should be left in the emergency heat mode at least six hours to allow the crankcase heater sufficient time to prevent compressor slugging. Crankcase Compressor Filter Drier Heater Start Kit All units have internal start components and do not require field installation of a compressor start kit. IMPORTANT The HP29 defrost system includes two components: a defrost thermostat and a defrost control. Defrost Thermostat cating light). The thermostat is not included with the unit and must be purchased separately. The defrost thermostat is located on the liquid line between the check/expansion valve and the distributor. When defrost thermostat senses 42°F (5.5°C) or cooler, the thermostat contacts close and send a signal to the defrost control board to start the defrost timing. It also terminates defrost when the liquid line warms up to 70°F (21°C). Emergency Defrost Thermostat Operation Some unit thermostats incorporate isolating contacts and an emergency heat function (which includes an amber indi- Heat Function An emergency heat function is designed into some room thermostats. This feature is applicable when isolation of the outdoor unit is required, or when auxiliary electric heat is staged by outdoor thermostats. When the room thermostat is placed in the emergency heat position, the outdoor unit control circuit is isolated from power and field-provided relays bypass the outdoor thermostats. An amber indicating light simultaneously comes on to remind the homeowner that he is operating in the emergency heat mode. Emergency heat is usually used during an outdoor unit Page 15 Control The defrost control board includes the combined functions of a time/temperature defrost control, defrost relay, diagnostic LEDs and terminal strip for field wiring connections. See figure 16. The control provides automatic switching from normal heating operation to defrost mode and back. During compressor cycle (call for defrost), the control accumulates compressor run times at 30, 60, or 90 minute field-adjustable intervals. If the defrost thermostat is closed when the selected compressor run time interval ends, the defrost relay is energized and defrost begins. HP29 Defrost Standard SERVICE (Remove factory= installed jumper OTST • 0 AMBIENT THERMISTOR TERMINALS HOT %? °'At °ST'C DIAGNOSTIC LEDs / 24V TERMINAL STRIP op$ og OR o0 Pressure LIGHT TERMINALS t DEFROST INTERVAL TIMING PINS PINS I o,, 24V TERMINAL OR STRIP _T O 0 Figure Timing ° PRESSURE SWITCH TERMINALS DEFROST INTERVAL High Control FAN ,.P=js _ O_ Defrost Units to install pressure switch.) oTIMING Switch i 0 PRESSURE SWITCH SAFETY CIRCUIT CONNECTIONS CONNECTION FOR OPTIONAL HIGH PRESSURE SWITCH Optional 0 HIGH NOTE - Remove factoryinstalled jumper to add pressure switch. Board Units FAN 0 Control oY, I'''''"3 0 16 that allows the application of an optional high pressure Pins Each timing pin selection provides a different accumulated compressor run time period during one thermostat run cycle. This time period must occur before a defrost cycle is initiated. The defrost interval can be adjusted to 30 (T1), 60 (T2), or 90 (T3) minutes, See figure 16, The defrost timing jumper is factory-installed to provide a 60-minute defrost interval, If the timing selector jumper is not in place, the control defaults to a 90-minute defrost interval, The maximum defrost period is 14 minutes and cannot be adjusted, A TEST option is provided for troubleshooting, The TEST mode may be started any time the unit is in the heating mode and the defrost thermostat is closed or jumpered. If the jumper is in the TEST position at power-up, the control will ignore the test pins. When the jumper is placed across the TEST pins for two seconds, the control will enter the defrost mode. If the jumper is removed before an additional 5-second period has elapsed (7 seconds total), the unit will remain in defrost mode until the defrost thermostat switch. See figure 16. During a demand cycle, the defrost control will lock out the unit if the optional high pressure switch opens. The diagnostic LEDs will display a pattern for an open high pressure switch. See table 7. The unit will remain locked out until the switch resets or is reset. Remove the factory-installed jumper before connecting the optional high pressure switch to the control board. NOTE - If not using a pressure switch, the factory-installed jumper wire must be connected. Diagnostic LEDs The defrost board uses two LEDs for diagnostics. The LEDs flash a specific sequence according to the condition. Table 7 Defrost Control Board Diagnostic LED Mode LED 1 LED 2 Normal operation / power to board Synchronized Flash with LED 2 Synchronized Frash with LED 1 opens or 14 minutes have passed. If the jumper is not removed until after the additional 5-second period has elapsed, the defrost will terminate and the test option will not function again until the jumper is removed and re-applied. Board failure or no power Off Off Board failure On On High pressure switch open Flash On Low pressure switch open* On Flash Pressure switch lockout* On Off Pressure Anti-short-cycle / 5-minute delay* Alternating Flash with LED 2 Alternating Flash with LED 1 Switch Circuit The defrost control incorporates a pressure switch circuit Page 16 *Optional units only. Outdoor Optionalunitsareequipped witha defrostcontrolwhichincludesa timed-off delayandtwopressure switchcircuits. A highpressureswitchis factory-installed andconnected. The boardwill accommodate an optionallowpressure switchor lossof chargeswitch. Time-Delay Relay The time delay is five minutes long. The delay feature protects the compressor in cased of an interruption in power to the unit. The time delay may be bypassed by placing the temperature select jumper across the TEST pins for 0,5 seconds. Pressure Switch Circuit The defrost control board used in optional units includes a three-strike lock-out feature and LOPS terminals to accommodate the addition of a field-provided low pressure or loss of charge pressure switch, See figure 16. During a single demand cycle, the defrost control will lock out the unit after the third time that the circuit is interrupted by any pressure switch that is wired to the control board, In addition, the diagnostic LEDs will indicate a locked out pressure switch after the third occurrence of an open pressure switch, See table 7. The unit will remain locked out until power is broken then remade to the control or until the jumper is applied to the TEST pins for 0.5 seconds. NOTE - The defrost control board ignores input from the low pressure switch terminals during the TEST mode, during the defrost cycle, during a 90-second start-up period, and for the first 90 seconds each time the reversing valve switches heat/cool modes, If the TEST pins are jumpered and the 5-minute delay is being bypassed, the LO PS terminal signal is not ignored during the 90-second start-up period. Ambient Thermistor & Service Light Connection Optional units include a defrost control board which provides terminal connections for an ambient thermistor and a service light. The thermistor compensates for changes in ambient temperature which might cause thermostat droop. The service light thermostat provides a signal which activates the room thermostat service light during periods of inefficient operation, Unit 1 - Clean and inspect outdoor coil (may be flushed with a water hose). Ensure power is off before cleaning. 2 - Outdoor unit fan motor is prelubricated and sealed, No further lubrication is needed. 3 - Visually inspect all connecting lines, joints, and coils for evidence of oil leaks, 4 - Check all wiring for loose connections, 5 - Check for correct voltage at unit (unit operating), 6 - Check amp draw on outdoor fan motor. Unit nameplate Actual 7 - Inspect drain holes in coil compartment base and clean if necessary. NQ TE - If insufficient heating or cooling occurs, the unit should be gauged and refrigerant charge should be checked, Indoor Coil 1 - Clean coil if necessary. 2 - Check connecting lines, joints and coil for evidence of oil leaks, 3 - Check condensate line and clean if necessary, Indoor Unit 1 - Clean or change filters, 2 - Lennox blower motors are prelubricated and permanently sealed, No more lubrication is needed. 3 - 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. 4 - Belt Drive Blowers - Check belt for wear and proper tension, 5 - Check all wiring for loose connections, 6 - Check for correct voltage at unit, (blower operating) 7 - Check amp draw on blower motor. Motor nameplate Actual Refer to the Engineering Handbook for optional accessories that may apply to this unit, The following may or may Maintenance and service must be performed by a qualified installer or service agency. At the beginning of each cooling or heating season, the system should be checked as follows: -&WARNING Page 17 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 Low Ambient Kit Monitor Kit Start-up JobName and Performance Job No, Job Location Installer Check List State City State City Unit Model No, Date Serial No, Service Technician Nameplate Voltage Indoor Filter Clean? [] Electrical Connections Tight? [] Indoor Blower RPM Cooling Liquid Line Pressure Heating Liquid Line Pressure Refrigerant Lines: S,R Drop Over Indoor (Dry) Supply Voltage (Unit Off) __ -- Outdoor Coil Entering Air Temp. Vapor Pressure Refrigerant Charge Checked? Vapor Pressure Leak Checked? [] Service Valves Fully Opened? [] Sequence of Operation Heating Correct [] Outdoor Fan Compressor Rated Load Ampacity Maximum Fuse or Circuit Breaker Properly Insulated? Cooling Correct [] Refrigerant Charge Checked? [] Outdoor Fan Checked? [] [] Service Valve Caps Tight? [] Voltage With Compressor Operating -Thermostat Calibrated? Page 18 [] [] Properly Set? [] Level? []
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