LENNOX Air Conditioner/heat Pump(outside Unit) Manual L0806493
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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ZENNDX INSTALLATION INSTRUCTIONS ,1_2000 Lennox industries Inc. Dallas Texas, USA HP40 Heat Pump Units HEAT PUMP UNITS 1-1/2 through 5 ton 504,538M 06/04 Supersedes 11/02 HP40 heat pumps use R407C 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. HP40 heat pumps are designed for use in expansion valve systems only. They are not designed to be used in RFC systems. An expansion valve and filter drier approved for use with R407C have been shipped with the unit. These components must be installed prior to unit operation. ,IMPORTANT _-_ Technical '_LLZ2 ' Publications Litho U.S.A. HP40 Heat Pump Unit .......................... Shipping & Packing List ......................... General Information ............................ Unit Dimensions ............................... Setting the Unit ................................ Electrical ...................................... Plumbing ...................................... Refrigerant Metering Device ..................... Manifold Gauge Set ............................ Liquid & Vapor Line Service Valves ............... Leak Testing ................................... System Evacuation ............................. Start-Up ....................................... Charging Considerations ....................... System Operation ............................. Defrost System ............................... Maintenance .................................. 1 1 1 2 3 4 5 5 7 7 8 9 9 10 12 12 13 RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE 1 - Assembled HP40 heat pump unit 1 - Bag assembly: 1 - Sight glass 1 - Coupling reducer, 5/16 x 3/8 inch (024) Check unit for shipping damage. If any damage is found, contact the last carrier immediately. ,WARNING 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. The HP40 unit is "CE marked" in accordance with the requirements of the latest European Directives for Electrical and Machinery Safety and Electromagnetic Compatibility. In addition, HP40 units have type Approval Certification with the Gas Appliance Directive. IMPORTANT A, WARNING 06/04 IIIIIIllllllllllllBIIIIlfllIIIIIIIIlI Page 1 504,538M IIIIIIIIIllllllllllIIIIIIIIII INLETS7 HP40 AIR 111 111 iiii!,!ii!i!i;i!!i!ii i!!i iiii i iiiii OPT,ONAL INLET © (Field-installed STAND-OFF 4 required)KIT _T AIR AIR (Around perimeter of base) 162 _ INLET'_ 111 LIQUID LINE AIR CONNECTION TOP VIEW e_. C TOP VIEW =.=1 BASE _-_ v C DISCNARGE_ OUTDOOR SECTION AIR COIL FAN _i!!i!!i!!i!iiiiiiii COMPRESSOR_ i_iiiiiiiiiiiiiiiiiiiiiiiiiiiiiii A VAPOR & LIQUID LINE CONNECTION ELECTRICAL INLETS i!_i_ii!!!i'i_i!!i_,i!_i!!,i_!!_!i'i_i!i!!!i'i 7O 51 OPTIONAL STAND-OFF KIT 19 (Field-installedJ 4 required) SIDE VIEW Model Number SIDE VIEW A B C HP40-018 HP40-024 mm 635 616 616 HP40-036 HP40-048 mm 838 819 616 HP40-060 mm 946 927 718 Page 2 Slab Mounting Heatpumpunitsoperateundera widerangeofweather conditions;therefore,severalfactorsmustbe consideredwhenpositioning theoutdoorunit,Theunitmustbe positionedtogiveadequate clearances forsufficientairflowandservicing,Maintain a minimumclearance d 610 mm between multiple units. Refer to figure 1 for installation clearances. Installation Clearances (See figure 2) When the unit is installed 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 unit. Slab should have a slope tolerance away from the building d 2 degrees or 51 mm per 1,5 m. This will prevent ice from building 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 AT GROUND LEVEL STRUCTURE DISCHARGE / AIR 0 i/I/i//I/l,I/i, / / / / *NOTE - A service clearance of 30" (762 ram) must be mainrained on one of the sides adjacent to the control box. Clearanee to one of the other three GROUND LEVEL MOUNTING SLAB MUST SLOPE AWAY FROM BUILDING. sides must be 36" (914 ram). FIGURE 2 Clearance to one of the remainingtwo sides may be 12"(304 ram) and the finalside may be 6"(152 ram). Roof Mounting NO TE - A clearance of 24" (6! 0 mm) must be maintained between two units. (See figure 3) If you are unable to mount the unit coil away from prevailing winter winds, construct a wind barrier. Size the barrier NOTE - 48" (!2!9 mm) clearance required on top of unit. Maximum soffit overhang is 36" (914 mm). at least the same height and width as the outdoor unit. Mount the barrier 610 mm from the sides of the unit in the FIGURE 1 direction of prevailing winds. 1 - 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. 2 - Install the unit high enough above the ground or roof to allow adequate drainage of defrost water and pre- Install the unit at a minimum of 152 mm above the roof surface to keep ice from building 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, ROOFTOP APPLICATION WIND BARRIER CONSTRUCTION vent ice buildup. PREVAILING WINTER WINDS 3 - In areas that receive heavy snow, do not locate the unit where drifting will occur. Ensure that the unit base I WIND BARRIER I INLET AIR is elevated above the depth of average snows. 0 NOTE - Elevate the unit by constructing a frame using suitable materials. If a support frame is constructed, it must not block drain holes in the base of the unit. 4 - When you install the unit in areas where low ambient INLET AIR INLET AIR 0 0 temperatures exist, locate the unit so winter prevailing winds do not blow directly into outdoor coil. 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. Page 3 INLET AIR FIGURE 3 Wiringmustconform withcurrentlocalcodes.Anapplicationdiagram isincludedinthisinstruction andintheindoor unitinstructions. Refertotheunitratingplate,locatedonthecontrolboxcover,forminimum circuitampacity andmaximum fusesize. 1 - Providelinevoltagepowersupplyto theunitfroma properlysizeddisconnectswitch.The disconnect switchshouldbelocatedsothatitiseasilyaccessible andwithinsightoftheunit. 2 - Routethepowerandgroundwiresfromthedisconnectswitchtothe unit.Theelectricalopeningsare providedunderthecontrolboxcover.Seetheunitdi- mensionsillustration onpage2, 3 - Removethecontrolboxcoverandconnectthepower wiringtothecontactor. Connect groundwiretoground lug. 4- Installthe roomthermostat(orderedseparately)in theconditioned area,Placethe thermostat whereit willnotbeaffectedbysunlight,drafts,orvibration. Do notinstallthethermostat onanoutsidewall.Themost desirablepositionforthethermostat isnearthecenterof theconditioned areaandapproximately 1,5m fromthefloor, 5 - Route24VACcontrolwiresfromthethermostat tothe indoorunitandfromtheindoorunittothedefrostcontrolterminals intheoutdoorunitasshowninfigure4, FIELD WIRING DIAGRAM FOR HP4O UNIT TB1 TERMINAL (INDOOR UNIT CONTROL $1 THERMOSTAT BOX) m -.o_o_ __........ -I OGO • // A\ \ A STRIP -I .'20, I' I ,, . L--.I-----. L'L............ :: "...... "O '_'_O I _1 O_.-_-O . =inn A A A THERMOSTAT HEAT ANTICIPATION SETTING .4 AMP ELECTRIC HEAT FOR THERMOSTATS WITH ADJUSTABLE ANTICIPATORS. 8 -® @ © =,_ A _1 =1 IF OUTDOOR IS USED, REMOVE JUMPER THERMOSTAT BETWEEN TERMINALS "R" AND "W2." EMERGENCY HEAT RELAY (USED ONLY IF OUTDOOR THERMOSTAT IS USED) FIELD PROVIDED AND INSTALLED NEAR INDOOR UNIT 24VAC 5VA MAX NEC CLASS 2. -© .© L .I- _.1. I _-----.-!,., eRie OUTDOOR THERMOSTAT J _l _1 <7_1 21 _L_ _l _l t --I--'--,'- -Z I ___L_, t L...... LOW VOLTAGE FIELD INSTALLED NOTE-ALL REMAINING WIRES FACTORY INSTALLED _l 1 -- ..@ ..@ -@ FIGURE 4 Page 4 HP40 LOW VOLTAGE TERMINAL CONNECTIONS Fieldrefrigerantpipingconsistsofliquidandvaporlines fromthe heatpump(sweatconnections) to the indoor evaporator coil,UseLennoxL15(sweatconnection) serieslinesetsasshownintable1orusefield-fabricated refrigerantlines,Referto Refrigerant PipingGuide(Corp. 9351-L9)for propersize,type,andapplication of fieldfabricatedlines. If refrigerant tubesareroutedthrougha wall,sealandisolatethe openingso vibrationis nottransmittedto the building. AIMPORTANT NOTE - Line length should be no greater than 15,2 m, Select line set diameters from table I to ensure that the oil returns to the compressor. TABLE 1 REFRIGERANT LINE SET KITS HP40 UNIT LIQUID LINE SUCTION LINE L15 LINE SETS HP40-024 8 mm* 16 mm L15-21 4.6m- 15m HP40-036 10 mm 19 mm L15 -41 4.6m- 15m HP40-048 10 mm 22 mm L15 - 65 4.6m- 15m 29 mm FIELD FABRICATED HP40-060 10 mm _&CAUTION Required 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 with a pump down feature, and two sets of gauges (one or use with R22 and one for use with the R407C). *Use the coupling reducer that is supplied in the bag assembly. Sweat Connection Equipment Procedure 1 - The ends of refrigerant lines must be cut square, free from nicks or dents and deburred. The pipe must remain round, Do not pinch the end of the line. 2 - Wrap a wet cloth around the liquid line valve body and copper tube stub to protect them from heat damage during brazing, Wrap another wet cloth underneath the liquid valve to protect the base paint, 3 - Quench the joints with a wet cloth to prevent possible heat damage to the valve core and opening port, HP40 units are applicable to thermal expansion valve systems only. An expansion valve appropriate for use with R407C refrigerant is shipped with the outdoor unit, Flushing Procedure 1 - Remove existing R22 refrigerant using the appropriate procedure below. If the existing outdoor unit is not equipped with shutoff valves, or if the unit is not operational AND you plan to use the existing R22 refrigerant to flush the system -- Disconnect all power to the existing outdoor unit. Connect the existing unit, a clean recovery cylinder and the recovery machine according to the instructions provided with the recovery machine. Remove all R22 refrigerant from the existing system. Refer to gauges after shutdown to confirm that the entire system is completely void of refrigerant. Disconnect the liquid and vapor lines from the existing outdoor unit. If the existing outdoor unit is equipped with manual shut-off valves AND you plan to use NEW R22 refrigerant to flush the system -- Start the existing R22 system in the cooling mode and close the liquid line valve. Pump all of the existing R22 refrigerant back into the outdoor unit. (It may be necessary to bypass A IMPORTANT Page 5 thelowpressure switchestoensurecompleterefrigerantevacuation.) Whenlowsidesystempressures reach0 psig,closethesuctionlinevalve.Disconnect allpowertotheexistingoutdoorunit,Refertogauges aftershutdown to confirmthatthevalvesarenotallowingrefrigerant toflowbackintothelowsideofthe system.Disconnect the liquidandvaporlinesfrom theexistingoutdoorunit, 2- Removethe existingoutdoorunit, Set the new R407Cunitandfollowthebrazingconnection proceduretomakelinesetconnections. DONOTinstall providedR407Ccheck/expansionvalveat this time. Makelowvoltageandlinevoltageconnections tothe newoutdoorunit.DONOTturn on powerto the unit or open the outdoorunit servicevalvesat this time. 3 - Removetheexistingrefrigerant flowcontrolorificeor thermalexpansion/check valvebeforecontinuing withflushingprocedures.Theexistingdevicesare notapproved forusewithR407Crefrigerant andmay preventproperflushing,Usea field-provided fittingto reconnect thelines. 4 - Removethepressure tapvalvecoresfromtheHP32 unit'sservicevalves,Connectan R22cylinderwith cleanrefrigerantto thesuctionservicevalve,Connectthe R22gaugesettothe liquidlinevalveand connecta recovery machine withanemptyrecovery tankto thegaugeset, FLUSHING /_ A, IMPORTANT 5 Set the recovery machine for liquid recovery and - start the recovery valves to allow the recovery machine to pull a vacuum on the existing system line set and indoor coil, _ Invert the cylinder of clean R22 and open its valve to allow liquid refrigerant to flow into the system through the suction line valve. Allow the refrigerant to pass from the cylinder, through the line set and the indoor coil before entering the recovery machine, _ After all of the liquid refrigerant has been recovered, switch the recovery machine to vapor recovery so that all of the R22 vapor is recovered, All the recovery machine to pull a vacuum on the system, NOTE - A single system flush should remove all of the mineral oil from the existing refrigerant lines and indoor coil. A second flushing may be done (using clean refrigerant) if insufficient amounts of mineral oil were removed during the first flush. Each time the system machine is flushed, CONNECTIONS CYLINDER SU__ SERVICE SUCTION EXISTING LIQUID LINE _" L INDOOR COIL LIQUID SERVICE TANK INLET RETURN DISCHARGE RECOVERY CYLINDER on the system end of the procedure. HP40 UNIT EXISTING you must allow the recovery to pull a vacuum INVERTED R22 J EXISTING machine, Open the gauge set RECOVERY MACHINE FIGURE 5 Page 6 VALV ×LIN_t X LINE VALVE LOW PRESSURE HIGH PRESSURE at the HP4O COOLING CYCLE (SHOWING MANIFOLD GAUGE CONNECTIONS) OUTDOOR UNIT DISTRIBUTOR DEFROSTTHERMOSTAT_,___ I EXPANSION/CHECK VALVE I _ 1_ _I_1"_ I © F,LT R/DR,ER OUTDOOR FLOW LOW PRESSURE REVERSING _ ,-]/ HIGH PRESSURE VALVE ) '_, COMPRESSOR E - J INDOOR UNIT / &M,T CO,L ,NTERNAL GAUGE MANIFOLD i p SUCTION SERVICE TO R407C DRUM LIQUID LINE SERVICE PORT _ VAPOR POR .._ COMPRESSOR k r""- ':, _ _(_ EXPANSION/CHECK VALVE NOTE - ARROWS INDICATE DIRECTION OF REFRIGERANT FIGURE 6 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 INDOOR I COIL L ..... -I FLOW LIQUID AND VAPOR LINE SERVICE VALVES VALVE OPEN) INSERT HEX WRENCH STEM CAP lines and indoor coil before removing the recovery machine, gauges and R22 refrigerant drum. Reinstall pressure tap valve cores into HP32 service valves. 10-Install the provided check/expansion valve (ap- SERVICE PORT X TO OUTDOOR COIL proved for use with R407C refrigerant) in the liquid line at the indoor coil. Manifold gauge sets used with systems charged with R407C refrigerant must be able to accommodate higher system operating pressures. The gauges should be rated for pressures of 0-800 psi on the high side and a low side of 30" vacuum to 250 psi with dampened speed of 500 psi. Gauge hoses must be rated for use at up to 800 psi of pressure with a 4000 psi burst rating. ) INDOOR COIL SERVICE' PORT CAP SCHRADER VALVE (VALVE CLOSED) STEM CAP SERVICE INSERT HEX TO OUTDOOR COIL Access the liquid line and vapor line service valves (figures 7 and 8) and the gauge ports from inside the unit, behind access panel. The service ports are used for leak testing, evacuating, charging, and checking the charge. The valve is equipped with a service port, and a Schrader valve is factory installed. A service port cap is supplied to protect the Schrader valve from contamination and to serve as the primary leak seal. Page 7 SERVICE PORT CAP TO INDOOR COIL SCHRADER VALVE OPEN TO LINE SET WHEN VALVE IS CLOSED (FRONT SEATED) (VALVE FRONT SEATED) FIGURE 7 Vapor Line (Bali-Type) Service Valve - 5-Ton Units A ball-type full-service valve is used on five-ton units. These vapor line service valves function the same way, the differences are in construction. Valves are not rebuildable, Ifa valve has failed, it must be replaced, A ball valve is illustrated in figure 8. IMPORTANT Accessing the Schrader Port: 1 - Remove service port cap with an adjustable wrench, The ball valve is equipped with a service port and a factory-installed Schrader valve. A service port cap is supplied to protect the Schrader valve from contamination and to assure a leak-free seal, 2 - Connect gauge to the service port. 3- When testing is completed, replace the service port cap. Tighten finger tight, then tighten an additional 1/6 turn. To Open Liquid or Vapor Line Service After the line set has been connected to the indoor and outdoor units, check all connections for leaks, Valve: 1 - Remove the 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 possible. IMPORTANT &WARNING AkWARNING 3 - Replace the stem cap, Tighten finger tight, then tighten an additional 1/6 turn, To Close Liquid or Vapor Line 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 firmly. 3 - Replace the stem cap, Tighten finger tight, then tighten an additional 1/6 turn, VAPOR LINE (BALL-TYPE) SERVICE VALVE (VALVE OPEN) USE ADJUSTABLE WRENCH. ROTATE STEM CLOCKWISE 90" TO CLOSE. ROTATE STEM COUNTERCLOCKWISE 90" TO OPEN. TO OUTDOOR COIL @ 2- Connect the high pressure hose of the manifold gauge set to the service port of the vapor valve, (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.) 3 - With both manifold valves closed, open the valve on the R407C cylinder (liquid only), 4 - Open the high pressure side of the manifold to allow R407C into the line set and indoor unit. Weigh in a trace amount of R407C, (A trace amount is a maximum of 59 ml or 21 kPa pressure,) Close the valve on the R407C cylinder and the valve on the high pressure side of the manifold gauge set, Disconnect R407C cylinder and attach a nitrogen cylinder. STEM CAP STEM BALL SHOWN OPEN) TO INDOOR COIL SERVICE PORT CAP Using an Electronic Leak Detector 1 - Connect a cylinder of nitrogen with a pressure regulating valve to center port of manifold gauge set, 5 - Adjust nitrogen pressure to 1034 kPa. Open the valve on the high side of the manifold gauge set which will pressurize line set and indoor unit, 6 - After a short period of time, open a refrigerant port to make sure the refrigerant added is adequate to be detected. (Amounts of refrigerant will vary with line lengths.) Check all joints for leaks. Purge nitrogen and R407C mixture. Correct any leaks and recheck, SERVICE POF SCHRADER VALVE FIGURE 8 Page 8 gen cylinder with the pressure regulator set to 150 psig (1034 kPa) and purge the hose. Open the manifold gauge valves to break the vacuum in the system. Close the manifold gauge valves. -&WARNING -&WARNING Evacuating the system of non-condensables is critical for the unit to operate properly. Non-condensables are defined as any gas that will not condense under temperatures and pressures present during operation d an air conditioning system. Non-condensables and water vapor combine with refrigerant to produce substances that corrode copper piping and compressor parts. 1- Connect manifold gauge set to the service valve ports as follows: • low pressure gauge to suction line service valve • high pressure gauge to liquid line service valve IMPORTANT- Compliant scroll compressors (as with any refrigerant compressor) should never be used to evacuate a refrigeration or air conditioning system. NOTE - Use a temperature vacuum gauge, mercury vacuum, or thermocouple gauge. The usual Bourdon tube gauges are inaccurate in the vacuum range. 2 -The nitrogen holding charge in the unit must be released. Open both manifold valves to release the nitrogen from the unit. See the liquid and suction line service valves section for how to operate the service valves. 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 system. 8 -Reconnect the manifold gauge to the vacuum pump, turn the pump on and continue to evacuate the system until the absolute pressure does not rise above .5 mm (500 microns) of mercury within a 20-minute period after shutting off the vacuum pump and dosing the manifold gauge valves. 9 - When the absolute pressure requirement from step 9 has been met, disconnect the manifold gauge hose from the vacuum pump. Then, weigh in a LIQUID charge of R407C through the liquid and suction service valves. Refer to the unit nameplate for the correct liquid charge. If you can not measure in the total amount, refer to the start-up section and set the final system charge according to the charging instructions. The R407C refrigerant cylinder should be chocolate brown. 3 -Connect the vacuum pump (with vacuum gauge) to the center port of the manifold gauge set. 4-Open both manifold valves and start the vacuum pump. 5-Evacuate the line set, condensing unit, and indoor unit to an absolute pressure of 23 mm (23,000 microns) 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, the leak testing procedure must be repeated. 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 mm (23,000 microns) of mercury, close the manifold gauge valves, turn off the vacuum pump, and disconnect the manifold gauge center port hose from the vacuum pump. Attach the manifold center port hose to a nitro- Page 9 Cooling Start-Up 1 - Check the unit disconnect switch to make sure power is off. 2 - Rotate the fan to check for frozen bearings or binding. 3 - Inspect all factory and field-installed wiring for loose connections. 4- Replace the stem caps. Tighten finger tight, then tighten an additional 1/6 turn. 5 - Check the 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 you have consulted the power company, and the voltage condition has been corrected. 6 - Set the thermostat for cooling demand, turn on the power to the indoor blower coil, and close the heat pump unit disconnect switch to start the unit. _ Recheck the unit voltage while the unit is running. The power must be within the range shown on the unit nameplate, Check the amperage draw of the unit. Refer to the unit nameplate for approximate running amps, the liquid line pressure to a range of 1379 to 1724 kPa, To do this, block off the outdoor coil with cardboard or a plastic sheet, BLOCKING OUTDOOR COIL BE BLOCKED ONE SIDE AT A TIME WITH CARDBOARD OR PLASTIC SHEET UNTIL PROPER TESTING PRESSURES ARE REACHED. OUTDOOR COIL SHOULD Liquid charge the unit with the amount of R407C refrigerant that is indicated on the nameplate. CARDBOARD OR PLASTIC SHEET ,IMPORTANT FIGURE 9 1 - Remove the cap from the liquid line service valve stem and turn the stem clockwise 1/4 to 1/2 turn, This will open the service port, 2 - With the manifold gauge hose still on the liquid service port and the unit operating, read the liquid line pressure. This charge is based on a matching indoor coil and outdoor coil with a 4.6 m line set, For varying lengths of line set, refer to table 2 for refrigerant charge adjustment, TABLE 2 Liquid Line Set Diameter g per 1524 mm adjust from 4.6 m line set* 8 mm 57 g per 1524 mm 10 mm 85 g per 1524 mm *If line length is greater than 4.6 3 - If the pressure is too low, block the airflow through the outdoor coil until the liquid line pressure stabilizes in a range from 1379 to 1724 kPa, At that time, record the liquid line temperature and the liquid line pressure reading. 4 - Use a temperature/pressure chart for R407C to determine the saturation temperature for the liquid line pressure reading. add this amount. If line length is less than 4.6 m, subtract this amounL Charging Using the Subcooling Method If the outdoor ambient temperature is below 13 _C, airflow over the outdoor coil will need to be reduced to drive up 5 - Subtract the liquid line temperature from the saturation temperature (according to the chart) to determine subcooling. (Saturation temperature - Liquid line temperature = Subcooling.) Subcooling should be between 4.4-5.5°C. If subcooling is greater than 4.4 - 5.5°C, recover some refrigerant. Ifsubcooling is less than 4,4 - 5,5°C, add some refrigerant, Page 10 TABLE 3 R407C Saturated Liquid Temperature and Pressure Chart Use this chart for subcooling only, not superheat. Saturated Liquid Temperature °C Liquid Line Pressure Liquid Line Pressure Saturated Liquid Temperature °C 15 16 16 17 17 18 18 19 2O 2O 21 21 22 22 23 23 24 25 25 26 26 27 27 28 28 29 30 30 31 31 32 32 33 33 34 35 35 36 36 37 37 38 38 39 40 40 41 41 42 42 43 43 44 45 45 46 47 47 47 48 48 51 54 57 Page 11 Filter Drier Theunitisequipped witha bifiowfilterdrier.Seefigure6. If the filter needsto be replaced,orderanotherof the samedesign. Thermostat Operation Someheatpumpthermostats incorporate isolatingcontactsandanemergency heatfunction(whichincludes an amberindicatinglight).Thethermostatis not included withtheunitandmustbepurchased separately. Emergency Heat Function Somethermostatshavean emergencyheatfunction. Thisfeatureis applicable onlytothosesystems thathave auxiliaryelectricheatstagedby outdoorthermostats. Whenthe thermostatis placedin the emergencyheat position,the outdoorunitcontrolcircuitis isolatedfrom thepowersource,andfield-provided relaysbypassthe outdoorthermostats. An amberindicatinglightsimultaneouslycomesontoremindthehomeowner thattheunit is operating in theemergency heatmode. Emergency heatis usuallyusedduringa heatpumpshutdown.However, emergency heatshouldalsobeusedfollowinga poweroutageifthepowerhasbeenoffforover anhour,andtheoutdoortemperature is below10_C.The systemshouldbeleftintheemergency heatmodeforat leastsix hoursto allowthe crankcaseheatersufficient timetopreventcompressor fromslugging. TheHP40defrostsystemincludes twocomponents: adefrostthermostat anda defrostcontrol. Defrost Thermostat Thedefrostthermostatis locatedon the liquidlinebetweenthe check/expansion valveand the distributor, Whendefrostthermostat senses5,5°Corcooler,thethermostatcontactscloseandsenda signalto the defrost controlboardtostartthedefrosttiming,Italsoterminates defrostwhentheliquidlinewarmsupto21°C. Defrost Control Thedefrostcontrolboardincludesthecombinedfunctionsofa time/temperature defrostcontrol,defrostrelay, diagnosticLEDsandterminalstripfor fieldwiringconnections.Seefigure10, The controlprovidesautomaticswitchingfromnormal heatingoperation todefrostmodeandback.Duringcompressorcycle(callfor defrost),the controlaccumulates compressor runtimesat30,60,or 90minutefield-adjustableintervals. If thedefrostthermostat isclosedwhenthe selectedcompressor runtimeintervalends,the defrost relayisenergizedanddefrostbegins, HP40DEFROSTCONTROLBOARD FAH HIGH PRESSURE SWITCH SAFETY CIRCUIT CONNECTIONS NOTE - Remove factoryinstalled jumper to add pressure switch. DEFROST O _ O TIMING INTERVAp_N_ _ CONNECTION FOR OPTIONAL HIGH PRESSURE SWITCH High Pressure Switch oTST DIAGNOSTIC LEDs \ o.ou=, 24V TERMINAL STRIP oC oR O o0 oY_ Hot [_ FIGURE 10 Page 12 ECCC3 O Defrost Control Timing 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 10. 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 powerup, 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 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, Pressure Switch Circuit The defrost control incorporates a pressure switch circuit that allows the application of an optional high pressure switch, See figure 10, 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 3, 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 factoryinstalled 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 3 DEFROST CONTROL At the beginning of each heating or cooling season, check the system as follows: Heat Pump Unit 1 - Clean and inspect the outdoor coil, You may flush the coil with a water hose, Make sure the power is off before you clean the coil. 2- The outdoor unit fan motor is pre-lubricated and sealed, The fan motor requires no more lubrication, 3 - 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 the unit while the unit is operating. 6 - Check amp draw on the heat pump fan motor. Unit nameplate Actual 7 - Inspect the drain holes in the coil compartment base and clean them if necessary, NOTE - If insufficient heating or cooling occurs, gauge the unit and check the refrigerant charge. Indoor Coil 1 - If necessary, clean the coil. 2 - Inspect the connecting lines, joints, and coil for evidence of oil leaks, 4 - Check all wiring for loose connections, 5 - Check for correct voltage at the unit. 6 - Check the amp draw on the blower motor. Motor nameplate Actual 3 - Check the condensate line and clean it if necessary, Indoor Unit 1 - Clean or change the filters, BOARD DIAGNOSTIC MODE _WARNING LED 1 LED LED 2 Normal operation / power to board Synchronized Flash with LED 2 Synchronized Flash with LED 1 Board failure or no power Off Off Board failure On On Hiqh pressure switch open Flash On 2- Lennox blower motors are pre-lubricated and permanently sealed, The blower motor requires no more lubrication, 3- Adjust the blower speed for cooling. Measure the pressure drop over the coil to determine the correct blower m3/s, Page 13 JobName JobNo. Date JobLocation City State Installer City State UnitModelNo, Nameplate Voltage MinimumCircuitAmpacity SerialNo. ServiceTechnician Amps: Supply MaximumOvercurrent Protection Size OutdoorFan Compressor ElectricalConnections Tight?[] IndoorFilterClean?[] SupplyVoltage(UnitOff) IndoorBlowerRPM COOLING SECTION S.RDropOverEvaporator (Dry) Refrigerant Lines: LeakChecked?[] OutdoorCoilEnteringAir Temperature ProperlyInsulated? [] Refrigerant ChargeChecked? [] Discharge Pressure SuctionPressure OutdoorFanChecked? [] ServiceValveCapsTight? [] THERMOSTAT ServiceValvesFullyOpened? [] Calibrated? [] ProperlySet?[] VoltageWithCompressor Operating Level?[] Page14 Page15 LENNOX Lennox Industries RO. Box 174, Westgate Interchange, Northampton NN5 5AG Telephone: 01604 591159 Facsimile: 01604 587536 Page 16
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