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

,1_2000 Lennox industries Inc.

Dallas Texas, USA

HP40 heat pumps use R407C which is an ozone friendly

HFC refrigerant. This unit must be installed with a match-

ing indoor coil and line set as outlined in the Lennox Engi-

neering Handbook. HP40 heat pumps are designed for

use in expansion valve systems only. They are not de-

signed 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

INSTALLATION

INSTRUCTIONS

HP40 Heat Pump Units

HEAT PUMP UNITS

1-1/2 through 5 ton

504,538M _-_ Technical

06/04 ''_LLZ2Publications

Supersedes 11/02 Litho U.S.A.

HP40 Heat Pump Unit .......................... 1

Shipping & Packing List ......................... 1

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

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

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

Electrical ...................................... 4

Plumbing ...................................... 5

Refrigerant Metering Device ..................... 5

Manifold Gauge Set ............................ 7

Liquid & Vapor Line Service Valves ............... 7

Leak Testing ................................... 8

System Evacuation ............................. 9

Start-Up ....................................... 9

Charging Considerations ....................... 10

System Operation ............................. 12

Defrost System ............................... 12

Maintenance .................................. 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. Con-

sult authorities having jurisdiction before installation.

The HP40 unit is "CE marked" in accordance with the re-

quirements 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.

A, WARNING IMPORTANT

06/04

IIIIIIllllllllllllBIIIIlfllIIIIIIIIlI Page 1 504,538M

IIIIIIIIIllllllllllIIIIIIIIIIIIIIIIIIIIIIIIlllllI

INLET

AIR

INLETS7 AIR HP40

iiii!,!ii!i!i;i!!i!ii iiii i iiiiii!!i OPT,ONAL

_T STAND-OFF KIT

(Field-installed

4 required)

AIR (Around perimeterof base)

_ LIQUID LINE

AIR CONNECTION

INLET'_

TOP VIEW

111

162

TOP VIEW BASE SECTION

111

e_. C=.=1

SIDE VIEW 19

ELECTRICAL

INLETS

OUTDOOR

COIL FAN

COMPRESSOR_

VAPOR &

LIQUID LINE

CONNECTION

OPTIONAL

STAND-OFF KIT

(Field-installedJ

4required)

_-_ C

DISCNARGE_

_i!!i!!i!!i!iiiiiiii

SIDE VIEW

AIR

i_iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii!!_

i!_i_ii!!!i'i_i!!i_,i!_i!!,i_!!_!i'i_i!i!!!i'i_i!i!!!i'i_i!_

Model Number 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

Heatpumpunitsoperateunderawiderangeofweather

conditions;therefore,severalfactorsmustbe consid-

eredwhenpositioningtheoutdoorunit,Theunitmustbe

positionedtogiveadequateclearancesforsufficientair-

flowandservicing,Maintainaminimumclearanced610

mm between multiple units. Refer to figure 1 for installa-

tion clearances.

Installation Clearances

*NOTE -Aservice clearance of 30" (762 ram) must be main-

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

anee to one of the other three sides must be 36" (914 ram).

Clearance toone of the remainingtwosides may be 12"(304

ram)and the finalside may be 6"(152 ram).

NO TE -Aclearance of 24" (6! 0 mm) must be maintained

between two units.

NOTE -48" (!2!9 mm) clearance required on top

of unit. Maximum soffit overhang is 36" (914 mm).

FIGURE 1

1 - Place a sound-absorbing material, such as Isomode,

under the unit if it will be installed in a location or posi-

tion 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-

vent ice buildup.

3 - In areas that receive heavy snow, do not locate the

unit where drifting will occur. Ensure that the unit base

is elevated above the depth of average snows.

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

temperatures exist, locate the unit so winter prevail-

ing 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.

Slab Mounting (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 d2

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

i/I/i//I/l,I/i,

MOUNTING SLAB MUST SLOPE

AWAY FROM BUILDING.

GROUND LEVEL

FIGURE 2

Roof Mounting (See figure 3)

If you are unable to mount the unit coil away from prevail-

ing winter winds, construct a wind barrier. Size the barrier

at least the same height and width as the outdoor unit.

Mount the barrier 610 mm from the sides of the unit in the

direction of prevailing winds.

Install the unit at a minimum of 152 mm above the roof

surface to keep ice from building up around the unit. Lo-

cate 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

PREVAILING WINTER WINDS

I WIND BARRIER I

INLET AIR

FIGURE 3

Page 3

Wiringmustconformwithcurrentlocalcodes.Anapplica-

tiondiagramisincludedinthisinstructionandintheindoor

unitinstructions.

Refertotheunitratingplate,locatedonthecontrolboxcov-

er,forminimumcircuitampacityandmaximumfusesize.

1- Providelinevoltagepowersupplyto theunitfroma

properlysizeddisconnectswitch.Thedisconnect

switchshouldbelocatedsothatitiseasilyaccessible

andwithinsightoftheunit.

2- Routethepowerandgroundwiresfromthediscon-

nectswitchtotheunit.Theelectricalopeningsare

providedunderthecontrolboxcover.Seetheunitdi-

mensionsillustrationonpage2,

3- Removethecontrolboxcoverandconnectthepower

wiringtothecontactor.Connectgroundwiretoground

lug.

4- Installtheroomthermostat(orderedseparately)in

theconditionedarea,Placethethermostatwhereit

willnotbeaffectedbysunlight,drafts,orvibration.Do

notinstallthethermostatonanoutsidewall.Themost

desirablepositionforthethermostatisnearthecen-

terof theconditionedareaandapproximately1,5m

fromthefloor,

5- Route24VACcontrolwiresfromthethermostattothe

indoorunitandfromtheindoorunittothedefrostcon-

trolterminalsintheoutdoorunitasshowninfigure4,

A\\

TB1 TERMINAL STRIP

(INDOOR UNIT CONTROL BOX)

-.o_o_ __........ -I I'

OGO • ,, ::

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

.'20, L'L............ "......

"O '_'_O

O_.-_-O.

THERMOSTAT HEAT ANTICIPATION SET-

TING .4 AMP ELECTRIC HEAT FOR THER-

MOSTATS WITH ADJUSTABLE ANTICI-

PATORS.

A IF OUTDOOR THERMOSTAT IS USED, RE-

MOVE JUMPER BETWEEN TERMINALS "R"

AND "W2."

AEMERGENCY HEAT RELAY (USED ONLY

IF OUTDOOR THERMOSTAT IS USED)

FIELD PROVIDED AND INSTALLED NEAR

INDOOR UNIT 24VAC 5VA MAX NEC

CLASS 2.

FIELD WIRING DIAGRAM FOR HP4O UNIT A

$1 THERMOSTAT

=inn =,_

L_-----.-!,.,

OUTDOOR

THERMOSTAT

I _1

_1 _.1.

=1 .I- I

_L_

eRie

_l _1

<7_1

_l _l

_l t1

--I--'--,'- -Z

I --

___L_, ..@

L...... ..@

LOW VOLTAGE

FIELD INSTALLED

NOTE-ALL REMAINING WIRES FACTORY INSTALLED

-©

.©

-®

HP40

LOW VOLTAGE

TERMINAL

CONNECTIONS

FIGURE 4

Page 4

Fieldrefrigerantpipingconsistsofliquidandvaporlines

fromtheheatpump(sweatconnections)to theindoor

evaporatorcoil,UseLennoxL15(sweatconnection)se-

rieslinesetsasshownintable1orusefield-fabricatedre-

frigerantlines,Referto RefrigerantPipingGuide(Corp.

9351-L9)for propersize,type,andapplicationof field-

fabricatedlines.

Ifrefrigeranttubesareroutedthroughawall,sealandiso-

latetheopeningsovibrationis nottransmittedto the

building.

NOTE -Line length should be no greater than 15,2 m, Se-

lect line set diameters from table I to ensure that the oil

returns to the compressor.

TABLE 1

REFRIGERANT LINE SET KITS

HP40 UNIT LIQUID SUCTION L15 LINE

LINE LINE SETS

L15-21

HP40-024 8 mm* 16 mm 4.6m- 15m

L15 -41

HP40-036 10 mm 19 mm 4.6m- 15m

L15 - 65

HP40-048 10 mm 22 mm 4.6m- 15m

FIELD

HP40-060 10 mm 29 mm FABRICATED

*Use the coupling reducer that is supplied in the bag assembly.

Sweat Connection Procedure

1 - The ends of refrigerant lines must be cut square, free

from nicks or dents and deburred. The pipe must re-

main 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,

A IMPORTANT

AIMPORTANT

_&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 with a pump down

feature, and two sets of gauges (one or use with R22 and

one for use with the R407C).

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 existing out-

door unit. Connect the existing unit, a clean recovery

cylinder and the recovery machine according to the

instructions provided with the recovery machine. Re-

move all R22 refrigerant from the existing system.

Refer to gauges after shutdown to confirm that the

entire system is completely void of refrigerant. Dis-

connect 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 refrig-

erant to flush the system -- Start the existing R22 sys-

tem 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

Page 5

thelowpressureswitchestoensurecompleterefrig-

erantevacuation.)Whenlowsidesystempressures

reach0psig,closethesuctionlinevalve.Disconnect

allpowertotheexistingoutdoorunit,Refertogauges

aftershutdownto confirmthatthevalvesarenotal-

lowingrefrigeranttoflowbackintothelowsideofthe

system.Disconnecttheliquidandvaporlinesfrom

theexistingoutdoorunit,

2- Removethe existingoutdoorunit,Set the new

R407Cunitandfollowthebrazingconnectionproce-

duretomakelinesetconnections.DONOTinstall

providedR407Ccheck/expansionvalveat this

time.

Makelowvoltageandlinevoltageconnectionstothe

newoutdoorunit.DONOTturn on powerto the

unit or openthe outdoorunit servicevalvesat

thistime.

3- Removetheexistingrefrigerantflowcontrolorificeor

thermalexpansion/checkvalvebeforecontinuing

withflushingprocedures.Theexistingdevicesare

notapprovedforusewithR407Crefrigerantandmay

preventproperflushing,Useafield-providedfittingto

reconnectthelines.

4 - RemovethepressuretapvalvecoresfromtheHP32

unit'sservicevalves,ConnectanR22cylinderwith

cleanrefrigerantto thesuctionservicevalve,Con-

necttheR22gaugesettotheliquidlinevalveand

connecta recoverymachinewithanemptyrecovery

tankto thegaugeset,

5 -

A, IMPORTANT

Set the recovery machine for liquid recovery and

start the recovery machine, Open the gauge set

valves to allow the recovery machine to pull a vacu-

um 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 is flushed, you must allow the recovery

machine to pull avacuum on the system at the

end of the procedure.

FLUSHING CONNECTIONS

EXISTING

INDOOR COIL

/_ INVERTED R22

JCYLINDER

EXISTING SU__

EXISTING LIQUID LINE _"

SUCTION LIN_t

SERVICE VALV

LIQUID LINE

SERVICE VALVE

HP40 UNIT

RECOVERY

CYLINDER

TANK RETURN

INLET

DISCHARGE

RECOVERY MACHINE

LOW HIGH

PRESSURE PRESSURE

FIGURE 5

Page 6

HP4O COOLING CYCLE (SHOWING MANIFOLD GAUGE CONNECTIONS)

OUTDOOR UNIT

DEFROSTTHERMOSTAT_,___

EXPANSION/CHECK I

VALVE _

LOW HIGH

PRESSURE PRESSURE

GAUGE MANIFOLD

TO LIQUID LINE

R407C SERVICE

DRUM PORT

DISTRIBUTOR

1_ _I_1"_ I REVERSING VALVE

FLOW _ '_,

CO,L,NTERNAL

,-]/ COMPRESSORE -

J/&M,T

SUCTION

SERVICE _ VAPOR

POR .._

COMPRESSOR ':,

k r""- _

EXPANSION/CHECK

VALVE

NOTE - ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW

INDOOR UNIT

_(_ INDOOR

I COIL

L..... -I

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

lines and indoor coil before removing the recovery

machine, gauges and R22 refrigerant drum. Rein-

stall pressure tap valve cores into HP32 service

valves.

10-Install the provided check/expansion valve (ap-

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.

Access the liquid line and vapor line service valves (fig-

ures 7 and 8) and the gauge ports from inside the unit, be-

hind 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.

LIQUID AND VAPOR LINE SERVICE VALVES

VALVE OPEN)

INSERT HEX

WRENCH STEM CAP

SERVICE

PORT X

TO OUTDOOR

COIL

SERVICE'

PORT

CAP SCHRADER

VALVE

(VALVE CLOSED)

SERVICE

)INDOOR

COIL

STEM CAP

TO OUTDOOR

COIL

INSERT HEX

SERVICE

PORT CAP

SCHRADER VALVE OPEN

TO LINE SET WHEN VALVE IS

CLOSED (FRONT SEATED)

TO INDOOR COIL

(VALVE FRONT

SEATED)

FIGURE 7

Page 7

IMPORTANT

Accessing the Schrader Port:

1 - Remove service port cap with an adjustable wrench,

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 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 pos-

sible.

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 differ-

ences are in construction. Valves are not rebuildable, Ifa

valve has failed, it must be replaced, A ball valve is il-

lustrated in figure 8.

The ball valve is equipped with a service port and a fac-

tory-installed Schrader valve. A service port cap is

supplied to protect the Schrader valve from contami-

nation and to assure a leak-free seal,

After the line set has been connected to the indoor and

outdoor units, check all connections for leaks,

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 tight-

en an additional 1/6 turn,

TO OUTDOOR

COIL

VAPOR LINE (BALL-TYPE) SERVICE VALVE

(VALVE OPEN)

USE ADJUSTABLE WRENCH.

ROTATE STEM CLOCKWISE 90" TO CLOSE.

ROTATE STEM COUNTERCLOCKWISE 90" TO OPEN.

@ STEM CAP

STEM

BALL

SHOWN OPEN)

TO INDOOR COIL

SERVICE

PORT

CAP SERVICE POF

SCHRADER

VALVE

FIGURE 8

Using an Electronic Leak Detector

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

ing valve to center port of manifold gauge set,

2- Connect the high pressure hose of the manifold

gauge set to the service port of the vapor valve, (Nor-

mally, the high pressure hose is connected to the liq-

uid line port, however, connecting it to the vapor port

better protects the manifold gauge set from high pres-

sure 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 maxi-

mum of 59 ml or 21 kPa pressure,) Close the valve on

the R407C cylinder and the valve on the high pres-

sure side of the manifold gauge set, Disconnect

R407C cylinder and attach a nitrogen cylinder.

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 de-

tected. (Amounts of refrigerant will vary with line

lengths.) Check all joints for leaks. Purge nitrogen

and R407C mixture. Correct any leaks and recheck,

Page 8

-&WARNING

gen cylinder with the pressure regulator set to 150

psig (1034 kPa) and purge the hose. Open the man-

ifold gauge valves to break the vacuum in the system.

Close the manifold gauge valves.

-&WARNING

Evacuating the system of non-condensables is critical for

the unit to operate properly. Non-condensables are de-

fined as any gas that will not condense under temperatures

and pressures present during operation dan air condition-

ing 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 re-

leased. Open both manifold valves to release the ni-

trogen from the unit. See the liquid and suction line

service valves section for how to operate the service

valves.

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 mi-

crons) of mercury. During the early stages of evacua-

tion, it is desirable to close the manifold gauge valve

at least once to determine if there is a rapid rise in ab-

solute 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 pres-

sure 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-

7 -Shut off the nitrogen cylinder and remove the man-

ifold 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 af-

ter shutting off the vacuum pump and dosing the man-

ifold 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 ser-

vice valves.

Refer to the unit nameplate for the correct liquid

charge. Ifyou can not measure in the total amount, re-

fer to the start-up section and set the final system

charge according to the charging instructions. The

R407C refrigerant cylinder should be chocolate

brown.

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 volt-

age 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.

Page 9

_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,

Liquid charge the unit with the amount of R407C refriger-

ant that is indicated on the nameplate.

,IMPORTANT

This charge is based on a matching indoor coil and out-

door 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

8 mm

10 mm

*If line length is greater than 4.6

g per 1524 mm adjust

from 4.6 mline set*

57 g per 1524 mm

85 g per 1524 mm

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

the liquid line pressure to a range of 1379 to 1724 kPa, To

do this, block off the outdoor coil with cardboard or a plas-

tic sheet,

BLOCKING OUTDOOR COIL

OUTDOOR COIL SHOULD

BE BLOCKED ONE SIDE

AT A TIME WITH CARD-

BOARD OR PLASTIC

SHEET UNTIL PROPER

TESTING PRESSURES

ARE REACHED.

CARDBOARD OR

PLASTIC SHEET

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 ser-

vice port and the unit operating, read the liquid line

pressure.

3 - If the pressure is too low, block the airflow through

the outdoor coil until the liquid line pressure stabi-

lizes 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 de-

termine the saturation temperature for the liquid line

pressure reading.

5 - Subtract the liquid line temperature from the satura-

tion 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

SaturatedLiquid

Temperature°C

TABLE 3

R407C Saturated Liquid Temperature and Pressure Chart

Use this chart for subcooling only, not superheat.

Liquid Line Pressure Liquid Line Pressure

Saturated Liquid

Temperature °C

Page 11

Filter Drier

Theunitisequippedwitha bifiowfilterdrier.Seefigure6.

If thefilterneedsto be replaced,orderanotherof the

samedesign.

Thermostat Operation

Someheatpumpthermostatsincorporateisolatingcon-

tactsandanemergencyheatfunction(whichincludesan

amberindicatinglight).Thethermostatis notincluded

withtheunitandmustbepurchasedseparately.

Emergency HeatFunction

Somethermostatshavean emergencyheatfunction.

Thisfeatureisapplicableonlytothosesystemsthathave

auxiliaryelectricheatstagedby outdoorthermostats.

Whenthethermostatis placedin theemergencyheat

position,theoutdoorunitcontrolcircuitis isolatedfrom

thepowersource,andfield-providedrelaysbypassthe

outdoorthermostats.Anamberindicatinglightsimulta-

neouslycomesontoremindthehomeownerthattheunit

isoperatingintheemergencyheatmode.

Emergencyheatisusuallyusedduringa heatpumpshut-

down.However,emergencyheatshouldalsobeusedfol-

lowinga poweroutageifthepowerhasbeenoffforover

anhour,andtheoutdoortemperatureisbelow10_C.The

systemshouldbeleftintheemergencyheatmodeforat

leastsixhoursto allowthecrankcaseheatersufficient

timetopreventcompressorfromslugging.

TheHP40defrostsystemincludestwocomponents:ade-

frostthermostatandadefrostcontrol.

Defrost Thermostat

Thedefrostthermostatis locatedontheliquidlinebe-

tweenthe check/expansionvalveandthe distributor,

Whendefrostthermostatsenses5,5°Corcooler,thether-

mostatcontactscloseandsenda signalto thedefrost

controlboardtostartthedefrosttiming,Italsoterminates

defrostwhentheliquidlinewarmsupto21°C.

Defrost Control

Thedefrostcontrolboardincludesthecombinedfunc-

tionsofatime/temperaturedefrostcontrol,defrostrelay,

diagnosticLEDsandterminalstripfor fieldwiringcon-

nections.Seefigure10,

Thecontrolprovidesautomaticswitchingfromnormal

heatingoperationtodefrostmodeandback.Duringcom-

pressorcycle(callfor defrost),thecontrolaccumulates

compressorruntimesat30,60,or90minutefield-adjust-

ableintervals.Ifthedefrostthermostatisclosedwhenthe

selectedcompressorruntimeintervalends,thedefrost

relayisenergizedanddefrostbegins,

CONNECTION FOR

OPTIONAL

HIGH PRESSURE

SWITCH

High

Pressure

Switch

HIGH PRESSURE SWITCH

SAFETY CIRCUIT

CONNECTIONS

NOTE -Remove factory-

installed jumper to add

pressure switch.

HP40DEFROSTCONTROLBOARD

FAH

DEFROST _ O

INTERVAp_N_ _

OTIMING

DIAGNOSTIC

oTST LEDs

o.ou=,

o0Hot ECCC3

OoY_ [_ O

24V

TERMINAL

STRIP

FIGURE 10

Page 12

Defrost Control Timing Pins

Each timing pin selection provides a different accumu-

lated compressor run time period during one thermo-

stat run cycle, This time period must occur before a de-

frost cycle is initiated, The defrost interval can be ad-

justed to 30 (T1), 60 (T2), or 90 (T3) minutes, See figure

10. The defrost timing jumper is factory-installed to pro-

vide a 60-minute defrost interval, If the timing selector

jumper is not in place, the control defaults to a 90-min-

ute 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 heat-

ing 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 be-

fore an additional 5-second period has elapsed (7 sec-

onds 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-sec-

ond period has elapsed, the defrost will terminate and the

test option will not function again until the jumper is re-

moved 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 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 3

DEFROST CONTROL BOARD DIAGNOSTIC LED

MODE LED 1 LED 2

Normal operation /Synchronized Synchronized

power to board Flash with LED 2 Flash with LED 1

Board failure or no power Off Off

Board failure On On

Hiqh pressure switch open Flash On

_WARNING

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 be-

fore 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 evi-

dence 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 evi-

dence 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,

2- Lennox blower motors are pre-lubricated and perma-

nently sealed, The blower motor requires no more lu-

brication,

3- Adjust the blower speed for cooling. Measure the

pressure drop over the coil to determine the correct

blower m3/s,

Page 13

JobName

JobLocation

Installer

UnitModelNo,

NameplateVoltage

JobNo.

City

SerialNo.

Amps:

MinimumCircuitAmpacity

MaximumOvercurrentProtectionSize

ElectricalConnectionsTight?[]

SupplyVoltage(UnitOff)

Date

State

ServiceTechnician

COOLINGSECTION

RefrigerantLines:

LeakChecked?[]

ProperlyInsulated?[]

OutdoorFanChecked? []

ServiceValveCapsTight? []

ServiceValvesFullyOpened?[]

VoltageWithCompressorOperating

Supply OutdoorFan

Compressor

IndoorFilterClean?[]

IndoorBlowerRPM

S.RDropOverEvaporator(Dry)

OutdoorCoilEnteringAirTemperature

DischargePressure SuctionPressure

RefrigerantChargeChecked? []

THERMOSTAT

Calibrated?[] ProperlySet?[]

Level?[]

Page14

Page15

LENNOX

Lennox Industries

RO. Box 174, Westgate Interchange,

Northampton NN5 5AG

Telephone: 01604 591159

Facsimile: 01604 587536

Page 16

LENNOX Air Conditioner/heat Pump(outside Unit) Manual L0806493

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