INSTALLATION INSTRUCTIONS HS25 SERIES UNITS - Lennox

PRODUCT LITERATURE
¤1995 Lennox Industries Inc.
Dallas, Texas
£
INSTALLATION
INSTRUCTIONS
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TABLE OF CONTENTS
HS25 CONDENSING UNIT ......................... 1
SHIPPING AND PACKING LIST ...................... 1
GENERAL INFORMATION .......................... 1
HS25 UNIT DIMENSIONS .......................... 2
HS25 PARTS ARRANGEMENT ...................... 3
SETTING THE UNIT ................................ 3
ELECTRICAL ...................................... 3
PLUMBING ....................................... 5
REFRIGERATION .................................. 5
LEAK TESTING .................................... 5
EVACUATION ..................................... 5
START--UP ........................................ 6
CHARGING ....................................... 7
SYSTEM OPERATION .............................. 7
MAINTENANCE ................................... 7
HS25 CHECK POINTS .............................. 8
HS25 CONDENSING UNIT
HS25 condensing units are designed for expansion
valve systems only. They are not designed for RFC systems.
Refer to Lennox engineering handbook for expansion
valve kits which must be ordered separately.
SHIPPING AND PACKING LIST
1-- Assembled HS25 condensing unit
1-- Filter/drier (field--installed)
Check unit for shipping damage. Consult last carrier
immediately if damage is found.
GENERAL INFORMATION
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.
IMPORTANT
The Clean Air Act of 1990 bans the intentional
venting of refrigerant (CFC’s and HCFC’s) as of July
1, 1992. Approved methods of recovery, recycling
or reclaiming must be followed. Fines and/or incarceration
may be levied for non--compliance.
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose
you to fiberglass wool. Breathing this may cause
lung cancer. (Fiberglass wool is known to the
State of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact
your supervisor.
Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379--9900
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HS25 UNIT DIMENSIONS--INCHES (MM)
INLET AIR
HS25
CONDENSING
UNIT
COMPRESSOR
INLET
AIR
B
SUCTION LINE
INLET
(HS25-211-460)
LIQUID
LINE INLET
(HS25-510-650)
ELECTRICAL
INLETS
INLET AIR
TOP VIEW
C
DISCHARGE AIR
A
LIQUID
LINE INLET
(HS25-211-460)
SUCTION
LINE INLET
(HS25-510-650)
L
D
2-9/16
(65)
H
J
K
K
J
2-3/4 (70)
F
4-7/8 (22) 4
4
(102)
(102)
E
G
FRONT VIEW
H
1-3/8
(35)
SIDE VIEW
6-1/16
(154)
Model No. A B C D E F G H J K L
HS25-211
in. 27-7/8 25-7/8 29-7/8 7-1/4 22-7/16 14-7/16 22-1/8 1-7/8 2-7/8 5-1/2 4-1/2
HS25-261 mm 708 657 759 184 570 367 562 48 73 140 114
HS25-311 in. 30-7/8 32-1/8 34-1/16 8-1/4 26-5/8 18-5/8 28-1/8 2 3-7/8 7-1/2 4-1/2
HS25-411-413
413
HS25-461-463 mm 784 816 865 210 676 473 714 51 98 191 114
HS25-511-513
HS25-651-653
in. 40-7/8 32-1/8 34-1/16 15-1/4 26-5/8 18-5/8 28-1/8 2 3-7/8 7-1/2 8-1/2
mm 1038 816 865 387 676 473 714 51 98 191 216
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HS25 PARTS ARRANGEMENT
CONDENSER FAN
(NOT SHOWN)
TOP OF CABINET
DUAL CAPACITOR
(Single--Phase Units)
HS25 UNIT COMPONENTS
TD1--1
TIME DELAY
FAN CAPACITOR
(Three--Phase Units)
CONTACTOR
THERMOMETER
WELL
LIQUID LINE
SERVICE VALVE
AND GAUGE PORT
HIGH PRESSURE
SWITCH
COMPRESSOR
SUCTION
SERVICE
VALVE
AND GAUGE PORT
(LIVE)
SUCTION
GAUGE
PORT
COMPRESSOR
TERMINAL BOX
ACCUMULATOR
(HS25--511/651 ONLY)
SETTING THE UNIT
Refer to unit dimensions on page 1 for sizing mounting
slab, platforms or supports. Refer to figure 2 for installation
clearances.
INSTALLATION CLEARANCES
NOTE-- 48” (1219mm) CLEARANCE REQUIRED
ON TOP OF UNIT.
*36”
(914mm)
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A--Slab Mounting
When installing unit at grade level, install on a level
slab high enough above grade to allow adequate drainage
of water. Top of slab should be located so run--off
water from higher ground will not collect around unit.
B--Roof Mounting
Install unit at a minimum of 4 inches above surface of the
roof. Care must be taken to ensure weight of unit is properly
distributed over roof joists and rafters. Either redwood
or steel supports are recommended.
36”
(914mm)
*36”
(914mm)
FIGURE 2
36”
(914mm)
*One dimension may be 12” (305 mm).
ELECTRICAL
Wiring must conform to current standards of the National
Electric Code (NEC), Canadian Electrical Code
(CEC) and local codes. Refer to the furnace or blower
coil installation instructions for additional wiring application
diagrams and refer to unit rating plate for
minimum circuit ampacity and maximum overcurrent
protection size.
WARNING
Unit must be grounded in accordance with
national and local codes.
Electric Shock Hazard.
Can cause injury or death.
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A--Line Voltage
To facilitate conduit, knockouts are provided in cabinet
panel. Route conduit through knockout in cabinet and
connect to side of control panel. Refer to figure 3 for
thermostat, furnace and condensing unit wire connections
and figure 4 for field wiring diagram.
Note--Units are approved for use with copper conductors
only.
B--24V, Class II Circuit
24V, Class II Circuit connections are made up below control
box.
Note--A complete unit wiring diagram is located inside
the unit access panel.
HS25 and FURNACE (GAS OR ELECTRIC)
THERMOSTAT CONNECTIONS
(Some connections may not apply.
Refer to specific thermostat and furnace.)
Furnace Thermostat HS25
R
W1
W2
Y
G
C
POWER
1ST STAGE AUX. HEAT
2ND STAGE AUX. HEAT
W2
INDOOR BLOWER
COMMON
R
W1
Y
G
C
COMPRESSOR
COMMON
Condensing
Unit
HS25
COMPRESSOR
HS25
COMMON
FIGURE 3
HS25 CONDENSING UNIT
FIELD WIRING DIAGRAM
CONDENSING UNIT
ROOM THERMOSTAT
TYPICAL
INDOOR UNIT
C
Y1
G
W
RC
RH
TB1
TRANSFORMER
R
W1
G
TO
HEATING
CONTROLS
TO
COOLING SPEED
24v
T1
YELLOW
BLACK OR BLUE
NOTE--SEE UNIT WIRING DIAGRAM
FOR POWER SUPPLY CONNECTIONS.
TO 24V CLASS II POWER SOURCE
-- 20 VA MINIMUM
W2
W3
C
24V,
CLASS II
JUNCTION
BOX
TO
HEATING
SPEED
POWER
YELLOW
GROUND
PER NATIONAL
AND LOCAL
CODES
K3 INDOOR BLOWER RELAY
NOTE--IF INDOOR UNIT IS NOT EQUIPPED WITH BLOWER RELAY, IT MUST BE
FIELD PROVIDED AND INSTALLED (P--8--3251 OR EQUIVALENT)
24V, CLASS II VOLTAGE INSTALLED AT FACTORY
24V, CLASS II VOLTAGE FIELD INSTALLED
FIGURE 4
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PLUMBING
Field refrigerant piping consists of liquid and suction
lines from the condensing unit (sweat connections) to
the indoor evaporator coil. Use Lennox L10 (flare) or L15
(sweat) series line sets as shown in table 1 or use field--
fabricated refrigerant lines. Refer to the piping section of
the Lennox Unit Information Service Manual for proper
size, type and application of field--fabricated lines.
Sweat Connection Procedure
1-- End of refrigerant line must be cut square, kept
round, free from nicks or dents and deburred (I.D.
and O.D.)
2-- Wrap a wet cloth around the valve body and copper
tube stub; braze the line set tubing to the valve.
3-- Quench joint with water or a wet cloth to prevent
possible heat damage to the valve core and opening
port.
IMPORTANT--Tube end must stay bottomed in the
fitting during final assembly to ensure proper seating,
sealing and rigidity.
4-- Install filter drier, provided with unit, in the liquid
line as close as possible to the expansion device.
If refrigerant tubes are routed through a wall, seal and
isolate the opening so vibration is not transmitted to
the building.
NOTE-Line length should be no greater than 50 feet
(15.2 m). Select line set diameters from table 1 to ensure
oil return to compressor.
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REFRIGERATION
Service Valves and Gauge Manifold Attachment
The liquid line and suction line service valves and
gauge ports are accessible on inside of unit. These
gauge ports are used for leak testing, evacuating,
charging and checking charge.
IMPORTANT--Services valves are closed to line set connections.
Do not open until refrigerant lines and indoor
coil have been leak tested and evacuated. All precautions
should be exercised to keep the system free from
dirt, moisture and air.
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After the line set has been connected to the indoor and
outdoor units, the line set connections and indoor unit
must be checked for leaks.
WARNING
Never use oxygen to pressurize refrigeration or air
conditioning system. Oxygen will explode on contact
with oil and could cause personal injury.
When using high pressure gas such as nitrogen or
CO 2 for this purpose, be sure to use a regulator
that can control the pressure down to 1 or 2 psig
(6.9 to 13.8 kPa).
Using an Electronic Leak Detector or Halide
1-- Connect a cylinder of nitrogen with a pressure regulating
valve to the center port of the manifold
gauge set.
2-- Connect the high pressure hose of the manifold
gauge set to the service port of the suction valve.
(Normally, the high pressure hose is connected to
the liquid line port, however, connecting it to the
suction port better protects the manifold gauge set
from high pressure damage.)
3-- With both manifold valves closed, open the valve
on the R22 bottle (vapor only).
4-- Open the high pressure side of the manifold to allow
R22 into the line set and indoor unit. Weigh in a
trace amount of R22. [A trace amount is a maximum
of 2 ounces (57g) refrigerant or 3 pounds (31
kPa) pressure]. Close the valve on the R22 bottle
and the valve on the high pressure side of the manifold
gauge set. Disconnect R22 bottle.
5-- Adjust 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.
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 R22 mixture. Correct any leaks and recheck.
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Evacuating the system of non--condensables is critical
for proper operation of the unit. Non--condensables are
defined as any gas that will not condense under temperatures
and pressures present during operation of 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.
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2-- Connect the vacuum pump (with vacuum gauge)
to the center port of the manifold gauge set.
3-- Open both manifold valves and start vacuum pump.
4-- Evacuate the line set and indoor unit to anabsolute
pressure of 23mm of mercury or approximately 1
inch 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.
5-- When the absolute pressure reaches 23mm 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.
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Danger of Equipment Damage.
Avoid deep vacuum operation. Do not use compressors
to evacuate a system.
Extremely low vacuums can cause internal arcing
and compressor failure.
Damage caused by deep vacuum operation will
void warranty.
6-- 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.
7-- 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 .5mm of mercury within a
20 minute period after shutting off the vacuum
pump and closing the manifold gauge valves.
8-- Depending on the equipment used to determine
the vacuum level, absolute pressure of .5mm of
mercury is equal to 500 microns.
9-- When the absolute pressure requirement above has
been met, disconnect the manifold hose from the
vacuum pump and connect it to an upright bottle of
R22 refrigerant. Open the manifold gauge valves to
break the vacuum in the line set and indoor unit.
Close manifold gauge valves and shut off R22 bottle
and remove manifold gauge set.
START--UP
Cooling Start--up
1-- Rotate the fan to check for frozen bearings or binding.
2-- Inspect all factory and field--installed wiring for
loose connections.
3-- Open liquid line and suction line service valves to
release refrigerant charge (contained in condensing
unit) into system. Replace and tighten caps.
Use a back--up wrench on the suction and liquid
valves when removing or replacing valve caps.
4-- To open suction valve, remove hex cap and turn
valve stem fully open using an Allen (hex) wrench.
To open liquid valve, remove cap and turn valve
stem until it is fully open and back--seated.
NOTE--When replacing valve caps, the caps should
be made finger tight and then tightened an additional
1/6th of a turn.
5-- Check voltage supply at the disconnect switch. The
voltage must be within range listed on unit nameplate.
If not, do not start equipment until the power
company has been consulted and the voltage
condition corrected.
6-- Set thermostat for a cooling demand, turn on power
to blower and close condensing unit disconnect
switch to start.
7-- Recheck unit voltage with unit running. Power
must be within range shown on unit nameplate.
Check amperage draw of unit. Refer to unit nameplate
for correct running amps.
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 suction pressures indicate proper compressor
phasing and operation. If discharge and suctions
pressures do not perform normally, follow the
steps below to correctly phase in the unit.
1-- Disconnect power to the unit.
2-- Reverse any two field power leads to the unit.
3-- Reapply power to the unit.
Discharge and suction pressures should operate at
their normal start--up ranges.
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NOTE--Compressor noise level will be significantly
higher when phasing is incorrect and the unit will not
provide cooling when compressor is operating backwards.
Continued backward operation will cause the
compressor to cycle on internal protector.
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CHARGING
Units are factory charged with the amount of R--22 refrigerant
indicated on the unit rating plate. This charge
is based on a matching indoor coil and outdoor coil
with 20 ft. (6.1m) line set. For varying lengths of line set,
refer to table 2 for refrigerant charge adjustment.
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If the system is void of refrigerant, the recommended
and most accurate method of charging is to weigh
the refrigerant according to the total amount shown
on the unit nameplate. If weighing facilities are not
available or if unit is just low on charge, use the following
procedure:
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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 70E F
(21EC) to 80E F (26EC). Be sure to monitor system
pressures while charging.
1-- Record outdoor ambient temperature.
2-- Operate unit to allow system to stabilize both before
and after each charge adjustment.
3-- Check to make sure thermometer well is filled
with mineral oil before checking liquid line temperature.
4-- Outdoor temperature should be 60E F(16EC) or
above. Place thermometer in well and read liquid
line temperature. Difference between ambient
and liquid temperatures should match values
given in table 3. Refrigerant must be added to
lower approach temperature and removed to increase
approach temperature. Loss of charge results
in low capacity and efficiency.
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SYSTEM OPERATION
Condensing unit and indoor blower cycle on demand
from room thermostat. When thermostat blower
switch is moved to ON position, indoor blower operates
continuously.
Compressor Time Delay (TD1)
A compressor time delay is used to prevent compressor
short cycling and to prevent the compressor from
running backwards. When there is demand for a cooling
cycle, the control delays the compressor from starting
for a minimum of 8.5 seconds. Do not bypass the
control.
Discharge Thermostat
The Copeland Scroll compressor is equipped with a
discharge line thermostat that removes power from
the compressor when discharge temperatures reach
approximately 280E F (138EC). The thermostat resets
automatically at 130E F (54EC).
CAUTION
Danger of equipment damage. Do not bypass the
discharge thermostat.
High Pressure Switch
HS25 units are equipped with a high pressure switch
that is located in the discharge line of the compressor.
The switch (SPST, manual reset, normally closed) removes
power from the compressor when discharge
pressure rises above factory setting at 410 + 10 psi
(2827 + 69 kPa).
Low Pressure Switch
HS25 units are also equipped with a low pressure
switch that is located in the suction line of the compressor.
The switch (SPST, auto--reset, normally closed) removes
power from the compressor when suction line
pressure drops below factory setting at 25 +5 psi (172 +
34 kPa).
MAINTENANCE
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn
the electrical power to unit OFF at disconnect
switch(es). Unit may have
multiple power supplies.
At the beginning of each cooling season, the system
should be checked as follows:
1-- Clean and inspect condenser coil. Coil may be
flushed with a water hose.
2-- Condenser fan motor is prelubricated and sealed.
No further lubrication is needed.
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3-- Visually inspect connecting lines and coils for evidence
of oil leaks.
4-- Check wiring for loose connections.
5-- Check for correct voltage at unit (unit operating).
6-- Check amp--draw condenser fan motor.
Unit nameplate _________ Actual ____________ .
NOTE--If owner complains of insufficient cooling, the unit
should be gauged and refrigerant charge checked. Refer
to section on refrigerant charging in this instruction.
Evaporator Coil
1-- Clean coil, if necessary.
2-- Check connecting lines and coils for evidence of oil
leaks.
3-- Check condensate line and clean, if necessary.
Indoor Unit
1-- Clean or change filters.
2-- Adjust blower speed for cooling. The pressure
drop over the coil should be measured to determine
the correct blower CFM. Refer to the unit information
service manual for pressure drop tables
and procedure.
3-- On belt drive blowers, check belt for wear and
proper tension.
4-- Check all wiring for loose connections
5-- Check for correct voltage at unit (blower operating).
6-- Check amp--draw on blower motor
Unit nameplate_________ Actual ____________.
HS25 CHECK POINTS
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