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1. latching relay K167 HL Co ground lug contactor K1 capacitor low ambient thermostat C1 C2 S41 FIGURE 5 HS29 180 amp HS29 240 CONTROL BOX g TIMER DL33 OUTDOOR FAN 1 Gm CIRCUIT BREAKER CB7 CONTACTOR CONTACTOR K2 2 208 230V ONLY 2 2 gt E Upon ONIY ATCHING 2 K68 OUTDOOR FAN 2 CINES sos TIMER DL34 l STAGE 1 COOL K149 OUTDOOR e S le 9 TERMINAL mem C STRIP K67 STAGE2 COOL K150 OUTDOOR FAN4 35 1 1 1 J 1 2 9 C1 C2 LOW AMBIENT THERMOSTAT S41 TRANSFORMER T18 FIGURE 6 Page 6 I UNIT COMPONENTS ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A CAUTION Electrostatic discharge can affect electronic components Take precautions during unit instal lation and service to protect the unit s electronic controls Precautions will help to avoid control exposur2. ELE S THICKNESS 534 1900 2002 Lennox Industries Inc Litho U S A Page 27 HS29 180 240 First stage cool Cooling demand energizes K66 relay coil at thermostat terminal Y1 K66 1 contacts close voltage passes through S87 low pressure switch to terminal 1 on DL33 timer to K167 latching relay coil K167 1 contacts close energizing DL33 Timer begins After 5 minutes DL33 is de energized Voltage passes through S4 high pressure limit energiz ing K1 compressor contactor K1 1 contacts close en ergizing compressor B1 K167 2 contacts close Contacts 8 and 2 open energiz ing indoor blower K167 3 contacts close sending voltage to K58 low am bient contact terminal 4 K66 2 contacts close Voltage passes through S11 low ambient pressure switch switch will be closed pro vided liquid line pressure is high enough to K10 out door fan relay coil K10 1 contacts close energizing outdoor fan B4 K10 2 contacts open de energizing HR1crankcase heater K66 3 contacts close sending voltage through low am bient limit switch S41 switch will close provided ambi ent is warm enough to K58 low ambient coil K58 1 closes energizing K68 outdoor fan coil K68 1 contacts close energizing outdoor fan B5 Second stage cool 10 Cooling demand energizes K67 relay coil at thermostat terminal Y2 11 K67 1 contacts close voltage passes through S88 low pressure switch to terminal 1 on DL34 timer to K168
3. LENNGX UNIT INFORMATION HS29 Corp 0104 L2 Service Literature Revised 04 2003 HS29 SERIES UNITS The HS29 units are designed for light commercial applica tions with a remotely located blower coil unit or a furnace with an add on evaporator coil Capacities for the series are 6 7 1 2 10 15 and 20 tons 21 26 35 53 and 70 kW All HS29 units use single speed scroll compressors The 15 53kW and 20 ton 70kW units each have two single speed scroll compressors The HS29 units match with the CB17 blower coil units All HS29 units are three phase This manual covers HS29 072 HS29 090 HS29 120 HS29 180 and HS29 240 units It is divided into sections which discuss the major components refrigerant system charging procedure maintenance and operation se quence Information in this manual is intended for qualified service technicians only All specifications are subject to change Procedures in this manual are presented as a recommen dation only and do not supersede or replace local or state codes A WARNING Electric shock hazard Can cause injury ALL major components indoor blower coil must or death Before attempting to perform be matched to Lennox recommendations for any service or maintenance turn the compressor to be covered under warranty Refer to electrical power to unit OFF at discon Engineering Handbook for approved system nect switch es Unit may have multiple matchups power sup
4. msraec x 3 HS29 180 tested with CB17 CBH17 185V HS29 240 tested with CB17 CBH17 275V NOTE System charging is not recommended below 60 F 15 C If the temperature is below 60 F 15 C the charge must be weighed into the system Units are shipped with a holding charge of dry air and helium which must be removed before the unit is evac uated and charged with refrigerant The most accurate method of charging is to weigh the refrigerant into the unit as indicated in the following procedure Page 20 1 Recover the refrigerant from the unit 2 Conduct a leak check then evacuate as previously outlined 3 Weigh in the amount of charge listed in tables 2 and 3 If weighing facilities are not available or if the charge needs to be checked use the following method 1 Attach the gauge manifolds and operate the unit in cooling mode until the system stabilizes approximate ly five minutes 2 Use a digital thermometer to accurately measure the outdoor ambient temperature For HS29 180 and HS29 240 units check each system separately with all stages operating 3 Apply the outdoor temperature to table 4 or 6 to deter mine normal operating pressures 4 Compare the normal operating pressures to the pres sures obtained from the gauges Minor variations in these pressures may be expected due to differences in installations Significant differences could mean that the system is not properl
5. 16 35 1 52 2936 2 73 to 58 68 5 45 total Condenser sq ft m i D Inner coil 12 59 1 17 15 70 1 46 Tube diameter in mm amp no of rows 3 8 9 5 2 3 8 9 5 1 3 8 9 5 2 Fins per inch m 20 787 15 630 20 787 15 630 Diameter in mm amp no of blades 1 24 610 4 2 24 610 3 4 24 610 3 Motor hp W 1 1 2 373 2 1 3 249 4 1 3 249 ioni Cfm L s total air volume 4500 2125 4800 2265 8200 3870 16 000 7550 Rpm 1060 1100 1075 Watts 600 450 700 total 1500 total Refrigerant charge dry air holding charge Shipping weight Ibs kg 1 package 354 161 427 193 567 257 998 453 1189 539 Optional Accessories Must Be Ordered Extra Hail Guards 86K90 83K36 79K91 Hot Gas Bypass Kit hot gas bypass superheat valve 89K83 79K90 89K84 Hot Gas Bypass Kit hot gas bypass valve only 93K76 93K77 93K78 not available ELECTRICAL DATA Model No HS29 072 1 2 HS29 090 2 HS29 120 2 HS29 180 2 HS29 240 2 Line voltage data 60 hz phase 208 230v 460v 575v 208 230v 460v 575v 208 230v 460v 575v 208 230v 460v 575v 208 230v 460v 575v o 40 2 15 30 25 40 75 100 50 85 130 60 40 TMinimum circuit ampacity 27 18 11 39 20 15 53 25 18 75 39 29 95 44 3 bis Compres 1 1 1 2 2 Compressor 18 67 MEAE ME 19 8 es 094 ers Gas 14 46 amps 16 75 54 195 95 80 239 125 80 390
6. 180 160 478 250 160 No of motors 1 1 2 4 4 Condenser Full load amps 24 24 1 3 24 1 3 3 No total 3 15 121 3 115 1 2 48 les oe 5 oe 52 1 phase Locked rotor amps 6 29 6 29 4 7 24 1 9 4 7 24 1 9 4 7 2 4 1 9 total 9 4 4 8 3 8 18 8 9 6 7 6 18 8 9 6 7 6 Page 2 TRefer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements NOTE Extremes of operating range are plus and minus 10 of line voltage 1HACR type under 100 amps U S only SPECIFICATIONS Page 3 General Model No HS29 072 3 HS29 090 3 HS29 120 3 Data Nominal Size Tons kW 6 21 1 7 5 26 4 10 35 2 Connections Liquid line o d in mm 5 8 15 9 5 8 15 9 5 8 15 9 sweat Suction line o d in mm 1 1 8 28 6 1 3 8 34 9 1 3 8 34 9 Refrigerant dry air holding charge Condenser Net face area sq ft m2 Outer coil 12 92 1 20 22 50 2 09 29 36 2 73 total Goil Inner coil 12 59 1 17 21 70 2 02 Tube diameter in mm amp no of rows 3 8 9 5 2 3 8 9 5 2 3 8 9 5 2 Fins per inch m 20 787 20 787 15 630 Condenser Diameter in mm amp no of blades 1 24 610 4 1 24 610 4 2 20 610 3 Fan s Motor hp W 1 1 2 373 1 3 4 560 2 1 3 249 c
7. COOL COMPONENT CAPACITOR OUTDOOR FAN TIMER MINIMUM RUN HEATER COMPRESSOR JACK GFI RECEPTACLE JACK TEST COOL CONTACTOR COMPRESSOR RELAY OUTDOOR FAN RELAY LATCHING PLUG TEST COOL SENSOR AMBIENT WITCH LIMIT HI PRESS COMP ICH LOW PRESS LOW AMB KIT SWITCH DISCONNECT TCH LOW PRESS COMP_ TRANSF ORMER HOFFMAN CONTROL REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION A M VOLTAGE UNITS ONLY IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING AND INSULATION THICKNESS WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES COOLING UNITS CONDENSING UNITS HS29 072 1 6 J M Y HS29 090 2 6 J M Y COOLING SECTION B4I Supersedes LENNOX 2000 Lennox Industries Inc New Form No 533 540W Litho U S A Voltage passes through high pressure switch S4 ener gizing compressor contactor coil K1 K1 1 closes ener gizing compressor B1 Voltage passes through low ambient low pressure switch S11 Switch will close provided liquid line pres sure is high enough Outdoor fan coil K10 is ener gized K10 1 closes energizing outdoor fan B4 K10 2 opens de energizing HR1 crankcase heater B HS29 072 3 amp HS29 090 3 G J M Y 24V POWER 24V POWER ECONOMIZER
8. SCROLL FORM FIGURE 9 SUCTION ay ORBITING SCROLL STATIONARY SCROLL SUCTION POCKET CROSS SECTION OF SCROLLS DISCHARGE STATIONARY g SUCTION N SS N N A M NA Y Y SS S S S S SSSSSASSANM n cl k kk KKK SSS LP ELL Ld SSY SSSASAASASSY JZ SUMMOETODB 4 AIL NA NA A NA NY TIPS SEALED BY ORBITING SCROLL DISCHARGE PRESSURE FIGURE 10 IPA 7 GAS SUCTION En us INTERMEDIATE PRESSURE CRECENT SHAPED GAS POCKET FLANKS SEALED BY CENTRIFIGUAL SUCTION D S HIGH PRESURE GAS FORCE SUCTION 3x p MOVEMENT OF ORBIT 4 DISCHARGE POCKET FIGURE 11 The counterclockwise orbiting scroll draws gas into the outer crescent shaped gas pocket created by the two scrolls figure 11 1 The centrifugal action of the orbiting scroll seals off the flanks of the scrolls figure11 2 As the orbiting motion contin ues the gas is forced toward the center of the scroll and the gas pocket becomes compressed figure 11 3 When the compressed gas reaches the center it is discharged vertically into a chamber and discharge port in the top of the compressor figure 10 The discharge pressure forcing down on the top scroll helps seal off the upper and lower edges tips of the scrolls figure 10 During a single orbit several pockets of gas are compressed simultaneously providing smooth continuous compression The scroll compressor is tolerant to the effec
9. WITH NATIONAL AND LOCAL CODES COOLING UNITS CONDENSING UNITS HS29 120 5 6 J M Y COOLING SECTION B4I REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION Cooling demand energizes through thermostat termi nal Y1 Voltage passes through N C low pressure switch S87 to terminal 1 on N O timer DL33 to K167 latching relay coil and to S11 and S41 K167 1 contacts close energizing DL33 Timer begins After 5 minutes DL33 is de energized K167 2 con tacts close opening contacts 9 and 3 Indoor blower is energized Voltage passes through S4 high pressure switch ener gizing K1 compressor contactor coil K1 1 contacts close energizing compressor B1 2002 Lennox Industries Inc 4 Page 26 Supersedes 07021533 54 W New Form No 534 000W Litho U S A Voltage passes through low ambient low pressure switch S11 switch will close provided liquid line pres sure is high enough energizing K10 outdoor fan coil K10 1 closes energizing outdoor fan B4 K10 2 con tacts open de energizing HR1 crankcase heater Voltage passes through N C low ambient thermostat S41 switch will be closed provided ambient is warm enough K68 outdoor fan coil is energized K68 1 close energizing outdoor fan B5 E HS29 180 240 G J M Y 24V POWER 24V POWER _ ECONOMIZER BLOWER G HEAT 1 WI HEAT 2 W2 220 240 50 1 Bes COMPRESSOR MOTOR OUTDOOR FAN 1 B5 A MOTOR OUTDOO
10. switch S11 switch will close provided liquid line pres sure is high enough energizing K10 outdoor fan coil K10 1 closes energizing outdoor fan B4 K10 2 con tacts open de energizing HR1 crankcase heater Voltage passes through N C low ambient thermostat 541 switch will be closed provided ambient is warm enough K68 outdoor fan coil is energized K68 1 close energizing outdoor fan B5 D HS29 120 3 G J M Y TES 24V POWER DESIGNATION VOLTAGE 208 230 60 3 L 8 460 60 3 575 60 5 1380 420 50 3 7 DENOTES OPTIONAL COMPONENT CONNECTIONS M VOLTAGE UNITS ONLY WARNING 24V POWER COOL 1 1 MOTOR Q DOOR FAN MOTOR OUTDOOR FAN 2 CAPACITOR OUTDOOR FAN APA OR OQ OOR TIMER MINIMUM RUN 1 HEATER COMPRESSOR JACK TEST COOL JACK BLOWER MOTOR CONTACTOR COMPRESSOR ELAY OUTDOOR FAN 1 AY OUTDOOR FA ELAY LATCHING LUG TEST COOL b 2 2 167 1 2 56 L KEY Br B5 HRI IKi 1 IKIO 1 2 IK68 1 24V COMMON 0 0 SWITCH LIMIT HI PRESS COMP H LOW PR AMB THERMOSTAT LOW AMBIENT 587 SWITCH LOW PRESS COMP DISCONNECT ALL POWER BEFORE SERVICING FOR USE WITH COPPER CONDUCTORS ONLY IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING AND INSULATION THICKNESS ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE
11. The low pressure switch is an auto reset SPST N O switch which opens on pressure drop All HS29 units are equipped with S87 HS29 180 and 240 units are equipped with both S87 and S88 The switch is located on the suction line and is wired in series with the thermostat S87 is wired in series with Y1 and S88 is wired in series with Y2 When suction pressure drops to 25 5 psig 172 34 Pa the switch opens and the compressor is de energized The switch au tomatically resets when pressure in the suction line rises to 55 5 psig 379 34 kPa 7 Filter Drier all units All HS29 model units have a filter drier that is located in the liquid line of each refrigerant circuit at the exit of each con denser coil The drier removes contaminants and moisture from the system The drier is field installed 8 Condenser Fan B4 all units B5 120 180 240 B21 amp B22 180 240 See page 2 for the specifications on the condenser fans used in the HS29 units All condenser fans have single phase motors The HS29 072 and 090 units are equipped with a single condenser fan The HS29 120 is equipped with two fans HS29 180 and 240 units have four fans The fan assembly may be removed for servicing by removing the fan grill and turning the assembly until the motor brack ets line up with the notches in the top panel Lift the assem bly out of the unit and disconnect the jack plug on the motor 9 Hot Gas By Pass Kit Optional 072 090 120
12. charge Units are designed for line sets up to 50ft 15 2m Consult Lennox Refrigerant Piping Manual for line sets over 50ft 51 2m TABLE 2 UNT HCFC 22 FOR 25 FT 7 6M Adjust per 1ft LINE SET 3m HS29 072 12 Ibs 8 ozs 5 7kg 1 8 ozs 519 16 Ibs 0 ozs 7 5kg 17 Ibs 8 ozs 7 94 1 8 ozs 519 HS29 090 2 HS29 090 3 HS29 120 23 Ibs 8 ozs 10 4kg 1 8 ozs 519 If line set is greater than 25 ft 7 6m add this amount If line set is less than 25 ft 7 6m subtract this amount TABLE 3 HCFC 22 per 25 ft 7 6m HS29 180 14 5 Ibs 14 5 Ibs 1 8 ozs 51 0 6 6kg 6 6 kg Adjust per 1 ft 3m HS29 240 22 Ibs 22 lbs 1 8 ozs 51 g 10kg 10 kg If line set is greater than 25 ft 7 6m add this amount If line set is less than 25 ft 7 6m subtract this amount A WARNING Never use oxygen to pressurize refrigeration or air conditioning system Oxygen will explode on con tact with oil and could cause personal injury A Leak Testing Using an Electronic or Halide Leak Detector 1 Connect a cylinder of HCFC 22 with a pressure regu lating 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 da
13. counterclock wise until the valve stem just touches the retaining ring 3 Replace stem cap tighten firmly Tighten finger tight then tighten an additional 1 6 turn Do not over torque To Close Suction Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and turn stem in clockwise to seat the valve Tighten firmly 3 Replace stem cap Tighten finger tight then tighten an additional 1 6 turn Do not over torque 2 Suction Line Service Valve HS29 072 1 A full service front and back seating suction line service valve is used on HS29 072 1 series units Different manufacturers of valves may be used All suction line service valves function the same way differences are in construction Valves manufactured by Parker are forged assemblies Primore and Aeroquip valves are brazed together Valves are not rebuildable If a valve has failed it must be replaced The suction line service valve is illustrated in figure 18 The valve is equipped with a service port There is no schrader valve installed in the suction line service port A Service port cap is supplied to seal off the port 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 tighten an additional 1 6 turn Do not over torque To Open Suction Line Service Valve 1 Remove stem cap
14. de superheat valve will add liquid refrig Page 11 erant to cool the vapor to acceptable temperatures for the compressor Superheat is the difference between the tem perature of the refrigerant vapor and its saturation temper ature b Hot Gas Bypass Valve The hot gas bypass valve responds to changes down stream of the hot gas injection into the suction line or suc tion pressure When the evaporating pressure is above the valve setting the valve remains closed As the suction pressure drops below the valve setting the valve responds and begins to open As the suction pressure continues to drop the valve continues to open farther until limit of valve stroke is reached c Service Valve All hot gas by pass kits are equipped with a service valve located in the mixing line The service valve is manually op erated valve The service port is used for leak testing and evacuating HS29 072 3 HOT GAS BYPASS TO SUCTION LINE ASSEMBLY low ambient CER pressure 01 switch R high pressure switch C Discharge line Discharge line 4 K Mixing line low pressure switch L Suction line Liquid line K L N Discharge line O Liquid line R Mixing line O Shaded components are provided in kit FIGURE 13 Page 12 HOT GAS BYPASS TO SUCTION SCHEMATIC FLOW DIAGRAM CONDENSING EVAPORATOR UNIT UNIT 1 i pos DISCHARGE EVAPORATOR DE SUPERHEATING VAL
15. located in the suction and liquid lines The service valves are manual ly operated See figures 16 17 18 and 19 The service ports are used for leak testing evacuating charging and checking charge 1 Liquid Line Service Valve The liquid line valve made by one of several manufacturers may be used All liquid line service valves function the same way differences are in construction Valves are not rebuildable If a valve has failed it must be replaced All HS29 072 090 and 120 units and HS29 180 240 2 units produced after 10 01 01 use valves shown in figure 16 HS29 180 240 units produced before 10 01 01 use valves shown in figure 17 A schrader valve is factory installed A service port is supplied to protect the schrader valve from contamination and to serve as the primary leak seal To Access Schrader Port All HS29 UNITS 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 Do not over torque Page 15 Liquid And Suction Line Service Valve stem ca insert hex wrench here service port to outdoor coil A service port Schrader to indoor coil cap valve Liquid And Suction Line Service Valve stem cap service to outdoor coil insert hex wrench here service port cap to indoor coil Schrader valve open valve front seated to line s
16. operation increases indoor evaporator coil temperature to prevent icing 9 Condenser Fan Relay K10 all units K68 120 180 240 K149 K150 180 240 Condenser fan relays K10 and K149 are DPDT and relays K68 and K150 are SPDT with a 24V coil In all units K10 en ergizes condenser fan B4 fan 1 in response to thermostat demand In the HS29 120 180 and 240 K68 energizes condenser fan B5 fan 2 in response to thermostat de mand In the HS29 180 240 K149 and K150 energize condenser fans B21 fan 3 and B22 fan 4 in response to thermostat demand GFI J11 Option on HS29 1 and 2 units Some HS29 units may be equipped with a 110v ground fault interrupter GFI receptacle The GFI is located on the control box panel on the HS29 072 090 and 120 The GFI is located in a separate box on the opposite side of unit form the control box on the HS29 180 240 Separate wiring must be run for the 110v receptacle 10 Circuit Breaker CB7 180 240 Y only Circuit breaker CB7 is a manual reset switch that provides overcurrent protection to condenser fans B4 B5 B21 and B22 The breaker is rated at 15 amps B COOLING COMPONENTS A WARNING Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may result in person al injury or death 1 Compressor B1 all units B2 180 240 ALL HS29 072 090 120 and 180 240 model units use scroll compressors Compre
17. A PRIMARY OF 24 VOLT TRANSFORMER MUST BE PHASED WITH B4 FAN MOTOR EXAMPLE IF MOTOR IS HOOKED TO LI amp L3 TRANSFORMER PRIMARY MUST ALSO BE HOOKED ACROSS LI amp L3 WITH SII ON OFF FAN LOW AMBIENT CONTROL dd WITH A46 VARIABLE LOW AMBIENT CONTROL COOL I YI RTIS DISCONNECT ALL POWER BEFORE SERVICING 24V COMMON M VOLTAGE UNITS ONLY A REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION CI C DesienaTion _ voLrAge 6G X 4060 60 35 575 60 5 Mw 380 420 50 3 KEY OMPONEN A45 CONTROL OUTDOOR N B4 MOTOR OUTDOOR FAN CI CAPACITOR OUTDOOR FAN 1 HEATER COMPRESSOR 356 JACK 00 J45 CT JACK BLOWER MOTOR CONTACTOR COMPRESSOR IK167 1 2 RELAY LATCHING 1 PsSoG PLUG TEST COOL P425 PLUG DLOWER MOTOR 8 0 SENSOR AMBIENT ISI SWITCH LOW PRESS LOW AMB KIT SWITCH LOW PRESS COMP TRANSFORMER HOFFMAN CONTROL FOR USE WITH COPPER CONDUCTORS ONLY IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING AND INSULATION THICKNESS WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES DENOTES OPTIONAL COMPONENT CONNECTIONS COOLING UNITS CONDENSING 529 072 3 6 J M Y
18. COMPRESSOR C COMMONBLACK e Page 28
19. HS29 090 5 6 J M Y COOLING SECTION B4I 0702 New Form No 534 017W 2002 Litho U S A 1 Cooling demand energizes at thermostat terminal Y1 Voltage passes through high pressure switch S4 ener Voltage passes through N C low pressure switch S87 gizing compressor contactor coil K1 K1 1 closes ener to terminal 1 on timer DL33 and K167 latching relay gizing compressor B1 coil and to S11 low ambient low pressure switch 4 Voltage passes through low ambient low pressure 2 K167 1 closes energizing timer DL33 Timer begins switch S11 Switch will close provided liquid line pres After 5 minutes DL33 is de energized K167 2 con tacts close opening contacts 9 and 3 Indoor blower is energized sure is high enough Outdoor fan coil K10 is ener gized K10 1 closes energizing outdoor fan B4 K10 2 opens de energizing HR1 crankcase heater Page 24 C HS29 120 2 G J M Y 1 24V POWER _ ECON BLOWER 24V COMMON DISCONNECT ALL POWER BEFORE SERVICING DENOTES OPTIONAL A sA COMPONENT CONNECTIONS M VOLTAGE g UNITS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING AND INSULATION THICKNESS 120 1 60 Cooling demand energizes through thermostat termi nal Y1 Voltage passes through N C low pressure Switch S87 to terminal 1 on N O tim
20. O COMPRESSOR SERVICE R SERVICE PORT CAP FROM INDOOR COIL NO VALVE CORE NOTE When valve is front seated service port is not isolated blocked off from system FIGURE 18 SUCTION LINE BALL TYPE SERVICE VALVE HS29 072 2 3 HS29 090 120 180 240 USE ADJUSTABLE WRENCH ROTATE STEM CLOCKWISE 90 TO CLOSE ROTATE STEM COUNTERCLOCKWISE 90 TO OPEN STEM CAP TO COMPRESSOR FIGURE 19 Page 17 IlI STARTUP The following is a general procedure and does not apply to all thermostat control systems Refer to sequence of op eration in this manual for more information WARNING Crankcase heaters must be energized for 24 hours before attempting to start compressors Set ther mostat so there is no compressor demand before closing disconnect switch Attempting to start compressors during the 24 hour warm up period could result in damage or failed compressors 1 Set fan switch to AUTO or ON and move the system selection switch to COOL Adjust the thermostat to a setting far enough below room temperature to bring on compressors Compressors will start and cycle on de mand from the thermostat allowing for unit and thermo stat time delays 2 Each circuit is field charged with HCFC 22 refrigerant See unit name plate for correct charge amount 3 Refer to Charging section for proper method of check ing and charging the system A IMPORTANT Three phase scroll compressors must be phased sequentially t
21. Page 19 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 mi nus vacuum pressure 6 When the absolute pressure reaches 23mm of mercu ry close the manifold gauge valves turn off the vacu um pump and disconnect the manifold gauge center port hose from vacuum pump Attach the manifold cen ter port hose to a nitrogen cylinder with pressure regu lator set to 150 psig 1034 kPa and purge the hose Open the manifold gauge valves to break the vacuum in the line set indoor unit and outdoor unit Close the manifold gauge valves A CAUTION Danger of Equipment Damage Avoid deep vacuum operation Do not use com pressors to evacuate a system Extremely low vacuums can cause internal arcing and compressor failure Damage caused by deep vacuum operation will void warranty 7 Shutoff 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 indoor unit and outdoor unit 8 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 Depending on the equipment used to de
22. R FAN 2 B2 MOTOR OUTDOOR FAN 3 Be2 MOTOR OUTDOOR FAN 4 CAPACITOR OUTDOOR FAN C2 CAPACITOR OUTDOOR FAN 2 CIB X CAPACITOR OUTDOOR FAN 5 CIO CB7 RED 208V APA OR 0U R FAN 4 CIRCUIT BREAKER OUTDOOR FANS P36 4 J36 J36 43 ecm TIMER MINIMUM RUN C DL33 KI BLACK COM TIMER MINIMM RUN2 58 HEATER COMPRESSOR HEATER COMPRESSOR 2 K QO md 24V COMMON 24V COMMON DENOTES OPTIONAL COMPONENT CONNECTIONS ACK BLOWER M CONTACTOR COMPRESSOR CONTACTOR COMPRESSOR 2 ELAY OUTDOOR FAN K58 1 2 RELAY LOW AMB K66 1 2 S RELAY STAGE 1 COOL K67 1 2 5 RELAY STAGE 2 COOL W H LOW PR OW AMD K S4 THERMOSTA QW AMBIENT K S84 SWITCH LOW PRESS LOW AMB COMP 2 587 SWITCH LOW PRESS COMP CB7 USED ON Y S88 SWITCH LOW PRESS COMP 2 VOLTAGE UNITS ONLY TIB TRANSFORMER CONTACTOR REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION M VOLTAGE UNITS ONLY COOLING UNITS CONDENSING HS29 180 2 6 J M Y WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR HS29 240 2 G J M Y DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES COOLING SECTION Ot s LETTER DESIGNATION VOLTAGE FOR USE WITH COPPER CONDUCTORS ONLY 0702 523 512W 208 230 60 3 DISCONNECT ALL POWER BEFORE SERVICING 6G J 4650 60 3 No 575 60 3 IF ANY WIRE IN THIS APPLIANCE IS
23. RE SWITCH S4 LOW AMBIENT SWITCH 514 on liquid line not shown LOW PRESSURE SWITCH S87 on suction line not shown FIGURE 2 Page 4 B4 CONTROL BOX HIGH PRESSURE SWITCH S4 e LOW PRESSURE SWITCH S87 COMPRESSOR B1 HS29 120 3 PARTS ARRANGEMENT CONDENSER FANS B4 B5 CONTROL BOX SUCTION LINE SERVICE VALVE e LIQUID LINE SERVICE VALVE HS29 180 amp HS29 240 PARTS ARRANGEMENT B21 B22 B4 CONDENSER FANS B4 B5 B21 B22 SLIDE OUT CONTROL BOX LOW PRESSURE ACCESS PANEL b SWITCH S87 LOW PRESSURE un SUCTION LINE SWITCH S88 a SERVICE VALVE TYP HIGH PRESSURE SWITCH S7 LOW AMBIENT 5 UN be d il M Lees 4 LIQUID LINE o af b SERVICE VALVE TYP HIGH PRESSURE Eh COMPRESSOR B1 SWITCH S4 zx 1st STAGE COOL COMPRESSOR B2 LOW AMBIENT SWITCH 2nd STAGE COOL S11 ON LIQUID LINE NOT SHOWN FIGURE 3 HS29 072 amp HS29 090 CONTROL BOX outdoor fan relay latching relay minimum K10 K167 run timer DL33 ground lug contactor capacitor K1 C1 FIGURE 4 Page 5 HS29 120 CONTROL BOX outdoor fan outdoor fan relay 1 K10 relay 2 K68 minimum run timer
24. The hot gas bypass kit is used with split system units requir ing capacity reduction up to 6 tons capacity reduction in order to prevent evaparator coil icing due to abnormally low suction pressure The kit consists of De superheating valve bypass to the suction line only hot gas by pass valve and service valve The de superheating valve is pressure compensated temperature activated The hot gas bypass valve is pressure activated The kit will redirect hot gas to the evaporator where applications call for a single indoor unit matched with a single outdoor unit and are installed close together or into the suction line which is preferred in applications with multiple evaporators or long refrigerant lines BYPASS TO EVAPORATOR FIGURE 12 The discharge bypass valve is factory set to begin opening at a suction pressure of 57 5 psig 32 F 0 C saturation temperature The valve should reach its fully open position at a suction pressure of 50 psig 26 F 3 C saturation temperature The hot gas is then bypassed into the evaporator coil through the side connection distributor The coil s thermal expansion valve responds to the increased superheat of the vapor by opening to supply liquid refrigerant to cool the hot gas to the desired temperature Also since the evapo rator is an excellent mixing chamber a dry vapor going into the compressor suction line is ensured For flow diagram see figure 15 This method improves oil return from the evap
25. VE UNIT 2 MANUAL SHUT OFF VALVE o 4 2l DN 2 E A Z o COMPRESSOR LIQUID LINE SERVICE VALVE FIGURE 14 Hot Gas Bypass Performance Check 1 Start unit After unit operating conditions have sta bilized check unit volts and amps These must be within range shown on unit nameplate Remove unit access panel Determine whether or not unit is operating normally in hot gas bypass mode The unit is operating normally in hot gas by pass mode to the suction line if suction line super heat temperatures range from 35 F 19 5 C to 45 25 C with suction line pressures less than 57 5 psig 32 0 C saturated temperature The unit is operating normally without hot gas bypass if suction line superheat temperatures range from 10 F 5 5 C to 20 F 11 C with suction line pressures greater than 57 5psig 32 F 0 C saturated temper ature The unit is operating normally in hot gas by pass mode to the evaporator if suction line super heat temperatures are greater than 20 F 11 C with suction line pressures greater than or equal to 57 5 psig 32 F 0 C saturated temperature The unit is Page 13 SUCTION LINE p VALVE SOLENOID VALVE SOLENOID VALVE operating normally without hot gas bypass if suction line superheat temperatures range from 10 F 5 5 C to 20 F 11 C with suction line and discharge pres sures occurring within the range listed in table 4 on page18 Note S
26. approach temperature greater than the value shown indicates an undercharge An approach temperature that is less than the value shown indicates an overcharge TABLE 7 Approach Method MODEL NO LIQUID TEMP MINUS AMBIENT TEMP F C HS29 072 1 2 3 12 1 6 7 5 HS29 072 1 2 3 16 1 8 9 5 Note For best results use the same digital thermometer check both outdoor ambient and liquid line temperature at the exit of the condenser Matched with CB30U 65 or typical 5 ton indoor evaporator Matched with CB17 CBH17 95V Matched with CB17 CBH17 135V HS29 180 HS29 240 ONLY Use subcooling method to confirm readings Charge Verification Using the Subcooling Method 1 Use the same thermometer to take both liquid line temperature and outdoor ambient temperature 2 Note the liquid line pressure and convert the value to the saturated condensing temperature using a stan dard HCFC 22 temperature pressure table or the con version scale on the gauge TABLE 8 Subcooling Values Outdoor Coil Temperature 1 1 F 1 F 1 F 65 F 18 C 9 8 12 133 75 24 10 9 B 3 Subtract the liquid line temperature from the saturated condensing temperature to calculate the subcooling value Saturated condensing temperature Liquid line temperature Subcooling value The subcooling val ue should approximate the corresponding value found in table 8 4 Add ref
27. e to electrostatic discharge by putting the unit the control and the technician at the same electrostatic potential Neutralize electro static charge by touching hand and all tools on an unpainted unit surface before performing any service procedure The HS29 072 090 components are shown in figure 1 The HS29 120 components are shown in figure 2 and the HS29 180 240 components are in figure 3 A CONTROL BOX COMPONENTS The HS29 072 090 control box components are shown in figure 4 The HS29 120 control box components are shown in figure 5 and the HS29 180 240 control box components are in figure 6 The control box for the HS29 072 090 and 120 units is located in a separate compartment The HS29 180 240 has a slide out control box 1 Disconnect Switch S48 Option on HS29 1 and 2 units Some HS29 units may be equipped with an optional dis connect switch S48 S48 is a factory installed toggle switch which can be used to disconnect power to the unit S48 is located on the opposite side of the unit from the control box on HS29 180 240 units 2 Transformer T18 180 240 The HS29 15 and 20 ton units use a line voltage to 24VAC transformer mounted in the control box Trans former T18 supplies power to control circuits in the HS29 unit The transformer is rated at 70VA and is pro tected by a 3 5 amp circuit breaker CB18 CB18 is in ternal to the transformer The 208 230 Y voltage trans formers use two primary voltage taps as sh
28. ed as any gas that will not condense under temperatures and pressures present during operation of an air conditioning sys tem Non condensables such as water vapor nitrogen he lium and air combined with refrigerant to produce substances that corrode copper piping and compressor parts NOTE The compressor should never be used to evacuate a refrigeration or air conditioning system 1 Slowly open service valves to purge unit of factory holding charge of air and helium to the atmosphere 2 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 A CAUTION A temperature vacuum gauge mercury vacuum U tube or thermocouple gauge should be used The usual Bourdon tube gauges are not accurate enough in the vacuum range Connect the vacuum pump with vacuum gauge to the center port of the manifold gauge set 4 Open both manifold valves and start vacuum pump 5 Evacuate the HS29 unit the line set and indoor unit to an absolute pressure of 28mm 23 000m of mercury or approximately 1 inch of mercury During the early stages of evacuation it is desirable to close the man ifold gauge valve at least once to determine if there is a rapid rise in absolute pressure A rapid rise in pres sure indicates a relatively large leak If this occurs the leak testing procedure must be repeated after the leak is repaired
29. ee figure 13 for location of pressure tempera ture measurement for by pass to the suction line Re move low pressure switch during pressure measure ment then re install upon completion For by pass to the evaporator take pressure temperature measure ment close to compressor Note Superheat values are calculated as follows a measure suction line pressure for example 57 5 psig b convert 57 5 psig via pressure temperature chart for HCFC 22 to 32 F 0 C saturation temperature c measure suction line temperature for example 77 F 25 C d then superheat 77 F 25 C 32 F 0 C 45 F 25 C a BYPASS TO EVAPORATOR SCHEMATIC FLOW DIAGRAM CONDENSING UNIT DISCHARGE BYPASS MANUAL SHUT OFF CONDENSER COIL SUCTION LINE COMPRESSOR iN LIQUID LINE SERVICE J SERVICE VALVE CB17 CBH17 95 BLOWER COIL UNIT EVAPORATOR COIL 2 SIDE CONNECTION DISTRIBUTOR CHECK VALVE EVAPORATOR COIL 1 L R 2 EUN SOLENOID VALVE FIGURE 15 If unitis operating normally without hot gas bypass initiate hot gas bypass by either gradually closing liquid line service valve reducing air flow to evapo rator s or in multi evaporator units shutting off an evaporator s If normal hot gas bypass suction line superheat and pressures are not obtained check the following Pressures are less than 57 5 psig for both by pass to the suction line or evaporator If bypass to the evaporator super
30. er DL33 to K167 latching relay coil and to S11 and S41 K167 1 contacts close energizing DL33 Timer begins After 5 minutes DL33 is de energized K167 2 con tacts close opening contacts 9 and 3 Indoor blower is energized Voltage passes through S4 high pressure switch ener gizing K1 compressor contactor coil K1 1 contacts close energizing compressor B1 FOR USE WITH COPPER CONDUCTORS ONLY 24V POWER ECONOMIZER _ K167 2 BLOWER G Or m 2 le L HEAT OMNI _ HEAT 2 W2 COOL I YI DESIGNATION VOLTAGE Y 1208 230 60 5 08 230 60 G O 1 460 60 3 575 60 5 M 1380 420 50 ON COMPONENT Q MOTOR OUTDOOR FAN MOTOR OUTDOOR FAN 2 PACITOR OUTDOOR FA APACITOR OUTDOOR FAN HEATER COMPRESSOR JACK GFI RECEPTACLE 1 1 JACK TEST COOL 8 CONTACTOR COMPRESSOR IK10 1 2 RELAY OUTDOOR FAN IK68 1 DOOR AN 167 1 2 RELAY LATCHING I RELAY O PLUG TEST COOL SWITCH LIMIT HI PRESS COMP W H LOW PR QW AMD K THERMOSTAT LOW AMBIENT KIT SWITCH DISCONNECT ee eee SHOCK HAZARD CAN CAUSE INJURY OR ATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES LENNOX COOLING UNITS CONDENSING UNITS HS29 120 2 6 J M Y COOLING SECTION B4I New Form No 5355 541W 2000 Lennox Industries Inc 4 Page 25 Litho U S A Voltage passes through low ambient low pressure
31. et when valve is closed front seated FIGURE 16 HS29 072 090 120 To Open Liquid Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and 5 16 hex head extension if needed part 49A71 back the stem out counterclock wise until the valve stem just touches the retaining ring 3 Replace stem cap Tighten finger tight then tighten an additional 1 6 turn Do not over torque A DANGER HS29 1 and 2 units are equipped with service valves with a retaining ring Do not attempt to backseat these valves past the retaining ring past the Attempts to backseat these valves retaining ring will cause snap ring to explode from valve body under pressure of refrigerant Personal injury and unit damage will result To Close Liquid Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and 5 16 hex head extension if needed part 49A71 turn stem clockwise to seat the valve Tighten firmly Replace stem cap Tighten finger tight then tighten an additional 1 6 turn Do not over torque 6 LIQUID LINE SERVICE VALVE VALVE OPEN HS29 180 240 INSERT WRENCH HERE OUTLET TO INDOOR COIL RETAINING RING 2 early HS29 models only a OUTLET TO INDOOR COIL VALVE FRONT SEATED FIGURE 17 HS29 180 240 To Open Liquid Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench back the stem out
32. ff selection at the indoor thermostat mode This 5 min ute run time also allows oil circulation back to the compres sor DL33 and DL34 are one component of an integral two component run time circuit The timer is activated by an in put from the latching relay Do not bypass the control 7 Latching Relay K167 all units amp K168 180 240 Latching relays K167 1st stage and K168 2nd stage are 3PDT relays used in all units Units with a single com pressor will use DPDT relays When there is demand from the indoor thermostat K167 closes energizing timer DL33 which begins a 5 minute minimum run time If thermostat demand is satisfied or low pressure switch S87 opens with in the 5 minute run time DL33 will maintain input to the latch relay to keep the system operating In the HS29 180 240 units K167 and K168 close energizing tim ers DL33 and DL34 8 Low Ambient Thermostat S41 120 180 240 amp Relay K58 180 240 HS29 120 and HS29 180 240 units have a low ambient thermostat S41 is a N C switch which opens on tempera ture fall at 55 5 F The switch resets when temperature rises to 65 6 F On the HS29 120 S41 opens and de en ergizes K68 which de energizes outdoor fan B5 On the HS29 180 240 S41 opens and de energizes low ambient DPDT relay K58 This in turn de energizes fan relays K68 and K150 which de energize outdoor fans B5 and B22 When S41 closes fans are re energized on all units This intermittent fan
33. fm L s total air volume 4500 2125 5150 2430 8200 3870 Rpm 1075 1060 1100 Watts 600 570 700 total Shipping lbs kg 1 package 319 145 405 184 567 257 Optional Accessories Must Be Ordered Extra Hail Guards 29M43 29M44 79K91 Hot Gas Bypass Kit bypass to suction 28M73 79K90 89K84 Hot Gas Bypass Kit bypass to evaporator 28M72 93K77 93K78 ELECTRICAL DATA General Model No HS29 072 3 HS29 090 3 HS29 120 3 Data Line voltage data 60 hz 3 phase 208 230v 460v 575v 208 230v 460v 575v 208 230v 460v 575v Recommended maximum fuse or 40 20 15 60 35 25 80 40 25 circuit breaker size amps TMinimum circuit ampacity 27 18 11 40 21 16 54 25 18 Compressor No of Compressors 1 1 1 1 1 1 1 1 1 Rated load amps total 18 6 9 74 288 14 7 10 8 378 17 2 124 Locked rotor amps total 156 75 195 95 80 239 125 80 Condenser No of motors 1 1 1 1 1 1 2 2 2 Full load amps total 15 12 37 9 6 24 13 3 4 8 26 2 Locked rotor amps total 6 3 2 9 7 8 37 3 4 47 24 19 9 4 4 8 3 8 TRefer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements NOTE Extremes of operating range are plus and minus 10 of line voltage TIHACR type under 100 amps U S only HS29 072 3 amp HS29 090 3 PARTS ARRANGEMENT HS29 072 3 shown CONDENSER FAN LOW AMBIENT SWITCH S11 CCS LIQUID LINE SERVICE VALVE COMPRESSOR B1 HIGH PRESSU
34. heat values are less than 20 F 11 C The manual shut off valve may be closed Open it The discharge bypass valve may not be opening b SIDE CONNECTION DISTRIBUTOR CHECK vave P EXPANSION VALVE the correct amount Check to make sure that the valve core has been removed from the suction line pressure tap fitting The hot gas bypass circuit may be operating with an evaporator load of less than the 2 ton mini mum If bypass to the suction line superheat values are greater than 45 F 25 C The de superheating valve may not be opening the correct amount Check to make sure the sensing bulb has adequate thermal contact with the suction line 5 Re install unit access panel Page 14 ll REFRIGERANT SYSTEM A Plumbing Field refrigerant piping consists of liquid and suction lines from the condensing unit sweat connections to the indoor evaporator coil sweat connections Refer to table 1 for field fabricated refrigerant line sizes Refer to Lennox Re frigerant Piping manual Corp 9351 L9 for proper size type and application of field fabricated lines Separate dis charge and suction service ports are provided at the com pressor for connection of gauge manifold during charging procedure TABLE 1 REFRIGERANT LINE SIZES HS29 LIQUID SUCTION UNIT LINE LINE 5 8 in 1 1 8 in 090 120 180 240 5 8 in 1 3 8 in 16 mm 85 mm B Service Valves All HS29 units are equipped with service valves
35. latching relay coil 12 K168 1 contacts close energizing DL34 Timer begins After 5 minutes DL34 is de energized 13 Voltage passes through S7 high pressure switch ener gizing K2 compressor contactor coil K2 1 contacts close energizing compressor B2 14 K168 2 contacts close Contacts 8 and 2 open energiz ing indoor blower 15 K168 3 contacts close sending voltage to K58 low am bient contact terminal 6 16 K67 2 contacts close Voltage passes through S84 low ambient pressure switch switch will close provided liq uid line pressure is warm enough to outdoor fan relay coil K149 17 K149 1 contacts close energizing outdoor fan B21 K149 2 contacts close de energizing HR2 crankcase heater 18 K67 3 contacts close sending voltage through S41 low ambient limit switch will closed provided ambient is high enough to low ambient relay coil K58 K58 2 con tacts close energizing K150 outdoor fan relay coil K150 1 contacts close energizing B22 outdoor fan HS29 FIELD WIRING WITH BLOWER COIL UNIT AND AUXILIARY ELECTRIC HEAT THERMOSTAT HS29 CONDENSING UNIT YELLOW Y1 BLUE Y2 GREEN G LER A CB17 CBH17 WITH EH17 ELECTRIC HEAT G FAN e W1 HEAT WHITE e GREEN 24 BLUE GRAY 24V C Te G WIRE MUST BE ROUTED FROM THERMOSTAT TO CONDENSING UNIT AS SHOWN TO PROVIDE BLOWER INTERLOCK WITH THE
36. mage 3 With both manifold valves closed open the valve on the HCFC 22 bottle vapor only 4 Open the high pressure side of the manifold to allow HCFC 22 into the line set and indoor unit Weigh in a trace amount of HCFC 22 A trace amount is enough to equal 3 pounds 31 kPa pressure Close the valve on the HCFC 22 bottle and the valve on the high pres sure side of the manifold gauge set Disconnect HCFC 22 bottle 5 Connect a oylinder of nitrogen with a pressure regulat ing valve to the center port of the manifold gauge set 6 Adjust nitrogen pressure to a maximum 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 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 HCFC 22 mixture Correct any leaks and recheck 8 If brazing is necessary for repair bleed enough nitrogen through the system to ensure all oxygen is displaced Brazing with oxygen in the system will create copper ox ides which may cause restrictions the failure of compo nents and will affect the dielectric of refrigerant oil causing premature compressor failure Page 18 B Evacuating the System Evacuating the system of non condensables is critical for proper operation of the unit Non condensables are defin
37. o ensure correct compressor rota tion and operation At compressor start up a rise in discharge and drop in suction pressures indi cate proper compressor phasing and operation If discharge and suctions pressures do not perform normally follow the steps below to correctly phase in the unit Disconnect power to the unit 2 Reverse any two field power leads L1 and L3 pre ferred to the unit 3 Reapply power to the unit Discharge and suction pressures should operate at their normal start up ranges NOTE Compressor noise level will be significantly higher when phasing is incorrect and the unit will not provide cool ing when compressor is operating backwards Continued backward operation will cause the compressor to cycle on internal protector IV CHARGING A WARNING Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may result in person al injury or death HS29 units are to be field charged with the amount of HCFC 22 refrigerant indicated on the unit nameplate or unit Installation Instructions This charge is based on a matching indoor coil and outdoor coil with a 25 foot 7 6 m line set For varying lengths of line set and refrigerant charge refer to table 2 for HS29 072 HS29 090 and HS29 120 series units and table 3 for HS29 180 and HS29 240 units A blank space is provided on the unit rat ing plate to list actual field
38. orator since the hot gas keeps velocities higher Refer to Refrigerant Piping Guideline manual Corp 9351 L9 Page 10 HS29 072 3 HOT GAS BYPASS TO EVAPORATOR PLUMBING ASSEMBLY e WERE BREWS SS V NES Ses M liquid line ae Ka t s F e E Discharge line F Mixing line G Discharge line H Discharge line Suction line J Mixing line Shaded Components Provided In Kit high pressure switch C1 low pressure switch FIGURE 12 BYPASS TO SUCTION LINE FIGURE 13 The discharge bypass valve is factory set to begin opening at a suction pressure of 57 5 psig 82 F 0 C saturation temperature The valve should reach its fully open position at a suction pressure of 50 psig 26 F 3 C saturation temperature The hot gas is then bypassed into the suction line upstream of the thermal sensing bulb The de superheating thermal expansion valve then opens to supply liquid refrigerant to cool the hot gas to the desired suction temperature This method reduces flow through the evaporator and suc tion lines Special handling of suction risers is required Re fer to Refrigerant Piping Guideline manual Corp 9351 19 For flow diagram see figure 14 a De Superheat Valve TXV The de superheat valve together with the hot gas bypass valve de super heats the vapor going back to the com pressor In order to maintain proper compressor operating temperatures the
39. own in figure 208 230V TRANSFORMER While 460 G and 575 BLUE YELLOw J voltage transformers SECONDARY use a single primary voltage tap VOL PRIMARY ORANGE FIGURE 7 BLACK NOTE 208 volt units are field wired with the red wire connected to control transformer 230 volt units are factory wired with the orange wire connected to control transfomer primary Page 7 3 Terminal Strip TB35 180 240 TB35 terminal strip distributes 24V power and common from the transformer T18 to the control box components 4 Condenser Fan Capacitors C1 C2 C18 C19 All HS29 units use single phase condenser fan motors Motors are equipped with a fan run capacitor to maximize motor effi ciency Condenser fan capacitors C1 C2 C18 and C19 assist in the start up of condenser fan motors B4 B5 B21 and B22 Capacitor ratings will be on condenser fan motor nameplate 5 Compressor Contactor K1 all units K2 180 240 All compressor contactors are three pole double break contactors with a 24V coil In HS29 072 090 and the HS29 120 units K1 energizes compressor B1 In HS29 180 240 units K1 and K2 energize compressors B1 and B2 6 Minimum Run Timer DL33 all units DL34 180 240 All HS29 units have a minimum run time control which pre vents the compressor from short cycling The timer allows the compressor to run approximately 5 minutes before shut down to prevent short cycling due to irregular or rapid on o
40. plies A WARNING A WARNING Improper installation adjustment alteration Refrigerant can be harmful if it is inhaled Refrigerant service or maintenance can cause property must be used and recovered responsibly damage personal injury or loss of life Installation and service must be performed by a qualified installer or service agency Failure to follow this warning may result in person al injury or death TABLE of CONTENTS Introduction 1 START UP Page 17 Specifications Electrical Page 2 IV CHARGING Page 18 Parts Arrangement Page 4 V MAINTENANCE Page 22 I UNIT COMPONENTS Page 7 VI WIRING amp OPERATION SEQUENCE II REFRIGERANT SYSYTEM Page 15 l ANTEP aa ade Page 23 Technical Page 1 2001 Lennox Industries Inc Publications Litho U S A SPECIFICATIONS Model No HS29 072 1 2 HS29 090 2 HS29 120 2 HS29 180 2 HS29 240 2 Nominal Size Tons kW 6 21 1 7 5 26 4 10 35 2 15 52 8 20 70 3 Liquid line in mm connection sweat 5 8 15 9 2 5 8 15 9 Suction line mm connection sweat 1 1 8 28 6 1 3 8 34 9 2 1 3 8 34 9 Wr Outer coil 1292 120
41. pressor B1 and heater HR2 is wrapped around compressor B2 HR1 and HR2 assure proper compressor lubrication at all times 4 High Pressure Switch S4 all units amp S7 120 180 240 The high pressure switch is a manual reset SPST N C switch which opens on a pressure rise The switch is lo cated in the compressor discharge line and is wired in se ries with the compressor contactor coil When discharge pressure rises to 450 10 psig 3101 69 kP the switch opens and the compressor is de energized 5 Low Ambient Switch S11 all units amp S84 180 240 The low ambient switch is an auto reset SPST N O pres sure switch which allows for mechanical cooling operation at low outdoor temperatures All LSA units are equipped with S11 HS29 180 and 240 units are equipped with both S11 and S84 A switch is located in each liquid line In all HS29 units S11 is wired in series with fan relay K10 In the HS29 180 and 240 S84 is wired in series with fan relay K149 When liquid pressure rises to 275 10 psig 1896 69 kPa the switch closes and the condenser fan is ener gized When the liquid pressure drops to 150 10 psig 1034 69 kPa the switch opens and the condenser fan in that refrigerant circuit is de energized This intermittent fan operation results in higher evaporating temperature allow ing the system to operate without icing the evaporator coil and losing capacity 6 Low Pressure Switches S87 all units S88 180 240
42. rigerant to increase the subcooling value Re move refrigerant to reduce the subcooling value Charge adjustments should be done in increments and the system should be allowed to stabilize between ad justments D Oil Charge See compressor nameplate for oil charge V MAINTENANCE IMPORTANT CAUTION If insufficient cooling occurs the unit should be gauged and refrigerant charge checked Electrical shock hazard Turn off power to unit be fore performing any maintenance cleaning or ser vice operation on the unit At the beginning of each heating or cooling season the system should be cleaned as follows B Indoor Unit 1 Clean or change filter if necessary 2 Clean coil if necessary A Outdoor Unit 3 Check connecting lines and coil for leaks 1 Clean and inspect condenser coil Coil may be flushed 4 Check condensate line and clean if necessary with water hose 5 Adjust blower speed for cooling The pressure drop 2 Visually inspect all connecting lines joints and coils for over the coil should be measured to determine the cor evidence of oil leaks rect blower CFM Refer to unit information service 3 Condenser fan motor is prelubricated and sealed No manual for pressure drop tables and procedure tuner Ubrcatiowis needed 6 On belt drive blowers check belt for wear and proper 4 Check wiring for loose connections tension Check pulleys for wear Anything less than a 5 Check for co
43. rrect voltage at unit unit operating true V should be replaced 6 Check amp draw of condenser fan motor s 7 Check wiring for loose connections y je 8 Check for correct voltage at unit unit operating Unit nameplate Actual 9 Check amp draw on blower motor Unit nameplate Actual Unit nameplate Actual Page 22 VI Wiring Diagram and Sequence of Operation A HS29 072 1 2 amp HS29 090 2 G J M Y 24V POWER 24V POWER DENOTES OPTIONAL COMPONENT CONNECT IONS ECONOMIZER BLOWER G DISCONNECT ALL POWER BEFORE SERVICING A FACTORY INSTALLED OPTION FOR USE WITH COPPER COND _ _ _ __ _ HEAT 2 W2 A WITH 511 ON OFF FAN LOW AMBIENT CONTROL Ay WITH A46 VARIABLE LOW AMBIENT CONTROL PRIMARY OF 24 VOLT TRANSFORMER MUST BE PHASED amp WITH B4 FAN MOTOR EXAMPLE IF MOTOR IS HOOKED TO UCTORS ONLY A GROUND NOTE USE COPPER CONDUCTORS H An ONLY 120 1 60 1 Cooling demand energizes at thermostat terminal Y1 Voltage passes through N C low pressure switch 87 to terminal 1 on timer DL33 and K167 latching relay coil and to S11 low ambient low pressure switch 2 K167 1 closes energizing timer DL33 Timer begins After 5 minutes DL33 is de energized K167 2 con tacts close opening contacts 9 and 3 Indoor blower is energized Page 23 LI ACROSS LI amp L3 amp LS TRANSFORMER PRIMARY MUST ALSO BE HOOKED
44. ssor B1 operates during all cooling demand and is energized by contactor K1 upon re ceiving first stage demand Compressor B2 operates only during second stage cooling demand and is energized by contactor K2 See ELECTRICAL section or compressor nameplate for compressor specifications SCROLL COMPRESSOR FIGURE 8 The scroll compressor design is simple efficient and requires few moving parts A cutaway diagram of the scroll compressor is shown in figure 8 The scrolls are located in the top of the compressor can and the motor is located just below The oil level is immediately below the motor The scroll is a simple compression concept centered around the unique spiral shape of the scroll and its inherent properties Figure 9 shows the basic scroll form Two identical scrolls are mated together forming concentric spiral shapes figure 10 One scroll remains stationary while the other is allowed to or bit figure 11 Note that the orbiting scroll does not rotate or turn but merely orbits the stationary scroll NOTE During operation the head of a scroll compressor may be hot since it is in constant contact with discharge gas A IMPORTANT Three phase scroll compressor noise will be sig nificantly higher if phasing is incorrect Compres sor will operate backwards so unit will not provide cooling If phasing is incorrect disconnect power to unit and reverse any two power leads L1 and L3 prefered to unit Page 8
45. termine the vacuum level absolute pressure of 5mm of mercury is equal to 500 microns C Charging TABLE 4 HS29 072 1 2 3 amp HS29 090 2 amp HS29 120 2 Units HS29 072 HS29 072 HS29 072 HS29 072 HS29 090 HS29 090 HS29 120 Discharge Suction Discharge Suction Discharge Discharge 10 psig 10 psig Outdoor Coil Entering Air epee HS29 120 Suction ere m s as ui Sm pom 9 7n Peres m p no pow ss 7 ae TEL 072 tested with CB30U 65 Pressure shown is with typical 5 ton indoor coil match up HS29 072 and HS29 090 tested with CB17 CBH17 95V HS29 120 tested with CB17 CBH17 135V TABLE 5 HS29 090 3 and HS29 120 3 Units HS29 090 HS29 090 HS29 120 Discharge Suction Discharge 10 psig 5 psig 10 psig eren om pos srr eae m 3w erar ae HS29 072 and HS29 090 tested with CB17 CBH17 95V HS29 120 tested with CB17 CBH17 135V Outdoor Coil Entering Air Temperature HS29 120 Suction 5 psig TABLE 6 Outdoor Coil HS29 180 Circuit 1 HS29 180 Circuit 2 HS29 240 Circuit 1 HS29 240 Circuit 2 Entering Air Discharge Suction Discharge Suction Discharge Suction Discharge ener 10 psig 5 psig 10psig 5psig 10psig 5psig 10 psig rero mr Suction 5 psig 20 zs 7 o ze 2 75 ore orere me e 7 39
46. ts of liquid return If liquid enters the scrolls the orbiting scroll is allowed to sepa Page 9 rate from the stationary scroll The liquid is worked toward the center of the scroll and is discharged If the compressor is re placed conventional Lennox cleanup practices must be used Due to its efficiency the scroll compressor is capable of draw ing a much deeper vacuum than reciprocating compres sors Deep vacuum operation can cause internal fusite arcing resulting in damaged internal parts and will result in compressor failure Never use a scroll compressor for evacuating or pumping down the system This type of damage can be detected and will result in denial of war ranty claims The scroll compressor is quieter than a reciprocating com pressor however the two compressors have much different sound characteristics The sounds made by a scroll com pressor do not affect system reliability performance or indi cate damage 2 Cooling Relays K66 amp K67 180 240 only Cooling relays K66 and K67 are N O 3PDT relays used in the HS29 180 240 K66 is energized from Y1 1st stage cool which in turn energizes latching relay K167 K67 is energized by Y2 2nd stage cool which in turn energizes latching relay K168 This sequence is the start up of com pressors B1 and B2 3 Crankcase Heaters HR1 all units amp HR2 180 240 All LSA series units use a belly band type crankcase heat er Heater HR1 is wrapped around com
47. with an adjustable wrench 2 Using service wrench back the stem out counterclock wise until the valve stem just touches the retaining ring 3 Replace stem cap tighten firmly Tighten finger tight then tighten an additional 1 6 turn Do not over torque To Close Suction Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and turn stem in clockwise to seat the valve Tighten firmly 3 Replace stem cap Tighten finger tight then tighten an additional 1 6 turn Do not over torque 3 Suction Line Service Valve HS29 072 2 3 HS29 090 120 180 240 The HS29072 2 3 and all HS29 090 through 240 model units are equipped with a full service ball valve as shown in figure 19 One service port that contains a valve core is present in this valve A cap is also provided to seal off the service port The valve is not rebuildable so it must always be replaced if failure has occurred Opening the Suction Line Service Valve 1 Remove the stem cap with an adjustable wrench 2 Using a service wrench turn the stem counterclock wise for 1 4 of a turn 3 Replace the stem cap and tighten it firmly Closing the Suction Line Service Valve 1 Remove the stem cap with an adjustable wrench 2 Using service wrench turn the stem clockwise for 1 4 of a turn 3 Replace the stem cap and tighten firmly Page 16 SUCTION LINE SERVICE VALVE VALVE OPEN HS29 072 1 VALVE FRONT SEATED OUTLET T
48. y charged or that a problem exists with some component in the system Correct any system problems before proceeding 5 Add or remove the charge in increments and allow the System to stabilize each time you add or remove the re frigerant HS29 072 HS29 090 HS29 120 ONLY Use the approach method to confirm readings Verifying the Charge Using Approach Method for Temperatures 60 F only Do not use the approach method if the system pressures do not match the pressures given in table 4 The approach method is not valid for grossly over or undercharged sys tems A IMPORTANT Use tables 4 5 and 6 as a general guide for perform ing maintenance checks These tables are not a pro cedure for charging the system Minor variations in these pressures may be expected due to differ ences in installations Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the sys tem Used prudently these tables could serve as a useful service guide 1 Use the same digital thermometer to take the liquid line temperature and the outdoor ambient temperature Measure the liquid line temperature at the condenser outlet Then compare the liquid line temperature to the outdoor ambient temperature The approach temper ature equals the liquid line temperature minus the outdoor ambient temperature Page 21 2 The approach temperature should match values given in table 7 An
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