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1. 9 Use dry nitrogen to break the vacuum on the refriger ant lines and indoor coil before removing the recovery machine gauges and HCFC 22 refrigerant drum Re install pressure tap valve cores into HSXB15 service valves 10 Install the field provided expansion valve approved for use with R 410A refrigerant in the liquid line at the indoor coil Refrigerant Metering Device HSXB15 units are used in check expansion valve systems only See the Lennox Engineering Handbook for approved TXV match ups and application information Check expansion valves equipped with Chatleff fittings are available from Lennox Refer to the Engineering Hand book for applicable expansion valves for use with specific match ups If you install a check expansion valve with an indoor coil that includes a fixed orifice remove the orifice be fore installing the check expansion valve See figure 11 for installation of the check expansion valve Metering Device Installation EXPANSION VALVE amp Wa O RING See NOTE 1 STRAINER DISTRIBUTOR amp O RING LIQUID LINE STUB NOTE If necessary remove R 22 flow control device fixed orifice thermal expansion valve from existing line set before installing R 410A approved expansion valve and o ring Figure 11 Manifold Gauge Set Manifold gauge sets used with systems charged with R 410A refrigerant must be capable of handling the higher system operating pressures The gauges should
2. upside down The cylinder will be marked if it is equipped with a dip tube This system is charged with R410A refrigerant which oper ates at much higher pressures than HCFC 22 The expan sion valve and liquid line filter drier provided with the unit are approved for use with R 410A Do not replace them with components designed for use with HCFC 22 This unit is NOT approved for use with coils which include metering orifices or capillary tubes Factory Charge Units are factory charged with the amount of R 410A re frigerant indicated on the unit rating plate This charge is based on a matching indoor coil and outdoor coil with 15 feet 4 6 m line set For varying lengths of line set refer to table 3 for refrigerant charge adjustment Table 3 Refrigerant Charge per Line Set Lengths Liquid Line Ounces per 5 feet grams per 1 52 meter Set Diameter adjust from 15 ft 4 57m line set 3 8 in 9 5mm 3 ounces per 5 feet 85 grams per 1 52 me ter Add the amount shown if line length is greater than 15 4 57m sub tract the amount shown if less than 15 Units Delivered Void of Charge A IMPORTANT Mineral oils are not compatible with R 410A If oil must be added it must be a polyol ester oil The compressor is charged with sufficient polyol ester oil for approved line set lengths If the system is void of refrigerant clean the system us ing the following procedure 1 Use dry nitrogen to pressuri
3. 1 Record outdoor ambient temperature using a digital thermometer 2 Attach high pressure gauge set and operate unit for several minutes to allow system pressures to stabilize 3 Compare stabilized pressures with those provided in table 5 Normal Operating Pressures Minor varia tions in these pressures may be expected due to differ ences in installations Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system Pressures higher than those listed indicate that the system is overcharged Pressures lower than those listed indicate that the system is undercharged A tem perature pressure chart for R 410A refrigerant is pro vided in table 6 for your convenience Verify adjusted charge using the approach method 4 Use the same digital thermometer you used to check the outdoor ambient temperature to check the liquid line temperature 5 The difference between the ambient and liquid tem peratures should match values given in table 4 If the values don t agree with the those in table 4 add refrig erant to lower the approach temperature or recover refrigerant from the system to increase the approach temperature Be aware of the R 410A refrigerant cylin der It will be light maroon colored Refrigerant should be added through the vapor valve in the liquid state Table 4 Approach Values Approach Temperature Model No Liquid Line Outdoor Am
4. 2 Parts Arrangement amp Unit Dimensions 2 Setting The Unit 0000 0000 00 eee 3 El tical cemas egw a aaea ty 4 Refrigerant Piping naana rrara 4 Flushing Existing Line Set amp Indoor Coil 7 Refrigerant Metering Device 9 Manifold Gauge Set 0 0 0 cece eee eee 9 Service Valves 0 cc cece eee n nee 9 Leak Testing itv chee nee ued oles BR ed nes 10 EVACUATION renei eneen i cin dot Saute ENE a Sales 10 StartUp 4 itso ie ae a Redes A AS 11 Refrigerant Charging 0c cece eee uae 11 System Operation 0 0 0 00 c eee eee 13 Maintenance 006s cece ec ee eee eens 15 Optional Accessories 00 66 cece eee eee 15 Homeowner Information 00000 c eae 15 Thermostat Operation 00 0000 cece 16 Start Up amp Performance Check List 16 HSXB15 Outdoor Unit HSXB15 outdoor units use R 410A HFC refrigerant This unit must be installed with a matching indoor coil and line set as outlined in the Lennox Engineering Handbook HSXB15 outdoor units are designed for use in expansion valve sys tems only They are not designed to be used with other refrig erant flow control devices The filter drier is factory installed The Lennox Engineering Handbook lists indoor TXV kits that must be ordered separately Shipping amp Packing List 1 Assembled HSXB15 outdoor unit 2 Grommets for liquid and su
5. above has been met disconnect the manifold hose from the vac uum pump and connect it to an upright cylinder of R 410A refrigerant Open the manifold gauge valves to break the vacuum from 1 to 2 psig positive pressure in the line set and indoor unit Close manifold gauge valves and shut off the R 410A cylinder and remove the manifold gauge set 1 Rotate fan to check for frozen bearings or binding 2 Inspect all factory and field installed wiring for loose connections 3 After evacuation is complete open the liquid line and vapor line service valves to release the refrigerant charge contained in outdoor unit into the system 4 Replace the stem caps and secure finger tight then tighten an additional one sixth 1 6 of a turn 5 Check voltage supply at the disconnect switch The voltage must be within the range listed on the unit s nameplate If not do not start the equipment until you have consulted the power company and the voltage condition has been corrected 6 Set the thermostat for a high stage cooling demand Y1 and Y2 demand Turn on power to the indoor blower and close the outdoor unit disconnect switch to start the unit 7 Recheck voltage while the unit is running Power must be within range shown on the nameplate Refrigerant Charging A IMPORTANT Some R 410A cylinders are equipped with a dip tube which allows you to draw liquid refrigerant from the bottom of the cylinder without turning the cylinder
6. be installed on exterior of outside wall OUTSIDE WALL IMPORTANT Refrigerant lines must not contact wall VAPOR LINE LIQUID LINE WOOD BLOCK BETWEEN STUDS WIRE TIE INSIDE WALL STRAP Reva SLEEVE VAPOR LINE WRAPPED WITH ARMAFLEX quip WIRE TIE OUTSIDE WALL IMPORTANT WOOD BLOCK Refrigerant lines must not contact structure WIRE TIE A OY SEY EG A SE OT oT N AT SLY ST AIT AS OT SY EY AY PA i STRAP ii m x ie B a F C C Sl CAULK PVC PIPE FIBERGLASS INSULATION SLEEVE Figure 8 Refrigerant Line Sets Transition From Vertical To Horizontal ANCHORED AUTOMOTIVE HEAVY NYLON MUFFLER TYPE WIRE TIE HANGER Strap Liquid eras Line To Va Strap Liquid Line por Line To Vapor Line LIQUID LINE LIQUID LINE METAL VAPOR LINE WRAPPED METAL VAPOR LINE WRAPPED SLEEVE IN ARMAFLEX SLEEVE IN ARMAFLEX Figure 9 Page 6 504710M 03 06 4 WARNING Polyol ester POE oils used with R 410A refriger ant absorb moisture very quickly It is very impor tant that the refrigerant system be kept closed as much as possible DO NOT remove line set caps or service valve stub caps until you are ready to make connections Brazing Connection Procedure 1 Cut ends of the refrigerant lines square free from nicks or dents Debur the ends The pipe must remain round do not pinch end of the line 2 Before making line set connections use dry nitrogen to purge the refrigerant pipi
7. be rated for use with pressures of 0 800 on the high side and a low side of 30 vacuum to 250 psi with dampened speed to 500 psi Gauge hoses must be rated for use at up to 800 psi of pressure with a 4000 psi burst rating rvice Valves The liquid line and vapor line service valves and gauge ports are used for leak testing evacuating charging and checking charge Each valve is equipped with a service port which has a factory installed Schrader valve A ser vice port cap protects the Schrader valve from contamina tion and serves as the primary leak seal Front Seated Service Valve Liquid Line The front seated service valve is shown in figure 12 When this valve is closed the service port is open to the line set Access the service port and open and close valves as de scribed in the following paragraphs Front Seated Liquid Line Service Valve Valve Shown Closed SERVICE P Insert hex wrench here ea indoor coil To outdoor coil SERVICE Valve Shown Open insert hex wrench here l indoor coil Service port Is open to line set when valve is closed front seated To outdoor coil Figure 12 To Access Schrader Port 1 Remove access panel 2 Remove service port cap with an adjustable wrench 3 Connect gauge to the service port 4 When testing is completed replace service port cap Tighten finger tight then torque per table 1 Page 2 To Open Front Seated Service Valves 1 Remove stem c
8. screws 16 in Ib G 22 1 8 562 28 1 8 718 28 1 8 718 28 1 8 718 MARERE AO cre H 2 7 8 73 3 7 8 98 3 7 8 98 3 7 8 98 Compressor bolts 90 in Ib J 5 1 2 140 7 1 2 191 7 1 2 191 7 1 2 191 Gauge port seal cap Page 2 504710M 03 06 Setting the Unit Refer to unit dimensions figure 1 on page 2 for sizing mounting slab platforms or supports Refer to figure 2 for installation clearances Installation Clearances A service access clearance of 30 762 mm must be maintained in front of the service access panel Clearance to one side must be 36 914 mm Clearance to one of the remaining two sides may be 12 305 mm and the final side may be 6 152 mm A clearance of 24 610 mm must be maintained between two units 48 1219 mm clearance required on top of unit Maximum soffit overhang is 36 914 mm Figure 2 4 CAUTION In order to avoid injury take proper precaution when lifting heavy objects 4 CAUTION Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury Be aware of and use caution when working near these areas during installation or while servicing this equipment Slab Mounting When installing a unit at grade level the top of the slab should be high enough above the grade so that water from higher ground would not collect around the u
9. 6 9 to 13 8 kPa Using an Electronic Leak Detector 1 Connect the high pressure hose of the manifold gauge set to the vapor valve service port Normally the high pressure hose is connected to the liquid line port how ever connecting it to the vapor port helps to protect the manifold gauge set from damage caused by high pres sure 2 With both manifold valves closed connect the cylinder of R 410A refrigerant Open the valve on the R 410A cylinder vapor only 3 Open the high pressure side of the manifold to allow R 410A into the line set and indoor unit Weigh in a trace amount of A trace amount is a maximum of 2 ounces 57 g refrigerant or 3 pounds 31 kPa pres sure Close the valve on the R 410A cylinder and the valve on the high pressure side of the manifold gauge set Disconnect R 410A cylinder 4 Connect a cylinder of dry nitrogen with a pressure reg ulating valve to the center port of the manifold gauge set 5 Adjust dry nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor coil 6 After afew minutes open a refrigerant port to check that an adequate amountof refrigerant has been add ed fordetection refrigerant requirements will vary with line lengths Check all joints for leaks Purge dry nitro gen and R 410A mixture Correct any leaks and re check A IMPORTANT Leak detector must be capable of s
10. LENNOX 2006 Lennox Industries Inc Dallas Texas USA RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE 4 WARNING Improper installation adjustment alteration ser vice or maintenance can cause property damage personal injury or loss of life Installation and ser vice must be performed by a qualified installer or service agency A IMPORTANT This unit must be matched with an indoor coil as specified in Lennox Engineering Handbook Coils previously charged with R 22 must be flu shed 4 WARNING This product and or the indoor unit it is matched with may contain fiberglass wool Disturbing the insulation during installation main tenance or repair will expose you to fiberglass wool dust Breathing this may cause lung cancer Fiber glass 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 03 06 CAAA Page 1 INSTALLATION MANUAL HSXB15 Series Units CONDENSING UNITS leone ublications poe mn Litho U S A Supersedes 11 05 Table of Contents HSXB15 Outdoor Unites pinen aera d gaha 1 Shipping amp Packing List 0 0 04 1 General Information 0 0 0 e eee eens
11. ant Line Sets Valve Field Size Connections Recommended Line Set Model Liquid Vapor Liquid Vapor L15 No Line Line Line Line Line Sets 024 3 8 in 3 4 in 3 8 in 3 4 in L15 41 030 10 mm 19mm 10mm 19 mm 15 ft 50 ft 036 4 6 m 15m 042 3 8 in 7 8 in 3 8 in 7 8 in L15 65 048 10mm 22mm 10mm 22 mm 15 ft 50 ft 4 6 m 15 m 060 3 8 in 1 1 8 in 3 8 in 1 1 8 in Field 10 mm 29mm 10mm 29 mm Fabricated NOTE Units are designed for line sets of up to 50 15m Refrigerant Connections HSXB15 Matched with New Indoor Coil and Line Set If an existing indoor coil that was equipped with an RFCI metering device is being replaced the liquid line must also be replaced prior to the installation of the HSXB15 unit If refrigerant lines are routed through a wall seal and iso late the opening so vibration does not transmit to building Installing Refrigerant Line During the installation of any heat pump or a c system it is important to properly isolate the refrigerant lines to prevent unnecessary vibration Line set contact with the structure wall ceiling or floor causes some objectionable noise when vibration is translated into sound As a result more energy or vibration can be expected Closer attention to line set isolation must be observed Following are some To hang line set from joist or rafter use either metal s
12. ap with an adjustable wrench 2 Use a service wrench with a hex head extension 3 16 for liquid line valve sizes 5 16 for vapor line valve sizes to back the stem out counterclockwise as far as it will go 3 Replace the stem cap Tighten finger tight then torque per table 1 Page 2 To Close Front Seated Service Valves 1 Remove the stem cap with an adjustable wrench Page 9 HSXB15 SERIES 2 Use a service wrench with a hex head extension 3 16 for liquid line valve sizes 5 16 for vapor line valve sizes to turn the stem clockwise to seat the valve Tighten it firmly 3 Replace the stem cap Tighten finger tight then torque per table 1 Page 2 ene testn After the line set has been connected to the indoor and out door units the line set connections and indoor unit must be checked for leaks 4 WARNING Refrigerant can be harmful if it is inhaled Refriger ant must be used and recovered responsibly Failure to follow this warning may result in personal injury or death amp AWARNING AAWARNING e of explosion Can cause inju ry or death or equipment damage Never use oxygen to pressurize a re frigeration or air conditioning system Oxygen will explode on contact with oil and could cause personal injury When using a high pressure gas such as dry nitrogen to pressurize a refrig eration or air conditioning system use a regulator that can control the pressure down to 1 or 2 psig
13. bient F C HSXB 15 030 8 1 4 5 5 HSXB 15 036 6 1 3 3 5 HSXB15 042 9 1 5 5 HSXB15 048 8 1 4 5 5 HSXB15 060 12 1 6 7 5 NOTE For best results the same electronic thermometer should be used to check both outdoor ambient and liquid line temperatures Table 5 Normal Operating Pressures Liquid 10 and Vapor 5 psig Outdoor Coil HSXB15 024 HSXB15 030 HSXB15 036 HSXB15 042 HSXB15 048 Entering Air HSXB15 060 TES Page 12 504710M 03 06 R 410A Temperature F Pressure Psig F Psig F Psig F Psig Psig 100 8 63 102 9 64 105 0 65 107 1 66 109 2 67 1114 68 113 6 69 115 8 70 118 0 71 120 3 72 122 6 73 125 0 74 127 3 75 129 7 76 132 2 77 134 6 78 137 1 79 139 6 80 142 2 81 144 8 82 147 4 83 150 1 84 54 152 8 47 8 85 57 161 0 88 266 0 119 412 2 150 608 1 61 i 92 i 2 93 a a a 1 2 3 4 45 6 7 8 9 OEN oa ae oa a oO N a oO 172 6 282 3 123 434 5 154 637 5 6 175 4 286 5 124 440 2 155 645 0 System Operation The outdoor unit and indoor blower cycle on demand from the room thermostat When the thermostat blower switch is in the ON position the indoor blower operates continu ously High Pressure Switch HSXB15 units are equipped with a high pres
14. cedure below see figure 10 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 R 22 refrigerant to flush the system e Disconnect all power to the existing outdoor unit e Connect to the existing unit a clean recovery cyl inder and the recovery machine according to the instructions provided with the recovery machine e Remove all R 22 refrigerant from the existing sys tem Check gauges after shutdown to confirm that the entire system is completely void of refrigerant e Disconnect the liquid and vapor lines from the ex isting outdoor unit Page 7 HSXB15 SERIES Flushing Connections Inverted R 22 Cylinder Contains clean R 22 to be used for flushing z Low High Pressure Pressure bo ee HSXB15 Vapor Line UNIT EXISTING VAPOR LINE Service Valve a m d H GAUGE MANIFOLD m D m EXISTING INDOOR COIL EXISTING LIQUID LINE Liquid Line Service Valve Tank Return NOTE The inverted R 22 cylinder must contain at least the same Inlet amount of refrigerant as was recov Discharge ered from the existing system RECOVERY CYLINDER RECOVERY MACHINE Figure 10 A IMPORTANT The line set and indoor coil must be flushed with If the existing outdoor unit is equipped with manual shut off valves AND you plan to use NEW R 22 refrigerant to flush the system e Start the existing R 22 system in the coo
15. ction lines 1 Bushing for low voltage wiring Check equipment for shipping damage If you find any damage immediately contact the last carrier 504 710M TL COMPRESSOR SYSTEM OPERATION RUN MONITORS CONTACTOR CAPACITOR VAPOR LINE GROUND LUG VAPOR VALVE AND GAUGE PORT COMPRESSOR LIQUID LINE POWER SERVICE VALVE TERMINALS AND GAUGE PORT J FILTER DRIER x n a DISCHARGE LOW PRESSURE HIGH PRESSURE O INLET AIR LINE SWITCH SWITCH PARTS ARRANGEMENT TOP VIEW ELECTRICAL INLETS C a B p a VAPOR LINE INLET Bd scharce AIR LIQUID LINE INLET ACCESS VIEW SIDE VIEW Figure 1 a HSXB15 Model General Information seis Weenies 2 Boe These instructions are intended as a general guide and do A 27 718 708 30 7 8 784 34 7 8 886 40 7 8 1038 not supersede local codes in any way Consult authorities B 25 7 8 657 32 1 8 816 32 1 8 816 32 1 8 816 who have jurisdiction before installation c 29 7 8 759 34 1 16 865 34 1 16 865 34 1 16 865 Table 1 D 12 1 4 311 12 3 4 324 13 3 4 349 19 3 4 602 Torque Requirements E 22 7 16 570 26 5 8 676 26 5 8 676 26 5 8 676 Recommended Torque F 14 7116 367 18 5 8 473 18 5 8 473 18 5 8 473 peice valve cap Sheet metal
16. e Valves Fully Opened J Caps Tight Voltage With Compressor Operating Vapor Pressure Refrigerant Charge Checked d Outdoor Fan Checked J g Thermostat Calibrated Properly Set Level J Page 16 504710M 03 06
17. ensing HFC re frigerant Evacuation Evacuating the system of noncondensables is critical for proper operation of the unit Noncondensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system Noncondensables and water vapor combine with refrigerant to produce substances that corrode copper pip ing and compressor parts A IMPORTANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns Use an instrument that reads from 50 microns to at least 23 000 microns 1 Connect manifold gauge set to the service valve ports e low pressure gauge to vapor line service valve e high pressure gauge to liquid line service valve 2 Close manifold gauge set valves Connect the center manifold hose to an upright cylinder of R 410A 3 Connect micron gauge 4 Connect the vacuum pump with vacuum gauge to the center port of the manifold gauge set 5 Open both manifold valves and start the vacuum pump 6 Evacuate the line set and indoor unit to an absolute pressure of 23 000 microns 29 01 inches of mercu ry During the early stages of evacuation it is desir able to close the manifold gauge valve at least once to determine if there is a rapid rise in absolute pressure A rapid rise in pressure indicates a relatively large leak If this occurs repeat the leak testing procedure NOTE The term absolute pressure means the t
18. er manifold hose to an upright cylinder of R 410A 2 Set the room thermostat to call for heat This will create the necessary load for properly charging the system in the cooling cycle 3 Use a digital thermometer to record the outdoor ambi ent temperature 4 When the heating demand has been satisfied switch the thermostat to cooling mode with a set point of 68 F 20 C When pressures have stabilized use a digital thermometer to record the liquid line temperature 5 The outdoor temperature will determine which charg ing method to use Proceed with the appropriate charging procedure Charge Using the Weigh in Method Outdoor Temperature lt 65 F 18 C If the system is void of refrigerant or if the outdoor ambient temperature is cool the refrigerant charge should be weighed into the unit Do this after any leaks have been re paired 1 Recover the refrigerant from the unit 2 Conduct a leak check then evacuate as previously outlined 3 Weigh in the unit nameplate charge If weighing facilities are not available or if you are charging the unit during warm weather follow one of the other pro cedures outlined below Charge Using the Approach Method Outdoor Temperature gt 65 F 18 C The following procedure is intended as a general guide and is for use on expansion valve systems only For best re sults indoor temperature should be 70 F 21 C to 80 F 26 C Monitor system pressures while charging
19. h is open and requires manual reset 5 Open circuit in compressor supply wiring or connections 6 Unusually long compressor protector reset time due to extreme ambient temperature 7 Compressor windings are damaged Open Start Circuit Current 1 Run capacitor has failed only in run circuit 2 Open circuit in compressor start wiring or connections 3 Compressor start winding is damaged Open Run Circuit Current 1 Open circuit in compressor start wiring or connections only in start circuit 2 Compressor start winding is damaged Welded Contactor Com 1 Compressor contactor failed to open pressor always runs 2 Thermostat demand signal not connected to module Low Voltage Control circuit 1 Control circuit transformer is overloaded lt 17VAC 2 Low line voltage contact utility if voltage at disconnect is low Flash code number corresponds to a number of LED flashes followed by a pause and then repeated TRIP and ALERT LEDs flashing at the same time indicates that the control circuit voltage is too low for operation Reset ALERT flash code by removing 24VAC power from monitor Last ALERT flash code will display for 1 minute after monitor is powered on 504710M 03 06 Page 14 Maintenance l AWARNING Electric shock hazard Can cause inju ry or death Before attempting to per form any service or maintenance turn ly the electrical power to unit OFF at dis W connect switch es Unit may have multiple power su
20. his instruction NOTE Outdoor fan motor is prelubricated and sealed No further lubrication is needed Optional Accessories Refer to the Engineering Handbook for optional accesso ries that may apply to this unit The following may or may not apply Compressor crankcase heater Mounting bases Start kit Timed off control Freezestat Low ambient kit Low ambient cut off kit SignatureStat room thermostat Homeowner Information Maintenance In order to ensure peak performance your system must be properly maintained Clogged filters and blocked airflow prevent your unit from operating at its most efficient level 1 Ask your Lennox dealer to show you where your indoor unit s filter is located It will be either at the indoor unit installed internal or external to the cabinet or behind a return air grille in the wall or ceiling Check the filter monthly and clean or replace it as needed 2 Disposable filters should be replaced with a filter of the same type and size NOTE If you are unsure about the filter required for your system call your Lennox dealer for assistance A IMPORTANT Turn off electrical power to the unit at the disconnect switch before performing any maintenance The unit may have multiple power supplies 3 Many indoor units are equipped with reusable foam fil ters Clean foam filters with a mild soap and water solution rinse thoroughly allow filter to dry com
21. ling mode and close the liquid line valve at least the same amount of clean refrigerant that previously charged the system Check the charge e Pump all of the existing R 22 refrigerant back into the outdoor unit It may be necessary to bypass the low pressure switches to ensure complete re frigerant evacuation e When the low side system pressures reach 0 psig close the vapor line valve e Disconnect all power to the existing outdoor unit Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system e Disconnect the liquid and vapor lines from the ex isting outdoor unit 2 Remove the existing outdoor unit Set the new R 410A unit and follow the brazing connection procedure which begins on the previous page to make line set connections DO NOT install the expansion valve at this time Make low voltage and line voltage connec tions to the new outdoor unit DO NOT turn on power to the unit or open the outdoor unit service valves at this time Remove the existing refrigerant flow control orifice or thermal expansion valve before continuing with flush ing procedures The existing devices are not approved for use with R 410A refrigerant and may prevent prop er flushing Useafield provided fitting to reconnect the lines Page 8 504710M 03 06 in the flushing cylinder before proceeding Remove the pressure tap valve cores from the HSXB15 unit s
22. mode to maintain predetermined comfort settings Temperature Indicator The temperature indicator displays the actual room temperature Programmable Thermostats Your Lennox system may be controlled by a programmable thermostat These thermostats provide the added feature of programmable time of day setpoints for both heating and cooling Refer to the user s information manual provided with your thermostat for detailed pro gramming and operation details Preservice Check If your system fails to operate check the following before calling for service e Make sure all electrical disconnect switches are ON e Make sure the room thermostat Temperature Selector and System Switch Heat Cool Auto are properly set e Check for and replace any blown fuses or reset any tripped circuit breakers e Make sure unit access panels are in place e Make sure air filter is clean e Write down the unit model number and have it handy before calling Electrical Connections Tight J Indoor Blower RPM Discharge Pressure S P Drop Over Indoor Dry Job Name Job no Date Job Location City State Installer City State Unit Model No Serial No Service Technician Nameplate Voltage Rated Load Ampacity Amps Maximum Fuse or Circuit Breaker Compressor Outdoor Fan Indoor Filter clean Supply Voltage Unit Off Outdoor Coil Entering Air Temp Refrigerant Lines Leak Checked Properly Insulated _ Servic
23. n to the Manifold Gauge Set section A IMPORTANT If this unit is being matched with an approved line set or indoor coil which was previously charged with mineral oil or if it is being matched with a coil which was manufactured before January of 1999 the coil and line set must be flushed prior to instal lation Take care to empty all existing traps Polyol ester POE oils are used in Lennox units charged with R 410A refrigerant Residual mineral oil can act as an insulator preventing proper heat trans fer It can also clog the expansion device and re duce the system performance and capacity Failure to properly flush the system per the in structions below will void the warranty A IMPORTANT The Environmental Protection Agency EPA pro hibits the intentional venting of HFC refrigerants during maintenance service repair and disposal of appliance Approved methods of recovery recycl ing or reclaiming must be followed 4 CAUTION This procedure should not be performed on sys tems which contain contaminants Example com pressor burn out Required Equipment You will need the following equipment in order to flush the existing line set and indoor coil two clean HCFC 22 recov ery bottles an oilless recovery machine with a pump down feature and two sets of gauges one for use with HCFC 22 and one for use with the R 410A Flushing Procedure 1 Remove existing HCFC 22 refrigerant using the ap propriate pro
24. ng This will help to prevent oxidation and the introduction of moisture into the sys tem 3 Wrap a wet cloth around the valve body and copper tube stub to protect it from heat damage during braz ing Wrap another wet cloth underneath the valve body to protect the base paint NOTE The tube end must stay bottomed in the fitting during final assembly to ensure proper seating seal ing and rigidity 4 Install the field provided thermal expansion valve ap proved for use with R 410A refrigerant in the liquid line at the indoor coil 5 Use silver alloy brazing rods 5 or 6 percent minimum silver alloy for copper to copper brazing or 45 percent silver alloy for copper to brass or copper to steel brazing which are rated for use with R 410A refriger ant Wrap a wet cloth around the valve body and the copper tube stub Remove light maroon washers from service valves and shield light maroon stickers in order to protect them during brazing Braze the line set to the service valve Flushing Existing Line Set amp Indoor Coil AWARNING Danger of fire Bleeding the refriger ant charge from only the high side may result in the low side shell and ba suction tubing being pressurized Ap Pig plication of a brazing torch while pressurized may result in ignition of the refrigerant and oil mixture check the high and low pressures before un brazing NOTE If the indoor unit line and set is new skip this sec tion and go o
25. nit See figure 3 Slab may be level or have a slope tolerance away from the building of not more than 2 degrees or 2 inches per 5 feet 51 mm per 1524 mm Slab Mounting INSTALL UNIT LEVEL OR IF ON A SLOPE MAINTAIN SLOPE TOLERANCE OF 2 DISCHARGE AIR DEGREES OR 2 INCHES PER 5 FEET 51 MMPER 1 5 MI AWAY FROM BUILDING STRUCTURE BUILDING STRUCTURE NS MOUNTING SLAB HHHHHHH I GROUND LEVEL Figure 3 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 proper ly distributed over roof joists and rafters Either redwood or steel supports are recommended Page 3 HSXB15 SERIES Electrical l In the U S A wiring must conform with current local codes and the current National Electric Code NEC In Canada wiring must conform with current local codes and the cur rent Canadian Electrical Code CEC Refer to the furnace or blower coil installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size A WARNING Electric Shock Hazard Can cause in jury or death Unit must be grounded in accordance with national and local codes Line voltage is present at all compo nents on units with single pole con tactors even when unit is not in op eration Unit may have multiple power sup plies Disconnect all remote electric powe
26. onnection of the mod ule Alert LED yellow communicates an abnormal system condition through a unique flash code The alert LED will flash a number of times consecutively pause and then re peat the process The number of consecutive flashes de fined as the Flash Code correlates to a particular abnor mal condition Trip LED red indicates there is a demand signal from the thermostat but no current to the compressor is de tected by the module Flash code number corresponds to a number of LED flashes followed by a pause and then repeated TRIP and ALERT LEDs flashing at the same time indicates that the control circuit voltage is too low for operation Reset ALERT flash code by removing 24VAC power from monitor Last ALERT flash code will display for 1 minute af ter monitor is powered on Page 13 HSXB15 SERIES Table 7 Status LED Troubleshooting Green Power Red Trip Yellow Alert Flash Code 1 Yellow Alert Flash Code 2 Yellow Alert Flash Code 3 Yellow Alert Flash Code 4 Yellow Alert Flash Code 5 Yellow Alert Flash Code 6 Yellow Alert Flash Code 7 Yellow Alert Flash Code 8 Yellow Alert Flash Code 9 Module has power Supply voltage is present at module terminals Thermostat demand signal 1 Compressor protector is open Y1 is present but the com 2 Outdoor unit power disconnect is open pressor is not running 3 Comp
27. ons If indoor unit is not equipped with blower relay It must be field provided and installed P 8 3251 or equivalent Figure 4 Outdoor Unit Field Wiring Diagram B4 OUTDOOR FAN GROUND LEADLESS LUG De CAPET SYSTEM COMPRESSOR CAPACITOR OPERATION 7 5 HIGH MONITOR CONTACTOR L2 L1 B4 OUTDOOR FAN BLACK COMMON cl2 ORANGE RUN DUAL PURPLE CAPACITOR 208 230 60 I CAPACITOR CHECHA ANNOTE FOR USE WITH COPPER CONDUCTORS A WARNING ONLY REFER TO UNIT RATING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY PLATE FOR MINIMUM CIRCUIT OR DEATH UNIT MUST BE GROUNDED IN AMPACITY AND MAXIMUM OVER ACCORDANCE WITH NATIONAL AND LOCAL CODES CURRENT PROTECTION SIZE LINE VOLTAGE FIELD INSTALLED Figure 5 Refrigerant Piping If the HSXB15 unit is being installed with a new indoor coil and line set the connections should be made as outlined in this section If an existing line set and or indoor coil used with mineral oil is going to be used to complete the HSXB15 system refer to the following section which in cludes flushing procedures Page 4 504710M 03 06 Field refrigerant piping consists of liquid and vapor lines from the outdoor unit sweat connections to the indoor coil flare or sweat connections Use Lennox L15 sweat non flare series line sets as shown in table 2 or use field fabri cated refrigerant lines Valve sizes are also listed in table 2 Table 2 Refriger
28. otal 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 7 When the absolute pressure reaches 23 000 microns 29 01 inches of mercury close the manifold gauge valves turn off the vacuum pump and disconnect the manifold gauge center port hose from vacuum pump Attach the manifold center port hose to a dry 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 Page 10 504710M 03 06 4 WARNING Danger of Equipment Damage Avoid deep vacu um operation Do not use compressors to evacu ate a system Extremely low vacuums can cause internal arcing and compressor failure Damage caused by deep vacuum operation will void war ranty 8 Shut off the dry nitrogen cylinder and remove the man ifold gauge hose from the cylinder Open the manifold gauge valves to release the dry nitrogen from the line set and indoor unit 9 Reconnect the manifold gauge to the vacuum pump turn the pump on and continue to evacuate the line set and indoor unit until the absolute pressure does not rise above 500 microns 29 9 inches of mercury within a 20 minute period after shutting off the vacuum pump and closing the manifold gauge valves 10 When the absolute pressure requirement
29. pletely before it is returned to the unit or grille NOTE The filter and all access panels must be in place any time the unit is in operation 4 Some systems are equipped with an electronic air cleaner designed to remove the majority of airborne particles from the air passing through the cleaner If your system is so equipped ask your dealer for main tenance instructions 5 Inspect and clean indoor coil The indoor evaporator coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the in side air Have your dealer show you the location of the drain line and how to check for obstructions This would also apply to an auxiliary drain if installed A IMPORTANT Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to the outdoor unit by treated water Prolonged exposure of the unit to treated water i e sprinkler systems soakers waste water etc will corrode the surface of steel and aluminum parts and diminish performance and longevity of the unit 6 Inspect and clean outdoor coil e Make sure no obstructions restrict airflow to the outdoor unit Leaves trash or shrubs crowding the unit cause the outdoor unit to work harder and use more energy Keep shrubbery trimmed away from the unit and periodically check for debris which collects around the unit e The outdoor coil may require frequent cleaning depending on environmental condi
30. pplies Before the start of each heating and cooling season the following service checks should be performed by a quali fied service technician First turn off electrical power to the unit prior to performing unit maintenance e Inspect and clean the outdoor and indoor coils The outdoor coil may be flushed with a water hose NOTE It may be necessary to flush the outdoor coil more frequently if it is exposed to substances which are corrosive or which block airflow across the coil e g pet urine cottonwood seeds etc e Visually inspect the refrigerant lines and coils for leaks e Check wiring for loose connections e Check voltage at the indoor and outdoor units with units operating Check the amperage draw at the outdoor fan motor compressor and indoor blower motor Values should be compared with those given on unit nameplate e Check clean or replace indoor unit filters Check the refrigerant charge and gauge the system pressures e Check the condensate drain line for free and unob structed flow clean if necessary e Adjust blower speed for cooling Measure the pressure drop over the coil to determine the correct blower CFM Refer to the unit information service manual for pressure drop tables and procedure e Check drive belt for wear and proper tension NOTE If owner reports insufficient cooling the unit should be gauged and refrigerant charge checked Re fer to section on refrigerant charging in t
31. r supplies before opening ac cess panel 1 Install line voltage power supply to unit from a properly sized disconnect switch 2 Ground unit at unit disconnect switch or to an earth ground NOTES e Connect conduit to the contro box using a proper conduit fitting e Units are approved for use only with copper con ductors e 24V Class II circuit connections are made in the low voltage junction box Refer to figure 5 for field wiring diagram e A complete unit wiring diagram is located inside the unit s front access panel NOTE For proper voltages select thermostat wire gauge per the following chart Wire run length less than 100 30m more than 100 30m 3 Install room thermostat ordered separately on an in side wall approximately in the center of the conditioned area and 5 feet 1 5 m from the floor It should not be installed on an outside wall or where it can be effected by sunlight drafts or vibrations Insulation type color coded temperature rating 35 C minimum 4 Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit See figure 4 Typical Field Low Voltage Wiring Diagram Outdoor Unit Thermostat v heat Cw Y1 Outdoor cooling Unit G indoor blower G j common Indoor Unit R System Operation Monitor C Outdoor Unit Ne NOTE see unit wiring diagram for power supply connec ti
32. ressor circuit breaker or fuse s is open 4 Broken wire or connector is not making contact 5 Low pressure switch open if present in the system 6 Compressor contactor has failed to close Long Run Time Compres 1 Low refrigerant charge sor is running extremely long 2 Evaporator blower is not running run cycles 3 Evaporator coil is frozen 4 Faulty metering device 5 Condenser coil is dirty Liquid line restriction filter drier blocked if present 7 Thermostat is malfunctioning System Pressure Trip Dis 1 High head pressure charge or suction pressure 2 Condenser coil poor air circulation dirty blocked damaged out of limits or 3 Condenser fan is not running compressor overloaded 4 Return air duct has substantial leakage 5 If low pressure switch is present check Flash Code 1 information Short Cycling Compressor 1 Thermostat demand signal is intermittent is running only briefly 2 Time delay relay or control board is defective 3 If high pressure switch is present check Flash Code 2 information 4 If low pressure switch is present check Flash Code 1 information Locked Rotor 1 Run capacitor has failed 2 Low line voltage contact utility if voltage at disconnect is low 3 Excessive liquid refrigerant in the compressor 4 Compressor bearings are seized Open Circuit 1 Outdoor unit power disconnect is open 2 Unit circuit breaker or fuse s is open 3 Unit contactor has failed to close 4 High pressure switc
33. service valves Connect an HCFC 22 cylinder with clean refrigerant to the vapor service valve Connect the HCFC 22 gauge set to the liquid line valve and connect a recovery machine with an empty recovery tank to the gauge set 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 vacuum on the ex isting system line set and indoor coil Invert the cylinder of clean HCFC 22 and open its valve to allow liquid refrigerant to flow into the system through the vapor line valve Allow the refrigerant to pass from the cylinder and through the line set and the indoor coil before it enters the recovery machine After all of the liquid refrigerant has been recovered switch the recovery machine to vapor recovery so that all of the HCFC 22 vapor is recovered Allow the re covery machine to pull a vacuum on the system NOTE A single system flush should remove ail of the mineral oil from the existing refrigerant lines and in door 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 a vacuum on the system at the end of the procedure 8 Close the valve on the inverted HCFC 22 drum and the gauge set valves Pump the remaining refrigerant out of the recovery machine and turn the machine off
34. sure switch that is located in the liquid line of the compressor The switch SPST manual reset normally closed removes power from the compressor when discharge pressure rises above factory setting at 640 10 psi Low Pressure Switch HSXB15 units are also equipped with a low pressure switch that is located in the vapor line of the compressor The switch SPST auto reset normally closed removes power from the compressor when vapor line pressure drops below factory setting at 40 5 psi Filter Drier A filter drier is factory installed with each HSXB15 unit This filter drier is installed to ensure a clean mois ture free system A replacement filter drier is available as Lennox part no 37L5201 System Operation Monitor The diagnostic indicator detects the most common fault conditions in the air conditioning system When an abnor mal condition is detected the module communicates the specific condition through its ALERT and TRIP lights The module is capable of detecting both mechanical and elec trical system problems See figure 13 for the system op eration monitor A IMPORTANT This monitor does not provide safety protection The monitor is a monitoring device only and cannot control or shut down other devices System Operation Monitor Figure 13 LED Functions See table 7 for LED troubleshooting diagnostic codes Power LED green indicates voltage within the range of 19 28VAC is present at the power c
35. tions Clean the outdoor coils with an unpressurized water hose to remove surface contaminants and debris Page 15 HSXB815 SERIES e If necessary clean the outdoor coil more frequent ly especially if it is exposed to substances which are corrosive or which block airflow across the coil ie pet urine cottonwood seeds etc Thermostat Operation Thermostat operations vary from one thermostat to anoth er The following provides general operation procedures Refer to the user s information manual provided with your thermostat for specific operation details Temperature Setting Levers Set the lever or dial to the desired temperature setpoints for both heating and cooling Avoid frequent temperature adjustment turning the unit off then back on before pressures can equalize will put unusual stress on the unit s compressor Fan Switch In AUTO or INT intermittent mode the blower operates only when the thermostat calls for heating or cooling This mode is generally preferred when humidity control is a priority The ON or CONT mode provides continuous in door blower operation regardless of whether the com pressor or furnace is operating This mode is required when constant air circulation or filtering is desired System Switch Set the system switch for heating cooling or auto opera Up amp Performance Check List tion The auto mode allows the system to automatically switch from heating mode to cooling
36. trapping material or anchored heavy nylon wire ties 8 feet STRAPPING MATERIAL Around vapor line only ROOF RAFTER TAPE OR WIRE TIE FLOOR JOIST OR 44 oe TN points to consider when placing and installing a high effi ciency outdoor unit 1 Placement Be aware that some localities are adopt ing sound ordinances based on how noisy the unit is from the adjacent property not at the original installa tion Install the unit as far as possible from the property line When possible do not install the unit directly out side a window Glass has a very high level of sound transmission 2 Line Set Isolation The following illustrations demon strate procedures which ensure proper refrigerant line set isolation Figure 6 shows how to place the outdoor unit and line set Figure 7 shows how to install line sets on horizontal runs Figure 8 shows how to install line sets on vertical runs Finally figure 9 shows how to make a transition from horizontal to vertical Outside Unit Placement and Installation Install unit away from windows and neighbors windows WIRE TIE Around vapor line only Strap the vapor line to the joist or rafter at 8 ft intervals then strap the liquid line to the vapor line FLOOR JOIST OR ROOF RAFTER Figure 7 Page 5 HSXB15 SERIES Refrigerant Line Sets Installing Vertical Runs new construction shown NOTE Similar installation practices should be used if line set is to
37. ze the system and check for leaks Repair leaks if possible 2 Evacuate the system to remove as much of the mois ture as possible triple evacuation 3 Use nitrogen to break the vacuum and install the pro vided filter drier in the system 4 Evacuate the system again Then weigh the appropri ate amount of R 410A refrigerant listed on unit name plate into the system 5 Start the unit and monitor the system to determine the amount of moisture remaining in the oil Use test kit 10N46 to verify that the moisture content is within the kit s dry color range 6 If the moisture content is not within the dry color range add a new filter drier between the liquid valve and the TXV You may have to add a new filter drier several times to achieve the required level of dryness If system dryness is not verified the compressor will fail in the future Checking Charge The outdoor unit should be charged during warm weather However applications arise in which charging must occur in the colder months The method of charging is deter mined by the unit s refrigerant metering device and the outdoor ambient temperature Measure the liquid line temperature and the outdoor ambi ent temperature as outlined below Page 11 HSXB15 SERIES 1 Connect the manifold gauge set to the service valves e low pressure gauge to vapor valve service port e high pressure gauge to liquid valve service port Close manifold gauge set valves Connect the cent

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