HSXA15 HSXB15
Contents
1. 8 High pressure fitting pressure liquid line valve pressure filter drier pressure drop 9 If pressure drop is greater than 4 psig replace filter drier See figure 7 10 Re install high pressure switch FIGURE 6 REPLACING FILTER DRIER 1 Recover all refrigerant from unit 2 Remove original filter drier 3 Install new filter drier in existing location or alternate location as shown Proper brazing procedures should be followed 4 Evacuate system See section IV part B 5 Recharge system See section IV part C FIGURE 7 Page 8 I Condenser Fan Motor B4 All units use single phase PSC fan motors which require a run capacitor The FAN side of the dual capacitor is used for this purpose The specifications tables on page 1 and 2 of this manual show the specifications of outdoor fans used in HSXA15 units In all units the outdoor fan is controlled by the compressor contactor See figure 8 if condenser fan motor replacement is necessary A IMPORTANT Route fan motor leads away from fan blades when replacing fan motor Use wire drip loop as shown in figure 8 FAN WAG Guara A SEE TABLE Z f Condenser fan and motor MI Wiring Drip loop FIGURE 8 TABLE 3 399 o 2389 III REFRIGERANT SYSTEM A Plumbing Field refrigerant piping consists of liquid and s2. 3 Visually inspect connecting lines and coils for evidence of oil leaks 4 Check wiring for loose connections 5 Check for correct voltage at unit unit operating 6 Check amp draw condenser fan motor Page 13 NOTE If owner complains of insufficient cooling the unit should be gauged and refrigerant charge checked Refer to section on refrigerant charging in this instruction Indoor Coil 1 Clean coil if necessary 2 Check connecting lines and coils for evidence of oil leaks 3 Check the condensate line and clean it if necessary Indoor Unit 1 Clean or change filters 2 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 3 Belt Drive Blowers Check belt for wear and proper tension 4 Check all wiring for loose connections 5 Check for correct voltage at unit blower operating 6 Check amp draw on blower motor and compressor Compressor Replacement Standard procedures can be followed when replacing the compressor in the 030 through 060 models However the compressor has minimal clearances in the 024 If com pressor replacement is necessary it may be helpful to raise the filler panel allowing adequate space for compressor movement Follow the steps below using a 5 16 driver 1 Remove access panel 2 Remove lower screw in the left side of th
3. LENNOX Service Literature UNIT INFORMATION Corp 0128 L12 Revised 10 2004 HSXA15 HSXB15 HSXA15 amp HSXB15 SERIES UNITS The HSXA15 and HSXB15 are high efficiency residential split system condensing units which features a scroll com pressor and R410A refrigerant HSXA15 and HSXB15 units are available in sizes ranging from 2 through 5 tons The series is designed for use with an expansion valve only approved for use with R410A in the indoor unit This manual is divided into sections which discuss the major components refrigerant system charging procedure maintenance and operation sequence Information contained in this manual is intended for use by qualified service technicians only All specifications are subject to change A IMPORTANT Operating pressures of this R410A unit are higher than pressures in R22 units Always use service equipment rated for R410A AWARNING Improper installation adjustment alteration service maintenance cause property damage person al injury or loss of life Installation and service must be performed by a qualified installer or service agency DANGER Electric Shock Hazard May cause injury or death Line voltage is present at all compo nents when unit is not in operation on units with single pole contactors Disconnect all remote electrical power supplies before opening unit panel Unit may have multiple power supplies A IMPORTANT The Clean Air
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5. application Because POE oils absorb moisture the dryness of the system must be verified any time the refrigerant sys tem is exposed to open air A compressor oil sample must be taken to determine if excessive moisture has been introduced to the oil Table 2 lists kits available from Lennox to check POE oils Foreign Matter Check It is recommended that a liquid line filter drier be replaced when the pressure drop across the filter drier is greater than 3 psig TABLE 2 10N46 Refrigerant Analysis Checkmate RT700 utt t2 2 3 years room temperature 3 10N45 Acid Test Tubes Checkmate RT750A three pack years refrigerated Checkmate RT751 Tubes three 6 12 months room temperature 2 10N44 Moisture Test Tubes pack years refrigerated Checkmate RT752C Tubes three 2 3 years room temperature 3 pack years refrigerated 74N40 Easy Oil Test Tubes 74N39 Acid Test Kit Sporlan One Shot TA 1 MEASURING FILTER DRIER PRESSURE DROP 1 Shut off power to unit 2 Remove high pressure switch from fitting next to filter drier A schrader core is located under the high pressure switch 3 Install high pressure gauge hose onto high pressure switch fitting 4 Turn power on to unit and turn room thermostat to call for cooling 5 Record pressure reading on gauge 6 Remove hose from high pressure fitting and install on liquid line valve 7 Read liquid line valve pressure
6. is permanently adjusted to trip open at 40 5 psi The switch automatically resets when suction line pressure rises above 90 5 psi See figure 5 for switch location Page 5 D Lennox System Operation Monitor A132 HSXB15 Only The Lennox system operation monitor LSOM is a 24 volt powered module wired directly to the indoor unit The LSOM is located in the control box and is used to trouble shoot problems in the system The module has three LED s for troubleshooting GREEN indicates power status YEL LOW indicates an abnormal condition and RED indicates thermostat demand but compressor not operating See table 1 for troubleshooting codes NOTE The LSOM is not a safety component and can not shut down or control the HSXB15 The LSOM is a monitoring device only ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A CAUTION Electrostatic discharge affect electronic components Take precautions during unit instal lation and service to protect the unit s electronic controls Precautions will help to avoid control exposure 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 Green Power Red Trip Yellow Alert Flash Code 1 Does not apply to heat pump or to two stage split sys
7. 042 HSXA15 048 HSXA15 060 Data 230 230 230 230 230 230 Line voltage data 60 2 208 230v 1ph 208 230v 1ph 208 230v 1ph 208 230v 1ph 208 230v 1ph 208 230v 1ph Rec Max fuse size amps 30 30 35 40 45 60 1 Minimum circuit ampacity 17 9 19 6 20 4 25 3 27 5 36 2 Compressor Rated load amps 13 5 14 8 15 4 19 3 20 6 27 6 Locked rotor amps 61 73 83 104 109 158 Power factor 0 98 0 98 0 95 0 97 0 97 0 98 Condenser Full load amps 1 1 1 1 1 1 1 1 1 7 1 7 ran Motor Locked rotor amps 2 2 2 2 3 1 3 1 i Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements SPECIFICATIONS HSXB15 General Model HSXB15 024 HSXB15 030 HSXB15 036 HSXB15 042 HSXB15 048 HSXB15 060 Data 230 230 230 230 230 230 Nominal Tonnage kW 2 7 0 2 5 8 8 3 10 6 3 5 12 3 4 14 1 5 17 6 Connections Liquid line o d in mm 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 sweat Suction line o d in mm 3 4 19 1 3 4 19 1 3 4 19 1 7 8 22 2 7 8 22 2 1 1 8 28 6 Refrigerant 1R 410A charge furnished 4 Ibs 10 oz 5 lbs 10 oz 7 Ibs 8 oz 7 Ibs 13 oz 7165 13 10 Ibs 13 oz 2 10 kg 2 55 kg 3 40 kg 3 54 kg 3 54 kg 4 90 kg Condenser Net face area sq ft m2 Outer coil 11 9 1 11 16 1 49 16 1 49 16 1 49 18 3 1 70 21 8 2 03 Coil Inner coil 5 5 0 51 5 6 0
8. 3 oz 7 lbs 13 oz 10 165 15 oz 2 28 kg 2 54 kg 3 39 kg 3 53 kg 3 53 kg 4 95 kg Condenser Net face area sq ft m2 Outer coil 11 9 1 11 16 1 49 16 1 49 16 1 49 18 3 1 70 21 8 2 03 Inner coil 5 5 0 51 5 6 0 52 13 3 1 24 13 3 1 24 13 3 1 24 21 1 1 96 Tube diameter in mm 5 16 7 9 5 16 7 9 5 16 7 9 5 16 7 9 5 16 7 9 5 16 7 9 No of rows 1 46 1 35 1 83 1 83 1 73 2 Fins per inch m 22 866 22 866 22 866 22 866 22 866 22 866 Condenser Diameter in mm 20 508 24 610 24 610 24 610 24 610 24 610 No of blades 4 3 3 3 3 3 Motor hp W 1 6 124 1 6 124 1 6 124 1 6 124 1 4 187 1 4 187 Cfm L s 2450 1115 3150 1485 3150 1485 3150 1485 3900 1840 4200 1980 Rpm 825 825 825 825 820 820 Watts 210 225 225 225 310 350 Shipping Data 1 package Ibs kg 187 85 222 101 238 108 238 108 258 117 312 142 OPTIONAL ACCESSORIES MUST BE ORDERED EXTRA Mounting Model MB2 S 69J06 MB2 L 69J07 MB2 L 69J07 MB2 L 69J07 MB2 L 69J07 MB2 L 69J07 Base Net Weight 6 Ibs 3 kg 15 Ibs 7 kg 15 Ibs 7 kg 15 Ibs 7 kg 15 Ibs 7 kg 15 Ibs 7 kg Dimensions mm 22 1 4 22 1 4 3 32 34x3 32 x 34x3 32 x 34x3 32 x 34x3 32 x 34x 3 565 x 565x76 813x864x76 813x864x76 813x864x76 813x864x76 813x864x76 HSXA15 ELECTRICAL DATA General Model No HSXA15 024 HSXA15 030 HSXA15 036 HSXA15
9. 52 13 3 1 24 13 3 1 24 13 3 1 24 21 1 1 96 Tube diameter in mm 5 16 7 9 5 16 7 9 5 16 7 9 5 16 7 9 5 16 7 9 5 16 7 9 No of rows 1 46 1 35 1 83 1 83 1 73 2 Fins per inch m 22 866 22 866 22 866 22 866 22 866 22 866 Condenser Diameter in mm 20 508 24 610 24 610 24 610 24 610 24 610 Fan No of blades 3 3 3 3 3 3 Motor hp W 1 10 75 1 6 124 1 6 124 1 6 124 1 4 187 1 4 187 L s 2230 1050 3150 1485 3150 1485 3150 1485 3900 1840 4100 1935 825 825 825 825 820 825 Watts 125 225 225 225 310 320 Shipping Data Ibs kg 1 pkg 190 86 227 103 243 110 243 110 263 119 317 144 ELECTRICAL DATA General Line voltage data 60hz 208 230v 1ph 208 230v 1ph 208 230v 1ph 208 230v 1ph 208 230v 1ph 208 230v 1ph Data Maximum fuse size amps 25 30 40 40 45 60 2Minimum circuit ampacity 16 6 19 6 23 5 25 3 27 5 36 2 Compressor Rated load amps 12 8 14 8 17 9 19 3 20 6 27 6 Locked rotor amps 60 73 95 104 109 158 Power factor 0 98 0 98 0 95 0 97 0 97 0 98 Condenser Full load amps 0 6 1 1 1 1 1 1 1 7 1 7 Fan Motor Locked rotor amps 1 6 2 2 2 3 1 3 1 OPTIONAL ACCESSORIES MUST BE ORDERED EXTRA CCB1 EfficiencyPlus Humidity Control 35H00 35H00 35H00 35H00 35H00 35H00 EBR1 Blower Relay Kit for CCB1 75H90 75H90 75H90 75H90 75H90 75H90 Compressor 40 watt 18K20 18K20 18K20 18K20 Crankease Heater 70 67K90 67 90 67 90 67 90 3120 31220 C
10. AWARNING Danger of explosion Can cause equipment damage injury or death Never use oxygen to pressurize a re frigeration air conditioning system Oxygen will explode on contact with oil and could cause personal injury A WARNING Danger of explosion Can cause equipment damage injury or death When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system use a regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa Using an Electronic Leak Detector or Halide 1 Connect a cylinder of R410A to the center port of the manifold gauge set 2 With both manifold valves closed open the valve on the R410A cylinder vapor only 3 Open the high pressure side of the manifold to allow the R410A into the line set and indoor unit Weigh in a trace amount of RA10A A trace amount is a maximum of 2 ounces 57 g or 3 pounds 31 kPa pressure Close the valve on the R410A cylinder and the valve on the high pressure side of the manifold gauge set Dis connect R410A cylinder 4 Connect a oylinder of nitrogen with a pressure regulat ing valve to the center port of the manifold gauge set Page 10 5 Connect the manifold gauge set high pressure hose to the vapor valve service port Normally the high pres sure hose is connected to the liquid line port however connecting it to the vapor port better protects the man ifold gauge set from high pres
11. Act of 1990 bans the intentional vent ing of CFC s and HFC s as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration my be levied for noncompliance Technical Publications Page 1 HSXB15 SHOWN TABLE OF CONTENTS General b eR Re ee a 1 Specifications Electrical Data 2 l Application Lro RD Ix 4 Unit Components 4 Ill Refrigerant System 9 IV 10 V Service and Recovery 12 Maintenance 13 VII Wiring Diagrams and Operating Sequence 15 92001 Industries Inc SPECIFICATIONS HSXA15 NOTE Extremes of operating range are plus 10 and minus 5 of line voltage Page 2 General Model No HSXA15 024 HSXA15 030 HSXA15 036 HSXA15 042 HSXA15 048 HSXA15 060 Data Nominal Tonnage kW 2 7 0 2 5 8 8 3 10 6 3 5 12 3 4 14 1 5 17 6 Connections Liquid line o d in mm 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 Suction line mm 3 4 19 1 3 4 19 1 3 4 19 1 7 8 22 2 7 8 22 2 1 1 8 28 6 Refrigerant R 410A charge furnished 5 Ibs 1 oz 5 Ibs 10 oz 7 Ibs 8 oz 7 Ibs 1
12. ITCH _ AMPACITY MAXIMUM OVER LN CURRENT PROTECTION SIZE A YELLOW L _24vac A REFER TO COMPRESSOR IN COMPRESSOR M UNIT FOR ACTUAL TERMINAL om AMO ARRANGEMENT OGO BEACK 51 S4 ROOM THERMOSTAT WARNING HIGH ELECTRIC SHOCK HAZARD CAN CAUSE INJURY PRESSURE OR DEATH UNIT MUST BE GROUNDED IN SWITCH ACCORDANCE WITH NATIONAL AND LOCAL CODES TO KI 1 FAN COMPRESSOR LEADED CONTACTOR A 208 230 60 I CAPACITO EQUIPMENT GROUND KS FAN MOTOR LEADLESS LINE VOLTAGE FIELD INSTALLED CLASS 11 VOLTAGE FIELD INSTALLED COOLING UNITS HIGH LENNOX CONDENSING UNITS O PRESSURE HSXA15 024 230 02 HSXAI5 042 230 02 KI HSXA15 030 230 02 HSXAI5 048 230 02 COMPRESSOR HSXA15 036 230 02 HSXAI5 060 230 02 CONTACTOR Supersedes Form No BLACK 533 995W New Form No 534 254W 6 2002 Lennox Industries Inc Litho U S A Operation Sequence 1 Cooling demand energizes thermostat terminal Y Voltage from terminal Y passes through the low pressure switch the timed off control on 1 units the high pressure switch and energizes the K1 compressor contac tor coil provided 5 minute delay is satisfied K1 closes energizing B1 compressor and B4 outdoor fan When cooling demand is satisfied K1 opens and de energizes the compressor and outdoor fan The timed off control begins a 5 minute delay on 1 units only Page 15 B Unit Diagram HSXB15 024 060 1P Joopjn
13. OSS SECTION OF SCROLLS Ye L V Ns y i Fe ita SSS SSS SY m NY NG A N Y TIPS SEALED BY ORBITING SCROLL DISCHARGE PRESSURE FIGURE 3 The counterclockwise orbiting scroll draws gas into the out er crescent shaped gas pocket created by the two scrolls figure 4 1 The centrifugal action of the orbiting scroll seals off the flanks of the scrolls figure 4 2 As the orbiting motion continues the gas is forced toward the center of the scroll and the gas pocket becomes compressed figure 4 3 When the compressed gas reaches the center it is dis charged vertically into a chamber and discharge port in the top of the compressor figure1 The discharge pressure forcing down on the top scroll helps seal off the upper and lower edges tips of the scrolls figure 3 During a single orbit several pockets of gas are compressed simultaneous ly providing smooth continuous compression The scroll compressor is tolerant to the effects of liquid re turn If liquid enters the scrolls the orbiting scroll is allowed to separate from the stationary scroll The liquid is worked toward the center of the scroll and is discharged If the com pressor is replaced conventional Lennox cleanup practic es must be used Due to its efficiency the scroll compressor is capable of drawing a much deeper vacuum than reciprocating com pressors Deep va
14. box G Contactor K1 The compressor is energized by a contactor located in the control box All units are single phase with single pole contac tors See figure 5 for location HSXB15 PARTS ARRANGEMENT condenser fan Y not shown top of cabinet Lennox system operation monitor run capacitor ground lug contactor vapor valve compressor power and gauge port terminals discharge line ers anm i 4 vapor line low pressure switch liquid line service valve and gauge port fd Ck CES filter drier d compressor FIGURE 5 Page 7 high pressure switch H Filter Drier A filter drier designed for all HSXA15 model units is factory supplied and must be installed in the liquid line The filter drier for the HSXB15 units is factory installed in the liquid line The filter drier is designed to remove moisture and for eign matter which can lead to compressor failure Moisture and or Acid Check If oil sample taken from a system that has been exposed to open air does not test in the dry color range the filter drier MUST be replaced IMPORTANT Replacement filter drier MUST be approved for R410A refrigerant and POE
15. compressor failure Components The contactor coil time delay HSXA15 1 units only and Lennox system operation monitor are energized by 24VAC supplied by the indoor unit All other components in the outdoor unit are powered by line voltage Refer to unit wiring diagram The HSXA15 and HSXB15 units are not equipped with an internal line voltage to 24V trans former A Scroll Compressor B1 SCROLL COMPRESSOR DISCHARGE FIGURE 1 The scroll compressors in all units are designed for use with R410A refrigerant and operation at high pressures Compressors are shipped from the factory with 3MA 32MMMA P O E oil See electrical section in this manual for compressor specifications The scroll compressor design is simple efficient and re quires few moving parts A cutaway diagram of the scroll compressor is shown in figure 1 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 2 shows the basic scroll form Two iden tical scrolls are mated together forming concentric spiral shapes figure 3 One scroll remains stationary while the other is allowed to orbit figure 4 Note that the orbiting scroll does not rotate or turn but merely orbits the station ary scroll SCROLL FORM FIGURE 2 CR
16. cuum operation can cause internal fusite arcing resulting in damaged internal parts and will result in compressor failure Never use a scroll compressor for eva cuating or pumping down the system This type of dam age can be detected and will result in denial of warranty claims NOTE During operation the head of a scroll compressor may be hot since it is in constant contact with discharge gas Page 4 ipd A SCROLL WORKS MOVEMENT OF ORBIT nue ORBITING iz SCROLL SUCTION POCKET 1 SCROLL PRESSURE oT INTERMEDIATE PRESSURE GAS CRESCENT SHAPED GAS POCKET SERANKS ALED TA CENTRIFUGAL Vg POCKET FIGURE 4 B High Pressure Switch S4 A IMPORTANT Pressure switch settings for R410A refrigerant will be significantly higher than units with R22 A manual reset single pole single throw high pressure switch is located in the liquid line This switch shuts off the compressor when liquid line pressure rises above the factory setting The switch is normally closed and is permanently ad justed to trip open at 640 10 psi and reset close at 448 10 psi See figure 5 for switch location C Low Pressure Switch S87 An auto reset single pole single throw low pressure switch is located in the suction line This switch shuts off the compressor when suction pressure drops below the facto ry setting The switch is closed during normal operating pressure conditions and
17. e 5 for sevice valve torque requirements Table 5 Torque Requirements Recommended Torque Sheet metal screws 16 in Ib Machine screws 10 28 in Ib Compressor bolts 90 in Ib 10 NM Gauge port seal cap 8 ft Ib 11 NM To Access Schrader Port 1 Remove service port cap with an adjustable wrench 2 Connect gauge to the service port 3 When testing is complete replace service port cap Tighten finger tight then an additional 1 6 turn To Open Service Valve 1 Remove the stem cap with an adjustable wrench 2 Use a service wrench with a hex head extension to back the stem out counterclockwise as far as it will go NOTE Use a 3 16 hex head extension for liquid line sizes or a 5 16 extension for vapor line sizes 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn To Close Service Valve 1 Remove the stem cap with an adjustable wrench 2 Use a service wrench with a hex head extension to turn the stem clockwise to seat the valve Tighten the stem firmly NOTE Use a 3 16 hex head extension for liquid line sizes or a 5 16 extension for vapor line sizes 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn Service Valve service to outdoor coil service Schrader valve open to indoor coil to line set when valve is closed front seated valve front seated Service Valve Valve Open insert hex stem cap service por
18. e control box and the screw located directly below it in the filler panel 3 Panels can now be adjusted to remove compressor 4 Re install screws after compressor has been replaced NOTE removing condenser fan grill and reaching in from back side may help re align panels to original posi tion TABLE 8 NORMAL OPERATING PRESSURES Liquid 10 and Suction 5 psig OUTDOOR COIL HSXA15 HSXA15 gt HSXB15 HSXB15 HSXB15 024 1 024 ENTERING 048 060 AIR TEMP F C Ed Ee mms pm 26 pm pe x om TABLE 9 R410A Temperature Pressure Chart Temperature Pressure Temperature Pressure Temperature Pressure Temperature Pressure _ Psig F Psig F Psig F Psig 1 Ca poma 349 5 82 as n ms o 39 895 a 249 o 39s _ 52s L4 powscpos o9 39 389 3589 E ata os 65 5 59 14 VII DIAGRAMS OPERATING SEQUENCE A Unit Diagram HSXA15 024 060 2P B4 OUTDOOR FAN LEADLESS COMPRESSOR CONTACTOR B4 OUTDOOR FAN C LEADED ORANGE RUN DUAL CAPACITOR SI CAPACITOR ROOM THERMOSTAT NOTE FOR USE WITH COPPER CONDUCTORS LOW ONLY REFER TO UNIT RATING PRESSURE HEAT PLATE FOR MINIMUM CIRCUIT SW
19. e results in low capacity and efficiency 1 5 If the values don t agree with the those in table 7 add refrigerant to lower the approach temperature or re cover refrigerant from the system to increase the ap proach temperature TABLE 7 APPROACH TEMPERATURES HSXA B15 Unit Approach Temperature Liquid Line Temp Outdoor Ambient F Mii NOTE For best results the same electronic thermometer should be used to check both outdoor ambient and liquid line temperatures IMPORTANT REFRIGERANT SHOULD BE ADDED THROUGH THE SUCTION VALVE IN THE LIQUID STATE D Oil Charge Refer to compressor nameplate V SERVICE AND RECOVERY AWARNING Polyol ester POE oils used with R410A refrigerant absorb moisture very quickly It is very important that the refrigerant system be kept closed as much as possible DO NOT remove line set caps ser vice valve stub caps until you are ready to make connections A IMPORTANT USE RECOVERY MACHINE RATED FOR R410A REFRIGERANT If the system must be opened for any kind of service such as compressor or filter drier replacement you must take extra precautions to prevent moisture from entering the system The following steps will help to minimize the amount of moisture that enters the system during recovery of R410A 1 Use a regulator equipped nitrogen cylinder to break the system vacuum Do not exceed 5 psi The dry ni trogen will fill the system
20. module 1 Control circuit transformer is overloaded 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 Page 6 E TOC Timed Off Control HSXA15 1 Units Only HSXA15 1 units are equipped with a TOC timed off con trol The TOC is located in the control box figure 5 The TOC is electrically connected between thermostat terminal Y and the compressor contactor When thermostat demand is satisfied the TOC opens the circuit to the compressor contactor coil and the compressor is de energized Between cycles the compressor contactor is delayed for 5 minutes 2 minutes At the end of the delay the compressor is allowed to energize Without the time delay it would be possible to short cycle the compressor F Dual Capacitor C12 The compressor and fan in all units use permanent split ca pacitor motors A single dual capacitor is used for both the fan motor and the compressor see unit wiring diagram The two sides fan and compressor of the capacitor have different mfd ratings and may change with each compres sor The capacitor is located inside the unit control
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22. ompressor Hard Start Kit 10J42 10J42 10J42 10J42 10J42 81J69 Low Ambient Kit 34M72 34M72 34M72 34M72 34M72 34M72 Mounting Model No MB2 S 69J06 MB2 L 69J07 MB2 L 69J07 MB2 L 69J07 MB2 L 69J07 MB2 L 69J07 Base Net Weight 6 Ibs 3 kg 15 Ibs 7 kg 15 Ibs 7 kg 15 Ibs 7 kg 15 Ibs 7 kg 15 Ibs 7 kg Dimensions in mm 22 1 4x22 1 4x3 32x 34 x 3 32x34 x3 32x34x3 32x34x3 32x34 x3 565 x 565x76 813x864x76 813x864x76 813x864x76 813x864x76 813x864x76 Refrigerant 15 ft 4 6 m length L15 41 15 L15 41 15 L15 41 15 L15 65 15 L15 65 15 Field Fabricate Line Set 30 ft 9 m length L15 41 30 L15 41 30 L15 41 30 L15 65 30 L15 65 30 Field Fabricate 40 ft 12 m length L15 41 40 L15 41 40 L15 41 40 L15 65 40 L15 65 40 Field Fabricate 50 ft 15 m length L15 41 50 L15 41 50 L15 41 50 L15 65 50 L15 65 50 Field Fabricate TRefrigerant charge sufficient for 15 ft 4 6 m length of refrigerant lines Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements NOTE Extremes of operating range are plus 10 and minus 5 of line voltage Page 3 I APPLICATION All major components indoor blower and coil must be matched according to Lennox recommendations for the compressor to be covered under warranty Refer to the En gineering Handbook for approved system matchups A misapplied system will cause erratic operation and can re sult in early
23. ow Approach and Normal Operating Pressures Systems Outdoor Temp 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 results indoor temperature should be 70 F 21 C to 80 F 26 Monitor system pressures while charging 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 8 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 Verify adjusted charge using the approach method Outdoor temperature should be 65 F 18 C or above Use the same digital thermometer used to check out door ambient temperature to check liquid line tempera ture Verify the unit charge using the approach method The difference between the ambient and liquid temper atures should match values given in table 3 Refriger ant must be added to lower approach temperature and removed to increase approach temperature Loss of charg
24. p 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 When the absolute pressure requirement above has been met disconnect the manifold hose from the vacu um pump and connect it to an upright cylinder of R410A 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 R410A cylinder and remove the manifold gauge set 1 1 C Charging AIMPORTANT Mineral oils are not compatible with R410A If oil must be added it must be a polyol ester oil The compressor is charged with sufficient polyol ester oil for line set lengths up to 50 ft Weighing in the Charge Fixed Orifice or TXV Systems Outdoor Temp 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 proce dures outlined bel
25. purging any moisture 2 Remove the faulty component and quickly seal the system using tape or some other means to prevent additional moisture from entering the system 3 Do not remove the tape until you are ready to install new component Quickly install the replacement com ponent 4 Evacuate the system to remove any moisture and oth er non condensables Page 12 The HSXA15 and HSXB15 system MUST be checked for moisture anytime the sealed system is opened Any moisture not absorbed by the polyol ester oil can be re moved by triple evacuation Moisture that has been ab Sorbed by the compressor oil can be removed by replacing the drier A IMPORTANT Evacuation of system only will not remove mois ture from oil Drier must be replaced to eliminate moisture from POE oil VI MAINTENANCE AWARNING Electric shock hazard Can cause ry or death Before attempting to per form any service or maintenance turn the electrical power to unit OFF at dis connect switch es Unit may have multiple power supplies Maintenance and service must be performed by a qualified installer or service agency At the beginning of each cooling season the system should be checked as follows 1 Clean and inspect the outdoor coil The coil may be flushed with a water hose Ensure the power is turned off before you clean the coil 2 Condenser fan motor is prelubricated and sealed No further lubrication is needed
26. ring device 5 Condenser coil is dirty 6 Liquid line restriction filter drier blocked if present 7 Thermostat is malfunctioning 1 High head pressure 2 Condenser coil poor air circulation dirty blocked damaged 3 Condenser fan is not running Return air duct has substantial leakage 5 If low pressure switch is present check Flash Code 1 information 1 Thermostat demand signal is intermittent 2 Time delay relay or control board is defective 3 f high pressure switch is present check Flash Code 2 information 4 If low pressure switch is present check Flash Code 1 information 1 Run capacitor has failed 2 Low line voltage contact utility if voltage at disconnect is low 3 Excessive liquid refrigerant in the compressor Compressor bearings are seized 1 Outdoor unit power disconnect is open 2 Unit circuit breaker or fuse s is open 3 Unit contactor has failed to close High pressure switch 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 1 Run capacitor has failed 2 Open circuit in compressor start wiring or connections 3 Compressor start winding is damaged 1 Open circuit in compressor start wiring or connections 2 Compressor start winding is damaged 1 Compressor contactor failed to open 2 Thermostat demand signal not connected to
27. 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 Page 11 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 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 nitrogen cylin der 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 1 A CAUTION Danger of Equipment Damage Avoid deep vacuum operation Do not use compres sors to evacuate a system Extremely low vacuums can cause internal arcing and compressor failure Damage caused by deep vacuum operation will void warranty 7 Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder Open the manifold gauge valves to release the nitrogen from the line set and indoor unit Reconnect the manifold gauge to the vacuum pum
28. sure damage 6 Adjust the nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set which will pressurize line set and indoor unit 7 After a few minutes open a refrigerant port to ensure the refrigerant you added is adequate to be detected Amounts of refrigerant will vary with line lengths Check all joints for leaks Purge nitrogen and R410A mixture Correct any leaks and recheck B Evacuating the System 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 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 10 000 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 iquid line service valve 2 Connect micron gauge 3 Connect the vacuum pump with vacuum gauge to the center port of the manifold gauge set 4 Open both manifold valves and start the vacuum pump 5 Evacuate the line set and indoor unit to an absolute pressure of 23 000 microns 29 01 inches of mercu
29. t cap to indoor coil Schrader valve FIGURE 9 Vapor Line Ball Valve 5 ton Only Vapor line ball valves function the same way as the other valves the difference is in the construction These valves are not rebuildable If a valve has failed you must replace it A ball valve is illustrated in figure 10 Ball Valve Valve Open Use Adjustable Wrench To open rotate Stem Clockwise 90 To close rotate Stem Counter clockwise 90 4A stem to outdoor coil ball shown open service port Schrader valve FIGURE 10 IV CHARGING Units are factory charged with the amount of R410A refrig erant indicated on the unit rating plate This charge is based on a matching indoor coil and outdoor coil with 15 ft 4 5m line set For varying lengths of line set refer to table 6 for refrigerant charge adjustment TABLE 6 Liquid Line Set Ozs per 5 ft grams per 1 5m adjust Diameter from 15 ft 4 5m line set 3 8 in 3 ounces per 5 feet If line length is greater than 15 ft 4 5 add this amount If line length is less than 15 ft 4 5m subtract this amount A Leak Testing After the line set has been connected to the indoor and outdoor units check the line set connections and indoor unit for leaks 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 personal injury or death
30. tems 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 TABLE 1 Lennox System Operation Monitor Troubleshooting Codes Status LED Status LED Description Status LED Troubleshooting Information Thermostat demand signal Y1 is present but the com pressor is not running Heat pump only Trip light will be on during defrost board 5 minute delay with Y thermostat call Long Run Time Compressor is running extremely long run cycles System Pressure Trip Discharge or suction pressure out of limits or compressor overloaded Short Cycling Compressor is running only briefly Locked Rotor Open Circuit Open Start Circuit Current only in run circuit Open Run Circuit Current only in start circuit Welded Contactor Compressor always runs Low Voltage Control circuit lt 17VAC Module has power Supply voltage is present at module terminals 1 Compressor protector is open 2 Outdoor unit power disconnect is open 3 Compressor circuit breaker or fuse s is open 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 1 Low refrigerant charge 2 Evaporator blower is not running 3 Evaporator coil is frozen Faulty mete
31. uction lines from the outdoor unit sweat connections Use Lennox L15 series line sets as shown in table 4 or field fabricated refrigerant lines Separate discharge and suction service ports are provided at the compressor for connection of gauge manifold during charging procedure TABLE 4 Valve Size Recommended Line Set Model Connections Liquid Vapor Liquid V L15 iqui Line Line iim Line Sets 024 7 L15 41 030 3Bin 3 4in 3 8in qi io 15 ft 50 ft 036 10 mm 19 mm 10 mm 19 mm 4 6 m 15 m 042 7 8in 3 8in 7 8 in MER uo F 048 10 mm 22 mm 10 mm 22 mm 4 6 m 15 m 3 8 in 1 1 8in 3 8in 1 1 8 in Field 10 mm 29 mm 10 mm 29 mm Fabricated Page 9 B Service Valves The liquid line and vapor line service valves and gauge ports are accessible by removing the compressor access cover Full service liquid and vapor line valves are used See figures 9 and 10 The service ports are used for leak testing evacuating charging and checking charge Ser vice valves have a factory installed schrader valve A ser vice port cap is supplied to protect the schrader valve from contamination and assure a leak free seal Valves are not rebuildable If a valve has failed it must be replaced The pressure tap fitting has a LIGHT MAROON tag to remind service technicians that the unit contains R410A See tabl
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