advertisement
201
9
Lennox Industries Inc.
Dallas, Texas, USA
INSTALLATION
INSTRUCTIONS
Elite
®
SSB*H4 Units
AIR CONDITIONER UNITS
50
8039
-01
11
/201
9
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause personal injury, loss of life, or damage to property.
Installation and service must be performed by a licensed professional installer (or equivalent) or a service agency.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFCs, HCFCs and HFCs) as of July 1, 1992.
Approved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarceration may be levied for noncompliance.
TABLE OF CONTENTS
Shipping and Packing List
General
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Number Identification
Unit Parts Arrangement
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
Operating Gauge Set and Service Valves . . . . . . . . .
Recovering Refrigerant from Existing System
New Unit Placement
. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and Installing Panels . . . . . . . . . . . . . . . . .
New or Replacement Line Set . . . . . . . . . . . . . . . . . . .
Brazing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Line Set and Indoor Coil . . . . . . . . . . . . . . . .
Installing Indoor Metering Device . . . . . . . . . . . . . . . .
Leak Test Line Set and Indoor Coil . . . . . . . . . . . . . . .
Evacuating Line Set and Indoor Coil . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Units Delivered Void of Charge
Unit Start-Up
. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List
IMPORTANT
This unit must be matched with an indoor coil as speci fied in Lennox SSB*H4 Product Specification bulletin .
Coils previously charged with HCFC-22 must be flushed.
NOTICE TO INSTALLER
UNIT PLACEMENT
It is critical for proper unit operation to place outdoor unit on an elevated surface as described in Unit Placement
BRAZING LINE SET TO SERVICE VALVES
It is imperative to follow the brazing technique illustrated starting on
page 12 to avoid damaging the service valve's internal seals.
Page 1
Check the unit for shipping damage and listed times below are intact. If damaged, or if parts are missing, immediately contact the last shipping carrier.
1 - Assembled outdoor unit.
General
Two-stage
Elite ®
SSB*H4 outdoor units use
HFC-410A refrigerant. This unit must be installed with a matching indoor coil and line set as outlined in the
Product Specification bulletin
(EHB)
.
Elite ®
SSB*H4 outdoor units are designed for use in expansion valve systems (TXV) only. They are not designed to be used with other refrigerant f l ow control devices. The
Product Specification bulletin lists a TXV kit that must be ordered separately.
Unit Dimensions - Inches (mm)
UNIT SUPPORT
FEET
D
K
E
J
F G H
BASE WITH ELONGATED LEGS
C
DISCHARGE AIR
B
LIQUID LINE
CONNECTION
ELECTRICAL
INLETS
SUCTION LINE
CONNECTION
A
2 (51)
4-1/4(1
08)
4-3/4
(121)
SIDE VIEW 1 (25) SIDE VIEW
Model
Number
A B C D E F G H
SSB036H4S4 31 (787) 30-1/2 (775)
SSB048H4S4 39 (991) 30-1/2 (775)
35 (889)
13-7/8 (352) 7-3/4 (197) 3-1/4 (83) 27-1/8 (689) 3-5/8 (92)
35 (889)
SSB060H4S4 45 (1143) 35-1/2 (902) 39-3/8 (1001) 16-7/8 (429) 8-3/4 (222) 3-1/8 (79) 30-3/4 (781) 4-5/8 (117)
J
4-1/2 (114)
3-3/4 (95)
K
20-5/8 (524)
26-7/8 (683)
Model Number Identification
S =
Brand/Family
Elite ®
Product Line
Unit Type
S = Air Conditioner Outdoor Unit
S S B 036 H 4 S 4 1 Y
Voltage
Y = 208/230V‐3 phase‐60hz
G = 460V‐3 phase‐60hz
Minor Design Sequence
1 = 1st Revision
2 = 2nd Revision
3 = 3rd Revision
Coil type
4 = Four-sided
Major Design Sequence
A = 1st Generation
B = 2nd Generation
Nominal Cooling Capacity -
Tons
036 = 3 Tons
048 = 4 Tons
060 = 5 Tons
Cooling Efficiency
H = High Efficiency
Part Load Capability
S = Part load capabilities with multi-stage operation.
Refrigerant Type
4 = HFC-410A
Page 2
Typical Unit Parts Arrangement
CONTROL PANEL
CRANKCASE HEATER RELAY
(K-191) (G-VOLTAGE UNITS
ONLY)
DUAL RUN CAPACITOR
(C12)
THREE POLE CONTACTOR (K1)
GROUND)
PLUMBING, SWITCHES AND ELECTRICAL COMPONENTS
COMPRESSOR
COMPRESSOR
HARNESS
CRANKCASE
THERMOSTAT
(S40)
LIQUID LINE FILTER
DRIER (SINGLE FLOW)
LIQUID LINE SERVICE
VALVE
FIELD CONNECTION
FOR LIQUID LINE SET
Figure 1. Typical Parts Arrangements
Page 3
CRANKCASE HEATER
(HR1)
HIGH PRESSURE SWITCH
(MANUAL RESET) (S4)
LOW PRESSURE
SWITCH (S87)
SUCTION LINE
SERVICE VALVE
FIELD CONNECTION
FOR SUCTION LINE
SSB*H4 SERIES
WARNING
Electric Shock Hazard. Can cause injury or death. Unit must be grounded in accordance with national and local codes.
Line voltage is present at all components when unit is not in operation on units with single‐pole contactors. Disconnect all remote electric power supplies before opening access panel. Unit may have multiple power supplies.
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.
Operating Gauge Set and Service Valves
These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation.
TORQUE REQUIREMENTS
When servicing or repairing heating, ventilating, and air conditioning components, ensure the fasteners are
appropriately tightened. Table 1 lists torque values for
fasteners.
IMPORTANT
Only use Allen wrenches of sufficient hardness (50Rc -
Rockwell Harness Scale minimum). Fully insert the wrench into the valve stem recess.
Service valve stems are factory-torqued (from 9 ft-lbs for small valves, to 25 ft-lbs for large valves) to prevent refrigerant loss during shipping and handling. Using an
Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench, or stripping the valve stem recess.
See the Lennox Service and Application Notes #C-08-1 for further details and information.
IMPORTANT
To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening.
Table 1. Torque Requirements
Parts
Service valve cap
Recommended Torque
8 ft.- lb.
11 NM
Sheet metal screws 16 in.- lb.
Machine screws #10 28 in.- lb.
2 NM
3 NM
Compressor bolts 90 in.- lb.
Gauge port seal cap 8 ft.- lb.
10 NM
11 NM
USING MANIFOLD GAUGE SET
When checking the system charge, only use a manifold gauge set that features low loss anti-blow back fittings.
Manifold gauge set used with HFC-410A refrigerant systems must be capable of handling the higher system operating pressures. The gauges should be rated for use with pressures of 0 - 800 psig on the high side and a low side of 30” vacuum to 250 psig with dampened speed to
500 psi. Gauge hoses must be rated for use at up to 800 psig of pressure with a 4000 psig burst rating.
OPERATING SERVICE VALVES
The liquid and vapor line service valves are used for removing refrigerant, flushing, leak testing, evacuating, checking charge and charging.
Each valve is equipped with a service port which has a
factory-installed valve stem. Figure 2 provides information
on how to access and operating both angle and ball service valves.
Page 4
Operating Angle-Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. Use a service wrench with a hex-head extension (3/16” for liquid line valve sizes and 5/16” for vapor line valve sizes) to back the stem out counterclockwise as far as it will go.
SERVICE PORT CAP
SERVICE PORT CORE
TO INDOOR
UNIT (VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE
(VALVE STEM SHOWN
CLOSED) INSERT HEX
WRENCH HERE
SERVICE PORT
CORE
STEM CAP
TO OUTDOOR UNIT
ANGLE-TYPE SERVICE VALVE
(BACK-SEATED / OPENED)
When service valve is OPEN , the service port is open to line set, indoor and outdoor unit.
ANGLE-TYPE SERVICE VALVE
(FRONT-SEATED / CLOSED)
WHEN SERVICE VALVE IS
CLOSED
, THE SERVICE PORT IS OPEN
TO THE LINE SET AND INDOOR UNIT.
Operating Ball-Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. To open valve, use a wrench to rotate stem counterclockwise
90°. To close, rotate stem clockwise 90°.
TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°.
TO CLOSE ROTATE STEM
CLOCKWISE 90°.
SERVICE PORT
SERVICE PORT
CORE
SERVICE PORT
CAP
TO OUTDOOR
UNIT
TO INDOOR UNIT
BALL (SHOWN
CLOSED)
VALVE
STEM
STEM CAP
To Access Service Port:
A service port cap protects the service port core from contamination and serves as the primary leak seal.
1. Remove service port cap with an appropriately sized wrench.
2. Connect gauge set to service port.
3. When testing is completed, replace service port cap and tighten as follows:
1/6 TURN
With torque wrench: Finger tighten and
Without torque wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/6 turn clockwise.
Reinstall Stem Cap:
10
11 12
9
8
7
6
1
5
2
4
3
Stem cap protects the valve stem from damage and serves as the primary seal. Replace the stem cap and tighten as follows:
1/12 TURN
With torque wrench: Finger tighten and
Without torque wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/12 turn clockwise.
9
10
8
11 12
7
6
1
5
2
4
3
NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
Figure 2. Angle and Ball-Type Service Valves
Page 5
SSB*H4 SERIES
Recovering Refrigerant from Existing System
1 DISCONNECT POWER
Disconnect all power to the existing outdoor unit at the disconnect switch or main fuse box/breaker panel.
2 CONNECT MANIFOLD GAUGE SET
Connect a gauge set, clean recovery cylinder and a recovery machine to the service ports of the existing unit. Use the instructions provided with the recovery machine to make the connections.
MAIN FUSE BOX/BREAKER PANEL
MAIN FUSE
BOX/BREAKER
PANEL
DISCONNECT
SWITCH
RECOVERY MACHINE
MANIFOLD GAUGES
LOW HIGH
OUTDOOR UNIT CLEAN RECOVERY
CYLINDER
RECOVER REFRIGERANT 3
Remove existing HCFC-22 refrigerant using one of the following procedures:
IMPORTANT - Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes, and/or long line sets.
METHOD 1:
Us this method 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
HCFC-22 to flush the system.
Remove all HCFC-22 refrigerant from the existing system. Check gauges after shutdown to confirm that the system is completely void of refriger ant.
METHOD 2:
Use this method if the existing outdoor unit is equipped with manual shut-off valves, and you plan to use new HCFC-22 refrigerant to flush the system.
The following devices could prevent full system charge recovery into the outdoor unit:
Outdoor unit's high or low-pressure switches (if applicable), when tripped, can cycle the compressor OFF .
Compressor can stop pumping due to tripped internal pressure relief valve.
Compressor has internal vacuum protection that is designed to unload the scrolls (compressor stops pumping) when the pressure ratio meets a certain value or when the suction pressure is as high as 20 psig. (Compressor suction pressures should never be allowed to go into a vacuum.
Prolonged operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips, drive bearings and internal seals.)
Once the compressor cannot pump down to a lower pressure due to one of the above system conditions, shut off the vapor valve. Turn OFF the main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set.
Perform the following task:
A Start the existing HCFC-22 system in the cooling mode and close the liquid line valve.
B Use the compressor to pump as much of the existing HCFC-22 refrigerant into the outdoor unit until the outdoor system is full. Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system.
Note - It may be necessary to bypass the low pressure switches (if equipped) to ensure complete refrigerant evacuation.
C When the low side system pressures reach 0 psig, close the vapor line valve.
D Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system.
Figure 3. Recovering Refrigerant
Page 6
CLEARANCE ON ALL SIDES — INCHES (MILLIMETERS)
6 (152)
12 (305)
36 (914)
ACCESS PANEL
CONTROL PANEL
ACCESS
LOCATION
30 (762)
NOTES:
Clearance to one of the other three sides must be 36 inches (914mm).
Clearance to one of the remaining two sides may be 12 inches
(305mm) and the final side may be
6 inches (152mm).
LINE SET
CONNECTIONS
MINIMUM CLEARANCE
ABOVE UNIT
48 (1219)
MINIMUM CLEARANCE BETWEEN
TWO UNITS
24 (610)
New Unit Placement
Figure 4. Installation Clearances
NOTE - If necessary for stability, anchor unit to slab as illustrated in
CAUTION
In order to avoid injury, take proper precaution when lifting heavy objects.
See Unit Dimensions on page 3 for sizing mounting slab,
platforms or supports. Refer to figure 4 for mandatory
installation clearance requirements.
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
Some localities are adopting sound ordinances based on the unit's sound level registered from the adjacent property, not from the installation property. Install the unit as far as possible from the property line.
When possible, do not install the unit directly outside a window. Glass has a very high level of sound transmission. For proper placement of unit in relation
to a window see the provided illustration in figure 5,
detail A.
PLACING UNIT ON SLAB
When installing unit at grade level, the top of the slab should be high enough above grade so that water from higher ground will not collect around the unit. The slab
should have a slope tolerance as described in figure 5,
detail B.
IMPORTANT
To help stabilize an outdoor unit, some installations may require strapping the unit to the pad using brackets and anchors commonly available in the marketplace.
ELEVATING THE UNIT
Units are outfitted with elongated support feet as illustrated
If additional elevation is necessary, raise the unit by extending the height of the unit support feet. This may be achieved by using a 2 inch (50.8mm) Schedule 40 female threaded adapter.
The specified coupling will fit snuggly into the recessed portion of the feet. Use additional 2 inch (50.8mm)
Schedule 40 male threaded adaptors which can be threaded into the female threaded adaptors to make additional adjustments to the level of the unit.
NOTE - Keep the height of extenders short enough to ensure a sturdy installation. If it is necessary to extend further, consider a different type of field-fabricated framework that is sturdy enough for greater heights.
Page 7
SSB*H4 SERIES
DETAIL A
— Outside Unit Placement
Install unit away from windows.
DETAIL B
— Slab Mounting at Ground Level
Install unit level or, if on a slope, maintain slope tolerance of two (2) degrees (or two inches per five feet [50 mm per 1.5 m]) away from building structure.
BUILDING
STRUCTURE
MOUNTING
SLAB
GROUND LEVEL TWO 90° ELBOWS INSTALLED IN LINE SET WILL
REDUCE LINE SET VIBRATION.
DETAIL C
— Elevated Slab Mounting using Feet Extenders
STABILIZING UNIT ON UNEVEN SURFACES
DETAIL D
— Slab Side Mounting
#10 1/2” LONG SELF-DRILLING
SHEET METAL SCREWS
STABILIZING BRACKET (18 GAUGE
METAL — 2” WIDTH; HEIGHT AS
REQUIRED)
COIL
BASE PAN
BASE
#10 1-1/4” LONG HEX HD SCREW
AND FLAT WASHER
CORNER POST
Concrete slab — use two plastic anchors (hole drill 1/4”)
Wood or plastic slab — no plastic an chor (hole drill 1/8”)
DETAIL E
— Deck Top Mounting
Stabilizing bracket (18 gauge metal — 2” (50.8mm) width; height as required); bend to form right angle as exampled below.
MINIMUM ONE
PER SIDE
LEG DETAIL
2” (50.8MM) SCH 40
FEMALE THREADED
ADAPTER
2” (50.8MM) SCH 40
MALE THREADED
ADAPTER SAME FASTENERS AS
SLAB SIDE MOUNTING.
FOR EXTRA
STABILITY
Use additional 2” SCH 40 male threaded adapters which can be threaded into the female threaded adapters to make additional adjustments to the level of the unit.
One bracket per side (minimum). For extra stability, two brackets per side, two inches
(51mm) from each corner.
IMPORTANT - To help stabilize an outdoor unit, some installations may require strapping the unit to the pad using brackets and anchors commonly available in the marketplace.
Figure 5. Placement, Slab Mounting and Stabilizing Unit
Page 8
ROOF MOUNTING
Install the unit a minimum of 6 inches (152 mm) above the roof surface to avoid ice build-up around the unit. Locate the unit above a load bearing wall or area of the roof that can adequately support the unit. Consult local codes for rooftop applications.
NOTICE
Roof Damage!
This system contains both refrigerant and oil. Some rubber roofing material may absorb oil and cause the rubber to swell when it comes into contact with oil. The rubber will then bubble and could cause leaks. Protect the roof surface to avoid exposure to refrigerant and oil during service and installation. Failure to follow this notice could result in damage to roof surface.
Removing and Installing Panels
IMPORTANT
Do not allow panels to hang on unit by top tab. Tab is for alignment and not designed to support weight of panel.
WARNING
To prevent personal injury, or damage to panels, unit or structure, be sure to observe the following:
While installing or servicing this unit, carefully stow all removed panels out of the way, so that the panels will not cause injury to personnel, nor cause damage to objects or structures nearby, nor will the panels be subjected to damage (e.g., being bent or scratched).
While handling or stowing the panels, consider any weather conditions, especially windy conditions, that may cause panels to be blown around and battered.
LOUVERED PANEL REMOVAL
Remove the louvered panels as follows:
1.
Remove two screws, allowing the panel to swing open slightly.
2.
Hold the panel firmly throughout this procedure. Rotate bottom corner of panel away from hinged corner post until lower three tabs clear the slots as illustrated in detail B.
3.
Move panel down until lip of upper tab clears the top slot in corner post as illustrated in detail A .
IMPORTANT! DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB. TAB IS FOR
ALIGNMENT AND NOT DESIGNED TO SUPPORT WEIGHT OF PANEL.
PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR
ENTER) TOP SLOT FOR REMOVING (OR INSTALLING) PANEL.
LIP
SCREW
HOLES
LOUVERED PANEL INSTALLATION
Position the panel almost parallel with the unit as illustrated in detail D with the screw side as close to the unit as possible. Then, in a continuous motion:
1. Slightly rotate and guide the lip of top tab inward as illustrated in detail A and
C ; then upward into the top slot of the hinge corner post.
2. Rotate panel to vertical to fully engage all tabs.
3. Holding the panel's hinged side firmly in place, close the right-hand side of the panel, aligning the screw holes.
4. When panel is correctly positioned and aligned, insert the screws and tighten .
DETAIL A
DETAIL B
Detail C
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL
WITH THE UNIT AS POSSIBLE) WHILE INSTALLING PANEL.
ANGLE MAY BE TOO
EXTREME
PREFERRED ANGLE
FOR INSTALLATION
HOLD DOOR FIRMLY TO THE HINGED
SIDE TO MAINTAIN
FULLY-ENGAGED TABS
ROTATE IN THIS DIRECTION;
THEN DOWN TO REMOVE
PANEL
Figure 6. Removing and Installing Panels
Page 9
SSB*H4 SERIES
New or Replacement Line Set
REFRIGERANT LINE SET
This section provides information on installation or replacement of existing line set. If new or replacement line set is not being installed then proceed to Brazing
Connections
NOTE - When installing refrigerant lines longer than 50 feet, see the Lennox Refrigerant Piping Design and
Fabrication Guidelines, CORP. 9351-L9, or contact
Lennox Technical Support Product Applications for assistance.
IMPORTANT
Lennox highly recommends changing line set when converting the existing system from HCFC-22 to
HFC-410A .
If that is not possible and the line set is the proper size as reference in table 2, use the procedure outlined under Flushing the System on page 13.
If refrigerant lines are routed through a wall, then seal and isolate the opening so vibration is not transmitted to the building. Pay close attention to line set isolation during installation of any HVAC system. When properly isolated from building structures (walls, ceilings. floors), the refrigerant lines will not create unnecessary vibration and
subsequent sounds. See figure 7 for recommended
installation practices. Also, consider the following when placing and installing a high-efficiency outdoor unit.
To obtain the correct information from Lennox, be sure to communicate the following information:
Model SSB*H4 and size of unit (e.g. -036).
Line set diameters for the unit being installed as listed
in table 2 and total length of piping.
Number of elbows vertical rise or drop in the piping.
The compressor is charged with sufficient Polyol ester oil for line set lengths up to 50 feet. Recommend adding oil to system based on the amount of refrigerant charge in the system. No need to add oil in system with 20 pounds of refrigerant or less. For systems over 20 pounds - add one ounce of oil for every five pounds of refrigerant.
Recommended topping-off POE oils are Mobil EAL
ARCTIC 22 CC or ICI EMKARATE RL32CF.
Liquid lines that meter the refrigerant, such as RFC1 liquid lines, must not be used in this application. Existing line set
of proper size as listed in table 2 may be reused. If system
was previously charged with HCFC-22 refrigerant, then existing line set must be flushed (see Flushing Line Set and Indoor Coil
WARNING
Polyol Ester (POE) oils used with HFC-410A 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 or service valve stub caps until you are ready to make connections.
Field refrigerant piping consists of liquid and vapor lines from the outdoor unit to the indoor unit coil (braze connections). Use Lennox L15 (sweat, non-flare) series line set or field-fabricated refrigerant line sizes as listed in
IMPORTANT
Mineral oils are not compatible with HFC-410A .
If oil must be added, it must be a Polyol Ester oil.
Table 2. Refrigerant Line Set — Inches (mm)
Model Number
Field Connections
Liquid Line Vapor Line
Recommended Line Set
Vapor Line L15 Line Sets Liquid Line
SSB036H4S4
3/8 in. (10 mm) 7/8 in. (22 mm) 3/8 in. (10 mm) 7/8 in (22 mm) L15-65 — 15 ft. - 50 ft. (4.6 m - 15 m)
SSB048H4S4
1-1/8 in. (29 mm) Field Fabricated SSB060H4S4 3/8 in. (10 mm) 1-1/8 in. (29 mm) 3/8 in. (10 mm)
NOTE - Some applications may required a field provided 7/8” to 1-1/8” adapter
Page 10
Line Set Isolation — The following illustrations are examples of proper refrigerant line set isolation:
REFRIGERANT LINE SET — TRANSITION
FROM VERTICAL TO HORIZONTAL
ANCHORED HEAVY NYLON
WIRE TIE OR AUTOMOTIVE
MUFFLER‐TYPE HANGER
AUTOMOTIVE
MUFFLER‐TYPE HANGER
REFRIGERANT LINE SET — INSTALLING
VERTICAL RUNS (NEW CONSTRUCTION SHOWN)
NOTE - Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig .
OUTSIDE WALL
LIQUID LINE
VAPOR LINE
WALL
STUD
STRAP LIQUID LINE TO
VAPOR LINE
LIQUID LINE
NON-CORROSIVE
METAL SLEEVE
VAPOR LINE - WRAPPED
IN ARMAFLEX
WOOD BLOCK
BETWEEN STUDS
WIRE TIE
INSIDE WALL
STRAP
NON-CORROSIVE
METAL SLEEVE
WIRE TIE
WOOD BLOCK
WIRE TIE
STRAP
REFRIGERANT LINE SET — INSTALLING
HORIZONTAL RUNS
To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties.
WIRE TIE (AROUND
VAPOR LINE ONLY)
8 FEET (2.43 METERS)
STRAPPING
MATERIAL (AROUND
VAPOR LINE ONLY)
FLOOR JOIST OR
ROOF RAFTER
TAPE OR
WIRE TIE
8 FEET (2.43 METERS)
TAPE OR
WIRE TIE
NON-CORROSIVE
METAL SLEEVE
STRAP THE VAPOR LINE TO THE JOIST
OR RAFTER AT 8 FEET (2.43 METERS)
INTERVALS THEN STRAP THE LIQUID
LINE TO THE VAPOR LINE.
FLOOR JOIST OR
ROOF RAFTER
SLEEVE
VAPOR LINE WRAPPED
WITH ARMAFLEX
OUTSIDE
WALL
LIQUID
LINE
PVC
PIPE
FIBERGLASS
INSULATION
CAULK
NOTE Similar installation practices should be used if line set is to be installed on exterior of outside wall.
Figure 7. Line Set Installation
Page 11
SSB*H4 SERIES
Brazing Connections
Use the procedures outline in figures 8 and 9 for brazing
line set connections to service valves.
WARNING
Danger of fire. Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing. Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture - Check the high and low pressures before applying heat.
WARNING
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).
CAUTION
Brazing alloys and flux contain materials which are hazardous to your health.
Avoid breathing vapors or fumes from brazing operations. Perform operations only in well-ventilated areas.
Wear gloves and protective goggles or face shield to protect against burns.
Wash hands with soap and water after handling brazing alloys and flux.
IMPORTANT
Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve.
IMPORTANT
Allow braze joint to cool before removing the wet rag from the service valve. Temperatures above 250ºF can damage valve seals.
IMPORTANT
Use silver alloy brazing rods with 5% minimum silver alloy for copper-to-copper brazing. Use 45% minimum alloy for copper-to-brass and copper-to-steel brazing.
WARNING
Fire, Explosion and Personal Safety Haz ard.
Failure to follow this warning could result in damage, personal injury or death.
Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when ex posed to a spark or open flame, can cause fire and/or an explosion, that could result in property damage, personal inju ry or death.
Page 12
1 CUT AND DEBUR
Cut ends of the refrigerant lines square (free from nicks or dents) and debur the ends. The pipe must remain round. Do not crimp end of the line.
2 CAP AND CORE REMOVAL
Remove service cap and core from both the vapor and liquid line service ports.
CUT AND DEBUR
SERVICE PORT
CAP
LINE SET SIZE MATCHES
SERVICE VALVE CONNECTION
COPPER TUBE
STUB
SERVICE VALVE
CONNECTION
REDUCER
SERVICE
PORT
CORE
LIQUID LINE SERVICE
VALVE
SERVICE
PORT
CORE
SERVICE
PORT CAP
SUCTION / VAPOR LINE
SERVICE VALVE
LINE SET SIZE IS SMALLER
THAN CONNECTION
REFRIGERANT LINE
DO NOT CRIMP SERVICE VALVE
CONNECTOR WHEN PIPE IS
SMALLER THAN CONNECTION
3 ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE
VALVES
Flow regulated nitrogen (at 1 to 2 psig) through the low-side refrigeration gauge set into the liquid line service port valve, and out of the suction / vapor line service port valve.
A Connect gauge set low pressure side to liquid line service valve (service port).
USE REGULATOR TO FLOW
NITROGEN AT 1 TO 2 PSIG.
B Connect gauge set center port to bottle of nitrogen with regulator.
LOW HIGH
C Remove Schrader valve in suction / vapor line service port to allow nitrogen to escape.
ATTACH
GAUGES
SUCTION / VAPOR SERVICE PORT MUST BE
OPEN TO ALLOW EXIT POINT FOR NITROGEN
C
INDOOR
UNIT
VAPOR LINE
LIQUID LINE
B
SUCTION /
VAPOR LINE
SERVICE
VALVE
OUTDOOR
UNIT
LIQUID LINE SERVICE
VALVE
A
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
NITROGEN
Figure 8. Brazing Procedures
Page 13
SSB*H4 SERIES
4 WRAP SERVICE VALVES
To help protect service valve seals during brazing, wrap a saturated cloth around service valve bodies and copper tube stub. Use another saturated cloth underneath the valve body to protect the base paint.
5 FLOW NITROGEN
Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and out of the suction / vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set connections
6 BRAZE LINE SET
Wrap both service valves with a saturated cloth as illustrated here before brazing to line set.
LIQUID LINE SERVICE VALVE
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
IMPORTANT - Allow braze joint to cool. Apply additional saturated cloths to help cool brazed joint. Do not remove wet rag until piping has cooled. Temperatures above 250ºF will damage valve seals.
WARNING
1.
FIRE, PERSONAL INJURY, OR PROPERTY
DAMAGE will result if you do not wrap a wet cloth around both liquid and suction line service valve bodies and copper tube stub while brazing in the line set! The braze, when complete, must be quenched with water to absorb any residual heat.
2. Do not open service valves until refrigerant lines and indoor coil have been leak-tested and evacuated.
Refer to procedures provided in this supplement.
SATURATED CLOTH
LIQUID LINE
SUCTION / VAPOR LINE
SERVICE VALVE
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
SUCTION / VAPOR LINE
SATURATED CLOTH
7 PREPARATION FOR NEXT STEP
After all connections have been brazed, disconnect manifold gauge set from service ports. Apply saturated rags to both services valves to cool piping. Once piping is cool, remove all wet cloths. Refer to the unit installation instructions for the next step in preparing the unit.
Figure 9. Brazing Procedures (continued)
Page 14
Flushing Line Set and Indoor Coil
1A TYPICAL EXISTING FIXED ORIFICE
REMOVAL PROCEDURE (UNCASED
COIL SHOWN)
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
OR
1B TYPICAL EXISTING EXPANSION VALVE REMOVAL
PROCEDURE (UNCASED COIL SHOWN)
STUB END
TWO PIECE PATCH PLATE
LIQUID LINE EXPANSION
(UNCASED COIL ONLY)
ORIFICE
VALVE
HOUSING
DISTRIBUTOR
TUBES
TEFLON
®
RING TEFLON
®
RING
FIXED ORIFICE
BRASS NUT
TEFLON®
RING
SENSING
LINE
DISTRIBUTOR
ASSEMBLY DISTRIBUTOR
ASSEMBLY
EQUALIZER
LINE REMOVE AND DISCARD
WHITE TEFLON
®
SEAL
(IF PRESENT) LIQUID LINE ASSEMBLY
(INCLUDES STRAINER) LIQUID LINE
ASSEMBLY WITH
BRASS NUT
A On fully cased coils, remove the coil access and plumbing panels.
B Remove any shipping clamps holding the liquid line and distributor as sembly.
C Using two wrenches, disconnect liquid line from liquid line orifice hous ing. Take care not to twist or damage distributor tubes during this pro cess.
D Remove and discard fixed orifice, valve stem assembly if present and
Teflon ® washer as illustrated above.
E Use a field-provided fitting to temporary reconnect the liquid line to the indoor unit's liquid line orifice housing.
2
CONNECT GAUGES AND EQUIPMENT FOR
FLUSHING PROCEDURE
A
INVERTED HCFC-22
CYLINDER CONTAINS
CLEAN HCFC-22 TO BE
USED FOR FLUSHING.
1
LOW
GAUGE
MANIFOLD
HIGH
MALE EQUALIZER
LINE FITTING
SENSING BULB
VAPOR
LINE
LIQUID
LINE
A On fully cased coils, remove the coil access and plumbing panels.
B Remove any shipping clamps holding the liquid line and distributor assembly.
C Disconnect the equalizer line from the expansion valve equalizer line fitting on the vapor line.
D Remove the vapor line sensing bulb.
E Disconnect the liquid line from the expansion valve at the liquid line assembly.
F Disconnect the expansion valve from the liquid line orifice housing.
Take care not to twist or damage distributor tubes during this process.
G Remove and discard expansion valve and the two Teflon ® rings.
H Use a field-provided fitting to temporary reconnect the liquid line to the indoor unit's liquid line orifice housing.
VAPOR LINE
SERVICE VALVE
EXISTING
INDOOR
UNIT
LIQUID LINE SERVICE
VALVE
RECOVERY
CYLINDER
D
B
NEW
OUTDOOR
UNIT
C
OPENED
TANK
RETURN
INLET
DISCHARGE
CLOSED
RECOVERY MACHINE
A Inverted HCFC-22 cylinder with clean refrigerant to the vapor service valve.
B HCFC-22 gauge set (low side) to the liquid line valve.
C HCFC-22 gauge set center port to inlet on the recovery machine with an empty recovery tank to the gauge set.
D Connect recovery tank to recovery machines per machine instructions.
3 FLUSHING LINE SET
The line set and indoor unit coil must be flushed with at least the same amount of clean refrigerant that previously charged the system. Check the charge in the flushing cylinder before proceeding.
A Set the recovery machine for liquid recovery and start the recovery machine. Open the gauge set valves to allow the
B set and indoor unit coil.
B 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 unit coil before it enters the recovery machine.
C 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 recovery machine to pull down to 0 the system.
D 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.
Figure 10. Installing Indoor Expansion Valve
Page 15
SSB*H4 SERIES
Installing Indoor Metering Device
This outdoor unit is designed for use in systems that use a expansion valve metering device at the indoor coil.
See the Lennox SSB*H4 Product Specification bulletin for approved expansion valve kit match-ups. The expansion valve unit can be installed either internal or external to the
INDOOR EXPANSION VALVE INSTALLATION
TWO PIECE
PATCH PLATE
(UNCASED
COIL ONLY)
DISTRIBUTOR
TUBES
(Uncased Coil Shown)
LIQUID LINE
ORIFICE
HOUSING
STUB
END
EXPANSION
VALVE
TEFLON
®
RING
DISTRIBUTOR
ASSEMBLY
TEFLON
®
RING
EQUALIZER
LINE
SENSING
LINE indoor coil. In applications where an uncased coil is being installed in a field-provided plenum, install the expansion valve in a manner that will provide access for field servicing of the expansion valve. Refer to below illustration for reference during installation of expansion valve unit.
1/2 Turn
C Install one of the provided Teflon ® rings around the stubbed end of the expansion valve and lightly lubricate the connector threads and expose surface of the Teflon ® ring with refrigerant oil.
D Attach the stubbed end of the expansion valve to the liquid line orifice housing. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above, or tighten to
20 ft-lb.
E Place the remaining Teflon ® washer around the other end of the expansion valve. Lightly lubricate connector threads and expose surface of the Teflon ® ring with refrigerant oil.
F Attach the liquid line assembly to the expansion valve.
Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or tighten to 20 ft-lb.
9
8
10
11 12
7
6
1
2
3
4
5
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
SENSING BULB INSTALLATION
MALE EQUALIZER LINE
FITTING (SEE
EQUALIZER LINE
INSTALLATION FOR
FURTHER DETAILS)
VAPOR
LINE
Sensing bulb insulation is required if mounted external to the coil casing. sensing bulb installation for bulb positioning.
LIQUID LINE
A Attach the vapor line sensing bulb in the proper orientation as illustrated to the right using the clamp and screws provided.
NOTE Confirm proper thermal contact between vapor line and expansion valve sensing bulb before insulating the sensing bulb once installed.
B Connect the equalizer line from the expansion valve to the equalizer vapor port on the vapor line. Finger tighten the flare nut plus 1/8 turn (7 ft-lbs) as illustrated below.
1/8 Turn
10
11 12
9
8
7
6
1
2
4
3
5
9 O'CLOCK TO
3 O'CLOCK
EQUALIZER LINE INSTALLATION
A Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right.
B Remove the field-provided fitting that temporarily recon nected the liquid line to the indoor unit's distributor assem bly
BULB
12
BULB
ON LINES SMALLER THAN
7/8”, MOUNT SENSING
BULB BETWEEN THE 9 AND
3 O'CLOCK POSITIONS.
FLARE SEAL CAP FLARE NUT
VAPOR LINE
VAPOR LINE
OR COPPER FLARE
SEAL BONNET
12
ON 7/8” AND LARGER LINES,
MOUNT SENSING BULB AT
EITHER THE 4 OR 8 O'CLOCK
POSITION. NEVER MOUNT
THE SENSING BULB ON
BOTTOM OF LINE.
MALE BRASS EQUALIZER
LINE FITTING
BULB
BULB
VAPOR LINE NOTE - NEVER MOUNT THE SENSING BULB ON
BOTTOM OF LINE.
Figure 11. Installing Indoor Expansion Valve
Page 16
IMPORTANT
The Environmental Protection Agency (EPA) prohibits the intentional venting of HFC refrigerants during maintenance, service, repair and disposal of appliance.
Approved methods of recovery, recycling or reclaiming must be followed.
IMPORTANT
If this unit is being matched with an approved line set or indoor unit 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 installation. Take care to empty all existing traps. Polyol ester (POE) oils are used in Lennox units charged with HFC-410A refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the expansion device, and reduce the system performance and capacity.
Failure to properly flush the system per the instructions below will void the warranty.
1 CONNECT GAUGE SET
A Connect an HFC-410A manifold gauge set high pressure hose to the vapor valve service port.
NOTE Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the vapor port better protects the manifold gauge set from high pressure damage.
B With both manifold valves closed, connect the cylinder of
HFC-410A refrigerant to the center port of the manifold gauge set.
NOTE - Later in the procedure, the HFC-410A container will be replaced by the nitrogen container.
Leak Test Line Set and Indoor Coil
WARNING
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).
IMPORTANT
Leak detector must be capable of sensing HFC refrigerant.
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.
B
LOW HIGH
MANIFOLD GAUGE SET
A
OUTDOOR UNIT
TO VAPOR
SERVICE VALVE
2
NITROGEN
HFC-410A
TEST FOR LEAKS
After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the following procedure to test for leaks:
A With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. Open the valve on the HFC-410A cylinder (vapor only).
B Open the high pressure side of the manifold to allow HFC-410A into the line set and indoor unit. Weigh in a trace amount of HFC-410A.
[A trace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kPa) pressure]. Close the valve on the HFC-410A cylinder and the valve on the high pressure side of the manifold gauge set. Disconnect the HFC-410A cylinder.
C Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set.
D 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 unit.
E After a few minutes, open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector .
F After leak testing disconnect gauges from service ports.
Figure 12. Leak Test
Page 17
SSB*H4 SERIES
Evacuating Line Set and Indoor Coil
1 CONNECT GAUGE SET
NOTE Remove cores from service valves (if not already done).
A Connect low side of manifold gauge set with 1/4 SAE in-line tee to vapor line service valve
B Connect high side of manifold gauge set to liquid line service valve
C Connect micron gauge available connector on the 1/4 SAE in-line tee.
D Connect the vacuum pump (with vacuum gauge) to the center port of the manifold gauge set. The center port line will be used later for both the
HFC-410A and nitrogen containers.
OUTDOOR
UNIT
A
NITROGEN
A34000 1/4 SAE TEE WITH
SWIVEL COUPLER
500
C
MICRON
GAUGE
MANIFOLD
GAUGE SET
TO VAPOR
SERVICE VALVE
LOW HIGH
HFC-410A
B
VACUUM PUMP
TO LIQUID LINE
SERVICE VALVE
D
2 EVACUATE THE SYSTEM
A Open both manifold valves and start the vacuum pump.
B Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury).
RECOMMEND
MINIMUM 3/8” HOSE
NOTE During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once. 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 total actual pressure within a given volume or system, above the absolute zero of pressure. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure.
C When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), perform the following:
Close manifold gauge valves
Close valve on vacuum pump
Turn off vacuum pump
Disconnect manifold gauge center port hose from vacuum pump
Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose.
Open manifold gauge valves to break the vacuum in the line set and indoor unit.
Close manifold gauge valves.
D Shut off the dry nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the dry nitrogen from the line set and indoor unit.
E 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.
F When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to an upright cylinder of HFC-410A refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit.
G Perform the following:
Close manifold gauge valves.
1/6 TURN
Shut off HFC-410A cylinder.
Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core tool while maintaining a positive system pressure.
Replace stem caps and secure finger tight, then tighten an additional one-sixth (1/6) of a turn as illustrated.
9
10
8
11 12
7
6
1
5
2
4
3
Figure 13. Evacuating System
Page 18
IMPORTANT
Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns.
WARNING
Danger of Equipment Damage. Avoid deep vacuum operation. Do not use compressors to evacuate a system. Extremely low vacuums can cause internal arcing and compressor failure. Damage caused by deep vacuum operation will void warranty.
Evacuating the system of non-condensables is critical for proper operation of the unit. Non-condensables are defined as any gas that will not condense under temperatures and pressures present during operation of
1 SIZE CIRCUIT AND INSTALL DISCONNECT
SWITCH
Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR per NEC). Install power wiring and properly sized disconnect switch.
MAIN FUSE
BOX/BREAKER
PANEL
DISCONNECT
SWITCH an air conditioning system. Non-condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts.
Electrical
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 current
Canadian Electrical Code (CEC).
Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size.
24VAC TRANSFORMER
Use the transformer provided with the furnace or air handler for low‐voltage control power (24VAC - 40 VA minimum)
INSTALL THERMOSTAT 2
Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and 5 feet
(1.5m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight or drafts.
THERMOSTAT
5 FEET
(1.5M)
NOTE - Units are approved for use only with copper conductors.
Ground unit at disconnect switch or to an earth ground.
3
UNIT LOW VOLTAGE CONNECTIONS
C
WIRE NUTS
A
CUTOUT WITH
GROMMET
24V CONTROL WIRES
B
NOTE - 24VAC, Class II circuit connections are made in the control panel.
HIGH VOLTAGE FIELD WIRING
FACTORY WIRING
LOW VOLTAGE (24V) FIELD WIRING
WIRE RUN LENGTH
LESS THAN 100' (30 METERS)
MORE THAN 100' (30 METERS)
AWG# INSULATION TYPE
18 TEMPERATURE RATING
16 35ºC MINIMUM.
A Run 24VAC control wires through cutout with grommet.
B Run 24VAC control wires through wire tie.
C Make 24VAC control wire connections using field provided wire nuts.
D Tighten wire tie to security 24V control wiring.
NOTE - FOR PROPER VOLTAGES, SELECT THERMOSTAT WIRE (CONTROL WIRES)
GAUGE PER TABLE ABOVE.
NOTE - WIRE TIE PROVIDES LOW VOLTAGE WIRE STRAIN RELIEF AND TO MAINTAIN
SEPARATION OF FIELD INSTALLED LOW AND HIGH VOLTAGE CIRCUITS.
NOTE - DO NOT BUNDLE ANY EXCESS 24VAC CONTROL WIRES INSIDE CONTROL
BOX.
D
TIGHTEN WIRE TIE
Page 19
SSB*H4 SERIES
Figure 14. Typical Wiring Diagram (Y-Voltage)
Figure 15. SSB*H4 Typical Factory Diagram (Y-Voltage)
Page 20
Figure 16. SSB*H4 Typical Wiring Diagram (G-Voltage)
Servicing Units Delivered Void of Charge
If the outdoor unit is void of refrigerant, clean the system using the procedure described below.
1. Leak check system using procedure outlined on page
Figure 17. SSB*H4 Typical Factory Diagram (G-Voltage)
2. Evacuate the system using procedure outlined on
3. Use nitrogen to break the vacuum and install a new filter drier in the system.
4. Evacuate the system again using procedure outlined
Page 21
SSB*H4 SERIES
5. Weigh in refrigerant using procedure outlined in figure
6. Monitor the system to determine the amount of moisture remaining in the oil. It may be necessary to replace the filter drier several times to achieve the required dryness level.
If system dryness is not verified, the compressor will fail in the future.
Unit Start-Up
IMPORTANT
If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start-up to prevent compressor damage as a result of slugging.
4. Replace the stem caps and tighten to the value listed
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 with the power company and the voltage condition has been corrected.
6. Set the thermostat for a cooling demand. Turn on power to the indoor indoor unit 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.
8. Check system for sufficient refrigerant by using the procedures listed under System Charge.
1. Rotate fan to check for binding.
System Refrigerant
2. Inspect all factory- and field-installed wiring for loose connections.
3. After evacuation is complete, open both the liquid and vapor line service valves to release the refrigerant charge contained in outdoor unit into the system.
This section outlines procedures for:
1. Connecting gauge set for testing and charging;
2. Checking and adjusting indoor airflow;
3. Adding or removing refrigerant.
GAUGE SET
CONNECTIONS FOR TESTING AND CHARGING
B
A Close manifold gauge set valves and connect the center hose to a cylinder of
SUCTION LINE
SERVICE PORT
CONNECTION
HFC-410A. Set for liquid phase charging.
REFRIGERANT TANK
B Connect the manifold gauge set's low pressure side to the suction line service port.
CHARGE IN
LIQUID PHASE
A
C Connect the manifold gauge set's high pressure side to the liquid line service port.
DIGITAL SCALE
D Position temperature sensor on liquid line near liquid line service port.
MANIFOLD GAUGE SET
LOW HIGH
OUTDOOR UNIT
VAPOR LINE
SERVICE VALVE
D
TEMPERATURE
SENSOR
C
TO LIQUID
LINE SERVICE
VALVE
TEMPERATURE SENSOR
(LIQUID LINE)
LIQUID LINE
SERVICE VALVE
Figure 18. Gauge Set Setup and Connections
Page 22
CHECKING AIR FLOW AT INDOOR COIL
Temp.
of air entering indoor coil ºF
A
D
T
80 24 24 24 23 23 22 22 22 20 19 18 17 16 15
78 23 23 23 22 22 21 21 20 19 18 17 16 15 14
76 22 22 22 21 21 20 19 19 18 17 16 15 14 13
74 21 21 21 20 19 19 18 17 16 16 15 14 13 12
72 20 20 19 18 17 17 16 15 15 14 13 12 11 10
70 19 19 18 18 17 17 16 15 15 14 13 12 11 10
Wet-bulb ºF 57 58 59 60 61 62 63 64 65 66 67 68 69 70
C
53º
DRY
BULB
T
Drop
19º air flow
All temperatures are expressed in ºF
INDOOR
COIL
B air flow B
64º
WET
BULB
A
72º
DRY
BULB
1. Determine the desired
D
T —Measure entering air temperature using dry bulb ( A ) and wet bulb ( B ).
D
T is the intersecting value of
A and B in the table (see triangle).
2. Find temperature drop across coil —Measure the coil's dry bulb entering and leaving air temperatures ( A and C ). Temperature Drop
Formula: ( T
Drop
) = A minus C .
3. Determine if fan needs adjustment —If the difference between the measured T
Drop
and the desired
D
T (T
Drop
–
D
T) is within +3º, no adjustment is needed. See examples: Assume
D
T = 15 and A temp. = 72º, these C temperatures would necessitate stated ac tions:
Cº T
Drop
–
D
T
=
ºF ACTION
53º 19 – 15
=
4 Increase the airflow
58º
62º
14 – 15
=
-1 (within +3º range) no change
10 – 15
=
-5 Decrease the airflow
4. Adjust the fan speed —See indoor unit instructions to increase/de crease fan speed.
Changing air flow affects all temperatures; recheck temperatures to confirm that the temperature drop and
D
T are within +3º.
Figure 19. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart
START: Determine how refrigerant is metered
WHEN TO CHARGE?
Warm weather best
Can charge in colder weather
CHARGE METHOD?
Determine by:
Metering device type
Outdoor ambient temperature
REQUIREMENTS:
Sufficient heat load in structure
Indoor temperature between 70‐80ºF (21-26ºC)
Manifold gauge set connected to unit
Thermometers:
to measure outdoor ambient temperature
to measure liquid line temperature
to measure suction line temperature
64ºF (17.7ºC) and Below
WEIGH‐IN
TXV
65ºF (18.3ºC) and Above
APPROACH OR
SUBCOOLING
Figure 20. Determining Charge Method
WEIGH-IN
CHARGING METHOD FOR LONG LINE SETS
64ºF (17.7ºC) and Below
Amount specified on nameplate
Adjust amount for variation in line set length and liquid line diameter using table below.
+ =
Total charge
Liquid Line
Set Diameter
5/16”
3/8”
1/2”
HFC-410A
(ounces per foot)
0.40
0.60
1.00
NOTE - Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig.
NOTE - The above nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information.
Charging Formula for Liquid Line Charge Adjustments
[(Line set oz./ft. x total length) (factory charge for line set)] = charge adjustment
Example : Units are factorycharged for 15 feet (4.6 meters) of 3/8" line set.
Factory charge for 3/8" is 0.60 oz/ft x 15 = 9.0 ounces.
Figure 21. Using HFC-410A Weigh-In Method
Page 23
SSB*H4 SERIES
START: Measure outdoor ambient temperature 65ºF
(18.3ºC) and
Above
64ºF
(17.7ºC) and
APPROACH TXV
Below
ABOVE or
BELOW
Once refrigerant charge is correct, disconnect gauge set and replace service port caps.
1. Connect gauge set as illustrated in figure 18.
2. Confirm proper airflow across coil using figure
3. Compare unit pressures with table 4,
Normal
Operating Pressures .
4. Set thermostat to call for heat (must have a cooling load between 70‐80ºF (21-26ºC).
5. When heat demand is satisfied, set thermostat to call for cooling.
6. Allow temperatures and pressures to stabilize.
7. Record outdoor ambient temperature:
AMBº =_________
8. Record liquid line temperature:
LIQº = __________
9. Subtract to determine approach (APPº):
LIQº_____ - AMBº _____ = APPº_____
10. Compare results with table below.
If refrigerant is added or removed, verify charge using the
Subcooling Method .
If value is MORE than shown, remove refrigerant.
If value is LESS than shown, add refrigerant.
MORE or
LESS
APPº (Approach) Values(F:+/-1.0° [C: +/-0.6°])
-036 -048 -060
TEMP* 6 (3.3) 8 (4.4) 4 (2.2)
*Temperature of air entering outdoor coil is 65ºF (18ºC) or above.
Figure 22. Using HFC-410A Approach (TXV) Charge Method
START: Measure outdoor ambient temperature
65ºF
(18.3ºC) and
Above
C
64ºF
(17.7ºC) and
Below
SUBCOOLING TXV
ABOVE or
BELOW
BLOCK OUTDOOR COIL: [sometimes necessary with lower temperatures] Use cardboard or plastic sheet to restrict the airflow through the outdoor coil to achieve pressures from 325-375 psig
(2240-2585 kPa).
Higher pressures are needed to check charge. Block equal sections of air intake panels and move coverings sideways until the liquid pressure is in the above noted ranges.
Once refrigerant charge is correct, disconnect gauge set and replace service port caps.
CARDBOARD OR
PLASTIC SHEETS
If refrigerant is added or removed, verify charge using the Approach
Method .
If value is LESS than shown, add refrigerant.
If value is MORE than shown, remove refrigerant.
MORE or
LESS
1. Connect gauge set as illustrated in figure 18.
2. Confirm proper airflow across coil using figure 19.
3. Compare unit pressures with table 4,
Normal
Operating Pressures .
4. Set thermostat to call for heat (must have a cooling load between 70‐80ºF (21-26ºC)
5. Measure outdoor ambient temperature
6. When heat demand is satisfied, set thermostat to call for cooling
7. Allow temperatures and pressures to stabilize.
NOTE - If necessary, block outdoor coil to maintain
325 - 375 psig.
8. Record liquid line temperature:
LIQº = ______
9. Measure liquid line pressure and use the value to
determine saturation temperature (see table 3):
SATº = ______
10. Subtract to determine subcooling (SCº):
SATº_____ - LIQº _____ = SCº _____
11. Compare results with table below.
SCº (Subcooling) Values (F:+/-1.0° [C: +/-0.6°])
-036 -048 -060
TEMP* 6 (3.3) 6 (3.3) 9 (5.0)
*Temperature of air entering outdoor coil is 65ºF (18ºC) or above.
Figure 23. Using HFC-410A Subcooling (TXV) Charge Method
Page 24
Table 3. HFC-410A Temperature (°F) - Pressure (Psig)
°F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig
42
43
44
45
46
39
40
41
32
33
34
35
36
37
38
47
58
59
60
61
62
55
56
57
48
49
50
51
52
53
54
115.8
118.0
120.3
122.6
125.0
127.3
129.7
132.2
100.8
102.9
105.0
107.1
109.2
111.4
113.6
134.6
155.5
158.2
161.0
163.9
166.7
169.6
172.6
175.4
137.1
139.6
142.2
144.8
147.4
150.1
152.8
73
74
75
76
77
70
71
72
63
64
65
66
67
68
69
78
89
90
91
92
93
86
87
88
79
80
81
82
83
84
85
200.6
203.9
207.2
210.6
214.0
217.4
220.9
224.4
178.5
181.6
184.3
187.7
190.9
194.1
197.3
228.0
258.0
262.0
266.0
270.0
274.1
278.2
282.3
286.5
231.6
235.3
239.0
242.7
246.5
250.3
254.1
101
102
103
104
105
106
107
108
94
95
96
97
98
99
100
109
321.8
326.4
331.0
335.7
340.5
345.3
350.1
355.0
290.8
295.1
299.4
303.8
308.2
312.7
317.2
360.0
117
118
119
120
121
122
123
124
110
111
112
113
114
115
116
401.3
406.7
412.2
417.7
423.2
428.8
434.5
440.2
365.0
370.0
375.1
380.2
385.4
390.7
396.0
132
133
134
135
136
137
138
139
125
126
127
128
129
130
131
140
487.8
494.0
500.2
506.5
512.9
519.3
525.8
532.4
445.9
451.8
457.6
463.5
469.5
475.6
481.6
539.0
148
149
150
151
152
153
154
155
141
142
143
144
145
146
147
593.8
601.0
608.1
615.4
622.7
630.1
637.5
645.0
545.6
552.3
559.1
565.9
572.8
579.8
586.8
Table 4. Normal Operating Pressures (Liquid +10 and Suction +5 psig)
IMPORTANT
Use this table to perform maintenance checks; it is not a procedure for charging the system. Minor variations in these pressures may be due to differences in installations. Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system.
Model
5 F ( 5 C)*
SSB036H4S4
Liquid Suction Liquid
SSB048H4S4
Suction Liquid
SSB060H4S4
Suction
65 (18)
75 (24)
85 (29)
95 (35)
105 (41)
115 (46)
217
251
292
337
387
440
141
143
146
147
150
154
First Stage (Low Capacity)
229
263
304
350
400
453
140
143
146
148
150
155
Second Stage (High Capacity)
229
264
305
349
402
455
65 (18)
75 (24)
85 (29)
95 (35)
230
265
307
354
137
140
141
144
234
269
312
359
135
137
140
141
244
282
324
371
129
131
133
136
105 (41)
115 (46)
405
460
146
149
409
465
143
146
422
474
*Temperature of air entering outdoor coil.
**(Liquid +10 psig; Vapor +5 psig) Typical pressures; indoor unit match up, indoor air quality equipment, and indoor load will cause the pressures to vary.
139
143
134
138
140
142
147
149
System Operation
SECOND-STAGE OPERATION
If the demand defrost control (A108) receives a call for second-stage compressor operation Y2 in heating or cooling mode and the first‐stage compressor output is active, the second‐stage compressor solenoid output will be energized.
If first‐stage compressor output is active in heating mode and the outdoor ambient temperature is below the selected compressor lock-in temperature, the second‐stage compressor solenoid output will be energized without the
Y2 input. If the jumper is not connected to one of the temperature selection pins on P3 (40, 45, 50, 55°F), the default lock-in temperature of 40°F (4.5°C) will be used.
IMPORTANT
Some scroll compressor have internal vacuum protector that will unload scrolls when suction pressure goes below 20 psig. A hissing sound will be heard when the compressor is running unloaded. Protector will reset when low pressure in system is raised above 40 psig. DO
NOT REPLACE COMPRESSOR.
Page 25
SSB*H4 SERIES
UNIT COMPONENTS
High Pressure Switch (S4)
This unit now employs a automatic pressure switch located on the liquid line of the compressor. The pressure switch (SPST, auto-reset, normally closed) removes power form the compressor when liquid pressure rises above factory setting (opens at 590 + 15 psig and closes at
418 + 15 psig).
Low Pressure Switch (S87)
SSB*H4 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.
Crankcase Heater Relay (K191)
(G Voltage Units Only)
All 460 volt SSB units require the S40 thermostat to be wired in series with the 24 volt coil of the K191 relay. The contacts of the K191 control operation of crankcase heater
HR1. When ambient temperature drops below 50° F, K191 contacts close energizing HR1. When the ambient temperature rises to 70° F the contacts open de-energizing HR1.
Crankcase Heater (HR1) and Crankcase Thermostat
(S40)
The reference models are equipped with a 70 watt, belly band type crankcase heater. HR1 prevents liquid from accumulating in the compressor. HR1 is controlled by a thermostat located on the liquid line. When liquid line temperature drops below 50° F the thermostat closes energizing HR1. The thermostat will open, de-energizing
HR1 once liquid line temperature reaches 70° F .
Internal Solenoid (L34)
The internal unloader solenoid controls the two-stage operation of the compressor by shifting a slide ring mechanism to open two by-pass ports in the first compression pocket of the scrolls in the compressor. The internal solenoid is activated by a 24 volt direct current solenoid coil. The coil power requires 20VAC. The internal wires from the solenoid in the compressor are routed to a 2 pin fusite connection on the side of the compressor shell.
The external electrical connection is made to the compressor with a molded plug assembly. This plug contains a full wave rectifier that converts 24 volt AC into
24 volt DC power to power the unloader solenoid. Refer to unit diagram for internal circuitry view of plug).
Liquid Line Bi-Flow Filter Drier
The unit is equipped with a large-capacity biflow filter drier which keeps the system clean and dry. If replacement is necessary, order another of like design and capacity. The replacement filter drier must be suitable for use with
HFC-410A refrigerant.
Maintenance
DEALER
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:
Page 26
Outdoor Unit
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. Outdoor fan motor is prelubricated and sealed. No further lubrication is needed.
3. Visually inspect connecting lines and coils for evidence of oil leaks.
4. Check wiring for loose connections.
5. Check for correct voltage at the unit (with the unit operating).
6. Check amp-draw outdoor fan motor.
UNIT NAMEPLATE: _________ ACTUAL: __________
NOTE - If owner reports insufficient cooling, the unit should be gauged and refrigerant charge checked.
Outdoor Coil
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, fertilizers, fluids that may contain high levels of corrosive chemicals such as salts)
Outdoor Coil — The outdoor coil may be flushed with a water hose.
Outdoor Coil (Sea Coast) — Moist air in ocean locations can carry salt, which is corrosive to most metal. Units that are located near the ocean require frequent inspections and maintenance. These inspections will determine the necessary need to wash the unit including the outdoor coil. Consult your installing contractor for proper intervals/procedures for your geographic area or service contract.
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. Check blower drive belt for wear and proper tension.
4. Check all wiring for loose connections
5. Check for correct voltage at unit (blower operating).
6. Check amp-draw on blower motor.
UNIT NAMEPLATE: _________ ACTUAL: __________
INDOOR COIL
1. Clean coil, if necessary.
2. Check connecting lines and coils for signs of oil leaks.
3. Check condensate line and clean, if necessary.
OWNER
Cleaning of the outdoor unit's coil should be performed by a trained service technician. Contact your dealer and set up a schedule (preferably twice a year, but at least once a year) to inspect and service your outdoor unit. The following maintenance may be performed by the homeowner.
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.
Outdoor Coil
The outdoor unit must be properly maintained to ensure its proper operation.
Please contact your dealer to schedule proper inspection and maintenance for your equipment.
Make sure no obstructions restrict airflow to the outdoor unit.
Grass clippings, leaves, or shrubs crowding the unit can cause the 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.
Cleaning of the outdoor unit's coil should be performed by a trained service technician. Contact your dealer and set up a schedule (preferably twice a year, but at least once a year) to inspect and service your outdoor unit.
Routine 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.
Air Filter — 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.
Checklists
Use the following checklist to verify part‐load and full‐load capacity operation of two‐stage modulation compressors.
TOOLS REQUIRED
Refrigeration gauge set
Digital volt/amp meter
Electronic temperature thermometer
On‐off toggle switch
2.
Disposable Filter — 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.
3.
Reusable Filter — Many indoor units are equipped with reusable foam filters. Clean foam filters with a mild soap and water solution; rinse thoroughly; allow filter to dry completely before returning it to the unit or grille.
NOTE - The filter and all access panels must be in place any time the unit is in operation.
4.
Indoor Unit — The indoor unit's evaporator coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the inside 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.)
Thermostat Operation
See the thermostat homeowner manual for instructions on how to operate your thermostat.
Preservice Check
If your system fails to operate, check the following before calling for service:
Verify room thermostat settings are correct.
Verify that all electrical disconnect switches are ON.
Check for any blown fuses or tripped circuit breakers.
Verify unit access panels are in place.
Verify air filter is clean.
If service is needed, locate and write down the unit model number and have it handy before calling.
Accessories
For update-to-date information, see any of the following publications:
Lennox SSB*H4 Product Specification bulletin
Lennox Product Catalog
Lennox Price Book
IMPORTANT
This performance check is ONLY valid on systems that have clean indoor and outdoor coils, proper airflow over coils, and correct system refrigerant charge. All components in the system must be functioning properly to correctly perform compressor operational check.
(Accurate measurements are critical to this test as indoor system loading and outdoor ambient can affect variations between low and high capacity readings).
Page 27
SSB*H4 SERIES
Two-Stage Modulation Compressors Field Operational Checklist
Y1 - First‐Stage
Expected results during Y2 demand
(Toggle switch On) Unit Readings
COMPRESSOR
Voltage
Amperage
OUTDOOR UNIT FAN MOTOR
Amperage
TEMPERATURE
Ambient
Outdoor Coil Discharge Air
Compressor Discharge Line
Indoor Return Air
Indoor Coil Discharge Air
PRESSURES
Suction (Vapor)
Same
Higher
Same or Higher
Same
Higher
Higher
Same
Lower
Lower
Liquid Higher
Y2 - Second‐Stage
Start-Up and Performance Checklist
Job Name
Job Location
Installer
Unit Model No. Serial No.
Nameplate Voltage
Rated Load Ampacity Compressor
Maximum Fuse or Circuit Breaker
Electrical Connections Tight?
Indoor Blower RPM
Indoor Filter clean?
S.P. Drop Over Indoor (Dry)
Discharge Pressure Suction Pressure
Job no.
City
City
Date
State
State
Service Technician
Outdoor Fan
Supply Voltage (Unit Off)
Outdoor Coil Entering Air Temp.
Refrigerant Charge Checked?
Refrigerant Lines: Leak Checked?
Service Valves: Fully Opened?
Voltage With Compressor Operating
Properly Insulated?
Caps Tight?
Outdoor Fan Checked?
Thermostat
Calibrated? Properly Set? Level?
Page 28
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