Lennox HS32 024, 030, 036, 042, 048, 060 air conditioner Installation instructions

¤2000 Lennox Industries Inc
INSTALLATION
INSTRUCTIONS
.
Dallas, Texas
HS32 SERIES UNITS
CONDENSING UNITS
504,179M
2/2000
Supersedes 503,987M
Litho U.S.A.
Table of Contents
HS32 Condensing Unit
HS32 condensing units use R410A which is an ozone
friendly HFC refrigerant. This unit must be installed with a
matching indoor coil and line set as outlined in the Lennox
Engineering Handbook. HS32 condensing units are designed for use in expansion valve systems only. They are
not designed to be used with other refrigerant flow control
devices. An expansion valve and filter drier approved for use
with R410A have been shipped with the unit. These components must be installed prior to unit operation.
HS32 CONDENSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SHIPPING AND PACKING LIST . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HS32 UNIT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HS32 PARTS ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . 3
SETTING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING EXISTING LINE SET AND INDOOR COIL . . 5
MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LIQUID & SUCTION LINE SERVICE VALVES . . . . . . . . . . 7
LEAK TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EVACUATION & DEHYDRATION . . . . . . . . . . . . . . . . . . . . . 8
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HS32 CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
General Information
These instructions are intended as a general guide and do
not supersede national or local codes in any way. Authorities having jurisdiction should be consulted before installation.
Shipping and Packing List
1 - Assembled HS32 condensing unit
1 - Drier (approved for use with R410A systems)
1 - Expansion valve (approved for use with R410A)
Check unit for shipping damage. Consult last carrier immediately if damage is found.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal injury or loss of life. Installation and service must
be performed by a qualified installer or service
agency.
IMPORTANT
WARNING
This product is matched with an indoor unit which
contains fiberglass wool.
Disturbing the insulation in the indoor unit during
installation, maintenance, or repair will expose you
to fiberglass wool. Breathing this may cause lung
cancer. (Fiberglass wool is known to the State of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin
and eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact your
supervisor.
Lennox Industries Inc.
P. O. Box 799900
Dallas, TX 75379-9900
This unit must be matched with an indoor coil as
specified in Lennox’ Engineering Handbook. Coils
previously charged with R22 must be flushed.
02/00
$
504,179M
Page 1
$!
HS32 Unit Dimensions -- Inches (mm)
INLET
AIR
INLET
HS32
CONDENSING UNIT
COMPRESSOR
AIR
INLET
ELECTRICAL
INLETS
AIR
TOP VIEW
C
B
SUCTION LINE
INLET
DISCHARGE
AIR
4-1/2 (114)
A
LIQUID
LINE INLET
D
J
J
H
2-3/4 (70)
H
4-7/8 (22)
2
(51)
2-9/16
(65)
2
(51)
G
1-3/8
(35)
4
(102)
HS32 024
HS32-024
HS32-030,
HS32-036
HS32-036,
HS32-042
HS32 048
HS32-048
HS32 060
HS32-060
4
(102)
E
ACCESS VIEW
Model No.
F
6-1/16
(154)
SIDE VIEW
in.
mm
A
27-7/8
708
B
25-7/8
657
C
29-7/8
759
D
12-1/4
311
E
22-7/16
570
F
14-7/16
367
G
22-1/8
562
H
2-7/8
73
J
5-1/2
140
in.
30-7/8
32-1/8
34-1/16
12-3/4
26-5/8
18-5/8
28-1/8
3-7/8
7-1/2
mm
784
816
865
324
676
473
718
98
191
in.
mm
in.
mm
34-7/8
886
40-7/8
1038
32-1/8
816
32-1/8
816
34-1/16
865
34-1/16
865
13-3/4
349
19-3/4
502
26-5/8
676
26-5/8
676
18-5/8
473
18-5/8
473
28-1/8
718
28-1/8
718
3-7/8
98
3-7/8
98
7-1/2
191
7-1/2
191
Page 2
HS32 Parts Arrangement
TIME DELAY
CONDENSER FAN
(NOT SHOWN)
TOP OF CABINET
GROUND LUG
RUN CAPACITOR
CONTACTOR
SUCTION VALVE
AND GAUGE PORT
TERMINAL BOX
LIQUID LINE
SERVICE VALVE
AND GAUGE
PORT
COMPRESSOR
LOW PRESSURE
SWITCH
HIGH PRESSURE
SWITCH
FIGURE 1
A - Slab Mounting
Setting the Unit
Refer to unit dimensions on page 1 for sizing mounting
slab, platforms or supports. Refer to figure 2 for installation
clearances.
INSTALLATION CLEARANCES
NOTE- 48” (1219mm) CLEARANCE REQUIRED
ON TOP OF UNIT.
*36”
(914mm)
When installing unit at grade level, install on a level slab
high enough above grade to allow adequate drainage of
water. Top of slab should be located so run-off water from
higher ground will not collect around unit.
B - Roof Mounting
Install unit at a minimum of 4 inches above surface of the roof.
Care must be taken to ensure weight of unit is properly distributed over roof joists and rafters. Either redwood or steel supports are recommended.
Electrical
36”
(914mm)
*36”
(914mm)
*36”
(914mm)
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 blower coil installation instructions
for additional wiring application diagrams and refer to unit
rating plate for minimum circuit ampacity and maximum
overcurrent protection size.
*NOTE—One side must be 36” (914mm). Two sides may be 12” (305mm).
FIGURE 2
3DJH WARNING
HS32 and FURNACE (GAS OR ELECTRIC)
THERMOSTAT CONNECTIONS
Unit must be grounded in accordance with national
and local codes.
ELECTRIC SHOCK HAZARD.
Can cause injury or death.
(Some connections may not apply.
Refer to specific thermostat and furnace.)
1 - Install line voltage power supply to unit from a properly
sized disconnect switch.
Typical
Furnace
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
effected by sunlight, drafts or vibrations.
POWER
R
W1
W2
Thermostat
1ST STAGE AUX. HEAT
2ND STAGE AUX. HEAT
Y
R
W1
W2
Y
COMPRESSOR
COMMON
G
C
COMMON
3 - Install low voltage wiring from outdoor to indoor unit
and from thermostat to indoor unit. See figures 3 and 4 .
FIGURE 3
4 - Ground unit at unit disconnect switch or to an earth
ground.
HS32 CONDENSING UNIT
FIELD WIRING DIAGRAM
YELLOW
Page 4
HS32
LOW PRESSURE
SWITCH
YELLOW
G
INDOOR BLOWER
C
FIGURE 4
HS32
Condensing
Unit
HS32
COMMON
BLACK
Plumbing
If the HS32 unit is being installed with a new indoor coil and
line set, the plumbing connections should be made as outlined in this section. If an existing line set and/or indoor coil
is going to be used to complete the HS32 system, refer to
the following section which includes flushing procedures.
Field refrigerant piping consists of liquid and suction lines
from the condensing unit (sweat connections). Use Lennox
L15 series line sets as shown in table 1 or use field-fabricated refrigerant lines. Refer to the refrigerant piping bulletin in the Lennox Unit Information Service Manual for proper size, type and application of field-fabricated lines.
Plumbing Connections
HS32 Matched with New Indoor Coil and Line Set
If an existing indoor coil which was equipped with an
RFCI metering device is being replaced, the liquid line
must also be replaced prior to the installation of the
HS32 unit.
If refrigerant lines are routed through a wall, seal and isolate the opening so vibration is not transmitted to the building.
NOTE - Line length should be no greater than 50 ft.
(15.2m). Select line set diameters from table 1 to ensure oil
return to the compressor.
TABLE 1
REFRIGERANT LINE KITS
2 - Before making line set connections, use dry nitrogen to
purge the refrigerant piping. This will help to prevent
oxidation and the introduction of moisture into the system.
3 - Use silver alloy brazing rods (5 or 6 percent silver alloy
for copper-to-copper brazing or 45 percent silver alloy
for copper-to-brass or copper-to-steel brazing) which
are rated for use with R410A refrigerant. Wrap a wet
cloth around the valve body and the copper tube stub.
Remove light maroon washers from service valves and
shield light maroon stickers in order to protect them
during brazing. Braze the line set to the service valve.
4 - Quench the joint with water or a wet cloth to prevent
heat damage to the valve core and opening port.
IMPORTANT-The tube end must stay bottomed in the
fitting during final assembly to ensure proper seating,
sealing and rigidity.
5 - Install the provided thermal expansion valve (approved for use with R410A refrigerant) in the liquid line
at the indoor coil.
6 - Install the provided filter drier (approved for use with
R410A refrigerant) in the liquid line as close as possible to the expansion device. Do not leave the drier
uncapped for more than 10 to 15 minutes prior to
brazing, evacuation and leak testing.
Flushing Existing Line Set and Indoor Coil
HS32 UNIT
LIQUID
LINE
SUCTION
LINE
L15 LINE
SETS
-024, -030,
-036
3/8 in.
(10mm)
3/4 in.
(19mm)
L15-41
20 ft. - 50 ft.
(6m - 15m)
-042, -048
3/8 in.
(10mm)
7/8 in.
(22mm)
L15-65
30 ft. - 50 ft.
(9m - 15m)
-060
3/8 in.
(10mm)
1-1/8 in.
(29mm)
Field Fabricated
IMPORTANT
If this unit is being matched with an approved line
set or indoor coil which was previously charged
with R22 refrigerant, 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 R410A refrigerant. Residual mineral
oil can act as an insulator, preventing proper heat
transfer. It can also clog the thermal expansion
valve, reducing system performance and capacity.
Failure to properly flush the system per the instructions below will void the warranty.
WARNING
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 or service valve stub caps until you are ready to make
connections.
CAUTION
This procedure should not be performed on systems which contain contaminants (Example: compressor burn out).
Required Equipment
Brazing Connection Procedure
1 - The end of the refrigerant line must be cut square and
its internal shape must remain round. The line must be
free of nicks or dents and must be deburred (I.D. and
O.D.)
You will need the following equipment in order to flush the
existing line set and indoor coil: two clean R22 recovery
bottles, an oilless recovery machine with a pump down feature, and two sets of gauges (one for use with R22 and one
for use with the R410A).
3DJH Flushing Procedure
1 - Remove existing R22 refrigerant using the appropriate procedure below.
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 R22 refrigerant to
flush the system -- Disconnect all power to the existing outdoor unit. Connect the existing unit, a clean recovery cylinder and the recovery machine according
to the instructions provided with the recovery machine. Remove all R22 refrigerant from the existing
system. Refer to gauges after shutdown to confirm
that the entire system is completely void of refrigerant.
Disconnect the liquid and suction lines from the existing outdoor unit.
If the existing outdoor unit is equipped with manual shut-off valves AND you plan to use NEW R22
refrigerant to flush the system -- Start the existing
R22 system in the cooling mode and close the liquid
line valve. Pump all of the existing R22 refrigerant
back into the oudoor unit. (It may be necessary to bypass the low pressure switches to ensure complete refrigerant evacuation.) When the low side system pressures reach 0 psig, close the suction line valve. Disconnect all power to the existing outdoor unit. Refer to
gauges after shutdown to confirm that the valves are
not allowing refrigerant to flow back into the low side of
the system. Disconnect the liquid and vapor lines from
the existing outdoor unit.
2 - Remove the existing outdoor unit. Set the new R410A
unit and follow the brazing connection procedure
which begins on the previous page to make line set
connections. DO NOT install provided R410A
check/expansion valve at this time.
Make low voltage and line voltage connections to the
new outdoor unit. DO NOT turn on power to the unit
or open the outdoor unit service valves at this
time.
3 - Remove the existing refrigerant flow control orifice or
thermal expansion valve before continuing with flushing procedures. The existing devices are not approved
for use with R410A refrigerant and may prevent proper
flushing. Use a field-provided fitting to reconnect the
lines.
IMPORTANT
The line set and indoor 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.
FLUSHING CONNECTIONS
INVERTED R22
CYLINDER
(Contains clean
R22 to be used for
flushing)
HS32 UNIT
SUCTION LINE
SERVICE VALVE
EXISTING SUCTION LINE
EXISTING
LOW
HIGH
PRESSURE PRESSURE
GAUGE MANIFOLD
EXISTING LIQUID LINE
LIQUID LINE
SERVICE VALVE
INDOOR COIL
OPENED
CLOSED
TANK RETURN
INLET
DISCHARGE
RECOVERY
CYLINDER
RECOVERY MACHINE
FIGURE 5
Page 6
NOTE - The inverted R22 cylinder must contain at least the
same amount of refrigerant as
was recovered from the existing
system.
4 - Remove the pressure tap valve cores from the HS32
unit’s service valves. Connect an R22 cylinder with
clean refrigerant to the suction service valve. Connect the R22 gauge set to the liquid line valve and
connect a recovery machine with an empty recovery
tank to the gauge set.
5 - Set the recovery machine for liquid recovery and start
the recovery machine. Open the gauge set valves to
allow the recovery machine to pull a vacuum on the existing system line set and indoor coil.
The valve is equipped with a service port. A schrader valve is
factory installed. A service port cap is supplied to protect the
schrader valve from contamination and serve as the primary
leak seal.
To Access Schrader Port:
1234-
Remove access panel.
Remove service port cap with an adjustable wrench.
Connect gauge to the service port.
When testing is completed, replace service port cap.
Tighten finger tight, then an additional 1/6 turn.
6 - Invert the cylinder of clean R22 and open its valve to
allow liquid refrigerant to flow into the system through
the suction line valve. Allow the refrigerant to pass
from the cylinder and through the line set and the indoor coil before it enters the recovery machine.
To Open Liquid or Suction Line Service Valve:
7 - After all of the liquid refrigerant has been recovered,
switch the recovery machine to vapor recovery so that
all of the R22 vapor is recovered. Allow the recovery
machine to pull a vacuum on the system.
LIQUID LINE SERVICE VALVE (VALVE OPEN)
1 - Remove stem cap with an adjustable wrench.
2 - Use a service wrench with a hex-head extension to
back the stem out counterclockwise until the valve
stem just touches the retaining ring.
INSERT HEX
WRENCH HERE
STEM CAP
SERVICE
PORT
NOTE - A single system flush should remove all of the
mineral oil from the existing refrigerant lines and indoor coil. A second flushing may be done (using clean
refrigerant) if insufficient amounts of mineral oil were
removed during the first flush. Each time the system
is flushed, you must allow the recovery machine
to pull a vacuum on the system at the end of the
procedure.
UNIT SIDE
SERVICE
PORT
CAP
8 - Close the valve on the inverted R22 drum and the
gauge set valves. Pump the remaining refrigerant out
of the recovery machine and turn the machine off.
FIELD SIDE
SCHRADER
VALVE
LIQUID LINE SERVICE VALVE (VALVE CLOSED)
RETAINING RING
9 - Use nitrogen to break the vacuum on the refrigerant
lines and indoor coil before removing the recovery machine, gauges and R22 refrigerant drum. Reinstall
pressure tap valve cores into HS32 service valves.
SERVICE
PORT
INSERT HEX
WRENCH HERE
UNIT SIDE
10 -Install the provided expansion valve (approved for use
with R410A refrigerant) in the liquid line at the indoor
coil.
SERVICE
PORT CAP
Manifold Gauge Set
FIELD SIDE
SCHRADER VALVE OPEN
TO LINE SET WHEN VALVE IS
CLOSED (FRONT SEATED)
Manifold gauge sets used with systems charged with
R410A refrigerant must be capable of handling the higher
system operating pressures. The gauges should be rated
for use with pressures of 0 - 800 on the high side and a low
side of 30” vacuum to 250 psi with dampened speed to 500
psi. Gauge hoses must be rated for use at up to 800 psi of
pressure with a 4000 psi burst rating.
(VALVE FRONT SEATED)
FIGURE 6
DANGER
Do not attempt to backseat this valve. Attempts to
backseat this valve will cause snap ring to explode
from valve body under pressure of refrigerant. Personal injury and unit damage will result.
Liquid & Suction Line Service Valves
The liquid line and suction line service valves (figures 6 and
7) and gauge ports are accessible from inside the unit, behind the access panel. The service ports are used for leak
testing, evacuating, charging and checking charge.
STEM CAP
3 - Replace the stem cap. Tighten finger tight, then tighten
an additional 1/6 turn.
3DJH To Close Liquid or Suction Line Service Valve:
WARNING
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 it
firmly.
Never use oxygen to pressurize refrigeration or air
conditioning systems. Oxygen will explode on
contact with oil and could cause personal injury.
When using high pressure gas such as nitrogen for
this purpose, be sure to use a regulator that can
control the pressure down to 1 or 2 psig (6.9 to 13.8
kPa).
3 - Replace the stem cap. Tighten finger tight, then tighten
an additional 1/6 turn.
SUCTION LINE SERVICE VALVE (VALVE OPEN)
INSERT HEX
WRENCH HERE
Using an Electronic Leak Detector
STEM CAP
1 - Connect the high pressure hose of the manifold gauge
set to the suction valve service port. (Normally, the high
pressure hose is connected to the liquid line port, however, connecting it to the suction port helps to protect
the manifold gauge set from damage caused by high
pressure.)
FIELD SIDE
SCHRADER
VALVE
2 - With both manifold valves closed, connect the cylinder
of R410A refrigerant. Open the valve on the R410A cylinder (vapor only).
UNIT SIDE
3 - Open the high pressure side of the manifold to allow
R410A into the line set and indoor unit. Weigh in a trace
amount of R410A. [A trace amount is a maximum of 2
ounces (57g) refrigerant 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. Disconnect R410A cylinder.
SERVICE PORT
CAP
SERVICE PORT
SUCTION LINE SERVICE VALVE (VALVE CLOSED)
RETAINING RING
STEM CAP
FIELD SIDE
4 - Connect a cylinder of nitrogen with a pressure regulating valve to the center port of the manifold gauge set.
INSERT HEX
WRENCH HERE
5 - Adjust nitrogen pressure to 150 psig (1034 kPa). Open
the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor coil.
SERVICE
PORT
(VALVE FRONT
SEATED)
6 - After a short period of time, open a refrigerant port to
make sure that an adequate amount of refrigerant has
been added for detection (refrigerant requirements will
vary with line lengths). Check all joints for leaks. Purge
nitrogen and R410A mixture. Correct any leaks and recheck.
SERVICE PORT
CAP
SCHRADER VALVE OPEN
TO LINE SET WHEN VALVE IS
CLOSED (FRONT SEATED)
UNIT SIDE
FIGURE 7
IMPORTANT
Leak Testing
Leak detector must be capable of sensing HFC refrigerant.
After the line set has been connected to the indoor and outdoor units, the line set connections and indoor unit must be
checked for leaks.
WARNING
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.
Evacuation & Dehydration
Evacuating the system of non-condensables is critical for
proper operation of the unit. Non-condensables are defined
as any gas that will not condense under temperatures and
pressures present during operation of an air conditioning
system. Non-condensables and water vapor combine with
refrigerant to produce substances that corrode copper piping and compressor parts.
Page 8
1 - Connect the manifold gauge set to the service valve
ports as follows: low pressure gauge to suction line
service valve; high pressure gauge to liquid line service valve.
IMPORTANT - Compliant scroll compressors (as with
any refrigerant compressor) should never be used to
evacuate a refrigeration or air conditioning system.
NOTE - A temperature vacuum gauge, mercury vacuum or thermocouple gauge should be used. The
usual bourdon tube gauges are inaccurate in the vacuum range.
2 - Connect the vacuum pump (with vacuum gauge) to the
center port of the manifold gauge set.
3 - Open both manifold valves and start vacuum pump.
4 - Evacuate the line set and indoor unit to an absolute
pressure of 23mm (23,000 microns) of mercury or
approximately 1 inch of mercury. During the early
stages of evacuation, it is desirable to close the manifold gauge valve at least once to determine if there is a
rapid rise in absolute pressure. A rapid rise in pressure indicates a relatively large leak. If this occurs, the
leak testing procedure must be repeated.
NOTE - The term absolute pressure means the total
actual pressure within a given volume or system,
above the absolute zero of pressure. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure.
5 - When the absolute pressure reaches 23mm (23,000
microns) of mercury, close the manifold gauge valves,
turn off the vacuum pump and disconnect the manifold
gauge center port hose from vacuum pump. Attach the
manifold center port hose to a nitrogen cylinder with
pressure regulator set to 150 psig (1034 kPa) and
purge the hose. Open the manifold gauge valves to
break the vacuum in the line set and indoor unit. Close
the manifold gauge valves.
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.
8 - 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 R410A
refrigerant. Open the manifold gauge valves to break
the vacuum in the line set and indoor unit. Close manifold gauge valves and shut off R410A cylinder and remove manifold gauge set.
Start-Up
1 - Rotate fan to check for frozen bearings or binding.
2 - Inspect all factory and field-installed wiring for loose
connections.
3 - Open liquid line and suction line service valves to release refrigerant charge (contained in condensing
unit) into system. Replace and tighten caps. Use a
back-up wrench on the suction and liquid valves when
removing or replacing valve caps.
4 - To open suction valve, remove hex cap and turn valve
stem fully open using an Allen (hex) wrench. To open
liquid valve, remove cap and turn valve stem until it is
fully open.
NOTE - When replacing valve caps, the caps should
be made finger tight and then tightened an additional
1/6th of a turn.
5 - Check voltage supply at the disconnect switch. The
voltage must be within range listed on unit nameplate.
If not, do not start equipment until the power company
has been consulted and the voltage condition corrected.
6 - Set thermostat for a cooling demand, turn on power to
blower and close the condensing unit disconnect
switch to start.
7 - Recheck unit voltage with unit running. Power must be
within range shown on unit nameplate. Check amperage draw of unit. Refer to unit nameplate for correct
running amps.
Charging
6 - Shut off the nitrogen cylinder and remove the manifold
gauge hose from the cylinder. Open the manifold
gauge valves to release the nitrogen from the line set
and indoor unit.
7 - Reconnect the manifold gauge to the vacuum pump,
turn the pump on and continue to evacuate the line set
and indoor unit until the absolute pressure does not
rise above .5mm (500 microns) of mercury within a
20-minute period after shutting off the vacuum pump
and closing the manifold gauge valves.
This system is charged with R410A refrigerant which operates at much higher pressures than R22. The expansion
valve and liquid line drier provided with the unit are approved for use with R410A. Do not replace them with components designed for use with R22. This unit is NOT approved for use with coils which include metering orifices or
capillary tubes.
Processing Procedure
Units are factory charged with the amount of R410A refrigerant indicated on the unit rating plate. This charge is
based on a matching indoor coil and outdoor coil with 20 ft.
(6.1m) line set. For varying lengths of line set, refer to table
2 for refrigerant charge adjustment.
3DJH TABLE 2
Liquid Line Set
Diameter
Ozs. per 5 ft. (grams per 1.5m) adjust
from 20 ft. (6.1m) line set*
5/16 in
(8mm)
2 ounces per 5 feet
(57g per 1.5m)
3/8 in.
(10mm)
3 ounces per 5 feet
(85g per 1.5m)
exists with some component in the system. Pressures
higher than those listed indicate that the system is
overcharged. Pressures lower than those listed indicate that the system is undercharged. A temperature/
pressure chart for R410A refrigerant is provided in
table 5 for your convenience. Verify adjusted charge
using the approach method.
*If line length is greater than 20 ft. (6.1m), add this amount.
If line length is less than 20 ft. (6.1m), subtract this amount.
4 - Outdoor temperature should be 60EF (16EC) or above.
Use the same digital thermometer used to check outdoor ambient temperature to check liquid line temperature. Verify the unit charge using the approach method.
The difference between the ambient and liquid temperatures should match values given in table 3. Refrigerant
must be added to lower approach temperature and removed to increase approach temperature. Loss of
charge results in low capacity and efficiency.
IMPORTANT
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. If line set lengths longer than 50 ft. will be required, add 1 ounce of oil for every additional 10 ft. of line set. Do not add any more than
7 oz. of oil. Copeland has approved Mobil EAL Arctic
22CC and ICI EMKARATE RL32CF for use with these
compressors when oil must be added in the field.
5 - If the system is low on charge, R410A refrigerant
must be added. Be aware of the R410A refrigerant
cylinder. It will be light maroon-colored. Refrigerant
should be added through the suction valve in the liquid state. Some R410A cylinders are equipped
with a dip tube which allows you to draw liquid
refrigerant from the bottom of the cylinder without turning the cylinder upside-down. The cylinder will be marked if it is equipped with a dip
tube.
If the system is void of refrigerant, the unit must be returned to the warehouse for exchange. Do not install a
unit which has been delivered void of refrigerant.
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 70EF (21EC) to
80EF (26EC). Be sure to monitor system pressures while
charging.
TABLE 3
APPROACH TEMPERATURES
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.
Model Number
Approach Temperature
Liquid Line Temp. - Outdoor Ambient °F (°C)
HS32-024
8 ± 1 (4.5 ± .5)
HS32-030
8 ± 1 (4.5 ± .5)
HS32-036
6 ± 1 (3.3 ± .5)
HS32-042
9 ± 1 (5 ± .5)
HS32-048
8 ± 1 (4.5 ± .5)
3 - Compare stabilized pressures with those provided in
HS32-060
12 ± 1 (6.7 ± .5)
table 4, Normal Operating Pressures. Minor variations
NOTE - For best results, the same electronic thermometer
in these pressures may be expected due to differences
should be used to check both outdoor ambient and liquid
in installations. Significant differences could mean that
line temperatures.
the system is not properly charged or that a problem
TABLE 4
NORMAL OPERATING PRESSURES
(Liquid ±10 and Suction ±5 psig)
MODE
TXV
OUTDOOR
EN
COIL ENTERING AIR
TEMP. °F (°C)
Liquid
Suction
Liquid
Suction
Liquid
Suction
Liquid
Suction
Liquid
Suction
Liquid
Suction
65 (18.3)
239
129
232
130
235
128
241
131
226
130
240
130
75 (23.9)
278
131
271
132
276
130
282
133
266
132
279
132
85 (29.4)
321
133
314
135
320
132
326
135
310
135
321
135
95 (35.0)
368
135
360
137
367
134
373
137
356
137
368
137
105 (40.6)
420
138
412
140
421
137
424
139
407
139
418
140
HS32-024
HS32-030
HS32-036
Page 10
HS32-042
HS32-048
HS32-060
TABLE 5
R410A Temperature/Pressure Chart
Temperature
°F
Pressure
Psig
Temperature
°F
Pressure
Psig
Temperature
°F
Pressure
Psig
Temperature
°F
Pressure
Psig
32
100.8
63
178.5
94
290.8
125
445.9
33
102.9
64
181.6
95
295.1
126
451.8
34
105.0
65
184.3
96
299.4
127
457.6
35
107.1
66
187.7
97
303.8
128
463.5
36
109.2
67
190.9
98
308.2
129
469.5
37
111.4
68
194.1
99
312.7
130
475.6
38
113.6
69
197.3
100
317.2
131
481.6
39
115.8
70
200.6
101
321.8
132
487.8
40
118.0
71
203.9
102
326.4
133
494.0
41
120.3
72
207.2
103
331.0
134
500.2
42
122.6
73
210.6
104
335.7
135
506.5
43
125.0
74
214.0
105
340.5
136
512.9
44
127.3
75
217.4
106
345.3
137
519.3
45
129.7
76
220.9
107
350.1
138
525.8
46
132.2
77
224.4
108
355.0
139
532.4
47
134.6
78
228.0
109
360.0
140
539.0
48
137.1
79
231.6
110
365.0
141
545.6
49
139.6
80
235.3
111
370.0
142
552.3
50
142.2
81
239.0
112
375.1
143
559.1
51
144.8
82
242.7
113
380.2
144
565.9
52
147.4
83
246.5
114
385.4
145
572.8
53
150.1
84
250.3
115
390.7
146
579.8
54
152.8
85
254.1
116
396.0
147
586.8
55
155.5
86
258.0
117
401.3
148
593.8
56
158.2
87
262.0
118
406.7
149
601.0
57
161.0
88
266.0
119
412.2
150
608.1
58
163.9
89
270.0
120
417.7
151
615.4
59
166.7
90
274.1
121
423.2
152
622.7
60
169.6
91
278.2
122
428.8
153
630.1
61
172.6
92
282.3
123
434.5
154
637.5
62
195.5
93
286.5
124
440.2
155
645.0
Discharge Thermostat
System Operation
Condensing unit and indoor blower cycle on demand from
room thermostat. When thermostat blower switch is moved
to ON position, indoor blower operates continuously.
Compressor Time Delay (TD1)
A compressor time delay is used to prevent compressor
short cycling and to prevent the compressor from running
backwards. When there is demand for a cooling cycle, the
control delays compressor operation for about 5 minutes.
Do not bypass the control.
The Copeland Scroll compressor is equipped with a discharge line thermostat that removes power from the compressor when discharge temperatures reach approximately 280E F (138EC). The thermostat resets automatically at
130E F (54EC).
CAUTION
Danger of Equipment Damage.
Do not bypass the discharge thermostat.
3DJH High Pressure Switch
HS32 units are equipped with a high pressure switch that is
located in the discharge line of the compressor. The switch
(SPST, manual reset, normally closed) removes power
from the compressor when discharge pressure rises above
factory setting at 640 + 10 psi.
Low Pressure Switch
HS32 units are also equipped with a low pressure switch
that is located in the suction line of the compressor. The
switch (SPST, auto-reset, normally closed) removes power
from the compressor when suction line pressure drops below factory setting at 40 + 5 psi.
Filter Drier
A drier is shipped with each HS32 unit. The drier must be
field installed in the liquid line between the liquid line service valve and the expansion valve. This drier must be
installed to ensure a clean, moisture-free system. A replacement drier is available as Lennox part no. 37L5201.
Maintenance
1 - Clean and inspect condenser coil. Coil may be flushed
with a water hose.
2 - Condenser fan motor is prelubricated and sealed. No
further lubrication is needed.
3 - Visually inspect connecting lines and coils for evidence
of oil leaks.
4 - Check wiring for loose connections.
5 - Check for correct voltage at unit (unit operating).
6 - Check amp-draw condenser fan motor.
Unit nameplate _________ Actual ____________ .
NOTE - If owner complains of insufficient cooling, the unit
should be gauged and refrigerant charge checked. Refer
to section on refrigerant charging in this instruction.
Evaporator Coil
1 - Clean coil, if necessary.
2 - Check connecting lines and coils for evidence of oil
leaks.
3 - Check condensate line and clean, if necessary.
Indoor Unit
1 - Clean or change filters.
2 - Adjust blower speed for cooling. The pressure drop over
the coil should be measured to determine the correct
blower CFM. Refer to the unit information service manual
for pressure drop tables and procedure.
3 - On belt drive blowers, check belt for wear and proper
tension.
WARNING
Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn
the electrical power to unit OFF at disconnect switch(es). Unit may have
multiple power supplies.
At the beginning of each cooling season, the system
should be checked as follows:
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 ____________.
HS32 Check Points
START-UP AND PERFORMANCE CHECK LIST
Job Name
Job Location
Installer
Unit Model No.
Nameplate Voltage
Date
Job No.
City
City
Serial No.
State
State
Service Technician
Amps:
Supply
Minimum Circuit Ampacity
Maximum Overcurrent Protection Size
Electrical Connections Tight?
Indoor Filter Clean?
S.P. Drop Over Evaporator (Dry)
Indoor Blower RPM
Discharge Pressure
Suction Pressure
Refrigerant Lines: Leak Checked?
Properly Insulated?
Outdoor Fan
Compressor
Supply Voltage (Unit Off)
Outdoor Coil Entering Air Temp.
Refrigerant Charge Checked?
Outdoor Fan Checked?
Service Valves Fully Opened?
Service Valve Caps Tight?
Voltage With Compressor Operating
Calibrated?
Page 12
Thermostat
Properly Set?
Level?