Lennox 90W84 User manual

10/2012 506944-01

*2P102012* *P506944-01*

Page 1

LITHO U.S.A.

506944-01

10/2012

Supersedes 2/2012 HOT WATER HEAT KIT

KITS COMMON TO AIR HANDLERS

INSTALLATION INSTRUCTION FOR HOT WATER HEAT KIT (90W84)

E2012 Lennox Industries Inc.

Dallas, Texas, USA

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.

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.

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.

Shipping and Packing List

Check unit for shipping damage. Consult last carrier

immediately if damage is found.

Catalog

Number Part Names Part

Numbers Qty.

90W84

DC Relay, 22VDC 102297-01 1

3PDT Relay 67K6601 1

Delay-On-Make Relay 99P41 1

9-Pin Wiring Harness 609345-01 1

Wiring Diagram 537516-01 1

Field-Provided Supplies

The following field-provided supplies may be required.

S1/4” quick connects

SControl wiring (various lengths)

General

Hot water heat kit (90W84) adapts CBX32MV and

CBX40UHV units for use with a boiler to provide hot water

heating in select applications. When used with an air

conditioner, the hot water provides first-stage heating.

When used with a heat pump, the hot water provides

second-stage heating.

This kit is only approved for use in systems using either the

ComfortSense®7000 thermostat or icomfortt

thermostat. Wiring modifications shown are in addition to

field wiring detailed in the instructions provided with the air

handler.

Thermostat Configuration

HEAT PUMP APPLICATIONS

The ComfortSense®7000 will need to be reconfigured for

use with:

SHeat pump with hot water heat (see figure 7).

SCompressor low balance set point of 40ºF.

Since the hot water coil is downstream of the coil, the heat

pump and boiler can be operated simultaneously. In

emergency heat mode, the blower CFM drops to the lower

heat table CFM setting.

AIR CONDITIONER APPLICATIONS

In applications with condensing units, configure

ComfortSense®7000 for hot water heat (see figure 7).

In icomfortt-enabled systems, see figure 7 for heat

discovery procedures and the icomforttthermostat

installer guide to configure the thermostat.

Kit Installation

This kit can be installed for any of the following variations:

SAir handler - hot water heat and air conditioner

SAir handler - hot water heat and heat pump

FREEZESTAT INSTALLATION

Since the hot water coil is downstream of the indoor a

freezestat will need to be installed to protect the indoor

coil during summer air conditioning operation.

1. All units will require one field-provided properly sized

freezestat (S49) for use with this kit. Order part using

table 1.

Page 2

Table 1. Freezestat Selection (S49)

Tubing

Size

Wire

Length

Wire

Gauge

Lennox

Catalog

Number

Freezestat

Set Points

Open Close

3/8” 90-13/16” 18 93G35 29ºF

(-2ºC)

58ºF

(10ºC)

5/8” 36-1/2” 18 50A93 36ºF

(2ºC)

58ºF

(10ºC)

Installation Method 1 — (Non-Communicating Unit)

This installation method is applicable to systems that use

standard thermostat wiring (see figure 2).

1. A freezestat, sized per table 1 and ordered separately,

must be installed. Install the freezestat on one of the

copper lines between the last hairpins and the suction

manifold (see figure 1) of the indoor coil.

2. The freezestat senses the line temperature and cycles

the compressor off when the line temperature fails

below its setpoint. The freezestat will open and closed

as listed in table 1.

3. Connect freezestat (S49) wires as exampled in figure

CLIP

COPPER

LINE

EXPANSION

VALVE

FREEZESTAT

SUCTION

MANIFOLD

LIQUID LINE

LAST HAIRPINS

COPPER LINES

Figure 1. Typical Freezestat (S49) Installation

(Indoor Coil)

reversing valve

Thermostat Designations

(Some connections may not apply.

Refer to specific thermostat and indoor unit.)

Thermostat Indoor

Unit

Outdoor

Unit

power power

common common

1st. stage aux. heat 1st. stage aux. heat

indoor blower

compressor

*Freezestat

See figure 1. Typical Freezestat (S49)

Installation (Indoor Coil)

Figure 2. S49 Freezestat Wiring

CAUTION

ELECTROSTATIC

DISCHARGE

(ESD)

PRECAUTIONS

AND

PROCEDURES

Electrostatic discharge can affect

electronic components. Take care

during unit installation and service to

protect the unit's electronic controls.

Precautions will help to avoid control

exposure to electrostatic discharge by

putting the unit, the control and the

technician at the same electrostatic

potential. Touch hand and all tools on an

unpainted unit surface before

performing any service procedure to

neutralize electrostatic charge.

Page 3

Installation Method 2 — (Communicating Unit)

This installation method is applicable to the models listed

below.

Table 2. Method 2 Models

XC17

In communicating mode only.

XP17 and XP17N

XP19-XXX-230-06

XC21-XX-230-04 and later

XP21 and XP21N

1. A freezestat, sized per table 1 and ordered separately,

must be installed. Install the freezestat near last bend

(tube) of the indoor coil before the suction manifold

(see figure 1).

2. The freezestat senses the line temperature and cycles

the compressor off when the line temperature fails

below its setpoint. The freezestat will open and closed

as listed in table 1.

3. Connect freezestat (S49) wires as exampled in the

applicable unit wiring diagrams and figure 3.

OUTDOOR UNIT CONTROL

(A175)

OUTDOOR UNIT LOW

PRESSURE SWITCH (S87)

INDOOR UNIT

FREEZESTAT

(S49)

BLACK

NOTE - For communicating systems only,

use a 6-conductor control cable between

the indoor and outdoor units. The freezestat

(S49) two wires will be spliced in series be

tween the outdoor unit low pressure switch

(S87) outdoor control (A175) LO and PS

terminals.

See figure 1. Typical Freezestat (S49)

Installation (Indoor Coil)

Figure 3. Freezestat (S49) Wiring for Communicating Systems

Page 4

OPTION 1 — AIR HANDLER - HOT WATER HEAT AND HEAT PUMP / AIR CONDITIONER WITH ICOMFORT™

THERMOSTAT

SCREWS TO

SECURE

RELAY (2)

AIR

HANDLER

CONTROL

9-PIN CONNECTOR

22V DIRECT CURRENT COIL

30 AMP CONTACT

RATING

NOTE — EVENHEAT MODE CANNOT BE ENABLED WITH HARMONY III DUE

TO EACH CONTROL REQUIRING ITS OWN DISCHARGE AIR SENSOR.

DETAIL B

CONNECT WIRES TO DISCHARGE AIR SENSOR

TERMINAL ON AIR HANDLER CONTROL.

AIR HANDLER CONTROL

PART NO. 50W28 or 65W70

ORANGE

TO BOILER CONTROL

RELAY

Heat discovery must be completed before powering the icomfort™ thermostat, if not, the icomfort™ setup will need to

be performed again after air handler heat discovery. The icomfort™ thermostat will control operation as single-stage

hot water heat.

Heat relay contacts 4 and 2

must be used to control

boiler when configured with

icomfort™ thermostat only.

Refer to icomforttThermostat Installer's System Setup Guide, Setting up Equipment Parame

ters for configuring hot water heating equipment.

1. Press start

2. Navigate to equipment tab.

3. Under system devices, select AIR HANDER and select edit to the right of the box.

4. Select Electric heating Air flow and select edit to the right of the box.

5. Use the UP or DOWN arrows to set the desired CFM. Select save when done.

6. Under Equipment Name, scroll down to Heating Indoor Blower OFF Delay and select edit

to the right of the box.

7. Use the UP or DOWN arrows to set a maximum of 10 seconds. Select save when done

8. Under Equipment Name, scroll down to Heating Indoor Blower ON Delay and select edit

to the right of the box.

9. Use the UP or DOWN arrows to set a maximum of five (5) seconds. Select save when done

10. Toggle to exit

All configurations will use the heat relay terminals 0and 1connected

to pins 1and 3 on the 9-pin connector.

Figure 4. Air Handler - Hot Water Heat and Heat Pump / Air Conditioner with icomfort™ Thermostat

Page 5

OPTION 2 — AIR HANDLER - HOT WATER HEAT AND AIR CONDITIONER WITH COMFORTSENSE®7000

99P41 67K66

TO BOILER

CONTROL

TO W1 ON

THERMOSTAT

DELAY−ON−MAKE

TIME DELAY RELAY

KIT INSTALLATION

1. Remove factory-installed P8 cable assembly.

2. Install provided P8 cable assembly.

3. Initiate air handler control heat discovery

mode (figure 7).

4. install 99P41 and 67K66 as shown.

5. Adjust 99P41 for average water warm-up time.

6. Adjust heat CFM for desired air temperature

rise.

HEAT DEMAND

1. Boiler zone to air handler will start.

2. Air handler blower will start after time delay.

CONTINUOUS FAN CALL

CFM jumper may be set 28%, 38%, 70% or 100%

without interfering with the hot water heating CFM.

HEAT

RELAY

Figure 5. Air handler - hot water heat and air conditioner with ComfortSense®7000

OPTION 3 — AIR HANDLER - HOT WATER HEAT AND HEAT PUMP WITH COMFORTSENSE®7000

99P41 67K66

TO BOILER

CONTROL

TO W1 ON

THERMOSTAT

TO Y1 ON

THERMOSTAT

DELAY−ON−MAKE

TIME DELAY RELAY

KIT INSTALLATION

1. Remove factory-installed P8 cable assembly.

2. Install provided P8 cable assembly.

3. Initiate air handler control heat discovery mode

(figure 7).

4. install 99P41 and 67K66 as shown.

5. Adjust 99P41 for average water warm-up time.

6. Adjust heat CFM for desired air temperature rise.

BACKUP HEAT DEMAND

1. Heat pump will turn off.

2. Boiler zone to air handler will start.

3. Air handler blower will start after time delay.

CONTINUOUS FAN CALL

CFM jumper may be set at 28%, 38%, 70% or 100%

without interfering with hot water heating CFM.

HEAT

RELAY

Figure 6. Air handler - hot water heat and heat pump with ComfortSense®7000

Page 6

Configuring/Detecting Hot Water Heat Section

IMPORTANT — Hot water heat installation

require the air handler control to be manually

configured to detect hot water heat section.

SSet desired Heating Mode Blower Speed jumper pin.

SHot water heat is stage by room thermostat. The air handler control comes with

factory jumper between W1 and W2 and W2 and W3.

SRefer to air handler control checkout flow diagram for operation.

Configuration

Air handler control in

Idle Mode (No heating

cooling or indoor fan

operation)

To enter hot water heat

configuration mode, push and

hold button next to

single-character LED display until

dash symbol (solid bar) appears.

Then, release button.

Turn room thermostat to OFF.

Yes

Solid dash starts blinking

on single character LED

display

Push and hold button until the solid Hsymbol is displayed on the

single-character LED display. Then, release button.

Finished

1 Air handler control will start the indoor blower motor to the selected heat jumper speed setting and cycle the hot water heat relay ON to automati

cally detect the hot water heat section.

2 Air handler control waits for maximum of ten seconds to detect the hot water heat 22VDC relay coil is energized:

A If relay coil current is detected within 10 seconds, the air handler control will show a 1 on the single-character LED display indicating that the

first-stage hot water heat has been detected. As each additional heat section is detected, the single-character LED will display that hot

water heat number.

B If relay coil current is not detected within 10 seconds, the air handler control will exit the current active mode and resume operation with hot

water heat disabled.

3 The air handler control will automatically exit current active mode when configuration is completed. To verify that the hot water section detected

matches the installed hot water heat package, the field MUST CONFIRM that the last number the single character LED display before exiting the

configuring/detectionmode matches the hot water heat section. The air handler control stores the hot water heat stage in non-volatile memory.

4 After the detection is finished, unit will continue to operate for an additional 30 seconds.

NOTE — If the air handler control is unable to verify all 22 volt DC hot water heat relay(s) were energized using hot water heater detection after

the air handler control button is pushed, or power to the air handler control is cycled, then the configuration procedure must be repeated.

This procedure is for the installation of one hot water heat section. This procedure is typically used to configure hot water heat

which is the same as configuring for electric heat.

Figure 7. Heat Discovery Mode

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