Lennox HS27-024 User manual

Page 1

504,669M

*P504669M*

02/04

*2P0204*

2000 Lennox Industries Inc.

Dallas, Texas, USA



HS27 Outdoor Unit

HS27 outdoor units are designed for expansion valve sys-

tems only. They are not designed for RFC systems. Refer to

Lennox engineering handbook for expansion valve kits

which must be ordered separately.

Shipping & Packing List

1 − Assembled HS27 outdoor unit

2 − Grommets (for liquid and vapor lines)

1 − Bushing (for low voltage wiring)

Check equipment for shipping damage. If you find any

damage, immediately contact the last carrier.

WARNING

Improper installation, adjustment, alteration, service

or maintenance can cause property damage, person-

al injury or loss of life. Installation and service must

be performed by a qualified installer or service

agency.

IMPORTANT

The Clean Air Act of 1990 bans the intentional vent-

ing of refrigerant (CFC’s and HCFC’s) as of July 1,

1992. Approved methods of recovery, recycling or

reclaiming must be followed. Fines and/or incarcera-

tion may be levied for noncompliance.

INSTALLATION

INSTRUCTIONS

HS27 SERIES UNITS

CONDENSING UNITS

504,669M

02/04

Supersedes 12/02

Table of Contents

HS27 Outdoor Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shipping & Packing List 1. . . . . . . . . . . . . . . . . . . . . . . . .

General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting the Unit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Piping 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Metering Device 9. . . . . . . . . . . . . . . . . . . . .

Manifold Gauge Set 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Valves 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leak Testing 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evacuation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charging 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Accessories 14. . . . . . . . . . . . . . . . . . . . . . . . . .

Start−up & Performance Check List 15. . . . . . . . . . . . . . .

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

General Information

These instructions are intended as a general guide and do

not supersede local codes in any way. Consult authorities

having jurisdiction before installation.

WARNING

This product and/or the indoor unit it is matched with

may contain fiberglass wool.

Disturbing the insulation during installation, mainte-

nance, or repair will expose you to fiberglass wool

dust. Breathing this may cause lung cancer. (Fiber-

glass wool is known to the State of California to

cause cancer.)

Fiberglass wool may also cause respiratory, skin,

and eye irritation.

To reduce exposure to this substance or for further

information, consult material safety data sheets

available from address shown below, or contact your

supervisor.

Lennox Industries Inc.

P.O. Box 799900

Dallas, TX 75379−9900

Litho U.S.A.

Page 2

Unit Dimensions − inches (mm)

electrical

inlets

vapor line

inlet

liquid

line inlet

DISCHARGE AIR

inlet

air

COMPRESSOR

Top View

Side ViewAccess View

4-1/2 (114)

2-3/4 (70) 4

(102)

6-1/16

(154)

1-3/8

(35)

4-7/8 (22) 4

(102)

2-9/16

(65)

18-5/8

(473)

26-5/8 (676)

34-1/16 (865)

(51)

28-1/8 (714)

7-1/2

(191) 7-1/2

(191)

3-7/8

(98)

3-7/8

(98)

airinlet

(51)

32-1/8 (816)

Model No. A B

HS27-024 in. 30-7/8 12-3/4

HS27-024

HS27-030 mm 784 324

HS27-036 in. 40-7/8 19-3/4

HS27-036

HS27-042 mm 1038 502

Page 3

Parts Arrangement

Figure 1

outdoor fan

(not shown)

top of cabinet

contactor

run capacitor

terminal box

liquid line

service valve

and gauge port

vapor valve

and gauge port

compressor

low pressure

switch

high pressure

switch

ground lug

Setting the Unit

CAUTION

In order to avoid injury, take proper precaution when

lifting heavy objects.

CAUTION

Danger of sharp metallic edges. Can cause injury.

Take care when servicing unit to avoid accidental

contact with sharp edges.

Refer to unit dimensions for sizing mounting slab, platform-

s, or supports. Refer to figure 2 for installation clearances.

36"

(914 mm)

36"

(914 mm)

*36"

(914 mm)

*36"

(914 mm)

Installation Clearances

Figure 2

NOTE − A service access

clearance of 30" (762 mm)

must be maintained in front

of the service access panel.

Clearance to one side must

be 36" (914 mm). Clearance

to one of the remaining two

sides may be 12" (304 mm)

and the final side may be 6"

(152 mm).

NOTE − A clearance of 24" (610 mm)

must be maintained between two units.

NOTE − 48" (1219 mm) clearance required on top

of unit. Maximum soffit overhang is 36" (914 mm).

Page 4

A − Slab Mounting

When you install the unit at grade level, the top of the slab

should be high enough above the grade so that water from

higher ground will not collect around the unit. See figure 3.

Slab should have a slope tolerance away from the building

of 2 degrees or 2 inches per 5 feet (51 mm per 1.5 m).

2 degrees or

2 in. per 5 foot

(51 mm per 1.5 m)

slope tolerance away

from building structure

Slab Mounting

ground level

mounting

slab

building

structure

discharge air

Figure 3

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 distrib-

uted over roof joists and rafters. Either redwood or steel sup-

ports are recommended.

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 blower coil installation instructions

for additional wiring application diagrams and refer to unit

nameplate for minimum circuit ampacity and maximum

overcurrent protection size.

WARNING

Unit must be grounded in accordance with

national and local codes.

Electric Shock Hazard.

Can cause injury or death.

1. Install line voltage power supply to unit from a properly

sized disconnect switch.

2. Ground unit at unit disconnect switch or to an earth

ground.

NOTE − To facilitate conduit, a hole is in the bottom of

the control box. Connect conduit to the control box us

ing a proper conduit fitting.

NOTE − Units are approved for use only with copper

conductors.

24V, Class II circuit connections are made in the low

voltage junction box. Refer to figure 4 for field wiring

diagram.

NOTE − A complete unit wiring diagram is located in

side the unit control box cover.

3. Install room thermostat (ordered separately) on an in-

side wall approximately in the center of the conditioned

area and 5 feet (1.5 m) from the floor. It should not be

installed on an outside wall or where it can be effected

by sunlight, drafts or vibrations.

4. Install low voltage wiring from outdoor to indoor unit

and from thermostat to indoor unit. See figure 5.

Page 5

Outdoor Unit

Field Wiring Diagram

YELLOW

(LEADLESS)

Figure 4

Thermostat Designations

Thermostat Furnace

Outdoor Unit

Y1 Outdoor Unit

C Outdoor Unit

power

heat

cooling

indoor blower

common

NOTE − see unit wiring diagram for

power supply connections.

NOTE − If the indoor unit is not equipped with blower relay, it must be field−provided and installed (P−8−3251 or equivalent).

Figure 5

Page 6

Refrigerant Piping

Field refrigerant piping consists of liquid and vapor lines

from the outdoor unit (sweat connections) to the indoor coil

(flare or sweat connections). Use Lennox L15 (sweat, non-

flare) series line sets as shown in table 1 or use field-fabri-

cated refrigerant lines. Refer to Refrigerant Piping Guide

(Corp. 9351−L9) for proper size, type, and application of

field−fabricated lines. Valve sizes are also listed in table 1.

Table 1

Refrigerant Line Sets

HS27

Field Valve Size

Connections Recommended Line Set

HS27 Liquid

Line

Vapor

Line Liquid

Line

Vapor

Line

L15

Line Sets

−024

−030

3/8 in

(10 mm)

3/4 in.

(19 mm)

3/8 in

(10 mm)

3/4 in.

(19 mm)

L15−41

15 ft. − 50 ft.

(4.6 m − 15 m)

−036

−042

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)

NOTE − Units are designed for line sets of up to 50 feet (15

m). For applications longer than 50 feet, consult the Len-

nox Refrigerant Piping Guide (Corp. 9351−L9).Select line

set diameters from table 1 to ensure that oil returns to the

compressor.

Installing Refrigerant Line

During the installation of any heat pump or a/c system, it is

important to properly isolate the refrigerant lines to prevent

unnecessary vibration. Line set contact with the structure

(wall, ceiling or floor) causes some objectionable noise

when vibration is translated into sound. As a result, more

energy or vibration can be expected. Closer attention to

line set isolation must be observed.

Following are some points to consider when placing and

installing a high−efficiency outdoor unit:

1- Placement −Be aware some localities are adopting

sound ordinances based on how noisy the unit is from

the adjacent property not at the original installation.

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 transmis-

sion.

2- Line Set Isolation − The following illustrations demon-

strate procedures which ensure proper refrigerant line

set isolation. Figure 6 shows how to install line sets on

vertical runs. Figure 7 shows how to install line sets on

horizontal runs. Figure 8 shows how to make a transition

from horizontal to vertical. Finally, figure 9 shows how to

place the outdoor unit and line set.

Page 7

Refrigerant Line Sets

How To Install Vertical Runs

(new construction shown)

PVC Pipe Fiberglass

Insulation

Caulk

Outside Wall

Vapor Line

(wrapped with Armaflex)

Liquid Line

IMPORTANT - Refrigerant

lines must not contact

structure.

Outside Wall

Inside Wall

Liquid LineVapor Line

IMPORTANT - Refrigerant

lines must not contact wall.

Wood Block

Between Studs

Strap

Sleeve

Wood Block

Strap

Sleeve

Wire Tie

NOTE - Similar installation practices should be used if

line set is to be installed on exterior of outside wall.

Figure 6

Page 8

Refrigerant Line Sets:

Installing Horizontal Runs

8 feet

Metal Sleeve

Strapping Material (around vapor line only)

Tape or Wire Tie

Wire Tie

(around vapor line only)

Floor Joist or

Roof Rafter

Tape or Wire Tie

Strap the vapor line to the joist or rafter at 8 ft.

intervals then strap the liquid line to the vapor line.

To hang line set from joist or rafter,

use either metal strapping material

or anchored heavy nylon wire ties.

Floor Joist or Roof Rafter

Figure 7

Page 9

Refrigerant Line Sets:

Transition From Vertical To Horizontal

Liquid Line

Vapor Line

Wrapped in

Armaflex

Strap Liquid Line

To Vapor Line

Metal

Sleeve

Anchored Heavy

Nylon Wire Tie

Automotive

Muffler-Type

Hanger

Wall

Stud

Wall

Stud

Liquid Line

Vapor Line

Wrapped in

Armaflex

Strap Liquid Line

To Vapor Line

Metal

Sleeve

Figure 8

Outside Unit Placement and Installation

Install unit away from windows.

Two 90° elbows

installed in line set

will reduce line set

vibration.

Figure 9

Page 10

Brazing Connection Procedure

1 − Cut ends of the refrigerant lines square (free from nicks

or dents). Debur the ends. The pipe must remain

round, do not pinch end of the line.

2 − Before making line set connections, use dry nitrogen to

purge the refrigerant piping. This will help to prevent

oxidation and the introduction of moisture into the sys-

tem.

3 − Use silver alloy brazing rods (5 or 6 percent minimum

silver alloy for copper−to−copper brazing or 45 percent

silver alloy for copper−to−brass or copper−to−steel braz-

ing) which are rated for use with HCFC−22 refrigerant.

Wrap a wet cloth around the valve body and the copper

tube stub. Braze the line set to the service valve.

4 − Wrap a wet cloth around the valve body and copper

tube stub to protect it from heat damage during braz-

ing. Wrap another wet cloth underneath the valve body

to protect the base paint.

NOTE − The tube end must stay bottomed in the fitting

during final assembly to ensure proper seating, sealing

and rigidity.

5 − Install a field−provided thermal expansion valve (ap-

proved for use with HCFC−22 refrigerant) in the liquid

line at the indoor coil.

Refrigerant Metering Device

H27 units are used in expansion valve systems only. See

the Lennox Engineering Handbook for approved TXV

match-ups and application information.

Expansion valves equipped with Chatleff fittings are avail-

able from Lennox. Refer to the Engineering Handbook for

applicable expansion valves for use with specific match-

ups.

If you install an expansion valve with an indoor coil that

includes a fixed orifice, remove the orifice before instal-

ling the expansion valve.

IMPORTANT

Failure to remove RFC orifice when installing an ex-

pansion valve on the indoor coil will result in improp-

er operation and damage to the system.

See figure 10 for installation of the check expansion valve.

Metering Device Installation

expansion

valve

o−ring

strainer

liquid line

stub

distributor

Figure 10

Manifold Gauge Set

When checking the unit charge, use a manifold gauge set

that is equipped with low loss" hoses. Do not use a man-

ifold gauge set with anything other than a low loss" hose.

Service Valves

The liquid line and vapor line service valves (figures 11 and

12) and gauge ports are used for leak testing, evacuating,

charging and checking charge. See table 2 for torque re-

quirements.

Each valve is equipped with a service port which has a fac-

tory−installed Schrader valve. A service port cap protects

the Schrader valve from contamination and serves as the

primary leak seal.

Table 2

Torque Requirements

Part Recommended Torque

Service valve cap 8 ft.− lb. 11 NM

Sheet metal screws 16 in.− lb. 2 NM

Machine screws #10 28 in.− lb. 3 NM

Compressor bolts 90 in.− lb. 10 NM

Gauge port seal cap 8 ft.− lb. 11 NM

To Access Schrader Port:

1 − Remove the service port cap with an adjustable wrench.

2 − Connect gauge to the service port.

3 − When testing is complete, replace the service port cap.

Tighten finger tight, then an additional 1/6 turn.

To Open Service Valve:

1 − Remove stem cap with an adjustable wrench.

2 − Use a service wrench with a hex−head extension to

back the stem out counterclockwise as far as it will go.

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