Lennox 13HPD−018, 13HPD−036, 13HPD−024, 13HPD−030, 13HPD−042 Installation Instructions Manual
...
INSTALLATION
2007 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
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.
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.
INSTRUCTIONS
Merit® Series13HPD Units
1−½ to 5 TONS
HEAT PUMP UNITS
505,361M
09/07
Supersedes 504,943M
Table of Contents
Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .
13HPD Outdoor Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Recovering Refrigerant from Existing System 4. . . . .
Disconnecting and Removing Old Outdoor Unit 5. . . .
Positioning New Outdoor Unit 5. . . . . . . . . . . . . . . . . . .
New or Replacement Refrigerant Line Set 6. . . . . . . .
Replacing Refrigerant Metering Device 8. . . . . . . . . . .
Brazing Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing for Leaks 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuating the System 11. . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections 12. . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up Procedures 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining Charge Method 15. . . . . . . . . . . . . . . . . . . .
System Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defrost System 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Homeowner Information 20. . . . . . . . . . . . . . . . . . . . . . . .
Start−Up and Performance Checklist 22. . . . . . . . . . . . .
Shipping and Packing List
1 − Assembled 13HPD outdoor unit
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
Litho U.S.A.
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.
09/07 505,361M
*2P0907* *P505361M*
13HPD Outdoor Unit
The Lennox 13HPD Heat Pumps, which will also be
referred to in this instruction as the outdoor unit, uses
HCFC−22 refrigerant. This unit must be installed with a
matching indoor unit and line set as outlined in the Lennox
Engineering Handbook. This unit is designed for use in
check thermal expansion valve (CTXV) and fixed orifice
systems.
Page 1
Unit Dimensions − inches (mm)
A
B
SIDE VIEW
Model Number A B
13HPD−018 24−1/4 (616) 33−1/4 (845)
13HPD−024 24−1/4 (616) 33−1/4 (845)
13HPD−030 24−1/4 (616) 29−1/4 (743)
13HPD−036 24−1/4 (616) 33−1/4 (845)
13HPD−042 28−1/4 (616) 33−1/4 (845)
13HPD−048 28-1/4 (718) 37 (940)
13HPD−060 32-1/4 (819) 37 (940)
WARNING
This product and/or the indoor unit it is matched
with may contain fiberglass wool.
Disturbing the insulation during installation,
maintenance, or repair will expose you to fiberglass
wool dust. 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
A
Outdoor Coil Fan
Compressor
Vapor and Liquid
Line Connections
Optional Unit Stand-off Kit
(4) (Field−installed)
Discharge Air
SIDE VIEW
General Information
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation. When servicing or
repairing HVAC components, ensure caps and fasteners
are appropriately tightened. Table 1 lists torque values for
typical service and repair items.
Table 1. 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
USING MANIFOLD GAUGE SETS
When checking the system charge, use a manifold gauge
set that features low−loss anti−blow back fittings. See figure
1 for a typical manifold gauge connection setup.
OPERATING SERVICE VALVES
The liquid and vapor lines service valves are typically 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.
505361M 09/07
Page 2
DISTRIBUTOR
CHECK
EXPANSION VALVE
BI−FLOW
LOW
PRESSURE
GAUGE MANIFOLD
PRESSURE
TO
HCFC−22
DRUM
HIGH
LIQUID
LINE
VALV E
FILTER /
DRIER
LIQUID
SERVICE
PORT
OUTDOOR
COIL
MUFFLER
COMPRESSOR
Figure 1. Typical Manifold Gauge Connection Setup
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.
1/6 TURN
12
11
10
9
8
7
This illustrates how to use an appropriately sized wrench to tighten
caps an additional 1/6 or 1/12 turn clockwise.
1
2
3
4
5
6
11
10
9
8
1/12 TURN
12
1
2
3
4
7
5
6
Figure 2. Cap Tightening Distances
IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and
fitted snugly over the cap before tightening.
Operating Angle−Type Service Valve
To Access Angle−Type Service Port:
A service port cap protects the service port core from
contamination and serves as the primary leak seal.
OUTDOOR UNIT
REVERSING VALVE
VAPOR
SERVICE
PORT
SERVICE PORT CAP
SERVICE PORT
CLOSED TO BOTH
INDOOR AND
OUTDOOR UNITS]
VALVE STEM
FRONT-SEATED
TO INDOOR
UNIT
TO OUTDOOR UNIT
VAPOR LINE
VALV E
CHECK EXPANSION VALVE OR
FIXED ORIFICE DEVICE
CORE
NOTE − Arrow indicate direction
of refrigerant flow.
INDOOR UNIT
INDOOR
COIL
SERVICE PORT
(VALVE STEM SHOWN
CLOSED) INSERT HEX
WRENCH HERE
STEM CAP
Figure 3. Angle−Type Service Valve
(Valve Font−Seated Closed)
1. Remove service port cap with an appropriately sized
wrench.
2. Connect gauge to the service port.
3. When testing is completed, replace service port cap and
tighten as follows:
With Torque Wrench: Finger tighten and then
tighten per table 1.
Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 2.
To Open and Close Angle−Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak−free seal.
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.
Page 3
13HPD SERIES
3. Replace the stem cap and tighten as follows:
With Torque Wrench: Tighten finger tight and then
tighten per table 1.
Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 2.
SERVICE PORT CAP
SERVICE PORT
CORE
OPEN TO BOTH
INDOOR AND
OUTDOOR UNITS]
TO INDOOR
UNIT
TO OUTDOOR
UNIT
STEM CAP
SERVICE PORT
(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE
With Torque Wrench: Finger tighten and then
tighten per table 1.
Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 2.
NOTE − A label with specific torque requirements may be
affixed to the stem cap. If the label is present, use the
specified torque.
NOTE− To prevent stripping of the cap, the wrench should
be appropriately sized and fit snugly over the cap before
tightening the cap.
Open to line set when valve is closed, to
both line set and unit when valve is open.
Use appropriately sized
wrench.
To open rotate stem
counterclockwise 90°.
To close rotate stem clockwise
90°.
TO INDOOR UNIT
VALV E
STEM
BALL
(SHOWN
CLOSED)
Figure 4. Angle−Type Service Valve
(Valve Back−Seated Opened)
NOTE − A label with specific torque requirements may be
affixed to the stem cap. If the label is present, use the
specified torque.
Operating Ball−Type Service Valve
To Access Ball−Type 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 to the service port.
3. When testing is completed, replace service port cap and
tighten as follows:
With Torque Wrench: Finger tighten and then
tighten per table table 1.
Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 2.
To Open and Close Ball−Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak−free seal.
1. Remove stem cap with a wrench.
2. Use an appropriately sized wrench to open. To open
valve, rotate stem counterclockwise 90°. To close
rotate stem clockwise 90°.
3. Replace the stem cap and tighten as follows:
SERVICE PORT
SERVICE PORT
CORE
SERVICE PORT CAP
STEM CAP
TO OUTDOOR UNIT
Figure 5. Ball−Type Service Valve
Recovering Refrigerant from Existing
HCFC−22 System
Remove existing HCFC−22 refrigerant using one of the
following methods:
METHOD 1:
If the existing outdoor unit is not equipped with shut−off
valves, or if the unit is not operational, then:
1. Disconnect all power to the existing outdoor unit.
2. Connect to the existing unit a gauge set, clean
recovery cylinder and a recovery machine. Use the
instructions provided with the recover machine on how
to setup the connections.
3. Remove all HCFC−22 refrigerant from the existing
system. Check gauges after shutdown to confirm that
the entire system is completely void of refrigerant.
4. Disconnect the liquid and vapor lines from the existing
outdoor unit.
5. Remove the existing outdoor unit.
NOTE − Use recovery machine instructions for specific
setup requirements.
505361M 09/07
Page 4
RECOVERY MACHINE
MANIFOLD GAUGES
(SEE NOTES
BELOW FIGURE)
CLEAN RECOVERY CYLINDER
OUTDOOR UNIT
Figure 6. Typical Refrigerant Recovery (Method 1)
METHOD 2:
If the existing outdoor unit is equipped with manual shut−off
valves then:
1. Start the existing HCFC−22 system in the cooling
mode and close the liquid line valve.
2. Pump all of the existing HCFC−22 refrigerant back into
the outdoor unit.
NOTE − It may be necessary to bypass the low pressure
switches to ensure complete refrigerant evacuation.
3. When the low side system pressures reach 0 psig,
close the vapor line valve.
4. Disconnect all power to the existing outdoor unit.
Check gauges after shutdown to confirm that the
valves are not allowing refrigerant to flow back into the
low side of the system.
5. Disconnect the liquid and vapor lines from the existing
outdoor unit.
Disconnecting and Removing Old
Outdoor Unit
Perform the following task at the existing outdoor unit:
Disconnect line set at the service valves.
Disconnect electrical service at the disconnect switch.
Remove old outdoor unit.
(SEE NOTES
BELOW
FIGURE)
SEE NOTES NOTES
BELOW FIGURE)
(SEE NOTES
BELOW
FIGURE)
Figure 7. Installation Clearances
NOTES:
Service clearance of 30 in. (762 mm) must be
maintained on one of the sides adjacent to the control
box.
Clearance to one of the other three sides must be 36
in. (914 mm)
Clearance to one of the remaining two sides may be
12 in. (305 mm) and the final side may be 6 in. (152
mm)
48 in. (1219 mm) clearance required on top of unit.
A clearance of 24 in. (610 mm) must be maintained
between two units
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 8.
INSTALL UNIT AWAY
FROM WINDOWS
Positioning New Outdoor Unit
CAUTION
In order to avoid injury, take proper precaution when
lifting heavy objects.
See Unit Dimensions on page 2 to determine the correct
mounting size slab, platform or support. Refer to figure 7
for mandatory installation clearance requirements
Page 5
TWO 90° ELBOWS INSTALLED IN LINE SET
WILL REDUCE LINE SET VIBRATION.
Figure 8. Outside Unit Placement
13HPD SERIES
PLACING OUTDOOR UNIT ON SLAB
Slab may be level or have a slope tolerance away from the
building of not more than two degrees, or two inches per
five feet (51 mm per 1524 mm).
When installing a unit at grade level, the top of the slab
should be high enough above the grade so that water from
higher ground would not collect around the unit as
illustrated in figure 9.
BUILDING
STRUCTURE
DISCHARGE AIR
MOUNTING
SLAB
GROUND LEVEL
Figure 9. Ground Level Slab Mounting
INSTALLING OUTDOOR UNIT ON ROOF
Install the unit a minimum of six 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.
If unit coil cannot be mounted away from prevailing winter
winds, a wind barrier should be constructed as illustrated in
figure 10. Size barrier at least the same height and width as
outdoor unit. Mount barrier 24 inches (610 mm) from the
sides of the unit in the direction of prevailing winds.
Prevailing Winter Winds
wind barrier
inlet air
inlet air
inlet air
inlet air
Figure 10. Rooftop Application and Wind Barrier
New or Replacement Refrigerant Line Set
This section provides information on new installation or
replacement of existing line set. If a new or replacement
line set is not required, then proceed to Brazing
Connections on page 9.
If refrigerant lines are routed through a wall, 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.
REFRIGERANT LINE SET
Field refrigerant piping consists of liquid and vapor lines
from the outdoor unit (braze connections) to the indoor unit
coil (flare or braze connections). Use Lennox L15 (braze,
non−flare) series line set, or use field−fabricated refrigerant
lines as listed in table 2.
Table 2. Refrigerant Line Set
Field
Model
−018
−024
−030
−036
−042
−048
−060
Connections
Liquid
Line
3/8 in.
(10 mm)
3/8 in.
(10 mm)
3/8 in.
(10 mm)
Vapor
Line
3/4 in
(19 mm)
7/8 in
(22 mm)
1−1/8 in.
(29 mm)
NOTE − When installing refrigerant lines longer than 50
feet, contact Lennox Technical Support Product
Applications for assistance or Lennox piping manual. To
obtain the correct information from Lennox, be sure to
communicate the following points:
Model (13HPD) and size of unit (e.g. −060).
Line set diameters for the unit being installed as listed
in table 2 and total length of installation.
Number of elbows and if there is a rise or drop of the
piping.
MATCHING WITH NEW OR EXISTING INDOOR COIL
AND LINE SET
The RFC1−metering line consisted of a small bore copper
line that ran from condenser to evaporator coil. Refrigerant
was metered into the evaporator by utilizing
temperature/pressure evaporation effects on refrigerant in
the small RFC line. The length and bore of the RFC line
corresponded to the size of cooling unit.
If the 13HPD is being used with either a new or existing
indoor coil which is equipped with a liquid line which served
as a metering device (RFCI), the liquid line must be
replaced prior to the installation of the 13HPD unit.
Typically a liquid line used to meter flow is 1/4" in diameter
and copper.
Recommended Line Set
Liquid
Line
3/8 in.
(10
mm)
3/8 in.
(10
mm)
3/8 in.
(10
mm)
Vapor
Line
3/4 in
(19 mm)
7/8 in
(22 mm)
1−1/8 in.
(29 mm)
L15
Line Sets
L15−41
15 ft. − 50 ft.
(4.6 m − 15 m)
L15−65
15 ft. − 50 ft.
(4.6 m − 15 m)
Field
Fabricated
505361M 09/07
Page 6
INSTALLING LINE SET
Line Set IsolationThis reference illustrates
procedures, which ensure proper refrigerant line set
isolation:
Line set for heat pump applications can not be installed
underground. For more information see the Lennox
Refrigerant Piping Design and Fabrication Guidelines, or
contact Lennox Technical Support Product Applications
for assistance.
Installation of line set on vertical runs is illustrated in
figure 11.
NOTE − Similar installation practices should be used if line
set is to be installed on exterior of outside wall.
ANCHORED HEAVY
NYLON WIRE TIE
WALL
STUD
Installation of a transition from horizontal to
vertical is illustrated in figure 12.
Installation of line set on horizontal runs is
illustrated in figure 13.
OUTSIDE WALL
WOOD BLOCK
BETWEEN STUDS
VAPOR LINE WRAPPED
IMPORTANT!
REFRIGERANT
LINES MUST NOT
CONTACT
STRUCTURE.
WITH ARMAFLEX
OUTSIDE
WALL
VAPOR LINE
LIQUID LINE
LIQUID LINE
WIRE TIE
INSIDE WALL
STRAP
SLEEVE
WIRE TIE
WOOD BLOCK
WIRE TIE
STRAP
SLEEVE
STRAP LIQUID LINE
TO VAPOR LINE
LIQUID LINE
METAL SLEEVE
AUTOMOTIVE
MUFFLER-TYPE HANGER
WALL
STUD
METAL SLEEVE
VAPOR LINE − WRAPPED
IN ARMAFLEX
VAPOR LINE WRAPPED
IN ARMAFLEX
STRAP LIQUID LINE
TO VAPOR LINE
LIQUID
LINE
Figure 12. Refrigerant Line Set: Transition from
Vertical to Horizontal
To hang line set from joist or rafter,
use either metal strapping material
or anchored heavy nylon wire ties.
STRAPPING MATERIAL
(AROUND VAPOR LINE
ONLY)
FLOOR JOIST OR
ROOF RAFTER
8 FEET
8 FEET
WIRE TIE
(AROUND
VAPOR LINE
TAPE OR
WIRE TIE
ONLY)
CAULK
PVC
PIPE
FIBERGLASS
INSULATION
IMPORTANT - REFRIGERANT LINES MUST
NOT CONTACT WALL.
Figure 11. Refrigerant Line Set: Installing Vertical
Runs (New Construction Shown)
Page 7
TAPE OR
WIRE TIE
FLOOR JOIST OR
ROOF RAFTER
METAL
SLEEVE
Strap the vapor line to the
joist or rafter at 8 feet
intervals then strap the
liquid line to the vapor line.
Figure 13. Refrigerant Line Set: Installing Horizontal
Runs
13HPD SERIES
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