Lennox HP27 SERIES, HP27-030, HP27-036, HS27-024, HP27-042 Installation Instructions Manual

Page 1

504,712M

*P504712M*

06/04

*2P0604*

2002 Lennox Industries Inc.

Dallas, Texas, USA

®

HP27 Outdoor Unit

HP27 outdoor units are designed for expansion valve sys­tems only. They are not designed for RFC systems. Refer to
Lennox engineering handbook for expansion valve kits
which you must order separately.

Shipping & Packing List

1 − Assembled HP27 outdoor unit

2 − Grommets (for liquid and vapor lines)

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, person­al 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 vent­ing 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 incarcera­tion may be levied for noncompliance.

INSTALLATION
INSTRUCTIONS

HP27 SERIES UNITS

HEAT PUMP UNITS

504,712M
06/04

Supersedes 12/03

Table of Contents

HP27 Outdoor Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

Electrical 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Piping 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Metering Device 10. . . . . . . . . . . . . . . . . . . .

Service Valves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leak Testing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evacuation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Gauge Set 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Charging 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defrost System 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HP27 Check Points 18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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, 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

Litho U.S.A.

Page 2

Unit Dimensions − inches (mm)

2-3/4

(70)

COMPRESSOR

INLET

INLET

AIR

TOP VIEW

SIDE VIEW

SERVICE ACCESS

ELECTRICAL

INLETS

VAP OR

LINE INLET

DISCHARGE

AIR

COIL DRAIN

OUTLETS

(Around perimeter

of base)

4

(102)

B

1-3/8

(35)

LIQUID

LINE INLET

4

(102)

6-1/16

(154)

AIR

INLET

AIR

A

4-7/8 (22)

4-1/2 (114)

2-9/16

(65)

2

(51)

2

(51)

13-5/8

(473)

26-5/8

(676)

7-1/2
(191)

7-1/2
(191)

3-7/8

(98)

3-7/8

(98)

28-1/8 (714)

32−1/8

(816)

34-1/16

(865)

Model No. A B

HS27-024

in. 40-7/8 19-13/16

HS27-024

HP27-030

mm 1038 503

HP27-036

in. 44-7/8 14-1/4

HP27-036

HP27-042

mm 1140 362

Page 3

Parts Arrangement

Figure 1

HP27 UNIT COMPONENTS

CONTACTOR

DEFROST CONTROL/TIMED−OFF CONTROL

LIQUID LINE

SERVICE VALVE

AND GAUGE

PORT

VAPOR LINE

SERVICE VALVE

AND GAUGE

PORT

MUFFLER

EXPANSION VALVE

WITH

INTERNAL CHECK VALVE

REVERSING

VALV E

AND SOLENOID

BIFLOW

FILTER/DRIER

DUAL

CAPACITOR

DISTRIBUTOR

HIGH PRESSURE

SWITCH

GROUND LUG

DEFROST

THERMOSTAT

TXV

SENSING BULB −036,

−042 ONLY

VAPOR GAUGE

PORT

ACCUMULATOR

TXV

SENSING BULB

−024, −030 ONLY

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.

The outdoor units operate under a wide range of weather
conditions; therefore, several factors must be considered
when positioning the outdoor unit. The unit must be posi­tioned to give adequate clearances for sufficient airflow
and servicing. A minimum clearance of 24inches (610 mm)
between multiple units must be maintained. Refer to figure
2 for installation clearances.

1 − Place a sound−absorbing material, such as Isomode,

under the unit if you intend to install it in a location or a
position that will transmit sound or vibration to the liv­ing area or adjacent buildings.

2 − Install the unit high enough above ground or roof to

prevent ice build−up and to allow adequate drainage of
defrost water.

3 − In areas that receive heavy snow, do not locate the unit

where drifting will occur. Ensure that the unit base is
elevated above the depth of average snows.

NOTE − Elevate the unit by constructing a frame using
suitable materials. If you construct a support frame, it
must not block drain holes in the base of the unit.

36"

(914 mm)

36"

(914 mm)

*36"

(914 mm)

*36"

(914 mm)

Installation Clearances

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).

Figure 2

Page 4

4 − When you install the unit in areas where low ambient

temperatures exist, locate the unit so winter prevailing
winds do not blow directly into outdoor coil.

5 − Locate the unit away from overhanging roof lines

which would allow water or ice to drop on, or in front of,
the coil or into the unit.

Slab Mounting

When installing 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.
The 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). This will prevent ice from building up under the unit dur­ing a defrost cycle. Refer to the roof mounting section for
barrier construction if the unit must face prevailing winter
winds.

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

Roof Mounting

If you are unable to mount the unit coil away from prevailing
winter winds, construct a wind barrier. See figure 4. Size
the barrier at least the same height and width as the out­door unit. Mount the barrier 24 inches (610 mm) from the
sides of the unit in the direction of prevailing winds.

WIND BARRIER

INLET AIR

PREVAILING WINTER WINDS

Rooftop Application

Wind Barrier Construction

INLET AIR

INLET

AIR

Figure 4

24 in.

(610 mm)

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.

Page 5

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 5 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 voltage wiring from outdoor to indoor unit and

from thermostat to indoor unit. See figures 6 and 7.

Typical Field Wiring Diagram

Figure 5

Page 6

R

C

W1

Y1

O

G

R

C

W1

W2

W3

G

reversing valve

Outdoor Unit and Blower Unit

Thermostat Designations

(Some connections may not apply.

Refer to specific thermostat and indoor unit.)

Thermostat

Indoor

Unit

R

C

W1

Y1

O

Outdoor

Unit

power

power

common common

1st. stage aux. heat

1st. stage aux. heat

indoor blower

compressor

Figure 6

R

C

W1

Y1

O

G

R

C

W1

W2

W3

G

Outdoor Unit and Blower Unit

Thermostat Designations

(with auxiliary heat)

(Some connections may not apply.

Refer to specific thermostat and indoor unit.)

Thermostat

Indoor

Unit

Outdoor

Unit

E

R

C

W1

Y1

O

reversing valve

indoor blower

compressor

power

power

common common

1st. stage aux. heat

1st. stage aux. heat

emergency heat

Figure 7

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, non­flare) series line sets as shown in table 1 or use field-fabri­cated 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 Set

s

Valve Field Size

Connections

Recommended Line Set

Model

Liquid

Line

Vapor

Line

Liquid

Line

Vapor

Line

L15

Line Sets

−024

−030

3/8 in.

9.5 mm

3/4 in.

19.1 mm

3/8 in.

9.5 mm

3/4 in.

19.1 mm

L15−41

15 ft.−50 ft.

4.6 m−15.2 m

−036

−042

3/8 in.

9.5 mm

7/8 in.

22.2 mm

3/8 in.

9.5 mm

7/8 in.

22.2 mm

L15−41

15 ft.−50 ft.

4.6 m−15.2 m

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 transmis­sion.

2- Line Set Isolation − The following illustrations demon-

strate procedures which ensure proper refrigerant line
set isolation. Figure 8 shows how to install line sets on
vertical runs. Figure 9 shows how to install line sets on
horizontal runs. Figure 10 shows how to make a transi­tion from horizontal to vertical. Finally, figure 11 shows
how to place the outdoor unit and line set.