Lennox HP40, HP40-018, HP40-024, HP40-036, HP40-048 Installation Instructions Manual
...
06/04
*2P0604*
504,538M
*P504538M*
Page 1
2000 Lennox Industries Inc.
Dallas, Texas, USA
®
HP40 Heat Pump Unit
HP40 heat pumps use R407C 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. HP40 heat pumps are designed for
use in expansion valve systems only. They are not designed to be used in RFC systems. An expansion valve
and filter drier approved for use with R407C have been
shipped with the unit. These components must be
installed prior to unit operation.
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox’ Engineering Handbook.
Coils previously charged with R22 must be
flushed.
WARNING
This equipment must only be installed and serviced
by properly qualified personnel. Equipment contains dangerous voltages and moving parts. Always switch off power supply before opening any
access panel. Electrical control panel doors and fan
access door must be locked to prevent unauthorized access at beginning of instruction.
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.
INSTALLATION
INSTRUCTIONS
HP40 Heat Pump Units
HEAT PUMP UNITS
1−1/2 through 5 ton
504,538M
06/04
Supersedes 11/02
Table of Contents
HP40 Heat Pump Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping & Packing List 1. . . . . . . . . . . . . . . . . . . . . . . . .
General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Unit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plumbing 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Metering Device 5. . . . . . . . . . . . . . . . . . . . .
Manifold Gauge Set 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid & Vapor Line Service Valves 7. . . . . . . . . . . . . . .
Leak Testing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Evacuation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging Considerations 10. . . . . . . . . . . . . . . . . . . . . . .
System Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defrost System 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Shipping & Packing List
1 − Assembled HP40 heat pump unit
1 − Bag assembly:
1 − Sight glass
1 − Coupling reducer, 5/16 x 3/8 inch (024)
Check unit for shipping damage. If any damage is found,
contact the last carrier immediately.
General Information
These instructions are intended as a general guide and
do not supersede national or local codes in any way. Consult authorities having jurisdiction before installation.
The HP40 unit is CE marked" in accordance with the requirements of the latest European Directives for Electrical
and Machinery Safety and Electromagnetic Compatibility.
In addition, HP40 units have type Approval Certification
with the Gas Appliance Directive.
IMPORTANT
International Legislation bans the intentional venting of refrigerant (CFCs and HCFCs). Approved
methods of recovery, recycling or reclaiming must
be followed. Fines and/or incarceration may be levied for noncompliance.
Litho U.S.A.
Page 2
Unit Dimensions − mm
SIDE VIEW
VAPOR &
LIQUID LINE
CONNECTION
INLET
AIR
INLET
AIR
DISCHARGE AIR
SIDE VIEW
TOP VIEW
A
OUTDOOR
COIL FAN
COMPRESSOR
INLET AIR
INLET AIR
B
70
HP40
ELECTRICAL
INLETS
111
162
162
TOP VIEW BASE SECTION
51
19
111
111
111111
111
COMPRESSOR
COIL DRAIN OUTLETS
(Around perimeter of base)
OPTIONAL
STAND-OFF KIT
(Field−installed
4 required)
LIQUID LINE
CONNECTION
VAPOR LINE
CONNECTION
C
C
OPTIONAL
STAND-OFF KIT
(Field−installed
4 required)
Model Number A B C
HP40-018
HP40-024
mm 635 616 616
HP40-036
HP40-048
mm 838 819 616
HP40-060 mm 946 927 718
Page 3
Setting the Unit
Heat pump 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. Maintain a minimum clearance of 610
mm between multiple units. Refer to figure 1 for installation clearances.
36
(914 mm)
Installation Clearances
36*
(914 mm)
*NOTE − A service clearance of 30" (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" (914 mm).
Clearance to one of the remaining two sides may be 12" (304
mm) and the final side may be 6" (152 mm).
36*
(914 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).
36
(914 mm)
FIGURE 1
1 − Place a sound-absorbing material, such as Isomode,
under the unit if it will be installed in a location or position that will transmit sound or vibration to the living
area or adjacent buildings.
2 − Install the unit high enough above the ground or roof
to allow adequate drainage of defrost water and prevent ice buildup.
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 a support frame is constructed, it
must not block drain holes in the base of the unit.
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 unit away from overhanging roof lines which
would allow water or ice to drop on, or in front of, coil
or into unit.
Slab Mounting (See figure 2)
When the unit is installed 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 unit. Slab
should have a slope tolerance away from the building of 2
degrees or 51 mm per 1.5 m. This will prevent ice from
building up under the unit during a defrost cycle. Refer to
roof mounting section for barrier construction if unit must
face prevailing winter winds.
SLAB MOUNTING AT GROUND LEVEL
DISCHARGE AIR
MOUNTING SLAB MUST SLOPE
AWAY FROM BUILDING.
GROUND LEVEL
STRUCTURE
FIGURE 2
Roof Mounting (See figure 3)
If you are unable to mount the unit coil away from prevailing winter winds, construct a wind barrier. Size the barrier
at least the same height and width as the outdoor unit.
Mount the barrier 610 mm from the sides of the unit in the
direction of prevailing winds.
Install the unit at a minimum of 152 mm above the roof
surface to keep ice from building 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.
WIND BARRIER
INLET AIR
INLET AIR
INLET AIR
INLET AIR
PREVAILING WINTER WINDS
ROOFTOP APPLICATION
WIND BARRIER CONSTRUCTION
FIGURE 3
Page 4
Electrical
Wiring must conform with current local codes. An application diagram is included in this instruction and in the indoor
unit instructions.
Refer to the unit rating plate, located on the control box cover, for minimum circuit ampacity and maximum fuse size.
1 − Provide line voltage power supply to the unit from a
properly sized disconnect switch. The disconnect
switch should be located so that it is easily accessible
and within sight of the unit.
2 − Route the power and ground wires from the discon-
nect switch to the unit. The electrical openings are
provided under the control box cover. See the unit di-
mensions illustration on page 2.
3 − Remove the control box cover and connect the power
wiring to the contactor. Connect ground wire to ground
lug.
4 − Install the room thermostat (ordered separately) in
the conditioned area. Place the thermostat where it
will not be affected by sunlight, drafts, or vibration. Do
not install the thermostat on an outside wall. The most
desirable position for the thermostat is near the center of the conditioned area and approximately 1.5 m
from the floor.
5 − Route 24VAC control wires from the thermostat to the
indoor unit and from the indoor unit to the defrost control terminals in the outdoor unit as shown in figure 4.
FIELD WIRING DIAGRAM FOR HP40 UNIT
W2
C
W1
G
O
Y1
S1 THERMOSTAT
1
LOW VOLTAGE
FIELD INSTALLED
1
EMERGENCY HEAT RELAY (USED ONLY
IF OUTDOOR THERMOSTAT IS USED)
FIELD PROVIDED AND INSTALLED NEAR
INDOOR UNIT 24VAC 5VA MAX NEC
CLASS 2.
2
NOTE−ALL REMAINING WIRES FACTORY INSTALLED
3
HP40
LOW VOLTAGE
TERMINAL
CONNECTIONS
THERMOSTAT HEAT ANTICIPATION SETTING .4 AMP ELECTRIC HEAT FOR THERMOSTATS WITH ADJUSTABLE ANTICIPATORS.
IF OUTDOOR THERMOSTAT IS USED, REMOVE JUMPER BETWEEN TERMINALS R"
AND W2."
R
Y2
E
COMMON
BEIGE (ELECTRIC HEAT)
ORANGE
YELLOW (COMPRESSOR)
RED (POWER)
TB1 TERMINAL STRIP
(INDOOR UNIT CONTROL BOX)
C
G
W1
W2
W3
R
S23
EM HEAT RELAY K26
OUTDOOR
THERMOSTAT
(IF USED)
2
3
R
C
O
W1
Y1
REVERSINNG VALVE
FIGURE 4
Page 5
Plumbing
Field refrigerant piping consists of liquid and vapor lines
from the heat pump (sweat connections) to the indoor
evaporator coil. Use Lennox L15 (sweat connection) 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.
If refrigerant tubes 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 15.2 m. Select line set diameters from table 1 to ensure that the oil
returns to the compressor.
TABLE 1
REFRIGERANT LINE SET KITS
HP40 UNIT
LIQUID
LINE
SUCTION
LINE
L15 LINE
SETS
HP40−024 8 mm* 16 mm
L15 − 21
4.6 m − 15 m
HP40−036 10 mm 19 mm
L15 − 41
4.6 m − 15 m
HP40−048 10 mm 22 mm
L15 − 65
4.6 m − 15 m
HP40−060 10 mm 29 mm
FIELD
FABRICATED
*Use the coupling reducer that is supplied in the bag assembly.
Sweat Connection Procedure
1 − The ends of refrigerant lines must be cut square, free
from nicks or dents and deburred. The pipe must remain round. Do not pinch the end of the line.
2 − Wrap a wet cloth around the liquid line valve body and
copper tube stub to protect them from heat damage
during brazing. Wrap another wet cloth underneath
the liquid valve to protect the base paint.
3 − Quench the joints with a wet cloth to prevent possible
heat damage to the valve core and opening port.
Refrigerant Metering Device
HP40 units are applicable to thermal expansion valve
systems only. An expansion valve appropriate for use
with R407C refrigerant is shipped with the outdoor unit.
IMPORTANT
Failure to remove an existing refrigerant flow control orifice when installing an expansion valve on
the indoor coil will result in improper operation and
damage to the system.
Flushing Existing Line Set and Indoor Coil
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 R407C refrigerant. Polyol ester oils
are not compatible with mineral oils. 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.
CAUTION
This procedure should not be performed on systems which contain contaminants (Example:
compressor burn out).
Required Equipment
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 or use with R22 and
one for use with the R407C).
Flushing Procedure
1 − Remove existing R22 refrigerant using the appropri-
ate 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 out-
door 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 vapor 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 sys-
tem in the cooling mode and close the liquid line
valve. Pump all of the existing R22 refrigerant back
into the outdoor unit. (It may be necessary to bypass
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