Lennox HPXA12 SERIES, HPXA12−018, HPXA12−024, HPXA12−030, HPXA12−036 Installation Instructions Manual
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®
INSTALLATION
2002 Lennox Industries Inc.
Dallas, Texas
HPXA12 Outdoor Unit
HPXA12 Elite® outdoor units use R410A, which is an ozone
friendly HFC refrigerant. This unit must be installed with a
matching indoor blower coil and line set as outlined in the
Lennox Engineering Handbook. HPXA12 outdoor units are
designed for use in expansion valve systems only. They
are not designed to be used with other refrigerant flow control devices. An expansion valve approved for use with
R410A must be ordered separately and must be installed
prior to operating the unit.
INSTRUCTIONS
HPXA12 SERIES UNITS
HEAT PUMP UNITS
504,777M
05/04
Supersedes 02/04
Table of Contents
HPXA12 Outdoor Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping & Packing List 1. . . . . . . . . . . . . . . . . . . . . . . . .
General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Unit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Piping 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Existing Line Set & Indoor Coil 6. . . . . . . . . . .
Refrigerant Metering Device 7. . . . . . . . . . . . . . . . . . . . .
Manifold Gauge Set 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Valves 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Operation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defrost System 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Accessories 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Homeowner Information 18. . . . . . . . . . . . . . . . . . . . . . . .
HPXA12 Check List 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Litho U.S.A.
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox’ Engineering Handbook. Coils
previously charged with R22 must be flushed
Shipping & Packing List
1 − Assembled HPXA12 outdoor unit
Check the unit components for shipping damage. If you find
any damage, immediately contact the last carrier.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFC’s, HFC’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.
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.
05/04
*2P0504*
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
504,777M
*P504777M*
Unit Dimensions − inches (mm)
HPXA12−048
INLET AIR
INLET
AIR
INLET AIR
Top View
A
INLET
AIR
VAPOR LINE
CONNECTION
LIQUID LINE
CONNECTION
Model No. A B C
HPXA12−018
HPXA12−024
in. 24-1/4 33−1/4 32-1/2
HPXA12−030
HPXA12−036
HPXA12−042
HPXA12−048
HPXA12−060
mm 616 845 826
in. 28-1/4 37−1/4 36-1/2
mm 718 946 927
A
OUTDOOR
COIL FAN
DISCHARGE AIR
Side View
3/4
(19)
BC
ELECTRICAL
INLETS
2 (51)
COMPRESSOR
LIQUID LINE
CONNECTION
OPTIONAL UNIT
STAND-OFF KIT (4)
(Field Installed)
VAPOR &
2-3/4 (70)
Side View
Page 2
Setting the Unit
CAUTION
In order to avoid injury, take proper precaution when
lifting heavy objects.
4 - When installed in areas where low ambient tempera-
tures exist, locate 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.
CAUTION
Sharp sheet metal edges can cause injury. When
installing the unit, avoid accidental contact with
sharp edges.
Outdoor units operate under a wide range of weather conditions; therefore, several factors must be considered
when positioning the outdoor unit. Unit must be positioned
to give adequate clearances for sufficient airflow and servicing. A minimum clearance of 24 inches (610 mm) between
multiple units must be maintained. Refer to figure 1 for
installation clearances.
Installation Clearances
as
noted
as
noted
as
noted
Slab Mounting−Figure 2
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 2.
The slab should have a slope tolerance away from the
building of 2 degrees or 2 inches per 5 feet (51 mm per
1524 mm). This will prevent ice build-up under the unit during a defrost cycle. Refer to roof mounting section for barrier construction if the unit must face prevailing winter winds.
Slab Mounting At Ground Level
STRUCTURE
DISCHARGE AIR
as
noted
*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" (305
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 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 - Mount unit high enough above ground or roof to allow
adequate drainage of defrost water and prevent ice
build-up.
3 - In heavy snow areas, do not locate unit where drifting
will occur. The unit base should be elevated above the
depth of average snows.
NOTE - Elevation of the unit may be accomplished by
constructing a frame using suitable materials. If a support frame is constructed, it must not block drain holes
in unit base.
MOUNTING SLAB MUST SLOPE
AWAY FROM BUILDING.
GROUND LEVEL
Figure 2
Roof Mounting−Figure 3
Install unit a minimum of 6 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.
Rooftop Application
Wind Barrier Construction
PREVAILING WINTER WINDS
WIND BARRIER
INLET AIR
INLET AIR
INLET AIR
INLET AIR
Figure 3
Page 3
If unit coil cannot be mounted away from prevailing winter
winds, construct a wind barrier. Size barrier at least the
same height and width as the outdoor unit. Mount barrier 24
inches (610 mm) from the sides of the unit in the direction of
prevailing winds.
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.
Refer to figure 4 for high voltage 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 figures 5 and 6.
NOTE − 24V, Class II circuit connections are made in
the low voltage junction box.
Typical Field Wiring Diagram
Figure 4
Page 4
HPXA12 and Blower Unit
Thermostat Designations
(Some connections may not apply.
Refer to specific thermostat and indoor unit.)
Thermostat
Indoor
Unit
R
C
W1
G
O
Y1
power
common common
1st. stage aux. heat
indoor blower
reversing valve
compressor
R
C
W1
W2
W3
G
1st. stage aux. heat
power
Outdoor
Unit
R
C
W1
O
Y1
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.
Plumbing Connections
HPXA12 Matched with New Indoor Coil and Line Set
If you are replacing an existing coil that is equipped
with a liquid line functioning as a metering orifice, replace the liquid line prior to installing the HPXA12 unit.
See table 1.
Table 1
Refrigerant Line Sets
Model
Valve Field Size
Connections
Liquid
Line
Vapor
Line
Recommended Line Set
Liquid
Line
Vapor
Line
L15
Line Sets
Figure 5
Outdoor Unit and Blower Unit
Thermostat Designations
(with auxiliary heat)
(Some connections may not apply.
Refer to specific thermostat and indoor unit.)
Thermostat
R
C
emergency heat
E
W1
1st. stage aux. heat
indoor blower
G
reversing valve
O
compressor
Y1
Indoor
Unit
power
common common
R
C
em.
heat rly
W1
1st. stage aux. heat
W2
W3
G
Outdoor
power
outdoor t’stat
Unit
R
C
W1
O
Y1
Figure 6
Refrigerant Piping
If the HPXA12 unit is being installed with a new indoor coil
and line set, the plumbing connections should be made as
outlined in this section. If an existing line set and/or indoor
coil is going to be used to complete the HPXA12 system,
refer to the following section that includes flushing procedures.
−18
−24
−30
−36
−42
−48
−60
3/8 in.
(10 mm)
3/8 in.
(10 mm)
3/8 in.
(10 mm)
3/4 in.
(19 mm)
7/8 in.
(22 mm)
1−1/8 in.
(29 mm)
3/8 in.
(10 mm)
3/8 in.
(10 mm)
3/8 in.
(10 mm)
3/4 in.
(19 mm)
7/8 in.
(22 mm)
1−1/8 in.
(29 mm)
L15−41
15 ft. − 50 ft.
(4.6 m − 15 m)
L15−65
15 ft. − 50 ft.
(4.6 m − 15 m)
Field
Fabricated
NOTE − Units are designed for line sets of up to fifty feet
(15m).
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 7 shows how to install line sets on
vertical runs. Figure 8 shows how to install line sets on
horizontal runs. Figure 9 shows how to make a transition
from horizontal to vertical. Finally, figure 10 shows how
to place the outdoor unit and line set.
Page 5
Refrigerant Line Sets
How To Install Vertical Runs
(new construction shown)
NOTE - Similar installation practices should be used if
line set is to be installed on exterior of outside wall.
Outside Wall
Wood Block
Between Studs
Liquid Line
Vapor Line
(wrapped with Armaflex)
Outside Wall
IMPORTANT - Refrigerant
lines must not contact wall.
Liquid LineVapor Line
Wire Tie
Inside Wall
Strap
Sleeve
Wire Tie
Wood Block
Wire Tie
Caulk
PVC Pipe
Fiberglass
Insulation
IMPORTANT - Refrigerant
lines must not contact
structure.
Strap
Sleeve
Figure 7
Page 6
Installing Horizontal Runs
To hang line set from joist or rafter,
use either metal strapping material
or anchored heavy nylon wire ties.
Floor Joist or
Roof Rafter
Refrigerant Line Sets:
Wire Tie
(around vapor line only)
8 feet
Tape or Wire Tie
8 feet
Strapping Material (around vapor line only)
Tape or Wire Tie
Metal Sleeve
Floor Joist or Roof Rafter
Strap the vapor line to the joist or rafter at 8 ft.
intervals then strap the liquid line to the vapor line.
Figure 8
Page 7
Refrigerant Line Sets:
Transition From Vertical To Horizontal
Anchored Heavy
Nylon Wire Tie
Wall
Stud
Metal
Sleeve
Vapor Line
Wrapped in
Armaflex
Strap Liquid Line
To Vapor Line
Liquid Line
Figure 9
Automotive
Muffler-Type
Hanger
Wall
Stud
Metal
Sleeve
Strap Liquid Line
To Vapor Line
Liquid Line
Vapor Line
Wrapped in
Armaflex
Outside Unit Placement and Installation
Install unit away from windows.
Two 90° elbows
installed in line set
will reduce line set
vibration.
Figure 10
Page 8
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