Lennox HPXA15-024, HPXA15-036, HPXA15 SERIES, HPXA15-030, HPXA15-048 Installation Instructions Manual
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INSTALLATION
2002 Lennox Industries Inc.
Dallas, Texas
HPXA15 Outdoor Unit
HPXA15 outdoor units use R410A 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. HPXA15 outdoor units are designed for use in expansion valve (TXV) systems only.
They are not designed to be used with other refrigerant flow
control devices. An expansion valve approved for use with
R410A has been shipped with the unit and must be
installed prior to operating the unit.
Shipping and Packing List
INSTRUCTIONS
HPXA15 SERIES UNITS
HEAT PUMP UNITS
504,713M
02/04
Supersedes 12/02
Table of Contents
HPXA15 Outdoor Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping & Packing List 1. . . . . . . . . . . . . . . . . . . . . . . . .
General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Unit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Piping 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Existing Line Set & Indoor Coil 10. . . . . . . . . .
Manifold Gauge Set 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Valves 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defrost System 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HPXA15 Check Points 21. . . . . . . . . . . . . . . . . . . . . . . . .
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox’ Engineering Handbook. Coils
previously charged with R22 must be flushed.
Litho U.S.A.
1 − Assembled HPXA15 outdoor unit
2 − Grommets (for liquid and vapor lines)
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
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.
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.
02/04
*2P0204*
Page 1
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
504,713M
*P504713M*
Dimensions −− Inches (mm)
HPXA15-030
HPXA15-048
inlet
air
inlet
air
compressor
inlet air
Top View
B
inlets
electrical
C
coil drain outlets
(around perimeter
of base)
discharge air
vapor
line inlet
A
4-1/2 (114)
H
liquid
D
2-9/16
(65)
line inlet
K
J
4-7/8 (22)
2
(51)
K
J
G
2
(51)
2-3/4
(70)
1-3/8
(35)
4
(102)
F
E
Side ViewService Access
Model No. A B C D E F G H J K
HPXA15-024
HPXA15-030
HPXA15-036
HPXA15-042
HPXA15-048
HPXA15−060
in. 27-7/8 25-7/8 29-7/8 12-1/4 22-7/16 14-7/16 22-1/8 16-3/4 2-7/8 5-1/2
mm 708 657 759 311 570 367 562 425 730 140
in. 30-7/8 32-1/8 34-1/16 12-3/4 26-5/8 18-5/8 28-1/8 17-1/4 3-7/8 7-1/2
mm 784 816 865 324 676 473 718 438 98 191
in. 34-7/8 32-1/8 34-1/16 13-3/4 26-5/8 18-5/8 28-1/8 18-1/4 3-7/8 7-1/2
mm 886 816 865 349 676 473 718 464 98 191
in. 44-7/8 32-1/8 34-1/16 14-1/4 26-5/8 18-5/8 28-1/8 18-3/4 3-7/8 7-1/2
mm 1140 816 865 362 676 473 718 476 98 191
4
(102)
6-1/16
(154)
Page 2
Parts Arrangement
dual capacitor
high pressure
switch
filter/drier
expansion valve
with internal check valve
defrost
thermostat
distributor
compressor
terminal box
defrost control/timed−off control
compressor
crankcase
heater
contactor
ground lug
sensing bulb
vapor line
service valve
and gauge port
liquid line
service valve
and gauge port
crankcase heater
thermostat
(2−1/2 through
5−ton units)
reversing valve
and solenoid
muffler
Figure 1
Setting the Unit
CAUTION
In order to avoid injury, take proper precaution when
lifting heavy objects.
CAUTION
Sharp sheet metal edges can cause injury. When
installing the unit, avoid accidental contact with
sharp edges.
These 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 24 inches (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 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.
Installation Clearances
*36"
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).
36"
(914 mm)
(914 mm)
*36"
(914 mm)
36"
(914 mm)
Figure 2
4 − When installed in areas where low ambient tempera-
tures exist, locate unit so winter prevailing winds do
not blow directly into outdoor coil.
Page 3
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
When installing unit at grade level, top of slab should be
high enough above the grade so that water from higher
ground will not collect around 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). This will
prevent ice build−up under unit during a defrost cycle. Refer
to roof mounting section for barrier construction if unit must
face prevailing winter winds.
Rooftop Application
Wind Barrier Construction
prevailing winter winds
wind barrier
inlet air
(610 mm)
INLET
AIR
24"
2 degrees or
2 in. per 5 foot
(51 mm per 1.5 m)
slope tolerance away
from building structure
ground level
Slab Mounting
discharge air
building
structure
mounting
slab
Figure 3
Roof Mounting
Install the 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.
If unit coil cannot be mounted away from prevailing winter
winds, a wind barrier should be constructed. See figure 3.
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.
inlet air
Figure 4
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.
Page 4
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
Typical Field Wiring Diagram
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.
Figure 5
Page 5
Outdoor Unit and Blower Unit
Thermostat Designations
(Some connections may not apply.
Refer to specific thermostat and indoor unit.)
Thermostat
R
C
1st. stage aux. heat
W1
G
O
Y1
Indoor
Unit
power
common common
indoor blower
reversing valve
compressor
R
C
W1
W2
W3
G
power
1st. stage aux. heat
Outdoor
Unit
R
C
W1
O
Y1
Figure 6
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 7
Refrigerant Piping
If the HPXA15 unit is being installed with a new indoor coil
and line set, the refrigerant 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 HPXA15 system, refer to the following section which includes flushing procedures.
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.
Refrigerant Connections
HPXA15 Matched with New Indoor Coil and Line Set
If an existing indoor coil which was equipped with an
RFCI metering device is being replaced, the liquid line
must also be replaced prior to the installation of the
HPXA15 unit.
Table 1
Refrigerant Line Sets
Valve Field Size
Connections
Model
−024
−030
−036
−042
−048
−060
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 − Units are designed for line sets of up to 50 feet (15
m). For applications longer than 50 feet, consult the Lennox 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:
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
15 ft. − 50 ft.
4.6 m − 15 m
15 ft. − 50 ft.
4.6 m − 15 m
L15
Line Sets
L15−41
L15−65
Field
Fabricated
Page 6
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.
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.
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.
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 8
Page 7
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