Lennox HSXA15, HSXA15-030, HSXA15-024, HSXA15-042, HSXA15-036 Installation Instructions Manual

INSTALLATION

2001 Lennox Industries Inc.

Dallas, Texas

HSXA15 Outdoor Unit

HSXA15 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. HSXA15 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 and filter drier approved for use with R410A
have been shipped with the unit. These components must
be installed prior to unit operation. Failure to install the

provided filter drier will void the warranty.

INSTRUCTIONS

HSXA15 SERIES UNITS

CONDENSING UNITS

504,668M
02/04

Supersedes 12/02

Table of Contents

HSXA15 Outdoor Unit 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Setting The Unit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Refrigerant Piping 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Existing Line Set & Indoor Coil 6. . . . . . . . . . .

Manifold Gauge Set 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Valves 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leak Testing 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evacuation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charging 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Accessories 13. . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up & Performance Check List 13. . . . . . . . . . . . . .

Retain These Instructions

For Future Reference

Litho U.S.A.

Shipping & Packing List

1 − Assembled HSXA15 outdoor unit
1 − Filter/Drier (approved for use with R410A systems)
1 − Expansion valve (approved for use with R410A)
2 − Grommets (for liquid and suction lines)
1 − Bushing (for low voltage wiring)

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

This unit must be matched with an indoor coil as
specified in Lennox’ Engineering Handbook. Coils
previously charged with HCFC−22 must be flushed.

02/04

*2P0204*

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

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

504,668M

Page 1

*P504668M*

Unit Dimensions – Inches (mm)

HSXA15

Outdoor Unit

AIRINLET

INLET

COMPRESSOR

AIR

AIRINLET

C

4

(102)

E

2

(51)

B

JJ

H

4-7/8 (22)

G

ELECTRICAL

INLETS

VAPOR LINE

INLET

A

LIQUID

LINE INLET

H

2

(51)

4-1/2 (114)

2-3/4 (70)

D

1-3/8

(35)

2-9/16

(65)

4

(102)

TOP VIEW

DISCHARGE AIR

F

SIDE VIEWACCESS VIEW

Model No. A B C D E F G H J

HSXA15-024

HSXA15-030,
HSXA15-036,
HSXA15-042

HSXA15-048

HSXA15-060

in. 27-7/8 25-7/8 29-7/8 12-1/4 22-7/16 14-7/16 22-1/8 2-7/8 5-1/2
mm 708 657 759 311 570 367 562 73 140

in. 30-7/8 32-1/8 34-1/16 12-3/4 26-5/8 18-5/8 28-1/8 3-7/8 7-1/2

mm 784 816 865 324 676 473 718 98 191

in. 34−7/8 32-1/8 34-1/16 13-3/4 26-5/8 18-5/8 28-1/8 3-7/8 7-1/2
mm 886 816 865 349 676 473 718 98 191
in. 40-7/8 32-1/8 34-1/16 19-3/4 26-5/8 18-5/8 28-1/8 3-7/8 7-1/2
mm 1038 816 865 502 676 473 718 98 191

6-1/16

(154)

Page 2

Parts Arrangement

CONDENSER FAN

(NOT SHOWN)

TOP OF CABINET

RUN CAPACITOR

GROUND LUG

CONTACTOR

COMPRESSOR POWER

TERMINALS

HIGH PRESSURE

SWITCH

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.

Refer to unit dimensions for sizing mounting slab, plat­forms or supports. Refer to figure 2 for installation clear­ances.

VAPOR VALVE

AND GAUGE PORT

LIQUID LINE

SERVICE VALVE

AND GAUGE

COMPRESSOR

LOW PRESSURE

SWITCH

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).

36"

(914 mm)

Figure 2

PORT

*36"

(914 mm)

*36"

(914 mm)

36"

(914 mm)

Page 3

A − Slab Mounting

When you install 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.
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). Refer
to the next section (roof mounting) 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

ground level

Slab Mounting

discharge air

building

structure

mounting

slab

Figure 3

B − Roof Mounting

Install unit at a minimum of 4 inches above surface of the roof.
Care must be taken to ensure weight of unit is properly distrib­uted over roof joists and rafters. Either redwood or steel sup­ports are recommended.

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.

24V, Class II circuit connections are made in the low
voltage junction box. Refer to figure 4 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 low voltage wiring from outdoor to indoor unit

and from thermostat to indoor unit. See figure 5.

Page 4

(LEADLESS)

Outdoor Unit

Field Wiring Diagram

YELLOW

Thermostat Designations

Thermostat Indoor Unit

R

W1

Y

G

C

power

heat

cooling

indoor blower

common

R

W

Y

G

C

Figure 4

NOTE − see unit wiring diagram for

power supply connections.

Outdoor Unit

Y1 Outdoor Unit

C Outdoor Unit

NOTE − If the indoor unit is not equipped with blower relay. It must be field−provided and installed (P−8−3251 or equivalent).

Figure 5

Page 5

Refrigerant Piping

Model

If the HSXA15 unit is being installed with a new indoor coil
and line set, the connections should be made as outlined in
this section. If an existing line set and/or indoor coil (used
with mineral oil) is going to be used to complete the
HSXA15 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.

Table 1

Refrigerant Line Sets

Model

No.

−024

−030

−036

−042

−048

−060

Valve Field Size

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)

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)

(4.6 m − 15 m)

(4.6 m − 15 m)

L15

Line Sets

L15−41

15 ft. − 50 ft.

L15−65

15 ft. − 50 ft.

Field

Fabricated

NOTE − Units are designed for line sets of up to fifty feet (15 m).
For applications longer than fifty 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:

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 6 shows how to install line sets on
vertical runs. Figure 7 shows how to install line sets on
horizontal runs. Figure 8 shows how to make a transition
from horizontal to vertical. Finally, figure 9 shows how to
place the outdoor unit and line set.

Page 6

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 6

Page 7

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 7

Page 8

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 8

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 9

Page 9

Refrigerant Connections

HSXA15 Matched with New Indoor Coil and Line Set
If an existing indoor coil that was equipped with an
RFCI metering device is being replaced, the liquid line
must also be replaced prior to the installation of the
HSXA15 unit.

If refrigerant lines are routed through a wall, seal and isolate
the opening so vibration is not transmitted to the building.

WARNING

Polyol ester (POE) oils used with R410A refrigerant

absorb moisture very quickly. It is very important

that the refrigerant system be kept closed as much

as possible. DO NOT remove line set caps or ser-

vice valve stub caps until you are ready to make

connections.

Flushing Existing Line Set & Indoor Coil

IMPORTANT

If this unit is being matched with an approved line
set or indoor coil which was previously charged
with mineral oil, 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 R410A refrigerant. 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.

Brazing Connection Procedure

1 − Cut ends of the refrigerant lines square (free from nicks

or dents). Debur the ends. The pipe must remain
round, do not pinch end of the line.

2 − Before making line set connections, use dry nitrogen to

purge the refrigerant piping. This will help to prevent
oxidation and the introduction of moisture into the sys­tem.

3 − Use silver alloy brazing rods (5 or 6 percent silver alloy

for copper−to−copper brazing or 45 percent silver alloy
for copper−to−brass or copper−to−steel brazing) which
are rated for use with R410A refrigerant. Wrap a wet
cloth around the valve body and the copper tube stub.
Remove light maroon washers from service valves and
shield light maroon stickers in order to protect them
during brazing. Braze the line set to the service valve.

4 − Wrap a wet cloth around the valve body and copper

tube stub to protect it from heat damage during braz­ing. Wrap another wet cloth underneath the valve body
to protect the base paint.

NOTE − The tube end must stay bottomed in the fitting
during final assembly to ensure proper seating, sealing
and rigidity.

5 − Install the provided thermal expansion valve (ap-

proved for use with R410A refrigerant) in the liquid line
at the indoor coil.

6 − Install the provided filter drier (approved for use with

R410A refrigerant) in the liquid line as close as pos­sible to the expansion device. Do not leave the filter

drier uncapped for more than 10 to 15 minutes
prior to brazing, evacuation and leak testing.
Polyol ester oils used in this system absorb mois­ture quickly. Failure to install the filter drier 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 HCFC−22 recov­ery bottles, an oilless recovery machine with a pump down
feature, and two sets of gauges (one for use with HCFC−22
and one for use with the R410A).

Flushing Procedure

1 − Remove existing HCFC−22 refrigerant using the ap-

propriate 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 HCFC−22 refrig­erant to flush the system – Disconnect all power to

the existing outdoor unit. Connect to the existing unit,
a clean recovery cylinder and the recovery machine
according to the instructions provided with the recov­ery machine. Remove all HCFC−22 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
HCFC−22 refrigerant to flush the system – Start the

existing HCFC−22 system in the cooling mode and
close the liquid line valve. Pump all of the existing
HCFC−22 refrigerant back into the outdoor unit. (It may
be necessary to bypass the low pressure switches to
ensure complete refrigerant evacuation.) When the
low side system pressures reach 0 psig, close the va-

Page 10

por line valve. Disconnect all power to the existing out­door unit. Refer to gauges after shutdown to confirm
that the valves are not allowing refrigerant to flow back
into the low side of the system. Disconnect the liquid
and vapor lines from the existing outdoor unit.

2 − Remove the existing outdoor unit. Set the new R410A

unit and follow the brazing connection procedure
which begins on the previous page to make line set
connections. DO NOT install provided R410A

check/expansion valve at this time.

Make low voltage and line voltage connections to the
new outdoor unit. DO NOT turn on power to the unit

or open the outdoor unit service valves at this time.

Flushing Connections

Inverted HCFC−22 Cylinder

(Contains clean HCFC−22 to be

used for flushing)

3 − Remove the existing refrigerant flow control orifice or

thermal expansion valve before continuing with flush­ing procedures. The existing devices are not ap­proved for use with R410A refrigerant and may pre­vent proper flushing. Use a field−provided fitting to re­connect the lines.

IMPORTANT

The line set and indoor coil must be flushed with at
least the same amount of clean refrigerant that pre­viously charged the system. Check the charge in
the flushing cylinder before proceeding.

Existing

Indoor Coil

RECOVERY

CYLINDER

EXISTING VAPOR LINE

EXISTING LIQUID LINE

VAPOR LINE

SERVICE VALVE

LIQUID LINE

SERVICE VALVE

TANK RETURN

INLET

DISCHARGE

RECOVERY MACHINE

Figure 10

HSXA15 UNIT

NOTE − The inverted HCFC−22
cylinder must contain at least
the same amount of refrigerant
as was recovered from the ex­isting system.

LOW

PRESSURE

GAUGE MANIFOLD

PRESSURE

HIGH

CLOSEDOPENED

Page 11

4 − Remove the pressure tap valve cores from the

HSXA15 unit’s service valves. Connect an HCFC−22
cylinder with clean refrigerant to the vapor service
valve. Connect the HCFC−22 gauge set to the liquid
line valve and connect a recovery machine with an
empty recovery tank to the gauge set.

5 − Set the recovery machine for liquid recovery and start

the recovery machine. Open the gauge set valves to
allow the recovery machine to pull a vacuum on the ex­isting system line set and indoor coil.

If you install a expansion valve with an indoor coil that
includes a fixed orifice, remove the orifice before the
expansion valve is installed.

Metering Device Installation

distributor

o−ring

expansion

valve

6 − Invert the cylinder of clean HCFC−22 and open its

valve to allow liquid refrigerant to flow into the system
through the vapor line valve. Allow the refrigerant to
pass from the cylinder and through the line set and the
indoor coil before it enters the recovery machine.

7 − After all of the liquid refrigerant has been recovered,

switch the recovery machine to vapor recovery so that
all of the HCFC−22 vapor is recovered. Allow the re­covery machine to pull a vacuum on the system.

NOTE − A single system flush should remove all of the
mineral oil from the existing refrigerant lines and in­door coil. A second flushing may be done (using clean
refrigerant) if insufficient amounts of mineral oil were
removed during the first flush. Each time the system

is flushed, you must allow the recovery machine
to pull a vacuum on the system at the end of the
procedure.

8 − Close the valve on the inverted HCFC−22 drum and

the gauge set valves. Pump the remaining refrigerant
out of the recovery machine and turn the machine off.

9 − Use nitrogen to break the vacuum on the refrigerant

lines and indoor coil before removing the recovery ma­chine, gauges and HCFC−22 refrigerant drum. Rein­stall pressure tap valve cores into HSXA15 service
valves.

10 −Install the provided expansion valve (approved for use

with R410A refrigerant) in the liquid line at the indoor
coil.

Refrigerant Metering Devices

Use HSXA15 units in TXV systems systems. See the Len-
nox Engineering Handbook for approved TXV match-ups
and application information.

o−ring

strainer

liquid line

stub

Figure 11

Manifold Gauge Set

Manifold gauge sets used with systems charged with
R410A refrigerant must be capable of handling the higher
system operating pressures. The gauges should be rated
for use with pressures of 0 − 800 on the high side and a low
side of 30" vacuum to 250 psi with dampened speed to 500
psi. Gauge hoses must be rated for use at up to 800 psi of
pressure with a 4000 psi burst rating.

Service Valves

The liquid line and vapor line service valves (figure 12) and
gauge ports are used for leak testing, evacuating, charging
and checking charge. See table 2 for torque requirements

Each valve is equipped with a service port which has a fac­tory−installed Schrader valve. A service port cap protects
the Schrader valve from contamination and serves as the
primary leak seal.

Table 2

Torque Requirements

Part Recommended Torque

Service valve cap 8 ft.− lb. 11 N M

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 N M

Expansion Valve Systems

Expansion valves equipped with either Chatleff or flare
type fittings are available from Lennox. Refer to the Engi­neering Handbook for expansion valves for use with specif­ic match−ups. See figure 11 for installation of the expansion
valve.

To Access Schrader Port:

1 − Remove access panel.
2 − Remove service port cap with an adjustable wrench.
3 − Connect gauge to the service port.
4 − When testing is complete, replace service port cap.

Tighten finger tight, then an additional 1/6 turn.

Page 12

To Open Service Valve:

1 − Remove stem cap with an adjustable wrench.
2 − Use a service wrench with a hex−head extension to

back the stem out counterclockwise as far as pos­sible.

NOTE − Use a 3/16" hex head extension for liquid line
sizes or a 5/16" extension for vapor line sizes.

3 − Replace the stem cap. Tighten finger tight, then tighten

an additional 1/6 turn.

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.

WARNING

Service Valve

(Valve Closed)

service

port

to outdoor coil

service

port cap

Schrader valve open

to line set when valve is

closed (front seated)

wrench here

(valve front seated)

stem cap

insert hex

to indoor coil

Service Valve

insert hex

wrench here

to outdoor coil

service port

cap

(Valve Open)

service

port

Schrader

valve

stem cap

to indoor coil

Figure 12

To Close Service Valve:

1 − Remove the stem cap with an adjustable wrench.
2 − Use a service wrench with a hex−head extension to

turn the stem clockwise to seat the valve. Tighten it
firmly.

NOTE − Use a 3/16" hex head extension for liquid line
sizes or a 5/16" extension for vapor line sizes.

3 − Replace the stem cap. Tighten finger tight, then tighten

an additional 1/6 turn.

Leak Testing

After the line set has been connected to the indoor and
outdoor units, check the line set connections and indoor
unit for leaks.

Danger of explosion: Can cause
equipment damage, injury or death.
Never use oxygen to pressurize a re­frigeration or air conditioning system.
Oxygen will explode on contact with
oil and could cause personal injury.

WARNING

Danger of explosion: Can cause equipment damage,
injury or death. When using a high pressure gas
such as dry nitrogen to pressurize a refrigeration or
air conditioning system, use a regulator that can
control the pressure down to 1 or 2 psig (6.9 to 13.8
kPa).

Using an Electronic Leak Detector

1 − Connect the high pressure hose of the manifold gauge

set to the vapor valve service port. (Normally, the high

pressure hose is connected to the liquid line port, how­ever, connecting it to the vapor port helps to protect the
manifold gauge set from damage caused by high pres­sure.)

2 − With both manifold valves closed, connect the cylinder

of R410A refrigerant to the center port of the manifold
gauge set. Open the valve on the R410A cylinder (va­por only).

3 − Open the high pressure side of the manifold to allow

R410A into the line set and indoor unit. Weigh in a trace
amount of R410A. [A trace amount is a maximum of 2

ounces (57 g) refrigerant or 3 pounds (31 kPa) pres­sure.] Close the valve on the R410A cylinder and the

valve on the high pressure side of the manifold gauge
set. Disconnect R410A cylinder.

4 − Connect a cylinder of nitrogen with a pressure regulat-

ing valve to the center port of the manifold gauge set.

5 − Adjust nitrogen pressure to 150 psig (1034 kPa). Open

the valve on the high side of the manifold gauge set in
order to pressurize the line set and the indoor coil.

6 − After a few minutes, open a refrigerant port to check

that an adequate amount of refrigerant has been add­ed for detection (refrigerant requirements will vary
with line lengths). Check all joints for leaks. Purge ni­trogen and R410A mixture. Correct any leaks and re­check.

Page 13

IMPORTANT

Leak detector must be capable of sensing HFC re-

frigerant.

Evacuation

Evacuating the system of noncondensables is critical for
proper operation of the unit. Noncondensables are defined
as any gas that will not condense under temperatures and
pressures present during operation of an air conditioning
system. Noncondensables and water vapor combine with
refrigerant to produce substances that corrode copper pip­ing and compressor parts.

IMPORTANT

Use a thermocouple or thermistor electronic vacuum

gauge that is calibrated in microns. Use an instrument

that reads from 50 microns to at least 10,000 microns.

1 − Connect manifold gauge set to the service valve ports :

 low pressure gauge to vapor line service valve
 high pressure gauge to liquid line service valve

2 − Connect micron gauge.

3 − Connect the vacuum pump (with vacuum gauge) to the

center port of the manifold gauge set.

4 − Open both manifold valves and start the vacuum

pump.

5 − Evacuate the line set and indoor unit to an absolute

pressure of 23,000 microns (29.01 inches of mercu­ry). During the early stages of evacuation, it is desir­able to close the manifold gauge valve at least once to
determine if there is a rapid rise in absolute pressure.
A rapid rise in pressure indicates a relatively large leak.
If this occurs, repeat the leak testing procedure.

NOTE − The term absolute pressure means the total
actual pressure within a given volume or system,
above the absolute zero of pressure. Absolute pres­sure in a vacuum is equal to atmospheric pressure mi­nus vacuum pressure.

6 − When the absolute pressure reaches 23,000 microns

(29.01 inches of mercury), close the manifold gauge
valves, turn off the vacuum pump and disconnect the
manifold gauge center port hose from vacuum pump.
Attach the manifold center port hose to a nitrogen cylin­der with pressure regulator set to 150 psig (1034 kPa)
and purge the hose. Open the manifold gauge valves
to break the vacuum in the line set and indoor unit.
Close the manifold gauge valves.

WARNING

Danger of Equipment Damage.
Avoid deep vacuum operation. Do not use com­pressors to evacuate a system.
Extremely low vacuums can cause internal arcing
and compressor failure.
Damage caused by deep vacuum operation will
void warranty.

7 − Shut off the nitrogen cylinder and remove the manifold

gauge hose from the cylinder. Open the manifold
gauge valves to release the nitrogen from the line set
and indoor unit.

8 − Reconnect the manifold gauge to the vacuum pump,

turn the pump on, and continue to evacuate the line set
and indoor unit until the absolute pressure does not
rise above 500 microns (29.9 inches of mercury) within
a 20−minute period after shutting off the vacuum pump
and closing the manifold gauge valves.

9 − When the absolute pressure requirement above has

been met, disconnect the manifold hose from the vacu­um pump and connect it to an upright cylinder of R410A
refrigerant. Open the manifold gauge valves to break
the vacuum from 1 to 2 psig positive pressure in the line
set and indoor unit. Close manifold gauge valves and
shut off the R410A cylinder and remove the manifold
gauge set.

Start−Up

1 − Rotate fan to check for frozen bearings or binding.

2 − Inspect all factory− and field−installed wiring for loose

connections.

3 − After evacuation is complete, open the liquid line and

vapor line service valves to release the refrigerant
charge (contained in outdoor unit) into the system.

4 − Replace the stem caps and secure finger tight, then

tighten an additional one-sixth (1/6) of a turn.

5 − Check voltage supply at the disconnect switch. The

voltage must be within the range listed on the unit’s
nameplate. If not, do not start the equipment until you
have consulted the power company and the voltage
condition has been corrected.

6 − Set the thermostat for a cooling demand. Turn on pow-

er to the indoor blower and close the outdoor unit dis­connect switch to start the unit.

7 − Recheck voltage while the unit is running. Power must

be within range shown on the nameplate.

Page 14

Charging

This system is charged with R410A refrigerant which oper­ates at much higher pressures than HCFC−22. The expan­sion valve and liquid line filter drier provided with the unit
are approved for use with R410A. Do not replace them with
components designed for use with HCFC−22. This unit is
NOT approved for use with coils which include metering
orifices or capillary tubes.

Processing Procedure

Units are factory charged with the amount of R410A refrig­erant indicated on the unit rating plate. This charge is
based on a matching indoor coil and outdoor coil with 15
feet (4.6 m) line set. For varying lengths of line set, refer to
table 3 for refrigerant charge adjustment.

Table 3

Liquid Line Set

Diameter

5/16 in

(8 mm)

3/8 in.

(10 mm)

*If line length is greater than 15 ft. (4.6 m), add this amount.
If line length is less than 15 ft. (4.6 m), subtract this amount.

Oz. per 5 ft. (grams per 1.5m) adjust

from 15 ft. (4.6 m) line set*

2 ounces per 5 feet

(57 g per 1.5 m)

3 ounces per 5 feet

(85 g per 1.5 m)

IMPORTANT

Mineral oils are not compatible with R410A. If oil
must be added, it must be a polyol ester oil.

The compressor is charged with sufficient polyol ester
oil for line set lengths up to 50 feet (15.2 m). If oil must
be added in the field, Copeland has approved Mobil
EALt Arctic 22CC and ICI EMKARATEt RL32CF for
use with these compressors.

If the system is void of refrigerant, clean the system us­ing the procedure described below.

1 − Use nitrogen to pressurize the system and check for

leaks. Repair leaks, if possible.

2 − Evacuate the system to remove as much of the mois-

ture as possible.

3 − Use nitrogen to break the vacuum and install the pro-

vided filter drier in the system.

4 − Evacuate the system again. Then, weigh the appropri-

ate amount of R410A refrigerant (listed on unit name­plate) into the system.

5 − Monitor the system to determine the amount of mois-

ture remaining in the oil. Use test kit 10N46 to verify
that the moisture content is within the kit’s dry color
range. It may be necessary to replace the filter drier
several times to achieve the required dryness level. If

system dryness is not verified, the compressor will
fail in the future.

The outdoor unit should be charged during warm weather.
However, applications arise in which charging must occur
in the colder months. The method of charging is deter-

mined by the unit’s refrigerant metering device and the
outdoor ambient temperature.

Measure the liquid line temperature and the outdoor ambi­ent temperature as outlined below:

1 − Connect the manifold gauge set to the service valves:

 low pressure gauge to vapor valve service port
 high pressure gauge to liquid valve service port

Connect the center manifold hose to an upright cylin­der of HCFC-22. Close manifold gauge set valves.

2 − Set the room thermostat to call for heat. This will create

the necessary load for properly charging the system in
the cooling cycle.

3 − Use a digital thermometer to record the outdoor ambi-

ent temperature.

4 − When the heating demand has been satisfied, switch

the thermostat to cooling mode with a set point of 68F
(20C). When pressures have stabilized, use a digital
thermometer to record the liquid line temperature.

5 − The outdoor temperature will determine which charg-

ing method to use. Proceed with the appropriate charg­ing procedure.

Weighing in the Charge Fixed Orifice or

TXV Systems – Outdoor Temp < 65F (18C)

If the system is void of refrigerant, or if the outdoor ambient
temperature is cool, the refrigerant charge should be
weighed into the unit. Do this after any leaks have been re­paired.

1 − Recover the refrigerant from the unit.

2 − Conduct a leak check, then evacuate as previously

outlined.

3 − Weigh in the unit nameplate charge.

If weighing facilities are not available or if you are charging
the unit during warm weather, follow one of the other proce­dures outlined below.

Charging Using Normal Operating Pressures

and the Approach Method

TXV Systems – Outdoor Temp. >

The following procedure is intended as a general guide and
is for use on expansion valve systems only. For best results,
indoor temperature should be 70°F (21°C) to 80°F (26°C).
Monitor system pressures while charging.

1 − Record outdoor ambient temperature using a digital

thermometer.

2 − Attach high pressure gauge set and operate unit for

several minutes to allow system pressures to stabilize.

3 − Compare stabilized pressures with those provided in

table 5, Normal Operating Pressures." Minor varia­tions in these pressures may be expected due to differ­ences in installations. Significant differences could
mean that the system is not properly charged or that a
problem exists with some component in the system.
Pressures higher than those listed indicate that the
system is overcharged. Pressures lower than those

65F (18C)

Page 15

listed indicate that the system is undercharged. Verify

Mod

Entering Air

pressures with the R410A refrigerant pressure chart in
table 6. Verify adjusted charge using the approach
method.

Approach Method

4 − Use the same digital thermometer you used to check

the outdoor ambient temperature to check the liquid
line temperature.

5 − The difference between the ambient and liquid temper-

atures should match values given in table 4. If the val­ues don’t agree with the those in table 4, add refriger­ant to lower the approach temperature, or recover re­frigerant from the system to increase the approach
temperature.

Normal Operating Pressure

(Liquid ±10 and Vapor ±5 psig)

TXV

Outdoor Coil

e

Temp. °F (°C)

Entering Air

65

(18.3)

75

(23.9)

85

(29.4)

95

(35.0)

105

(40.6)

HSXA15−024 HSXA15−030 HSXA15−036 HSXA15−042 HSXA15−048 HSXA15−060

Liquid Vapor Liquid Vapor Liquid Vapor Liquid Vapor Liquid Vapor Liquid Vapor

239 129 232 130 235 128 241 131 226 130 240 130

278 131 271 132 276 130 282 133 266 132 279 132

321 133 314 135 320 132 326 135 310 135 321 135

368 135 360 137 367 134 373 137 356 137 368 137

420 138 412 140 421 137 424 139 407 139 418 140

Table 4

Model Number

HSXA15−024 8 ± 1 (4.5 ± .5)
HSXA15−030 8 ± 1 (4.5 ± .5)

HSXA15−036 6 ± 1 (3.3 ± .5)

HSXA15−042 9 ± 1 (5 ± .5)

HSXA15−048 8 ± 1 (4.5 ± .5)

HSXA15−060 12 ± 1 (6.7 ± .5)

Liquid Line Temp. − Outdoor Ambient °F (°C)

NOTE − For best results, the same electronic thermometer
should be used to check both outdoor ambient and liquid line
temperatures.

Approach Temperature

Table 5

s

Page 16

Table 6

R410A Temperature/Pressure Chart

Temperature°FPressure

Psig

32 100.8 63 178.5 94 290.8 125 445.9

33 102.9 64 181.6 95 295.1 126 451.8

34 105.0 65 184.3 96 299.4 127 457.6

35 107.1 66 187.7 97 303.8 128 463.5

36 109.2 67 190.9 98 308.2 129 469.5

37 111.4 68 194.1 99 312.7 130 475.6

38 113.6 69 197.3 100 317.2 131 481.6

39 115.8 70 200.6 101 321.8 132 487.8

40 118.0 71 203.9 102 326.4 133 494.0

41 120.3 72 207.2 103 331.0 134 500.2

42 122.6 73 210.6 104 335.7 135 506.5

43 125.0 74 214.0 105 340.5 136 512.9

44 127.3 75 217.4 106 345.3 137 519.3

45 129.7 76 220.9 107 350.1 138 525.8

46 132.2 77 224.4 108 355.0 139 532.4

47 134.6 78 228.0 109 360.0 140 539.0

48 137.1 79 231.6 11 0 365.0 141 545.6

49 139.6 80 235.3 111 370.0 142 552.3

50 142.2 81 239.0 11 2 375.1 143 559.1

51 144.8 82 242.7 11 3 380.2 144 565.9

52 147.4 83 246.5 11 4 385.4 145 572.8

53 150.1 84 250.3 11 5 390.7 146 579.8

54 152.8 85 254.1 11 6 396.0 147 586.8

55 155.5 86 258.0 11 7 401.3 148 593.8

56 158.2 87 262.0 11 8 406.7 149 601.0

57 161.0 88 266.0 11 9 412.2 150 608.1

58 163.9 89 270.0 120 417.7 151 615.4

59 166.7 90 274.1 121 423.2 152 622.7

60 169.6 91 278.2 122 428.8 153 630.1

61 172.6 92 282.3 123 434.5 154 637.5

62 195.5 93 286.5 124 440.2 155 645.0

Temperature°FPressure

Psig

Temperature°FPressure

Psig

Temperature°FPressure

Psig

System Operation

The outdoor unit and indoor blower cycle on demand from
the room thermostat. When the thermostat blower switch is
in the ON position, the indoor blower operates continuously.

High Pressure Switch

HSXA15 units are equipped with a high pressure switch
that is located in the liquid line of the compressor. The
switch (SPST, manual reset, normally closed) removes
power from the compressor when discharge pressure rises
above factory setting at 640 + 10 psi.

Low Pressure Switch

HSXA15 units are also equipped with a low pressure switch
that is located in the vapor line of the compressor. The
switch (SPST, auto−reset, normally closed) removes power
from the compressor when vapor line pressure drops be­low factory setting at 40 + 5 psi.

Page 17

Filter Drier

A filter drier is shipped with each HSXA15 unit. The filter dri­er must be field installed in the liquid line between the liquid
line service valve and the expansion valve. This filter drier

must be installed to ensure a clean, moisture−free sys­tem. A replacement filter drier is available as Lennox part

no. 37L5201.

Maintenance

WARNING

Electric shock hazard. Can cause inju­ry or death. Before attempting to per­form any service or maintenance, turn
the electrical power to unit OFF at dis­connect switch(es). Unit may have
multiple power supplies.

Maintenance and service must be performed by a qualified
installer or service agency. At the beginning of each cooling
season, the system should be checked as follows:

1 − Clean and inspect the outdoor coil. The coil may be

flushed with a water hose. Ensure the power is turned
off before you clean the coil.

2 − Condenser fan motor is prelubricated and sealed. No

further lubrication is needed.

3 − Visually inspect connecting lines and coils for evidence

of oil leaks.

4 − Check wiring for loose connections.

5 − Check for correct voltage at unit (unit operating).

6 − Check amp−draw condenser fan motor.

Unit nameplate _________ Actual ____________ .

NOTE − If owner complains of insufficient cooling, the
unit should be gauged and refrigerant charge
checked. Refer to section on refrigerant charging in
this instruction.

Indoor Coil

1 − Clean coil, if necessary.

2 − Check connecting lines and coils for evidence of oil

leaks.

3 − Check condensate line and clean, if necessary.

Indoor Unit

1 − Clean or change filters.

2 − Adjust blower speed for cooling. Measure the pressure

drop over the coil to determine the correct blower CFM.
Refer to the unit information service manual for pressure
drop tables and procedure.

3 − Belt Drive Blowers − Check belt for wear and proper

tension.

4 − Check all wiring for loose connections

5 − Check for correct voltage at unit (blower operating).

6 − Check amp−draw on blower motor

Unit nameplate_________ Actual ____________.

Optional Accessories

Refer to the Engineering Handbook for optional accesso­ries that may apply to this unit. The following may or may
not apply:

 Loss of Charge Kit
 High Pressure Switch Kit
 Compressor Monitor
 Compressor Crankcase Heater
 Hail Guards
 Mounting Bases
 Timed Off Control
 Stand−off Kit
 Sound Cover
 Low Ambient Kit

Start−Up & Performance Check List

Job Name

Job Location
Installer

Unit Model No.
Nameplate Voltage

Rated Load Ampacity
Maximum Fuse or Circuit Breaker
Electrical Connections Tight?

Indoor Blower RPM
Discharge Pressure
Refrigerant Lines:

Service Valves Fully Opened?

Voltage With Compressor Operating

Leak Checked?

S.P. Drop Over Indoor (Dry)

Vapor Pressure

Start−up and Performance Check List

Job No.

City

City

Serial No.

Compressor

Indoor Filter Clean?

Properly Insulated?

Service Valve Caps Tight?

Calibrated? Properly Set?

Page 18

Outdoor Fan

Outdoor Coil Entering Air Temp.

Refrigerant Charge Checked?

Date

State

State

Service Technician

Supply Voltage (Unit Off)

Outdoor Fan Checked?

Thermostat

Level?