Lennox SPA036H4, SPA048H4, SPA060H4 Installation Instructions Manual

INSTALLATION

,t_2006 Lennox industries Inc,

Dallas, Texas, USA

WARNING

A IMPORTANT

CAUTION

INSTRUCTIONS

SPA Units

SPA036H4 (3 Ton)

SPA048H4 (4 Ton)
SPA060H4 (5 Ton)

S-CLASS " HEAT PUMP UNITS
504,867M

06/06
Supersedes 03/06

SPA Outdoor Unit ............................. 1

Shipping and Packing List ...................... 1

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

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

Parts Arrangement ............................ 2

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

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

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

Refrigerant Metering Device .................... 8

Flushing Existing Line Set & Indoor Coil .......... 8

Manifold Gauge Set ........................... 10

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

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

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

Start-Up ...................................... 12

Refrigerant Charging ........................... 13

System Operation ............................. 16

Defrost System ............................... 17

Maintenance .................................. 18

Optional Accessories .......................... 18

Start-Up and Performance Check List ............ 20

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

)puTeChnical

blications

Litho U.S.A.

The S-Class '" SPA outdoor units use R-410A HFC refrig-
erant. This unit must be installed with a matching indoor

coil and line set as outlined in the Lennox Engineering
Handbook. SPA outdoor units are designed for use in ex-

pansion valve (TXV) systems only. They are not designed
to be used with other refrigerant flow control devices. The

Lennox Engineering Handbook lists indoor TXV kits that
must be ordered separately.

06/06

IIIIIIIIIIIIIIIIIIIIIIIIIIIIHIIIIIIII

These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities

who have jurisdiction before installation.

Assembled SPA outdoor unit
Grommets (for liquid and vapor lines)

Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.

Page 1

504,867M

IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII

Dimen-

Model

sion SPA036 SPA048/060

Inches mm Inches mm

A 30-7/8 784 44-7/8 1140

B 32-1/8 816 32-1/8 816
C 34-1/16 865 34-1/16 865
D 12-3/4 324 14-1/4 362

E 26-5/8 676 26-5/8 676

F 18-5/8 473 18-5/8 473
G 28-1/8 718 28-1/8 718
H 17-1/4 438 18-3/4 476

J 3-7/8 98 3-7/8 98

K 7-1/2 191 7-1/2 191

VAPOR

INLET

TOP INLET

VIEW AIR

COMPRESSOR

ELECTRICAL

INLETS

X _ C r

INLETAIR

INLETAIR

DISCHARGEd&.

AIR BB

COIL DRAIN OUTLETS
(Around perimeter of base)

A

2 (51) -- G 2 (51)

RUN

CAPACITOR

DEFROST

CONTROL

DISCHARGE

LINE

COMPRESSOR

TERMINAL PLUG

TXV/CHECK

VALVE

VAPORLINE

DISCHARGE

TEMPERATURE

THERMOSTAT

LIQUID

LINE

INLET

4-

_" 1/2(114) 1: .......................................................................................................................................

n

T_

:: :__::_:;;................................................................

A 1102). I I I

2-3/4(70) F ----'1_"_ b

1-3/8 (35) _ _ 16-1/161

I:: "Yl (154)

INDEPENDENT
MOTOR MOUNT

CONTACTOR

TWO-STAGE

COMPRESSOR

VAPOR VALVE AND

GAUGE PORT

LOW PRESSURE

SWITCH

FILTER DRIER
CRANKCASE

HEATER
HIGH PRESSURE

SWITCH

SIDE
VIEW

504867M 06/06

Page 2

WARNING

CAUTION

These units operate under a wide range of weather condi-
tions; therefore, several factors must be considered when

positioning the outdoor unit. The unit must be positioned to
give adequate clearances for sufficient airflow and servic-

ing, Refer to figure 1 for installation clearances.

Installation Clearances

I AS NOTED TM

(762 _ AS NOTED
mm)

36" _}

I AS NOTEDj

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" (305 mm)
and the final side may be 6" (152 mm).

NO TE - 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 posi-
tion that will transmit sound or vibration to the to the

conditioned space.

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 sup-
port frame is constructed, it must not block drain holes

in unit base.

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,

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 2. 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. Re-

fer to roof mounting section for barrier construction if unit

must face prevailing winter winds,

Slab Mounting

2 degrees or

2 in. per 5 foot DISCHARGE

(51 mm per 1.5 m) AIR

slope tolerance away A
from building structure

-L[

BUILDING
STRUCTURE

:21-

ZZ-
CL

CZ-

GROUND

LEVEL

Figure 2

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,

Page 3

SPA SERIES

Rooftop Application with Wind Barrier

prevailir_Rer winds

wind barrier inlet

air

©

1

(610 ram)
24"

I

1

/r',

k_J

I
I •

©

inlet air

Figure 3

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).

WARNING l,

O inlet air

Refer to figure 4 for high voltage field wiring diagram.

NOTE -A complete unit wiring diagram is located in-
side the unit's access door.

NOTE - For proper voltages, select thermostat wire
gauge per the following chart:

Wire run length AWG # Insulation type

less than 100' (30m) 18 color-coded, temperature
more than 100' (30m) 16 rating 35°C minimum

3. Install room thermostat (ordered separately) on an inside
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 7.

NOTE - 24V, Class II circuit connections are made in
the low voltage junction box.

Three-Phase Scroll Voltage Phasing
Three-phase scroll compressors must be phased sequential-

ly to ensure correct compressor rotation and operation. In-
correct linevoltage phasing may cause compressor damage

and abnormal unit operation. Power wires are color-coded as
follows: Line 1 - red, line 2 - yellow, line 3 - blue.

To test for proper rotation and operation:

1. Install refrigeration gauges on system. Cycle compres-
sor "On" and observe that suction pressure decreases

and discharge pressure increases.

2. If pressures do not follow the above conditions, discon-
nect all power to unit. Reverse any two field-installed
main power wires to the lineside of the compressor con-

tactor. Make sure connections are tight. Repeat pres-
sure test with system.

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.

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 - Connect conduit to the unit using a proper
conduit fitting.

NO TE - Units are approved for use only with copper
conductors.

Typical Field Wiring Diagram

A 108 BROUND

_ DEFROST CONTROL LU6 _ "_C FAN

OUT _ sz_ "

OUTDOOR L LI

rAN

/ I _ ORAN6E-COM_ON _-PS Y2

PURPLE =

\_'_ C_]TOR ?[L _ Yl 2081

A ARNING! ELECTRIC SHOCK HAZARD! Can cause

cI o 230/

CAPACITOR =RV_---L o 3/60

For use with copper conductors only Refer to Unit rating

plate for minimum circuit ampacity and maximum overcur-
rent protection size.

injury or death. Unit must be grounded in accordance with
national and local codes.

C COMPRESSOR

-0UT K' A

K 195 SPEED

CONTACTOR

Figure 4

LZ

504867M 06/06

Page 4

Outdoor Unit, Blower Unit,

Thermostat Designations

SPA TB1 A2 Thermostat

(Some connections
may not apply.
Refer to specific

thermostat and in-
door unit,)

@--

©--
©--

@--

©--

$4 SZ3

HiGH $5 LOW

PRESSURE DISCH TEMP AMBIENT

SWITCH LIMIT

THERMOSTAT If¢7_,#_,/_%_I PLATE FOR MINIMUM CIRCUIT

©©

$87 LOW LI
PRESSURE REVERSING

SWITCH VALVE

RTIS

AMBIENT COIL ELECTRIC SHOCK HAZARD,CAN CAUSE INJURY
SENSOR SENSOR OR DEATH,UNIT MUST BE GROUNDED IN

©@

L_ ,C_

HR I CONTACT0 I A

_ _TA6rl _ L

)"L _

Indoor Unit

©E

GE ©1
@E @1

Figure 5

Typical SPA Wiring

DI_ z_ MOTE-

COMPRESSOR ONLY,REFER TO UNIT RATING

z:_ Z_ REFER TO COMPRESSOR IN UNIT

RT21 A FOR ACTUAL TERMINAL ARRANGEMENT.

DEFROST _ WARNING-

/_ ACCORDANCE WITH NATIONAL AND LOCAL CODES,

CE

CAPACITOR

FOR USE WITH COPPER CONDUCTORS

AMPACITY AND MAXIMUM OVER-
CURRENT PROTECTION SIZE

-,,e-_DENOTES OPTIONAL COMPONENTS

-- LINE VOLTAGE FIELD INSTALLED

-- -- -- CLASS II VOLTAGE FIELD INSTALLED

Be

FAN

LE

W

(I y KI

C K2 AN

Outdoor Unit, CB31MV/CB32MV,

Thermostat Designations

(Some connections may not apply,
Refer to specific thermostat and indoor unit.)

SPA T7300G

_ Thermostat

CB31MV

CBX32MV

TB1

®1

@-

@1
@1

@1
©1

I _>
I @-

©1

Figure 6

Z_ REMOVE JUMPER FOR TWO STAGE COOL
Z_ RTI4 SENSOR,OUTDOOR TEMP (OPTIONAL}
Z_ $25 CLOSES AT LOW AMBIENT TEMPERATURES

TO OPERATE SECOND STAGE COMPRESSOR

ON HEATING

z_ SII AND K58 ARE OPTIONAL LOW AMBIENT CONTROLS

Z_ L34,SECOND STAGE, SOLENOID IS LOCATED IN

COMPRESSOR. COIL IS 24VOC, DO NOT CONNECT
24VAO TO COIL TERMINALS.

CB31MV
CBXS2MV

TBI

F --

]
]

@-- -- __

_ y;i

A2

]

I

THERMOSTAT

T7300F

60L59
82N52

A_._

--{G>I

-{cYqs

-@ [

(B)

BE_

_ 8

EQUIPMENT c_
GROUND

KI-I

L_ _

+________] RV AMB

rIo£

c......................................I1 ?

z_ RTI3

Figure 7

Page 5

SPA SERIES

If the SPA 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 SPA system, refer

to the following section which includes flushing proce-
dures,

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, non-

flare) series line sets as shown in table 1 or use field-fabri-

cated refrigerant lines. Valve sizes are also listed in table 1.

Table 1

Refrigerant Line Sets

Valve Field Size

Model

036

048

060

Connections

Liquid Vapor

Line Line

3t8 in. 7/8 in.

10 mm 22 mm

3t8 in. 7/8 in.

10 mm 22 mm

3t8in. 1-1/8in.

10 mm 29 mm

Recommended Line Set

Liquid Vapor

Line Line

3/8 in. 7/8 in.

10 mm 22 mm

3/8 in. 7/8 in.

10 mm 22 mm

3/8 in. 1-1/8 in.

10 mm 29 mm

L15

Line Sets

L15-65

15-50 ft.

4.6-15m

Field

Fabricated

necessary 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 trans-

mission,

2. Line Set Isolation - The following illustrations demon-
strate procedures which ensure proper refrigerant line
set isolation. Figure 8 shows how to place the outdoor
unit and line set. Figure 9 shows how to install line sets
on horizontal runs. Figure 10 shows how to make a
transition from horizontal to vertical. Figure 11 shows
how to install line sets on vertical runs.

Outside Unit Placement and Installation

INSTALL UNIT AWAY _
FROM WINDOWS.

J

Refrigerant Line Set Connections - SPA
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 SPA unit,

"2 ,,

NOTE - Units are designed for line sets of up to 50 feet
(15 m).

Installing Refrigerant Line
During the installation of any heat pump system, it is impor-

tant to properly isolate the refrigerant lines to prevent un-

Refrigerant Line Sets: Installing Horizontal Runs

To hang line set from joist or rafter,
use either metal strapping material

or anchored heavy nylon wire ties. WIRE TIE

8 feet (Around vapor line only)

STRAPPING MATERIAL
(Around vapor line only),

FLOOR JOIST OR
ROOF RAFTER

8 feet WIRE TIE

TAPE OR

TWO 90 ° ELBOWS INSTALLED IN LINE SET

WILL REDUCE LINE SET VIBRATION.

Figure 8

Strap the vapor line to the joist or
rafter at 8 ft. intervals then strap

the liquid line to the vapor line.

TAPE OR WIRE TIE N

504867M 06/06

METAL FLOOR JOIST OR ,
SLEEVE ROOF RAFTER

Figure 9

Page 6