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Service Literature HS21 SERIES UNITS
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1. Unsteady Input OFF OFF Miel 4 Pressure Switch Open OFF MES OFF 2 minutes 5 Pressure Switch Open OFF 2 OFF gt 2 minutes Hot Compressor lt 5 OFF 2 open sensor 7 Hot Compressor gt 5 min OFF 2 open sensor Option 1 lt 5 minutes ON OFF Option 1 gt 5 minutes O 0 Option 2 Open OFF 1 Compressor Sensor O Problem 2 Not Used on TSC5 ON OFF Not Used ON ON 4 5 N OFF N ON IS OFF N ON ON 1 1 1 1 1 Test Mode ON OFF No Jumper in place Indication 1 Code 6 Hot Compressor lt Five Minutes Code 6 indicates the compressor temperature exceeded its limit after running less than five minutes Code 6 is stored Code 7 Hot Compressor gt Five Minutes Code 7 indicates the compressor temperature exceeded its limit after running more than five minutes Code 7 is stored Code 8 Option 1 gt Five Minutes Code 8 occurs if the Option 1 safety device switch opens after the compressor runs less than five minutes Code 8 is stored Code 9 Option 1 gt Five Minutes Code 9 occurs if the Option 1 safety device switch opens af ter the compressor runs more than five minutes Code 9 is stored Code 10 Option 2 Code 10 is displayed if the Option 2 safety device switch opens Code 10 is stored Page 11 Code 11 Compressor Temperature Sensor Shorted This code indicates that the compressor temperature sensor wires have shorted together Code 11
2. 1 CIRCUIT BREAKER 5 THERMOSTAT 44L L N 1 Eg Er 21 TERMINAL BOARD SINGLE PHASE LINE VOLTAGE FIELD WIRING 208 230 60 1 1211 COMPRESSOR CONTACTOR REFER TO UNIT RATING PLATE FOR MAXIMUM CIRCUIT AMPACITY AND MAXIMUM FUSE SIZE THREE PHASE LINE VOLTAGE FIELD WIRING 208 230 60 3 131211 TERMINAL BOX COMPRESSOR A COMMON TERMINAL C CONTACTOR LABELED X ON EARLY MODELS 6081 ZA FACTORY INSTALLED JUMPERS FIELD WIRING DIAGRAM HS21 WITH CB31MV NOTE USE COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTEC TION SIZE FACTORY LINE VOLTAGE FIELD INSTALLED INSTALLED CLASS 2 VOLTAGE FIELD INSTALLED JUMPER NEC CEC NOTE ALL REMAINING WIRES FACTORY INSTALLED TO EXTERNAL LOAD 24VAC AT 50AMP MAXIMUM CLASS 2 FACTORY SUPPLIED FIELD INSTALLED JUMPERS REQUIRED Humidity Unit Jumpers Single Speed Y1 to Y2 and With CCB1 Condensing Unit OtoR Humidity TwoSp ed wo Spee conyo Condensing Unit Without Single Speed Con DS to Y1 Y1 CCB1 densing Uni to Y2 and O to TERMINAL Humidity Two Speed DS to and pee BLOCK Control Condensing Unit OtoR 1 gt 6
3. LENNOX unirinronmarion HS21 e Corp 9406 L3 EARLY LATE Service Literature Revised 10 2000 MODEL SERIES HS21 SERIES UNITS HS21 early model units 411 511 651 and late model gt units 036 048 060 are high efficiency residential split system condensing units which features a two speed compressor Models are available in sizes ranging from 3 through 5 tons in either single or three phase configuration The series features solid state two speed control which reg ulates compressor speed in response to thermostat demand The HS21 is designed for use with an expansion valve at the indoor coil This manual is divided into sections which discuss the com ponents refrigerant system charging procedures maintenance and operation sequences Information contained in this manual is intended for use by Lennox service technicians only All specifications are subject to change Procedures outlined in this manual are presented as a recommendation only and do not super 4 sede replace local state codes the absence of V M LATE local or state codes the guidelines and procedures out E MODEL lined in this manual except where noted HS21 SHOWN recommended only SPECIFICATIONS Early Model area sq ft 214 64 00 2164 64 92 outside inside 20 81 20 81 23 01 Condenser Coil Tube diameter No of Bows _ Diameter
4. 20 Relay contacts K10 1 switch to energize the outdoor fan and to de energize the crankcase heater 21 TSC delays 3 seconds before responding 22 If the unit is changing from 1st stage to 2nd stage demand the TSC initiates speed change delay and de energizes JP44 8 and JP44 9 to stop all unit operation for 60 5 seconds After TSC completes the 60 5 second speed change delay or if the unit is starting up in 2nd stage directly from OFF mode TSC checks safety circuits by looking for 24VAC at JP44 7 by checking resistance through wires connected to S1 and 2 23 If all safety circuits check out TSC energizes K69 Compressor begins high speed start up 24 When thermostat demand is satisfied or if thermostat is switched OFF all outdoor unit operation stops after a delay of 3 seconds TSC then starts a 5 minute timed off delay FIELD WIRING DIAGRAM HS21 WITH 21 A THERMOSTAT ra 00999696 L 5 eed L 521 LOW VOLTAGE PIGTAIL LEADS TROL UNIT HUMIDITY TWO SPEED 0 TOR FIELD INSTALLED JUMPERS REQUIRED FOR TERMINAL STRIP TBI NTROL CONDENS ING HUMIDITY OUTDOOR JUMPERS CON REQUIRED WITH HS21 WITH NIT 521 WITH ME TROUT TWO SPEED DS TO Y2 ANI CONDENSING CONTROL UNIT 0 TO R L2 208 230 60 K20 INDOOR BLOWER RELAY Black L2 Orange CIRCUIT 1 m ge FIELD SUPPLIED WIRE NUTS
5. HS21 CONTROL BOX WEATHERPROOFING SCREWS WITH RUBBER WASHERS WASHERS PREVENT WATER FROM DRIPPING INTO CON TROL AREA MAKE SURE WASHERS ARE IN GOOD CONDITION AND MAKE SURE SCREWS SEAT SE CURELY AND ARE NOT CROSS THREADED top of the control box to the cabinet must have rubber wash ers installed Also the control box must be installed with a foam rubber weatherstrip installed along the top edge be tween the control box and the cabinet WEATHERSTRIPPING BE TWEEN CONTROL BOX AND FAN ORIFICE PANEL USED TO PREVENT FAN FROM THROWING WATER INTO CONTROL BOX FIGURE 13 Vill Operation Sequence Compressor Single Phase Compressor Start Up Figure 14 shows single phase compressor windings This compressor has a two speed capacitor start capaci tor run motor For starting the start and run capacitors are in parallel to provide the proper starting torque The start capacitor is disconnected by the start relay when the compressor comes up to speed The run capacitor re mains connected to the start winding and the motor runs as a two phase induction motor with improved power fac tor and torque characteristics provided by the capacitor Low speed compressor operation is provided by powering the run windings internally connected in ser
6. CAPACITOR 7 12 TRANSFORMER T19 FIGURE 3 HS21 THREE PHASE CONTROL BOX COMPONENTS OUTDOOR FAN LOW SPEED HIGH SPEED RELAY K10 CONTACTOR CONTACTOR K1 K69 TWO SPEED CONTROL A14 1 0000 8888 009 000 0 CAPACITOR DISCONNECT 1 TRANSFORMER T19 FIGURE 4 Page 4 I APPLICATION All major components indoor blower coils must be matched according to Lennox recommendations for the compressor to be covered under warranty Refer to Engi neering Handbook for approved system matchups A misapplied system will cause erratic operation can result in early failure of compressor or other components and could affect the warranty ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A CAUTION Electrostatic discharge affect electronic components Take precautions during unit instal lation and service to protect the unit s electronic controls Precautions will help to avoid control exposure to electrostatic discharge by putting the unit the control and the technician at the same electrostatic potential Neutralize electro static charge by touching hand and all tools on an unpainted unit surface before performing any service procedure II UNIT COMPONENTS 521 unit components are shown in
7. HEAT 1 HEAT 2 DESCRIPTION COMPONENT CONTROL TWO SPEED COMPRESSOR MOTOR OUTDOOR FAN CAPACITOR COMP HARD START CAPACITOR DUAL HEATER COMPRESSOR JACK TWO SPEED CONTROL CONTACTOR COMPRESSOR RELAY HARD START CONTACTOR COMPRESSOR TWO SPEED PLUG TWO SPEED CONTROL RESISTOR BLEED SWITCH LIMIT HI PRESS COMP SWITCH LOW PRESS LOW AMB SWITCH LOW PRESSURE COMP RANSF ORMER COOLING CONTROL RED LOW YELLOW 82 BLACK HI BLACK COM D 208V 230V IF USED 12 a o a a ra a lt FURNACE DIAGRAM PLACE ECONOMIZER DIAGRAM HERE RE ORANGE TO BLOWER MOTOR TAPS EQUIP GROUND 24V COMMON 4 LINE VOLTAGE FIELD INSTALLED A FOR USE WITH COPPER 24V CLASS 2 FIELD INSTALLED CONDUCTORS ONLY REFER TO UNIT RATING 2 PLATE FOR MINIMUM CIRCUIT AMPACITY DESCRIPTION 3 KD AND MAXIMUM FUSE SIZE ESCRITO 10 ZA COMPRESSOR MOTOR A20 CONTROL HUMIDITY T C7 N 51 OPTIONAL WITH TWO SPEED COMPRESSOR C 51 CONTROL EBRI KIT 62 THERMALLY PROTECTED THERMOSTAT ROOM 51 52 DENOTES TERMINAL NOTE DESIGNATIONS ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED CLASS II 24 VOLT FIELD WIRING 3 ACCORDA
8. K1 and K69 The indoor transformer supplies 24VAC to the indoor unit the indoor thermostat and the outdoor fan relay K10 On power up 24VAC is fed through JP44 1 and JP44 7 to the TSC TSC be gins a 10 second power up delay The TSC begins a 5 minute delay during which the outdoor unit is not operational After a 5 minute delay the TSC waits in mode for 1st stage or 2nd stage demand THREE PHASE COMPRESSOR START UP Low Speed 6 Low speed demand energizes outdoor fan relay K10 and JP44 6 K10 1 switches to energize the outdoor fan and de energize the crankcase heater Outdoor fan begins operating immediately 7 After appropriate time delay and if all safety circuits check out TSC energizes JP44 9 Contactor K1 is energized through K69 2 N C contacts K1 N O contacts close to begin compressor low speed start up K1 N C contacts open to disconnect the high speed wiring circuitry Compressor B1 terminal 1 is energized by K1 contacts L1 T1 Compressor termi nal 2 is energized by contactor K1 terminal L2 T2 Compressor terminal 3 is ener gized by contactor K1 terminal L3 T3 This arrangement forms a series DELTA connection to the motor windings for low speed High Speed 10 High speed demand energizes JP44 4 11 After appropriate time delay and if all safety circuits check out TSC energizes JP44 8 Contactor K69 is energized through K1 2 N C contacts 12 When contactor K1 is de energized contacts K1 1 nor
9. L2 T2 and contactor K69 terminal L2 T2 Compressor terminal 1 is energized di rectly by contactor K1 terminal L1 T1 Compressor terminal 7 is energized by con tactor K1 terminal L1 T1 and through contactor K69 terminal L1 T1 14 Outdoor fan B4 is energized when contactor K1 contacts L1 T1 and L2 T2 close 15 As the compressor nears full speed potential relay K31 energizes and K31 con tacts open to de energize start capacitor C7 SINGLE PHASE COOLING SEQUENCE 16 1st stage cooling demand energizes TB15 Y1 TB15 Y1 energizes TSC terminal JP44 6 NOTE 2nd stage cooling demand may be energized directly without passing through 1st stage 17 TSC delays 3 seconds before responding to the new command 18 If the unit is changing from 2nd stage to 1st stage demand TSC initiates speed change delay and de energizes JP44 8 and JP44 9 to stop all unit operation for 60 5 seconds After TSC completes the 60 5 second speed change delay or if the unit is starting up in 1st stage directly from OFF mode TSC checks safety cir cuits by looking for 24VAC at JP44 7 and by checking resistance through wires connected to 51 and 2 19 If all safety circuits check out TSC energizes K1 and compressor begins low speed start up 20 2nd stage cooling demand energizes TB15 Y1 and TB15 Y2 TB15 Y2 energizes TSC terminal JP44 4 TB15 Y1 energizes TSC terminal JP44 6 21 TSC delays 3 seconds before responding 22 If the unit is changing from 1st stage to 2nd
10. Remove service port cap and connect high pressure gauge to service port 3 Using service wrench open valve stem one turn clock wise from backseated position 4 When finished using port backseat stem with service wrench Tighten firmly 5 Replace service port and stem cap Tighten finger tight then tighten an additional 1 6 turn To Close Off Service Port 1 Using service wrench backseat valve a Turn stem counterclockwise b Tighten firmly To Open Liquid Line Service Valve 1 Remove the stem cap with an adjustable wrench 2 Using service wrench backseat valve a Turn stem counterclockwise until backseated b Tighten firmly 3 Replace stem cap finger tighten then tighten an addi tional 1 6 turn To Close Liquid Line Service Valve 1 Remove the stem cap with an adjustable wrench 2 Turn the stem in clockwise with a service wrench to front seat the valve Tighten firmly 3 Replace stem cap finger tighten then tighten an addi tional 1 6 turn 2 Suction Line Seating Type Service Valve A full service non backseating suction line service valve is used on all HS21 series units Different manufacturers of valves may be used All suction line service valves function the same way differences are in construction Valves manufactured by Parker are forged assemblies Primore and Aeroquip valves are brazed together Valves are not rebuildable If a valve has failed it must be re placed The suction line serv
11. The diagnostic codes can be re displayed by setting the jumper to the recall position The stored codes are dis played by pushing the push button As previously mentioned the push button is used to bypass the five minute delay and to initiate the test mode In addition the button is used to step back through the stored diagnostic codes and erase the diag nostic code memory Diagnostic codes are recalled in the Page 10 reverse order of actual occurrence Each subsequent button push will display additional codes until the last one which will stay on with additional button pushes Hold the button down until the lights go off approximately five seconds to erase the memory The control has a nonvolatile memory that stores the 63 most recent diagnostic codes These codes are stored in memory even in the event of a power loss Not all codes cause lockouts or indicate problems The pur pose of the diagnostic lights is to let the installer or service technician know what is going on with the entire system not just the two speed control Some codes do indicate malfunc tions or problems with either the control or the HS21 while others inform the technician of the units status All codes except for three are stored in memory and may be recalled Code 1 Power Loss for Two Electrical Cycles This code indicates that the unit s power skipped two electrical cycles 33 40 milliseconds It may suggest that power to the unit is dirty or is of
12. Unit faults are erased when power is in terrupted When thermostat demand changes stages compressor operation stops for approximately one minute to allow refrigerant pressure to equalize in the system A manual override button aids servicing and troubleshooting on the control The manual override button when pressed and released bypasses the five minute delay so low speed or high speed operation can be immediately energized Howev er the control provides a one minute delay between speed changes which can not be bypassed Do not use the override button immediately after power up If the button is pushed during the ten second power up delay it has no effect The control completes the five minute delay The control continually self tests its internal circuits and uses the diagnostic lights to indicate control failure 6 Normal Operation Sequence The control begins a five minute delay during which the unit is not operational control and outdoor unit do not re spond to thermostat demand Once the five minute delay is complete the control waits in OFF mode for thermostat demand After receiving a thermostat demand the TSC delays three seconds before responding Low speed demand JP44 9 energizes low speed eration OR high speed demand JP44 8 energizes high speed operation During unit operation if low speed demand changes to high speed demand or if high speed demand changes to low speed the control delays thr
13. in door temperature should be between 70 F and 80 F Outdoor temperature should be 60 F or above Slight varia tions in charging temperature and pressure should be expected Large variations may indicate a need for further servicing 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 ambi ent temperature as outlined below 1 Connect the manifold gauge set to the service valves e low pressure gauge to vapor valve service port high pressure gauge to liquid valve service port Connect the center manifold hose to an upright cylin der 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 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
14. installations Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system Used prudently tables 10 and 1160010 serve as useful service guide TABLE 10 NORMAL OPERATING PRESSURES HIGH SPEED OPERATION OUTDOOR COIL HS21 410 HS21 510 HS21 650 ENTERING AIR TEMPERATURE 65 F TXV 75 F TXV 85 F TXV 95 F 105 F TXV TABLE 11 NORMAL OPERATING PRESSURES HIGH SPEED OPERATION OUTDOOR COIL SUC LIQ SUC LIQ ENTERING AIR TEMPERATURE 10 10 10 10 0 PSIG PSIG PSIG PSIG PSIG PSIG eFax 149 72 142 72 142 142 2 75 F TXV 173 74 168 85 F 202 76 196 76 202 95 F TXV 218 78 227 238 105 F TXV 265 79 260 D Oil Charge Factory oil charge in all HS21 series units is 70 fl oz Suniso 3GS VI MAINTENANCE AWARNING Electric shock hazard Can cause inju ry or death Before attempting to per form any service or maintenance turn the electrical power to unit OFF at dis connect switch es Unit may have multiple power supplies Maintenance and service must be performed by a quali fied 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
15. is stored Code 12 Not used on TSC5 This code does not pertain to the two speed control 5 5 used on condensing units Code 13 Not Used This code may be used in future models of the two speed control but at this time has no function and therefore is not stored Code 14 Test Mode Code 14 does not indicate a problem The control is in TEST mode when this code is displayed See Mode Jumper Selec tions section Code 15 No Jumper in Place Code 15 is displayed when the mode jumper is not in place Make sure jumper is placed securely across the selected set of pins for the appropriate mode of operation SERVICE RELAY The control has a built in service relay This relay controls the thermostat service light or communicates with an alarm device The relay signals the alarm device in such a manner that the alarm device can distinguish between a lockout and a non lockout condition The relay contacts are normally open when no problems or lockout conditions occur A non lockout condition is reported by closing the contacts for the duration of the next no demand period If the control goes into a lockout state the relay will close and remain closed until the next loss of demand If the service light on the room thermostat is connected to the service relay the light will turn on if the control is in a lockout It will not turn on if the control is detecting non lockout problems In order for the service relay to indicate only a lockout con
16. low quality Code 1 is stored Code 2 Input Indication This code indicates that a change has been made and that the control acknowledges the change It does not in dicate a problem condition It indicates activity such as jumper setting changes delay overrides or addition of an optional safety device to Option 1 or 2 Code 2 is not stored Code 3 Unsteady Thermostat Input Code 3indicates intermittent inputs from the room ther mostat Most likely there is a loose connection at the thermostat when this condition appears Code 3 is stored Code 4 Pressure Switch Opens lt Two Minutes If the low or high pressure switch opens after the compressor has run for less than two minutes Code 4 will be displayed This may indicate blockage or fan failure Code 4 is stored If the unit still operates after code is displayed the low pressure switch stops operation low pressure is auto reset Check for low system charge Code 5 Pressure Switch Opens gt Two Minutes If the low or high pressure switch opens after the com pressor has run for more than two minutes Code 5 is displayed This may indicate an improper charge or coil obstruction Code 5 is stored If the unit stilloperates after code is displayed the low pressure switch stops opera tion low pressure is auto reset Check for low system charge TABLE 5 TSC5 DIAGNOSTICS CODES 1 Power loss for two OFF OFF OFF cycles 2 Input Indication
17. stage demand the TSC initiates speed change delay and de energizes JP44 8 and JP44 9 to stop all unit op eration for 60 5 seconds After TSC completes the 60 5 second speed change delay or if the unitis starting up in 2nd stage directly from OFF mode TSC checks safety circuits by looking for 24VAC at JP44 7 by checking resistance through wires connected to S1 and S2 23 If all safety circuits check out TSC energizes K1 and K69 Compressor begins high speed start up 24 When thermostat demand is satisfied or if thermostat is switched OFF all outdoor unit operation stops after a delay of 3 seconds TSC then starts a 5 minute timed off delay HS21 THREE PHASE 036 048 060 K6 K69 2 CONTACTOR QOO TBI TERMINAL STRIP CAPACITOR WARNING L ELECTRIC SHOCK HAZARD CAN S4 HIGH PRESSURE ED SWITCH CAUSE INJURY OR DEATH UNIT LEADER MUST BE GROUNDED IN ACCORDANCE COMPRESSOR WITH NATIONAL LOCAL CODES ORANGE COMMON O BROWN CAPACITOR Z LEADLESS BLACK RUN D 597 23 OUTDOOR O s4pA O D GROUND LUG i o SB 2075 TO 24VAC POWER SOURCE 20 MINIMUM NEC CLASS 2 BLUE YELLOW BLACK COM RED 208V ORANGE 240V L2 EQUIPMENT GROUND SENSORS LEADED FAN MOTOR NOTE FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVER CURRENT PROTECTION
18. 9 5 Suction line in mm o d connection sweat 7 8 22 2 1 1 8 28 5 Outer coil 21 77 2 02 24 06 2 24 Net face area sq ft m2 Inner coil 21 11 1 96 23 33 2 17 Condenser Coil Tube diameter in mm amp no of rows 5 16 7 9 2 Fins per inch m 22 866 Diameter in mm amp no of blades 24 610 3 24 610 4 Motor hp 1 6 124 1 4 187 UT Cfm L s 3200 1510 4200 1980 Rpm 815 Watts 170 310 Refrigerant charge furnished HCFC 22 10 Ibs 10 oz 4 80 kg 11 Ibs 0 oz 4 98 kg 12 Ibs 4 oz 5 55 kg Shipping weight Ibs kg 1 package 328 149 329 149 352 160 OPTIONAL ACCESSORIES MUST BE ORDERED EXTRA Mounting Base MB2 L 69J07 Low Ambient Kit LB 57113BC 24H77 Indoor Blower Speed Relay Kit 72G36 CCB1 EfficiencyPlus Humidity Control 35H00 EBR1 Blower Relay Kit 75H90 Compressor Monitor Canada Only T6 1469 45F08 Refrigerant charge is sufficient for 15 ft 4 5 m length line set ELECTRICAL DATA Late Models Model No 521 036 521 048 521 060 Line voltage data 60 hz 208 230v 1 208 230v 3ph 208 230v 1 208 230 3ph 208 230v 1 208 230 3ph Max fuse circuit breaker size amps 40 25 45 35 60 45 Minimum circuit ampacity 23 0 16 9 28 0 20 8 40 2 26 6 Rated load amps 17 6 12 7 21 6 15 8 30 8 19 9 Compressor Power factor 98 90 98 90 92 90
19. ART UP Low Speed 1st stage demand If all safety circuits check out TSC energizes JP44 9 Contactor K1 is energized through K69 2 N C contacts K1 2 contacts open to de energize the crankcase heater All other K1 contacts close to start outdoor fan operation and to begin compressor low speed start up Compressor B1 terminal 1 and the outdoor fan circuit are energized by K1 con tacts L1 T1 Compressor terminal 7 is energized by contactor K1 terminal L2 T2 through contactor K69 terminal T1 X1 Compressor terminal 8 start winding is energized by contactor K1 terminal L2 T2 through the start C7 and run C5 ca pacitors and contactor K69 terminal T3 X3 Outdoor fan B4 is energized when contactor K1 contacts L1 T1 and L2 T2 close 10 As the compressor nears full speed potential relay K31 energizes and K31 con tacts open to de energize the start capacitor High Speed 11 2nd stage demand If all safety circuits check out TSC energizes JP44 8 12 Contactor K69 energizes and K69 2 auxiliary contacts close to energize contactor K1 K1 2 auxiliary contacts open to de energize the crankcase heater All other K1 contacts close K69 contacts L1 T1 L2 T2 and L3 T3 close while contacts T1 X1 and T3 X3 open 13 Compressor B1 terminal 3 start winding is energized by contactor K1 terminal L2 T2 through the start C7 and the dual C12 capacitors and through contactor K69 terminal L3 T3 Compressor terminal 2 is energized by contactor K1 terminal
20. D START WINDINGS LOW SPEED START RELAY START WINDINGS FIGURE 14 THREE PHASE MOTOR WINDINGS LOW SPEED SERIES DELTA CIRCUIT L1 T1 THREE PHASE MOTOR WINDINGS HIGH SPEED PARALLEL DELTA CIRCUIT 74 COMPRESSOR CONTACTOR 1 1 FIGURE 15 19 WIRING DIAGRAMS AND SEQUENCE OPERATION HS21 SINGLE PHASE 036 048 060 HARD STAR RLA Rkeg 2 CONTACTOR 2 CONTACTOR 2 SPEED HIE Q CONTROL aj TH 02 START DUAL CAPACITOR CAPACITOR TBI GROUND LUG 8 Si 5 208 230 60 19 TRANSFORMER LBLUE _ amp v2 TO 24VAC 0 0 sis LEADED BLACK SWITCH L YELLOW vi NEC CLASS 2 WARNING OUTDOOR BI COMPRESSOR ELECTRIC SHOCK HAZARD CAN FAN MOTOR Y OR DEATH CAUSE INJURY OR DEATH UNIT 3 8 PRESSURE MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES LI EQUIPMENT GROUND 1 BLACK COM B4 LEADLESS FAN MOTOR NOTE FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVER CURRENT PROTECTION SIZE RED 208V ORANGE 240V L NE VOLTAGE FIELD INSTALLED lt CLASS 11 VOLTAGE FIELD INSTALLED BI sensors LENNOXe C 6 L 2 HS21 036 048 060 IP upersedes No New Form No 533 I5IW 2000 Lennox Industries Inc Litho U S A Page 20 521 SINGLE PHASE 411 511 651 24V POWER 4090 BLOWER
21. INIMUM CIRCUIT AMPACITY DESCRIPTION AND MAXIMUM FUSE SIZE KEY COMPONENT 20 CONTROL HUMIDITY A COMPRESSOR MOTOR ASI CONTROL EBRI KIT 24V COMMON 4 THERMALLY PROTECTED S1 THERMOSTAT ROOM 51 52 DENOTES TERMINAL 63 13 DAG A DESIGNATIONS CLASS II 24 VOLT FIELD WIRING LENNOX stios me WIRING DIAGRAM 11 93 LENNOX WIRING DIAGRAM 9 95 COOLING UNITS CONDENSING UNITS ACCESSORIES ELECTROMECHANICAL OR ELECTRONIC HS21 415 515 655 IY THERMOSTAT FOR G OR CB SERIES AND TWO SPEED CONDENSING UNIT WITH HUMIDITY CONTROL 2 HEAT 2 COOL COOLING SECTION 2B THERMOSTAT SECTION C Supersedes Form No New Form No Supersedes Form No New Form No 529 820W 529 564W 1993 Lennox Industries Inc Litho U S A 1993 Lennox Industries Inc Litho U S A HS21 THREE PHASE UNITS Electromechanical Thermostat Connected to HS21 413 513 653 036 048 060 THREE PHASE STARTING SEQUENCE Line voltage feeds through L1 L2 and L3 to energize outdoor transformer T19 and outdoor unit Crankcase heater is energized through relay K10 1 outdoor fan contacts Transformer T19 provides 24VAC to TSC A14 and contactors
22. Locked rotor amps 90 0 60 0 120 0 85 0 141 0 91 0 Full load amps 1 0 1 0 1 0 1 0 1 7 1 7 Fan Motor Locked rotor amps 1 9 1 9 1 9 1 9 2 9 2 9 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements NOTE Extremes of operating range are plus 1096 and minus 5 of line voltage Page 2 521 COMPONENTS EARLY MODEL 411 511 651 CONTROL BOX LIQUID LINE PP z gt LIQUID LINE gt SERVICE VALVE THERMOMETERWELL 1 5 COMPRESSOR TERMINAL BOX LOW PRESSURE SWITCH SUCTION LINE S87 a P to SUCTION LINE 2 SERVICE VALVE HIGH PRESSURE SWITCH 54 MUFFLER FIGURE 1 HS21 COMPONENTS LATE MODEL 036 048 060 CONTROL BOX LIQUID LINE SUCTION LINE THERMOMETERWELL LOW PRESSURE SWITCH 587 E ve SUCTION LINE in c lt Senn SERVICE VALVE LIQUID LINE HIGH PRESSURE SWITCH SERVICE VALVE MUFFLER COMPRESSOR TERMINAL BOX FIGURE 2 Page 3 HS21 SINGLE PHASE CONTROL BOX COMPONENTS POTENTIAL HIGH SPEED LOW SPEED RELAY K31 CONTACTOR CONTACTOR K69 K1 TWO SPEED CONTROL A14 COMPRESSOR DUAL START CAPACITOR
23. NCE WITH NATIONAL AND LOCAL CODES mS LENNOX uus me WIRING DIAGRAM 9 93 LENNOX stri me WIRING DIAGRAM 9 93 FIRM COOLING UNITS CONDENSING UNITS ACCESSORIES ELECTROMECHANICAL OR ELECTRONIC Ag E WINDING O 208 230 60 WITH HUMIDITY CONTROL 2 HEAT 2 COOL TERM BOX COOLING SECTION 2B THERMOSTAT SECTION C Supersedes Form No New Form No Supersedes Form No New Form No 529 819W 529 564W 1993 Lennox Industries Inc Litho U S A 1993 Lennox Industries Inc Litho U S A 4 521 SINGLE PHASE UNITS Electromechanical Thermostat Connected to 521 411 511 651 036 048 060 SINGLE PHASE STARTING SEQUENCE Line voltage feeds through L1 and L2 to energize outdoor transformer T19 and outdoor unit Crankcase heater is energized through relay K1 auxiliary contacts Transformer T19 provides 24VAC to TSC A14 and contactors K1 and K69 The indoor transformer supplies 24VAC to the indoor unit and the indoor thermo stat On power up 24VAC is fed through JP44 1 and JP44 7 to the TSC TSC be gins a 10 second power up delay The TSC begins a 5 minute delay during which the outdoor unit is not operational After a 5 minute delay the TSC waits in mode for 1st stage or 2nd stage demand SINGLE PHASE COMPRESSOR ST
24. RVICE PORT CAP UNIT SIDE SCHRADE VALVE FIELD SIDE BA SHOWN OPEN FIGURE 12 STEM CAP DANGER Do not attempt to backseat this valve Attempts to backseat this valve will cause snap ring to explode from valve body under pressure of refrigerant Personal injury and unit damage will result To Close Suction Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Use service wrench and 5 16 hex head extension turn stem clockwise to seat the valve Tighten firmly 3 Replace stem cap Tighten finger tight then tighten an additional 1 6 turn V CHARGING The unit is factory charged with the amount of HCFC 22 refrigerant indicated on the unit rating plate This charge as shown in the specification table on page 1 is based on a matching indoor coil and outdoor coil with 15 feet of line set For varying lengths of line set refer to table for refrigerant charge adjustment A blank space is provided on the unit rat ing plate to list actual field charge TABLE 7 LIQUID LINE Ounce per 5 foot ml per mm adjust SET DIAMETER from 15 foot 4 5 line set 1 4 in 6 mm 1 ounce 5 feet 30 1524 mm 5 16 in 8mm 2 ounce per 5 feet 60 ml per 1524 mm 3 ounce per 5 feet 90 ml per 1524 mm If line set is greater than 15 ft 4 5m add this amount If line set is less than 15 feet 4 5m subtract this amount 3 8 in 10 mm Units are designed for line sets
25. SIZE LINE VOLTAGE FIELD INSTALLED e CLASS VOLTAGE FIELD INSTALLED LENNOX LEADLESS FAN MOTOR 2000 Lennox Industries Inc Page 23 COOLING UNITS CONDENSING UNITS HS2 056 048 060 1 upersedes Form No 532 856W New Form No 555 152W Litho U S A 0600 HS21 THREE PHASE 413 513 653 24V POWER ae 8 6960 BLOWER HEAT HEAT 2 DESCRIPTION COMPONENT CONTROL TWO SPEED COMPRESSOR MOTOR OUTDOOR FAN CAPACITOR OUTDOOR FAN HEATER COMPRESSOR JACK TWO SPEED CONTROL CONTACTOR COMPRESSOR RELAY OUTDOOR FAN CONTACTOR COMPRESSOR TWO SPEED PLUG TWO SPEED CONTROL SWITCH LIMIT HI PRESS COMP SWITCH LOW PRESS LOW AMB SWITCH LOW PRESSURE COMP TRANSFORMER COOLING CONTROL BLACK COM 2 x D Q lt FURNACE DIAGRAM ve unin lt lt 5 iromo HOOKUP DIAGRAM HERE IF USED RED 208V ORANGE 230V TO BLOWER MOTOR TAPS PLACE ECONOMIZER EQUIP GROUND NOTE ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN Y ACCORDANCE WITH NATIONAL AND LOCAL CODES LINE VOLTAGE FIELD INSTALLED 24 CLASS 2 FIELD INSTALLED A FOR USE WITH COPPER REFER TO UNIT RATING A A51 OPTIONAL WITH TWO SPEED COMPRESSOR PLATE FOR M
26. 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 re paired 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 pro cedures outlined below Approach and Normal Operating Pressures Systems Outdoor Temp gt 65 F 18 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 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 stabi lize 3 Compare stabilized pressures with those provided in tables 10 and 11 Normal Operating Pressures Mi nor variations in these pressures may be expected due to differences in installations Significant differ ences could mean that the system is not properly charged or that a problem exists with some compo nent in the system Pressures higher than those listed indicate that the system is overcharged Pressures lower t
27. VAPOR L10 LINE L15 LINE 521 UNIT LINE LINE SETS SETS 210 ET L1041 L1541 036 20 amp sOf 157 501 510 L10 65 L15 65 3 8 78 308 506 150 508 pon 1 1 8 In FIELD FABRICATED B Discharge Muffler All units are equipped with a discharge muffler located in the discharge line of the compressor The muffler attenuates dis charge gas pulsations from the compressor to lower sound levels The discharge muffler is located immediately in front of the compressor in the compressor compartment See figure 1 or 2 C Thermometer Well All units are equipped with a thermometer well for use in mea suring liquid line temperature when charging the unit The thermometer well is used in all Lennox recommended charg ing procedures It is located in the liquid line adjacent to the liquid line service valve D Service Valves The liquid line and suction line service valves and gauge ports are accessible by removing the compressor access cover Full service liquid and suction line valves are used See fig ures 9 and 11 The service ports are used for leak testing evacuating charging and checking charge Page 12 1 Liquid Line Service Valve A full service liquid line valve made by of several manufacturers may be used All liquid line service valves function the same way differences are in construction Valves manufactured by Parker are forged assemblies Valves manufactured by Primore are brazed together Valves are no
28. and compressor parts A IMPORTANT Use a thermocouple or thermistor electronic vacuum that is calibrated Use 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 iquid 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 mercu ry 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 rapid rise in pressure indicates a relative ly 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 pres sure in a vacuum is equal to atmospheric pressure minus vacuum pressure 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 inder with pressure regulator set
29. continuous or intermittent blower operation The thermostat also has an in dicator light to indicate low or high speed compressor operation 4 Low Pressure Low Ambient Switch S11 The HS21 unit will operate satisfactorily down to 45 F 7 C outdoor air temperature without any additional controls For cases where operation of the unit is required at low ambi ents a Low Ambient Control Kit LB 57113BC 24H77 can be added in the field enabling the unit to operate properly down to 30 F 1 C Page 7 lll TSC5 TWO SPEED CONTROL OPERATION The TSC A14 two speed control contains relays which energize compressor operation in response to thermostat demand High speed operation can be energized and de energized without passing through low speed The control also contains safety timed off delays and compressor over temperature sensing which protect the compressor A timed off delay in the control prevents short cycling by lock ing out compressor operation for five minutes after the end of a thermostat demand or after a power failure The control also counts unit fault conditions When the compressor stops due to a safety limit trip or if the compressor winding temperature becomes too hot the control s internal cycle counter accumu lates one fault If three unit faults are counted during the same thermostat demand the control locks out and stops all unit operation The control can be reset by breaking and remaking thermostat demand
30. ction line pres sure drops below 25 5 psig When the pressure rises above 55 5 psig the switch automatically resets closes The switch is electrically connected in series with high pres sure switch S4 in the two speed control s safety circuit C Optional Equipment 1 Humidity control A20 The CCB1 EfficiencyPlus Comfort Management System may be used with the HS21 unit to control humidity The Ef ficiencyPlus automatically controls the compressor and the indoor blower to maintain a selected level of relative humid ity throughout the conditioned space during a thermostat demand The EfficiencyPlus DS output is designed to di rectly control the variable speed motors used in the CB21 G21V CB31MV and G32V indoor units 2 EBR1 Control Kit A51 EBR1 Blower Relay Kit provides the option of varying indoor blower speeds of multi tap motors when using the Efficiency Plus with a two speed HS21 When the EfficiencyPlus is used with the HS21 most of the dehumidification is provided by forcing the compressor into high speed when the thermo stat calls for low speed The kit provides more dehumidification by simultaneously decreasing the indoor blower speed 3 Room Thermostat 1 The HS21 unit can be used with numerous types of thermo stats The two heat two cool electromechanical thermostat 51H34 is recommended The subbase is furnished with the thermostat and features system selector switch Off Heat Auto Cool and fan switch Auto On for
31. des and problem code recall or test Choose one of the first four modes for operation Normal Normal operation default mode Unit runs on high or low speed as the indoor thermostat load demands Latch 1 After high speed demand is met the unit remains in high speed until the low speed demand is satisfied Latch 2 After the unit operates in low speed for 15 minutes consecutively it switches to high speed until low speed demand is satisfied Latch 3 After the unit operates in low speed for 30 minutes consecutively it switches to high speed until low speed demand is satisfied Recall Used in conjunction with the bypass button to recall the stored problem codes Test Used in conjunction with the control button to start test mode Latch 2 or 3 modes are recommended in high humidity areas If the jumper falls off or is removed the control will continue to operate in the previously set mode until the control is reset due to loss of power then the control will default to the Normal mode The latch feature does not af fect the indoor blower operation TEST MODE The control has a test mode To initiate this mode move the jumper to the test position and push the control button The unit will operate in low speed for 10 seconds turn off for ten seconds then operate in high speed for 10 sec onds The control will only go into the test mode if there is no thermostat demand and 5 minutes has elapsed since the unit ran The indoor bl
32. dition one side of the relay must be wired to the alarm and the other side to Y2 During a simultaneous Y1 and Y2 demand with a non lockout condition the alarm will energize for a very short duration 2 seconds If both an alarm device and thermo stat service lights are used an additional external relay may be required depending on the thermostat used OPTIONAL INPUTS The control has two optional inputs for additional protection devices If options 1 or 2 are going to be used move the three pin mini jumper to the YES side OPT 1 input will lock out the compressor on the third count OPT 2 input will not lock out the compressor at any time but will display and store the problem code see Diagnostic code Table These inputs are designed for normally closed switches connected to 24VAC A CAUTION Do not remove the jumpers unless additional protection controls are going to be installed If OPT 1 jumper is not connected to the NO pin the control will lock out the compressor If OPT 2 is not con nected to the NO pin the display only shows the problem code IV REFRIGERANT SYSTEM A Plumbing Field refrigerant piping consists of liquid and suction lines from the indoor coil to the outdoor unit sweat connections Use Lennox L10 series line sets as shown in table 6 or field fabri cated refrigerant lines Install filter drier provided with unit in the liquid line as close as possible to the expansion device TABLE 6 LIQUID
33. e capacitor when not in use R21 is a 15 000 ohm 2 watt resistor 8 Dual Capacitor C12 single phase only All single phase HS21 units use a single dual capacitor to maximize motor efficiency in both the fan motor and the compressor which use PSC motors A dual capacitor has two independent capacitors inside one can Each side of the capacitor has different ratings Ratings will be printed on side of capacitor The dual capacitor is wired in parallel with the start capacitor and is electrically connected as shown in the unit wiring diagram 9 Disconnect Tab The disconnect tab has 10 pins where 10 wire connections are made from the various components in the control box The disconnect tab simplifies the connections between the components in the control box 10 TSC5 Two Speed Control A14 The TSC A14 two speed control figure 7 is a Lennox built control designed for use with two speed condensing units The control provides automatic switching from low speed to high speed operation and back A14 is electrically connected as shown in the unit wiring diagram The two speed control is covered in detail in section Ill Page 6 B Unit Components 1 Compressor B1 All compressors are rated at 208 230 VAC and may be single phase or three phase All compressors are equipped with internal pressure relief valves set at 450 50 psig Compres sors all units use insertion type crankcase heaters See ELECTRICAL DATA or compressor nameplat
34. e for specifi cations Figure 5 shows the compressor terminal box TYPICALTWO SPEED COMPRESSOR TERMINAL BOX COPELAND SINGLE PHASE SHOWN T8 T1 T7 FIGURE 5 2 Compressor Heater HR1 all units A crankcase heater is used on all 1521 models The well mounted insertion type heater is self regulating Heaters are rated at 40 watts for all 1521 models The heater is thermostat actuated and operates only when demand is satified 3 Outdoor Fan Motor B4 The table on page 1 of this manual shows the specifications of outdoor fans used in all HS21 units In single phase units the outdoor fan is controlled by the compressor contactor K1 In three phase units the outdoor fan is controlled by relay K10 See figure 6 if outdoor fan motor replacement is neces sary FAN GUARD Condenser fan and motor Wiring Drip loop FIGURE 6 4 High Pressure Limit Switch S4 All units are equipped with a SPST N C high pressure limit switch mounted on the compressor discharge line When the pressure rises above 410 10 psig the switch opens to shut off the compressor The switch is manually reset and is electrically connected in series with low pres sure switch S87 in the two speed control s safety circuit 5 Low Pressure Switch S87 All units are equipped with a SPST N C low pressure Switch mounted on the compressor suction line The switch opens shutting off the compressor when su
35. ee seconds before re sponding Then all unit operation stops for 60 5 seconds control de energizes JP44 8 and JP44 9 This allows refrigerant pressure to equalize in the system At the end of the 60 5 second delay the control responds to what ever thermostat demand is present If no thermostat demand is present the control resets see unit fault con ditions section and retums to step 2 above When thermostat demand is satisfied all unit operation stops after a three second delay control de energizes JP44 8 and JP44 9 the control resets see unit fault conditions section and retums to step two General Operation On power up the control begins a ten second initial delay TSC5 A14 TWO SPEED CONTROL COM OPTION 1 ENABLE MODE JUMPER SELECTION JUMPERS HEARTBEAT LED MANUAL OVERRIDE BUTTON COMPRESSOR SENSOR CONNECTORS 1 2 SERVICE RELAY CONNECTORS FIGURE 7 Page 8 PONENTS OPTION 2 ENABLE JUMPER DIAGNOSTIC LEDs D8 D4 D2 D1 LOW SPEED HIGH SPEED LED LED TSC5 A14 MAIN CONTROL PLUG 24VAC POWER INPUT 24VAC COMMON 24VAC SPARE NOT USED 2nd STAGE THERMOSTAT DEMAND THERMOSTAT COMMON C 1st STAGE THERMOSTAT DEMAND 24VAC FROM SAFETY SWITCHES TO INTERNAL CONTACTOR COIL INPUT HIGH SPEED 24VAC OUTPUT LOW SPEED 24VAC OUTPUT JP44 FIGURE 8 Two Speed C
36. f single pole double throw auxiliary contacts located on the side of the con tactor The contactor is energized in response to low speed thermostat demand from two speed control jackplug J44 P44 pin 9 TABLE 2 Contactors Energized Single Phase Three Phase Low K1 K1 High K1 amp K69 K69 In single phase units K1 also de energizes the crankcase heater and energizes the condenser fan during compressor operation Contactor K69 energizes high speed operation in all units single phase and three phase K69 is a double break con tactor with three sets of normally open contacts and two sets of normally closed contacts for single phase models and is a three pole double break contactor for three phase models This contact arrangement provides unique switching charac teristics for two speed operation K69 is also equipped with a set of single pole double throw auxiliary contacts located on the side of the contactor The contactor is energized in re sponse to high speed thermostat demand from JP44 8 two speed control jackplug J44 P44 pin 8 DANGER Electric Shock Hazard May cause injury or death Compressor Speed Line voltage is present at all compo nents when unit is not in operation on units with single pole contactors Disconnect all remote electrical power supplies before opening this panel Unit may have multiple power supplies Page 5 Contactor Operation Single Phase Units Low s
37. figures 1 and 2 A Control Box Components HS21 control box is shown in figures 3 and 4 The control box is located in the top front section of the unit TABLE 1 HS21 Component Two Speed Control A14 Cowcorki Contactor kes 1 High Pressure misa Low Pressure Limit S87 Fan Relay K10 3 phase Potential Relay K31 1 phase 24VAC from Outdoor Unit Transformer T19 C12 1 phase 1 Bleed Resistor R21 1 phase Fan Capacitor C1 3 phase Line Voltage Compressor B1 Outdoor Fan 4 1 Control Transformer T19 All units are equipped with a line voltage to 24 transformer which supplies power to unit controls as shown in table 1 The transformer is rated at 70VA and has two primary voltage taps red 208V orange 230V and black common Refer to unit wiring diagram for detailed information regarding unit wiring 2 Contactors K1 and K69 The compressor is energized by a set of contactors K1 and K69 located in the control box Contactors in HS21 units are energized as shown in table 2 Contactor K1 energizes low speed compressor operation in all units single phase and three phase In single phase units K1 is a double pole double break contactor and in three phase units K1 is a double break contactor with three sets of normally open contacts and two sets of normally closed con tacts K1 is also equipped with a set o
38. gh pressure side of the manifold gauge set Disconnect the HCFC 22 cylinder Connect a cylinder of nitrogen with a pressure regulat ing valve to the center port of the manifold gauge set 1 Connect the manifold gauge set high pressure hose to the vapor valve service port Normally the high pres sure hose is connected to the liquid line port however connecting it to the vapor port better protects the man ifold gauge set from high pressure damage Adjust the nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set which will pressurize line set and indoor unit O 7 After a few minutes open a refrigerant port to ensure the refrigerant you added is adequate to be detected Amounts of refrigerant will vary with line lengths Check all joints for leaks Purge nitrogen and HCFC 22 mixture Correct any leaks and recheck 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 B Evacuating the System Evacuating the system of noncondensables is critical for proper operation of the unit Noncondensables are de fined 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
39. han those listed indicate that the system is un dercharged Verify adjusted charge using the approach method 4 Outdoor temperature should be 65 F 18 or above Use the same digital thermometer used to check out door ambient temperature to check liquid line temperature Verify the unit charge using the ap proach method The difference between the ambient and liquid temperatures should match values given in table 3 Refrigerant must be added to lower approach temperature and removed to increase approach tem perature Loss of charge results in low capacity and efficiency Page 16 5 If the values don t agree with the those in tables 8 and 9 add refrigerant to lower the approach temperature or recover refrigerant from the system to increase the approach temperature TABLE 8 APPROACH METHOD EXPANSION VALVE SYSTEMS Liquid Line F Warmer Than Outside Ambient Temperature HS21 411 413 HS21 511 513 HS21 651 653 TABLE 9 APPROACH METHOD EXPANSION VALVE SYSTEMS Liquid Line F Warmer Than Outside Model Ambient Temperature HS21 036 1 521 048 1 521 060 8 1 4 When unit is properly charged liquid and suction line pressures should approximate those in tables 10 or 11 IMPORTANT Use tables10 or 11 as a general guide for performing maintenance checks Tables 10 and 11 are not a pro cedure for charging the system Minor variations in these pressures may be expected due to differences in
40. ice valve for HS21 411 511 and 060 is illustrated in figure 11 The suction line service valve for HS21 036 048 and 060 is illustrated in figure 12 The valve is equipped with a service port A schrader valve is factory installed A service port cap is supplied to protect the schrader valve from contamination and assure a leak free seal To Access Schrader Valve 1 Remove service port cap with an adjustable wrench 2 Connect gauge to the service port 3 When testing is completed replace service port cap Tighten finger tight then an additional 1 6 turn To Open Suction Line Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and 5 16 hex head extension back the stem out counterclockwise until the valve stem just touches the retaining ring 3 Replace stem cap tighten firmly Tighten finger tight then tighten an additional 1 6 turn Page 13 LIQUID LINE SERVICE VALVE HS21 036 048 060 SERVICE PORT OUTLET TO COMPRESSOR INLET TO SCHRADER VALVE FIGURE 10 SUCTION LINE SERVICE VALVE HS21 411 511 651 VALVE OPEN INSERT HEX WRENCH HERE PART 49A71 AND SNAP RING SERVICE WRENCH INLET SEAL FROM INDOOR COIL STEM CAP SCHRADER VALVE SERVICE PORT CAP OUTLET SERVICE PORT O COMPRESSOR FIGURE 11 SUCTION LINE BALL TYPE SERVICE VALVE HS21 036 048 060 VALVE OPEN SE
41. ies from termi nals 1 common and 7 The windings form a four pole motor operating at 1800 RPM The four low speed start windings are in series and are connected to terminals 1 common and 8 They are used with the start and run capacitors and start relay to start and bring the motor up to speed High speed compressor operation is provided when the run windings are connected in parallel terminals 1 common and 7 to L1 and terminal 2 to L2 The windings form a two pole motor operating at 3600 RPM The two high speed start windings are in series and are connected to terminals 1 common and 3 Three Phase Compressor Start Up Figure 15 shows the windings of three phase two speed compressors The compressors have two speed three phase induction motors Capacitors are not needed to provide the proper phase and torque characteristics Low speed operation is provided when the motor windings are connected a series Delta circuit The motor operates at 1800 RPM High speed operation is provided when the motor windings are connected in a parallel Delta circuit Normally closed contacts on the low speed contactor provide this connec tion The motor operates at 3600 RPM Page 18 SINGLE PHASE MOTOR WINDINGS LOW SPEED MOTOR CER TERMINA COMMON RUN WINDINGS HIGH SPEED START WINDINGS LOW SPEED START WINDINGS START RELAY SINGLE PHASE MOTOR WINDINGS HIGH SPEED MOTOR LEAD TERMINALS RUN WINDINGS HIGH SPEE
42. in a j 24 NooBades 3 03104 O Condenser Moor lt ue mw 14 cim 8320 320 420 Rom 85 85 85 y O was jJ 170 470 30 Refrigerant Charge HCFC 22 fibs Goz 1 sibs 3 Cw S 2 F RN ELECTRICAL DATA Early Model Model No a HS21413 521511 521513 521651 521653 Line voltage data 60hz 208 230 1 208 230 3ph 208 230 1ph 208 230 3ph 208 230 1ph 208 230 3ph 322222222222 Compressor Powerfactor o 95 9 50 Lockedrotoramps 90 600 71200 141 0 Outdoor Fulloadamps 10 10 10 10 07 17 Fan Motor Lockedrotoramps 49 19 1 9 19 29 29 aus dr os we jou Minimumciruitampacity 230 969 0 28 652 266 Refer to National Electrical Code Manual to determine wire fuse and disconnect size requirements NOTE Extremes of operating range are plus 10 and minus 5 of line voltage Tech nical 1999 Lennox Industries Inc Publications Page 1 Litho U S A SPECIFICATIONS Late Models Model No HS21 036 HS21 048 HS21 060 Nominal Tonnage 3 4 5 Liquid line in mm o d connection sweat 3 8
43. mally closed contacts form a parallel DELTA connection to the motor windings for high speed 13 N O K69 1 contacts close to begin compressor high speed start up Compressor terminal 4 is energized by contactor K69 terminal L1 T1 Compressor terminal 6 is energized by contactor K69 terminal L2 T2 Compressor terminal 5 is energized by contactor K69 terminal L3 T3 THREE PHASE COOLING SEQUENCE 14 1st stage cooling demand energizes TB15 Y1 TB15 Y1 energizes TSC terminal JP44 6 and relay K10 NOTE 2nd stage cooling demand may be energized directly without passing through 1st stage 15 Relay contacts K10 1 switch to energize the outdoor fan and to de energize the crankcase heater 16 TSC delays 3 seconds before responding to the new command 17 If the unit is changing from 2nd stage to 1st stage demand TSC initiates speed change delay and de energizes JP44 8 and JP44 9 to stop all unit operation for 60 5 seconds Outdoor fan continues to operate After TSC completes the 5 second speed change delay or if the unit is starting up in 1st stage directly from OFF mode TSC checks safety circuits by looking for 24VAC at JP44 7 and by checking resistance through wires connected to S1 and S2 18 If all safety circuits check out TSC energizes K1 and compressor begins low speed start up 19 2nd stage cooling demand energizes TB15 Y1 and TB15 Y2 TB15 Y2 energizes TSC terminal JP44 4 TB15 Y1 energizes TSC terminal JP44 6 and outdoor fan relay K10
44. ngle phase only All single phase HS21 units use a potential relay to control the operation of the compressor starting circuit The relay is nor mally closed when the compressor contactor K1 is de energized Capacitor C7 is connected in series to a set of normally closed K31 contacts and assists the compressor in starting When K1 energizes the compressor immediately begins start up K31 remains de energized during compres sor start up and the start capacitor C7 remains in the circuit As the compressor gains speed K31 is energized by electro motive forces generated by the compressor When K31 energizes its contacts open to take the start capacitor out of the circuit 5 Fan Capacitor C1 three phase units only All three phase HS21 series units use single phase perma nent split capacitor PSC fan motors which require an external run capacitor Ratings will be printed on side of ca pacitor 6 Start Capacitor C7 single phase only All single phase HS21 units are equipped with a start ca pacitor connected in parallel with the compressor side of the dual capacitor The capacitor is switched off by the po tential relay when the compressor nears full speed The start capacitor is rated 145 175mfd 330VAC in all single phase units 7 Bleed Resistor R21 single phase only All single phase HS21 units are equipped with a bleed resistor connected in parallel with start capacitor C7 The resistor is used to slowly discharge th
45. ontrol Fault Conditions If the control is in low speed operation high speed operation OFF mode or speed change delay the control counts or accumulates faults on an internal cycle counter Only faults which occur during compressor operation and which cause the compressor to shut off are counted After a fault is counted the control stops unit operation resets and begins a five minute time delay step 2 operation sequence If the control senses a fault at the end of five minutes the unit will not restart If the control counts three faults during the same thermostat demand the control locks out unit operation IMPORTANT If the control locks out it can be reset by breaking IMPORTANT Intermittent continuity bad connection or failing components can cause false lockout or lit diagnos tic lights Check electrical connections thoroughly A fault occurs when 1 Compressor operation is monitored by high and low pressure switches These controls are wired in series If either one trips compressor operation is interrupted and one fault is counted The control locks out compressor operation for a minimum of five minutes when a safety device terminates operation High pressure switch must be reset manually but low pressure switch resets auto matically thermostat demand for about five seconds then re making thermostat demand Also anytime thermo stat demand is removed or power is interrupted the control re
46. ower does not run during this mode The test mode cannot run more than once every 5 minutes LED LIGHTS Y1 and Y2 lights are connected directly to the inputs from the thermostat They indicate low and high speed demand re spectively The HI and LO lights are connected directly across the con tactor coils They indicate if the high and low speed contactors are energized The HEARTBEAT light is connected to the microcontroller unit MCU It indicates when the control s MCU is operating correctly and also when the control is in delay mode It blinks at a rate of four times a second when the MCU is operating properly and at a rate of once every two seconds when in the delay mode such as the 1 or 5 minute delay If the LED is continuously on or off assuming the power is on the MCU is not operating properly and the control needs to be replaced The D1 D2 D4 and D8 see figure 7 diagnostic lights dis play diagnostic codes to aid in unit troubleshooting Refer to Diagnostic Code Table table 5 Diagnostic Code Display A problem code is normally displayed only for the duration of the error There is one exception During a lockout the code for the problem causing the lockout flashes once a second even if the problem condition no longer exists If other prob lems occur during a lockout condition the codes for those problems will be saved in memory but not displayed The stored problem codes are displayed by recalling them from memory
47. peed demand energizes contactor K1 K1 de en ergizes the crankcase heater and energizes the compressor and condenser fan High speed demand energizes both contactors K1 and K69 K69 N O con tacts close to redirect the circuit to the high speed start windings and the N C contacts open to de energize the low speed start windings K69 2 N C contacts and K69 2 N O contacts also switch when K69 is energized to ensure that K1 is energized with K69 during high speed operation refer to unit wiring diagram Contactor Operation Three Phase Units Low speed demand energizes contactor K1 K1 ener gizes the compressor and locks out contactor K69 High speed demand de energizes K1 and energizes contac tor K69 K69 locks out K1 through the K69 1 contacts and energizes the compressor on high speed K1 is wired so that when de energized the contactor forms a parallel common connection to the motor windings for high speed forming a parallel Delta connection for Copeland compressors When K1 is energized the contactor forms a series Delta connection to the compressor windings Refer to operation sequence in back of this manual for more infor mation 3 Outdoor Fan Relay K10 three phase only All three phase HS21 series units use an outdoor fan relay K10 to control the operation of the condenser fan and the crankcase heater The relay energizes the condenser fan and de energizes the crankcase heater during demand 4 Potential Relay K31 si
48. 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 evi dence 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 the condensate line and clean it 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 Page 17 VII Miscellaneous If the fan orifice should ever need to be removed for service make sure the control box seals watertight before placing the unit back in service Figure 13 shows the components used to make the control box watertight Two screws securing the
49. sets to zero faults IMPORTANT If the cycle counter counts three faults during the same thermostat demand the control locks out The outdoor unit remains inoperable until thermostat de mand is broken This indicates further troubleshoot ing is needed Though the control can be reset by breaking thermostat demand the unit may remain in operable The high pressure or low pressure condi tions may still exist and must be located and cor rected before the unit can be placed back in service See diagnostic codes to determine problem Page 9 It is likely that the control could count three unit faults from the low pressure switch during a single thermo stat demand since this switch resets automatically However the cycle counter can only count unit faults from the high pressure switch if the reset button is pushed without interrupting thermostat demand On all units using the TSC two speed control terminals S1 and 52 on the control are connected to temperature sensors thermistors which monitor the temperature of the compressor motor windings The two speed control measures the resistance through the sensors The sen sors increase their resistance as temperature increases for example too much superheat When the resistance through the sensors increases above preset limit the control stops compressor operation for a minimum of five minutes As the compressor windings cool the re sistance through the sensors drops below
50. t rebuildable If a valve has failed it must be replaced The liquid line service valve for 521 411 511 and 060 is illustrated in figure 9 The liquid line service valve for HS21 036 048 and 060 is illustrated in figure 10 The valve is equipped with a service port There is no schrad er valve installed in the liquid line service port A service port cap is supplied to seal off the port The liquid line service valve is a front and back seating valve When the valve is backseated the service port is not pressur ized The service port cap can be removed and gauge connections can be made CAUTION A schrader valve is not provided on the liquid line service port The service port cap is used to seal the liquid line on the service valve Access to service port requires backseating the service valve to isolate the service port from the system Failure to do so will cause refrigerant leakage LIQUID LINE SERVICE VALVE HS21 411 511 651 d A IMPORTANT A schrader valve is not provided on the liquid line service port Valve must be backseated to turn off pressure to service port q SERVICE PORT TO LINE SET WHEN FRONT SEATED AND CLOSED OFF WHEN BACK SEATED KNIFE EDGE SEAL VALVE STEM USE SERVICE WRENCH PART 18P66 54B64 or 12P95 FIGURE 9 To Access Service Port 1 Remove the stem cap Use a service wrench to make sure the service valve is backseated 2
51. the reset limit the control resets automatically and one fault is counted Check sensors by measuring resistance ohms through the sensors with the wires disconnected from the control unit not running The sensor wires are not polarity sensi tive Table 3 shows winding temperature sensor resistance values which will cause the TSC to lock out When unit is operating normally resistance through the sensors should be below the trip value shown in table 3 TABLE 3 Trip Ohms Temp Rise 25K to 35K Reset Ohms Temp Fall 8 4K to 10K Compressor Winding Temperature Sensor TSC5 Copeland Compressor The control can be checked by comparing the resist ance measured through the sensors to the voltage measured across the sensor terminals with the unit running Table 4 shows voltage measured across two speed control terminals S1 and S2 with the compressor running TABLE 4 COMPRESSOR WINDING SENSOR OPERATING RANGE Resistance Through Compressor Winding Temperature Sensor K ohms ohms x 1000 Voltage Across TSC5 compressor sensor terminals with Unit Running DC Volts 0 1 70 2 6 07 6 48 6 86 7 33 7 55 8 07 8 16 8 72 9 69 10 36 10 34 11 05 10 82 11 57 10 93 11 68 11 35 12 14 11 68 12 48 DC volts Measured with unit running MODE SELECTION JUMPERS The control has six mode selection jumpers for selection of operating mo
52. 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 CAUTION Danger of Equipment Damage Avoid deep vacuum operation Do not use compres sors 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 Page 15 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 lt When the absolute pressure requirement above has been met disconnect the manifold hose from the vacu um pump and connect it to an upright cylinder of HCFC 22 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 HCFC 22 cylinder and remove the manifold gauge set C Charging The following procedures are intended as a general guide for use with expansion valve systems only For best results
53. up to 50 ft Consult Len nox Refrigerant Piping Manual Corp 9351 L9 for line sets over 50 ft A 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 WARNING Refrigerant can be harmful if it is inhaled Refriger ant must be used and recovered responsibly Failure to follow this warning may result in personal injury or death AWARNING Danger of explosion Can cause equipment damage injury or death Never use oxygen to pressurize a re frigeration or air conditioning system Oxygen will explode on contact with oil and could cause personal injury Page 14 WARNING Danger of explosion cause equipment dam age 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 or Halide 1 Connect a cylinder of HCFC 22 to the center port of the manifold gauge set 2 With both manifold valves closed open the valve on the HCFC 22 cylinder vapor only 3 Open the high pressure side of the manifold to allow the HCFC 22 into the line set and indoor unit Weigh in a trace amount of HCFC 22 A trace amount is a max imum of 2 ounces 57 g or 3 pounds 31 kPa pressure Close the valve on the HCFC 22 cylinder and the valve on the hi
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