Lennox HP21 Unit Information
Hp21 series
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- Installation instructions manual (10 pages) ,
- Installation instructions manual (22 pages)
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Service Literature
HP21 SERIES UNITS INCLUDING TSC−2, TSC−3 AND TSC-6
The HP21 is a high efficiency residential split-system heat
pump with a two-speed compressor. Early models include
HP21−411, −511 and −651. Late models built after March 1,
2000 include HP21−36, −48 and −60. All models are avail-
able in sizes ranging from 3 through 5 tons in either single
or three-phase configuration. Early and late models feature
solid-state two-speed control and new solid-state demand
Defrost Control. The two-speed control regulates compres-
sor speed in response to thermostat demand during
cooling mode. Compressor speed is regulated by outdoor
air temperature during heating mode. The defrost control
monitors outdoor air temperature and liquid line tempera-
ture to determine when defrost is needed. The series uses
conventional heat pump circuitry with expansion valves in
the outdoor and indoor units.
This manual is divided into sections which discuss the com-
ponents,
refrigerant
system,
Maintenance and operation sequences. All specifications
in this manual are subject to change.
DANGER
Electric Shock Hazard.
May cause injury or death.
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 unit panel.
Unit may have multiple power supplies.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
be performed by a qualified installer or service
agency.
WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant
must be used and recovered responsibly.
Failure to follow this warning may result in person-
al injury or death.
Corp. 9434−L12
Revised 07−2007
procedures,
Page 1
TABLE OF CONTENTS
General
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Specifications / Electrical
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II Unit Components
. . . . . . . . . . . . . . . . . . . . . . . . . . .
TSC−2 Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TSC−3 Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TSC−6 Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
III Refrigerant System
. . . . . . . . . . . . . . . . . . . . . . . . .
IV Charging
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VI Miscellaneous
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII Wiring Diagrams and Operating Sequence
HP21
EARLY/LATE MODEL
. . . . . . . . . . . . . . . . . . . . . .
. . . .
© 1994 Lennox Industries Inc.
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Summary of Contents for Lennox HP21
- Page 1 The HP21 is a high efficiency residential split-system heat pump with a two-speed compressor. Early models include HP21−411, −511 and −651. Late models built after March 1, 2000 include HP21−36, −48 and −60. All models are avail- able in sizes ranging from 3 through 5 tons in either single or three-phase configuration.
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Page 2: Specifications
SPECIFICATIONS HP21−411 HP21−36−230 HP21−511 HP21−48−230 HP21−651 HP21−60−230 Model No. HP21−36−233 HP21−413 HP21−653 HP21−48−233 HP21−60−233 HP21−513 Face area (sq.ft.) 18.22/ 21.64/ 23.92/ outside / inside 17.53 20.81 23.01 Tube diameter (in.) Outdoor Coil No. of Rows Fins per inch Diameter (in.) No. - Page 3 B−Contactors K1 and K69 Bleed Resistor R21 Fan Capacitor C1 The compressor is energized by a set of contactors located Compressor B1 in the control box. Contactors in HP21 units are energized Outdoor Fan B4 as shown in table 2. Page 3...
- Page 4 DEFROST RELAY SPEED CONTROL 24V TERMINAL THERMOSTAT S55 STRIP TB15 EARLY HP21 -1 / -2 / -3 SINGLE PHASE SERIES UNITS USE FAN CAPACITOR C1 AND COMPRESSOR CAPACITOR C5 IN PLACE OF FIGURE 2 Contactor K1 Contactor Operation: Single-Phase Units Contactor K1 energizes low speed compressor operation Low speed demand energizes K1.
- Page 5 In three-phase units, the outdoor fan is controlled by contactor K10 and is de-energized All single-phase HP21 units are equipped with a hard start when the defrost relay is energized. See figure 4 if outdoor relay located in the unit control box which controls the op- fan motor replacment is necessary.
- Page 6 N−Fan Capacitor C1 compressor operation in response to thermostat demand. All early model HP21 -1 / -2 / -3 single phase and all HP21 High speed operation can be energized and de−energized three−phase series units (regardless of dash number) use without passing through low speed.
- Page 7 TSC-2 TWO-SPEED CONTROL S1 and S2 TO COMPRESSOR WINDING TEMPERATURE SENSORS JP44−1 24VAC POWER (INPUT) S1 MANUAL OVERRIDE JP44−2 24VAC NEUTRAL (GROUND) OF 5 MINUTE DELAY JP44−3 NOT USED JP44−4 2nd STAGE THERMOSTAT DEMAND RED DIAGNOSTIC LED JP44−5 THERMOSTAT COMMON (C) JP44−6 1st STAGE THERMOSTAT DEMAND JP44−7...
- Page 8 Two-Speed Control Fault Conditions It is likely that the control could count three unit faults from the crankcase temperature switch during a single If the control is in low speed operation, high speed opera- thermostat demand since this switch resets automati- tion, OFF"...
- Page 9 TABLE 3 tion). If compressor starts, the control is good and should Compressor Winding Trip Ohms Reset Ohms not be replaced. Proceed through the troubleshooting flow- Temperature Sensor Temp. Rise Temp. Fall chart in the Unit Information Manual to locate the source of TSC−2 Bristol or Copeland the lockout.
- Page 10 When temperature rises above the setpoint, the control TSC-3 Two-Speed Control initiates a speed change delay and automatically ener- All early model HP21 -2 series units (single and three gizes low speed. phase) are equipped with a TSC-3 two-speed control. The...
- Page 11 TSC-6 Two-Speed Control HP21 -4 and -5 and late model HP21 units (single and three phase) are equipped with a TSC-6 two-speed con- trol. The TSC-6 (A14) two-speed control contains relays which energize compressor operation in response to thermostat demand. High speed operation can be ener- gized and de-energized without passing through low speed.
- Page 12 TSC-6 (A14) TWO-SPEED CONTROL COMPONENTS OPTION 1 ENABLE MODE OPTION 2 ENABLE JUMPER DIAGNOSTIC LEDs SELECTION JUMPER D8, D4, D2, D1 JUMPERS HEARTBEAT MANUAL OVERRIDE BUTTON COMPRESSOR SENSOR Y1 LED CONNECTORS LOW SPEED lock out Y2 LED TEMP. ADJUSTMENT OUTDOOR TEMP.
- Page 13 watt resistor in series with one of the sensor connections on IMPORTANT the two−speed control. (The resistor can be found at elec- tronic stores such as Radio Shack). Table 7 shows the If the control locks out, it can be reset by breaking resistor in series with the control and compressor.
- Page 14 Some codes do indicate malfunc- TEST MODE tions or problems with either the control or the HP21, while The control has a test mode. To initiate this mode, move the others inform the technician of the unit’s status. All codes, ex- jumper to the test position and push the control button.
- Page 15 The unit wiring diagrams have been revised to reflect the Code 12 − Outdoor Temperature Sensor This code indicates a problem with the operation of the out- changes for the HP21-4/-5 (TSC-6), and are shown in section door temperature sensor. Code 12 is stored. VII−Wiring Diagrams and Operation Sequence.
- Page 16 S−Ambient Compensation Thermistor RT3 and S55 opens. HP21 units are equipped with an ambient compensation TABLE 9 thermistor (RT3) attached to the outdoor fan motor bracket. Speed Control Thermostat...
- Page 17 AMBIENT COMPENSATION THERMISTOR Ambient Temperature Resistance Through Sensor ambient temperature, the control proceeds to the next ° ohms step. TABLE 11 Lockout Time (Minutes) Ambient HP21−411/−511 HP21−651 ° Temperature HP21−413/−513 HP21−653 T−Defrost Control CMC1 HP21−36−230/233 HP21−60−230/233 HP21−48−230/233 The CMC defrost control (figure 13) is a solid state control manufactured by Ranco.
- Page 18 TABLE 12 SOLID STATE DEFROST CONTROL CMC1 DEFROST INITIATION NOTE−The symbol ∆T (pronounced delta T) is used to represent AMBIENT TEMP. the difference between liquid line temperature and ambient tem- SENSOR (RED) perature. The defrost control compares actual ∆T to a calculated LIQUID LINE ∆T to determine when to initiate defrost.
- Page 19 If the control HP21−3 Units determines that the coil temperature sensor has failed, the HP21−3 units are equipped with a demand defrost system control will not initiate a defrost cycle. which initiates a defrost cycle based on temperature differ- Test Mode ential and compressor run time.
- Page 20 MODEL NO. C−Reversing Valve LINE LINE LINE SETS HP21−410 L10−41 HP21 units are equipped with a reversing valve which is 3/8 in. 3/4 in. HP21−36 20 ft. − 50 ft. used to reverse refrigerant flow. The valve is de-energized HP21−510 L10−65...
- Page 21 The accumulator can be accessed without removing the compressor. To access the accumulator, remove the out- All HP21 units are equipped with a filter/drier located in a door fan guard. Then remove the fan motor and bracket as circuit parallel to the expansion valve. The filter/drier is an assembly.
- Page 22 SION VALVE WITH INTER- NAL CHECK VALVE FIGURE 19 J−Charge Compensator CHARGE COMPENSATOR OPERATION HP21−410, −650, −36 and −60 series units are equipped with HEATING MODE COOLING MODE a charge compensator located in the vapor line between Vapor Line the reversing valve and outdoor coil manifold. Figure 19...
- Page 23 L−Low Ambient Control Kit (Optional) should not be opened more than 5 turns. Opening The HP21 unit will operate satisfactorily down to 45°F (7°C) or closing the valve does not close the service port. outdoor air temperature without any additional controls. For...
- Page 24 NOTE−If electronic leak detector is used, add a trace of shown on the unit nameplate and in table 14. Refer to the refrigerant to the nitrogen for detection by the leak de- Lennox Unit Information Service manual for proper proce- tector. dure.
- Page 25 D−Oil Charge TABLE 16 Liquid Temp Minus Am- Model ° Factory oil charge in all HP21 series units is 70 fl. oz. Re- bient Temp. ( placement oil charge is 66 fl.oz. 9 + 2 HP21−411/413, HP21−36−230/233 HP21−511/513, HP21−48−230/233...
- Page 26 2− Inspect coil. Clean if necessary. along the top edge (between the control box and the cabi- net). 3− Rotate blower wheel to check for binding bearings. Lennox blower motors are prelubricated and sealed. HP21 CONTROL BOX No further lubrication is required. WEATHERPROOFING 4−...
- Page 27 VII−WIRING DIAGRAMS AND OPERATION SEQUENCE A−Field Wiring FIELD WIRING DIAGRAM HP21 WITH CB21 24VAC 18GA. MIN. THREE-PHASE LINE VOLTAGE FIELD WIRING 208−230/60/3 COMPRESSOR CONTACTOR USE COPPER CONDUCTOR ONLY SINGLE-PHASE LINE VOLTAGE FIELD WIRING 208−230/60/1 COMPRESSOR CONTACTOR REFER TO UNIT RATING PLATE FOR MAXIMUM CIRCUIT AMPAC- ITY AND MAXIMUM FUSE SIZE.
- Page 28 FIELD WIRING DIAGRAM HP21 WITH CB31MV FACTORY-SUPPLIED, FIELD-INSTALLED JUMPERS REQUIRED Humidity Jumpers Outdoor Unit Control Required With CCB1 Single-Speed Heat Pump Y1 to Y2 Humidity Two-Speed Heat Pump none Control DS to Y1 and Without CCB1 Single-Speed Heat Pump Y1 to Y2...
- Page 29 B−Operation Sequence − Compressor SINGLE-PHASE MOTOR WINDINGS LOW SPEED MOTOR LEAD TERMINALS Single-Phase Compressor Startup COMMON Figure 26 shows single-phase compressor windings. This compressor has a two speed capacitor-start, capacitor-run motor. For starting, the start and run capacitors are in par- allel to provide the proper starting torque.
- Page 30 FIGURE 28 C−SINGLE-PHASE STARTING SEQUENCE defrost control CMC1, reversing valve L1, speed control thermostat S55, service light thermostat S54 and ambient thermistor RT3 in out- 1− Line voltage feeds through L1 and L2 to energize outdoor transformer door unit. T19 and outdoor unit. Crankcase heater is energized through relay K1 4−...
- Page 31 D−SINGLE-PHASE COMPRESSOR STARTUP LOW SPEED 1− 1st stage demand: If all safety circuits check out, TSC energizes JP44-9. 2− 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- 3−...
- Page 32 FIGURE 30 E−SINGLE-PHASE COOLING SEQUENCE 5− 2nd stage cooling demand energizes TB15-Y1, TB15-Y2 and TB15-O. TB15-O energizes TSC terminal JP44-4. TB15-O energizes TSC ter- 1− 1st stage cooling demand energizes TB15-Y1 and TB15-O. TB15-O minal JP44-6 and defrost control terminal HOLD. energizes reversing valve L1.
- Page 33 FIGURE 31 F−SINGLE-PHASE HEATING SEQUENCE compressor begins operating at low or high speed as determined by speed control thermostat S55. 1− Speed control thermostat S55 determines whether the compressor is 4− 2nd stage heating demand energizes TB15-Y1 and TB15-W1. to operate on high or low speed based on outdoor temperature. If out- TB15-Y1 energizes TSC, speed control thermostat S55 and defrost door temperature drops below set temperature, S55 closes to shunt control terminal HOLD.
- Page 34 FIGURE 32 G−SINGLE-PHASE DEFROST SEQUENCE 3− Refer to the unit component section of this manual for detailed defrost control operation. Defrost is terminated when relay K4 is de-ener- 1− When the defrost control determines a defrost needs to be initiated it gized.
- Page 35 S1, S2 DENOTE TERMINAL DESIGNATIONS FIGURE 33 H−THREE-PHASE STARTING SEQUENCE defrost control CMC1, reversing valve L1, outdoor fan relay K10, speed control thermostat S55, service light thermostat S54 and ambi- 1− Line voltage feeds through L1, L2 and L3 to energize outdoor trans- ent thermistor RT3 in outdoor unit.
- Page 36 I−THREE-PHASE COMPRESSOR STARTUP LOW SPEED 1− Low speed demand energizes outdoor fan relay K10 and JP44−6. K10-1 switches to energize the outdoor fan and de-energize the crank- case heater. Outdoor fan begins operating immediately. 2− After appropriate time delay and if all safety circuits check out, TSC energizes JP44-9.
- Page 37 S1, S2 DENOTE TERMINAL DES- IGNATIONS FIGURE 35 J−THREE-PHASE COOLING SEQUENCE 6− 2nd stage cooling demand energizes TB15-Y1, TB15-Y2 and TB15-O. TB15-Y2 energizes TSC terminal JP44-4. TB15-Y1 energizes TSC 1− 1st stage cooling demand energizes TB15-Y1 and TB15-O. TB15-O terminal JP44-6, defrost control terminal HOLD and outdoor fan relay energizes reversing valve L1.
- Page 38 S1, S2 DENOTE TERMINAL DESIGNATIONS FIGURE 36 K−THREE-PHASE HEATING SEQUENCE compressor begins operating at low or high speed as determined by speed control thermostat S55. 1− Speed control thermostat S55 determines whether the compressor is 4− 2nd stage heating demand energizes TB15-Y1 and TB15-W1. to operate on high or low speed based on outdoor temperature.
- Page 39 S1, S2 DENOTE TERMINAL DESIGNATIONS FIGURE 37 L−THREE-PHASE DEFROST SEQUENCE 3− Refer to the unit component section of this manual for detailed defrost control operation. Defrost is terminated when relay K4 is de-ener- 1− When the defrost control determines a defrost needs to be initiated it gized.
- Page 40 HP21-2/-3 Wiring (Single Phase Units Shown)
- Page 41 HP21-2/-3 Wiring (Three Phase Units Shown)
- Page 42 HP21-4/-5 Wiring (Single Phase Units Shown)
- Page 43 HP21-4/-5 Wiring (Three Phase Units Shown)
- Page 44 HP21-36−230/60−230 Wiring...
- Page 45 HP21-36−233/60−233 Wiring...
- Page 46 HP21−36−230 / 60−230−3 UNITS SINGLE PHASE Page 46...
- Page 47 HP21−36−230 / 60−230−3 UNITS OPERATION SEQUENCE SINGLE-PHASE COOLING SEQUENCE SINGLE-PHASE HEATING SEQUENCE The TSC two−speed control has an external temperature probe 10−1st stage demand energizes TB15-Y1. TB15-Y1 energizes to lockout low speed during low temperatures, plus a poten- TSC, and defrost control. Defrost control initializes timing tiometer used for setting the low speed lock out temperature.
- Page 48 HP21−36−230 / 60−230−3 UNITS THREE PHASE Page 48...
- Page 49 HP21−36−230 / 60−230−3 UNITS OPERATION SEQUENCE THREE−PHASE COOLING SEQUENCE THREE−PHASE HEATING SEQUENCE The TSC two−speed control has an external temperature probe 10−1st stage demand energizes TB15-Y1. TB15-Y1 energizes to lockout low speed during low temperatures, plus a poten- TSC, and defrost control. Defrost control initializes timing tiometer used for setting the low speed lock out temperature.
- Page 50 VIII−TROUBLESHOOTING FLOWCHARTS wires as possible. Any time a repair is made, reassemble the unit and retest for operation. If the unit does not oper- ate, recheck up to that point and then continue through the The following flowcharts show how to diagnose problems chart.
- Page 51 TABLE 20a HP21 UNIT CONTROLS DIAGNOSTICS START HERE CHECK SUPPLY VOLTAGE. IS SUPPLY VOLTAGE WITHIN RANGE SHOWN ON UNIT RATING PLATE? CORRECT POWER SUPPLY. MANUALLY RESET HIGH PRESSURE SWITCH S4 IN OUTDOOR UNIT IF TRIPPED. CHOOSE COOLING OR HEATING MODE...
- Page 52 TABLE 20b CONTINUED FROM A ON PREVIOUS PAGE CONTINUED FROM B ON PREVIOUS PAGE CHECK VOLTAGE ACROSS TERMINALS Y1 AND X CHECK VOLTAGE ACROSS TERMINALS Y1 AND X AND Y2 AND X AT UNIT LOW VOLTAGE TERMINAL AT UNIT LOW VOLTAGE TERMINAL STRIP TB15. STRIP TB15.
- Page 53 SERVICE NOTES Page 53...