Lennox CHA16 Service Manual Download Page 13 | Manualshive

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Page 13

1353/1603 PARTS ARRANGEMENT

COMPRESSOR

AND CONTROL BOX

ACCESS

1st STAGE

CONDENSER

COIL

2nd STAGE

CONDENSER COIL

2nd STAGE

CONDENSER

FAN

FILTER SECTION

INDOOR BLOWER

1st STAGE

COMPRESSOR

2nd STAGE

COMPRES

SOR

1st STAGE EVAPORATOR

2nd STAGE EVAPORATOR

BLOWER ACCESS

HEATING ACCESS

HEATING ELEMENTS

ELECTRIC

HEAT

CONTROL BOX

MAKE-UP BOX

FIGURE 2

1353/1603 PARTS ARRANGEMENT

LEFT CONDENSER FAN

FILTER ACCESS

BLOWER ACCESS

COMPRESSOR/

CONTROL ACCESS

RIGHT CONDENSER COIL

LEFT

CONDENSER COIL

FILTERS

EVAPORATORS

BLOWER

BLOWER MOTOR

CONTROL BOX

HEATING ACCESS

HEATING ELEMENTS

ELECTRIC HEAT

CONTROL BOX

MAKE-UP BOX

FIGURE 3

COMPRESSORS

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Summary of Contents for CHA16

Page 1: ...s Arrangement Pages 12 16 I APPLICATION Page 16 II UNIT COMPONENTS Pages 16 27 Control Box Components Pages 16 19 Cooling Components Pages 19 25 Blower Compartment Power Make Up Pages 25 26 III ELECTR...

Page 2: ...ing evaporator air Using total air volume and system static pressure requirements determine from blower performance tables rpm and bhp required Maximum usable hp of motors furnished by Lennox are show...

Page 3: ...with ARI Standard 210 240 or 360 95 F outdoor air temperature and 80 F db 67 F wb entering evaporator air Using total air volume and system static pressure requirements determine from blower performa...

Page 4: ...entering evaporator air minimum external duct static pressure Using total air volume and system static pressure requirements determine from blower tables rpm and bhp required Maximum usable hp of moto...

Page 5: ...F wb entering evaporator air minimum external duct static pressure Using total air volume and system static pressure requirements determine from blower performance tables rpm and bhp required Maximum...

Page 6: ...oor air temperature and 80 F db 67 F wb entering evaporator air minimum external duct static pressure Using total air volume and system static pressure requirements determine from blower performance t...

Page 7: ...ompressors Rated load amps total 57 6 28 8 61 8 33 6 74 2 35 6 86 0 42 0 Compressors Locked rotor amps each 3 124 3 62 2 205 0 2 104 0 2 239 0 2 120 0 2 269 0 2 135 0 Locked rotor amps total 372 0 186...

Page 8: ...90 1050 2 05 1085 2 20 3200 815 1 20 885 1 45 940 1 70 975 1 75 1005 1 90 1045 2 10 1080 2 20 3400 860 1 45 920 1 65 975 1 85 1010 2 00 1045 2 15 1080 2 30 3600 900 1 70 960 1 90 1015 2 10 1045 2 25 3...

Page 9: ...ume cfm 20 40 60 70 80 90 1 00 1 10 1 30 1 50 cfm RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 5000 540 1 50 600 1 70 660 1 95 690 2 20 720 2 25 740 2 40 765 2 60 78...

Page 10: ...5 6 60 815 6 90 830 7 15 845 7 40 860 7 65 875 7 90 890 8 15 905 8 40 9000 620 4 50 645 4 80 665 5 05 685 5 30 700 5 50 720 5 75 740 6 05 755 6 25 775 6 55 790 6 75 805 7 00 825 7 30 840 7 55 855 7 80...

Page 11: ...0 10 06 06 22 19 16 10 4400 11 07 07 28 24 20 12 4600 12 07 07 34 29 24 15 4800 13 08 08 40 34 29 19 CHA16 1603 5000 14 08 08 46 39 34 23 CHA16 1603 5200 15 09 09 52 44 39 27 5400 16 10 10 58 49 43 31...

Page 12: ...0 43 52 40 50 4200 39 46 40 48 CHA16 1603 5000 41 50 43 52 5800 43 52 45 54 6000 45 55 48 55 CHA16 1853 6750 47 56 50 58 7500 49 58 55 66 CHA16 2553 8000 39 44 53 62 CHA16 2553 CHA16 2753 CHA16 3003 9...

Page 13: ...t STAGE EVAPORATOR 2nd STAGE EVAPORATOR BLOWER ACCESS HEATING ACCESS HEATING ELEMENTS ELECTRIC HEAT CONTROL BOX MAKE UP BOX FIGURE 2 1353 1603 PARTS ARRANGEMENT LEFT CONDENSER FAN FILTER ACCESS BLOWER...

Page 14: ...SOR 1st STAGE EVAPORATOR 2nd STAGE EVAPORATOR BLOWER ACCESS HEATING ACCESS HEATING ELEMENTS ELECTRIC HEAT CONTROL BOX MAKE UP BOX FIGURE 4 FIGURE 5 CHA16 823 953 CONTROL BOX COMPONENTS K2 K1 K3 K13 K1...

Page 15: ...MIT S3 2nd STAGE COM PRESSOR CONTAC TOR K2 CIRCUIT BREAKER CB5 FOR CONDENSER FAN B5 1603 UNITS ONLY CIRCUIT BREAKER CB4 FOR CONDENSER FAN B4 1603 UNITS ONLY COMBUSTION AIR BLOWER TRANSFORM ER T3 460V...

Page 16: ...an be removed from the unit and reused If unit must be lifted for service use only lifting brackets to lift unit B Control Box Components CHA16 control box is shown in figures 5 6 7 and 8 The control...

Page 17: ...rating 10 Compressor Contactor K1 all units K1 is a 24V to line voltage contactor used to energize the first compressor B1 in response to first stage cooling de mand All units use three pole double br...

Page 18: ...cond stage cooling In CHA16 1853 units the delay is energized si multaneously with compressor 1 contactor K1 and con denser outdoor fan contactor K10 In CHA16 1853 units once contactor K2 is energized...

Page 19: ...the compressor when resistance increases above a preset limit As the compres sor windings cool the resistance through the sensors drops and the control resets Table 2 shows the resistance values for...

Page 20: ...DENSER FAN 1st STAGE THERMOMETER WELL LIQUID LINE SERVICE PORT FILTER DRIER SUCTION LINE SERVICE PORT DISCHARGE LINE SERVICE PORT COMPRESSOR HIGH PRESSURE LIMIT S4 CONDENSER COILS 2 COMPARTMENT DIVIDE...

Page 21: ...TO LEFT CONDENSER RIGHT BRANCH TO RIGHT CONDENSER TEE FEEDS RIGHT CONDENSER TEE SUCTION LINE GAUGE PORT TEE FEEDS LEFT CONDENSER 2 3 CHA16 1853 PLUMBING COMPONENTS CONDENSING SECTION VAPOR LINES THERM...

Page 22: ...SERVICE VALVE GAUGE PORT HIGH PRESSURE SWITCH S4 LOSS OF CHARGE SWITCH S24 HIGH PRESSURE SWITCH S7 LOSS OF CHARGE SWITCH S25 HOT GAS SERVICE VALVE GAUGE PORT LIQUID SERVICE VALVE GAUGE PORT THERMOMETE...

Page 23: ...3 FREEZESTAT S50 FREEZESTAT S49 1ST STAGE PUMP 1 EXPANSION VALVE SUCTION LINE FIGURE 21 CHA16 2553 2753 3003 PLUMBING COMPONENTS EVAPORATOR SECTION 2 1 1st STAGE SUCTION RETURN TO COMPRESSOR 1st STAGE...

Page 24: ...p period could result in damaged or failed compres sors 2 Crankcase Heaters HR1 HR2 and HR5 CAUTION Self regulating crankcase heaters are connected to line voltage at all times not switched by unit ci...

Page 25: ...ure to eliminate all conditions which might promote evaporator ice buildup 7 Condenser Fans B4 and B5 The specifications tables on pages 2 6 in this manual shows the specifications of condenser fans u...

Page 26: ...in the base pan of the unit cabinet allow for passage of wires into conduit and roof mounting frame Special instructions are provided where needed for low volt age connections that cannot be made to...

Page 27: ...hour warm up period could result in damaged or failed compres sors 1 Set fan switch to AUTO or ON and move the system selection switch to COOL Adjust the thermostat to a setting far enough below room...

Page 28: ...he con trol system installed for detailed descriptions of blower operation 2 Generally blower operation is set at the thermostat fan switch With the fan switch in ON position the blower operates conti...

Page 29: ...ed with four pleated 2 throw away type filters Permanent 1 foam filters are ac ceptable replacements Filters should be checked monthly or more frequently in severe use and cleaned or replaced regularl...

Page 30: ...he fuse block factory installed Fuse block must be installed in field installed heaters See Optional Accessories tables CHA16 953 MODELS TABLE 5 Electric Heat Model No Net Weight No of Steps Volts Inp...

Page 31: ...ra Factory installed heaters will have the fuse block factory installed Fuse block must be installed in field installed heaters See Optional Accessories tables CHA16 1603 MODELS TABLE 7 Electric Heat...

Page 32: ...block must be installed in field installed heaters See Optional Accessories tables CHA16 2553 MODELS TABLE 9 Electric Heat Model No Net Weight No of Steps Volts Input kw Input Btuh Output Total Unit...

Page 33: ...ctory installed Fuse block must be installed in field installed heaters See Optional Accessories tables CHA16 3003 MODELS TABLE 11 Electric Heat Model No Net Weight No of Steps Volts Input kw Input Bt...

Page 34: ...275 300 75 which is equipped with two stages of heat is equipped with K18 K18 has a 24VAC coil which is energized after time delays DL2 DL4 DL5 and DL18 close in sequence When K18 is energized second...

Page 35: ...does not function when connected to CHA16 units 14 High Temperature Limit S20 Secondary Each heating element assembly is electrically connected to two high temperature limits S20 refer to wiring dia g...

Page 36: ...ts are listed in table 15 Heat Section Total Watts Number of Elements Arrangement CHA16 HEATING ELEMENTS ECH16 82 95 10 Y ECH16 82 95 10 G ECH16 82 95 10 J 10000 240V 10000 460V 10000 575V 3 Delta 3 W...

Page 37: ...y K19 2nd Stage Time Delay DL2 all units equipped with multiple stage heaters 3rd Stage Time Delay DL4 4th Stage Time Delay DL5 50 kW 208 230v Secondary Limit S20 2 each element 208 230V 15kW 2 208 23...

Page 38: ...Electric Heat Terminal Strip TB3 Electric Heat Transformer T2 2nd Stage Heat Demand 1st Stage Heat Demand Pilot Relay K9 Pilot Relay K19 2nd Stage Time Delay DL2 all units equipped with multiple stage...

Page 39: ...NT ELECTRIC HEAT SECTION 208 230V 75kW AND 460 575V 90kW 3rd Stage Heat 75kW Only 4th Stage Heat Time Delay DL18 3rd Stage Heat Contactor K17 4th Stage Heat Contactor K18 5th Stage Heat Contactor K75...

Page 40: ...s in CHA16 to allow a fixed amount of outside air into the system OAD16 consists of a set of manually operated dampers which may be adjusted and locked in place to allow up to 25 percent outside air i...

Page 41: ...hifted to the first stage compressor while the dampers remain open to provide first stage cooling If outdoor air be comes unacceptable the outdoor air dampers close to a predetermined minimum position...

Page 42: ...power exhaust fans figure 42 are used in conjunction with REMD16M economizer to pro vide forced ex haust of return air PED16 consists of two fans figure 42 which install in the return air por tion of...

Page 43: ...ergizes the indoor thermostat and energizes the setback thermostat d Differential Enthalpy all economizers Optional differential enthalpy control may be added to any economizer to monitor both indoor...

Page 44: ...inimum Positioner The second type of adjustment which may be made at the control is the minimum position of the outdoor damper blades Each economizer has a minimum po sitioner switch potentiometer whi...

Page 45: ...nt electrical connections are made in relay kits and con trols located in the filter access area of the unit All connections except for enthalpy sensor and mixed air sensor are made with quick connect...

Page 46: ...available for use with the CHA16 Refer to manufacturer s instructions included with transition for detailed installation procedures F Firestats Some local codes require the installation of discharge a...

Page 47: ...Page 47 FIGURE 52 CYCLE CONTROL KIT WIRING DIAGRAM...

Page 48: ...n denser fan and the fan resumes operation The pressure switch will continue to cycle the fan in this fashion as long as low ambient conditions exist The low ambient thermostat if used is connected to...

Page 49: ...dur ing a heating demand f The FILTER LED lights red when optionalpressure switch contacts close indicating dirty filters g The SYSTEM switch on the SSP11 has five posi tions to indicate the following...

Page 50: ...ed to the unit wiring harness and is used for the connection of an optional power exhaust damper PED16 con trol kit The matching plug P24 is located in the optional PED16 control kit The PED16 control...

Page 51: ...16M 185 Downflow Modulating Economizer Optional field installed in all CHA16 units Sensors continuously moni tor air conditions and adjust dampers accordingly Infi nite number of damper positions All...

Page 52: ...e unit wiring harness between the unit and economizer Unit plug P3 is removed and dis carded Relay kit plug P8 connects to unit jack J3 Relay kit jack J8 connects to economizer plug P4 3 C1 Wiring Dia...

Page 53: ...pleted You may find some CHA16 1853 units using it 7 C4 Wiring Diagram Flexstat L2F N is for units with an economizer and warm up Setback is built in Thermostat wiring con nections are made to unit s...

Page 54: ...o the CHA16 Optional CMC3 1 time clock must also be used for night setback capa bilities The relay kit changes the thermostat setpoints for night setback A night thermostat is not needed 12 C14 1 Wiri...

Page 55: ...Page 55 NOTES...

Page 56: ...L THERMOSTAT C1 DIAGRAM ONLY OPTIONAL 16 SERIES CONTROLS WIRING DIAGRAMS ARE NOT PRINTED IN THIS MANUAL LOOK FOR CONTROL SYSTEM DIA GRAMS AND OPERATION SEQUENCES IN INDIVIDUAL UNIT IN FORMATION CONTRO...

Page 57: ...essure limit S24 to energize compressor contactor K1 11 Contactor K1 1 contacts close to energize compressor B1 12 Simultaneously when K66 1 closes time delay DL15 and contactor K10 are energized DL15...

Page 58: ...C1diagram electromechanical thermostat with modulating economizer with D5 diagram Page 58...

Page 59: ...emand Y1 is sent to enthalpy control A6 and terminal 1 5 Enthalpy control A6 has determined that outside air can be used for cooling and has switched internal relays 1K and 2K 6 Cooling demand is rout...

Page 60: ...C2 1 diagram electromechanical thermostat with modulating economizer and warm up with D5 diagram Page 60...

Page 61: ...When clock contacts close relay K11 in the economizer and K42 in the warm up kit are energized 5 Contacts K11 1 open to disconnect power to thermostat S1 K11 2 open to drive the damp ers full closed 6...

Page 62: ...Page 62 B41 diagram with C1 diagram CHA16 2553 2753 3003 Operating Sequence...

Page 63: ...delay sec ond stage cooling demand Y2 is routed through N C freezstat S50 high pressure limit S7 and low pressure limit S25 energizing pilot relay K67 11 N O contacts K67 1 close energizing Compresso...

Page 64: ...Page 64 B9 diagram with C1 diagram CHA16 1853 Operating Sequence...

Page 65: ...s routed through N C freezstat S50 N C high pres sure limit S7 and N C loss of charge switch S25 energizing compressor contactor K2 11 N O Contacts K2 1 close energizing compressor B2 2nd Stage Coolin...

Page 66: ...zstat S49 N C high pressure limit S4 and N C low pressure limit S24 to energize compressor contactor K1 13 N O Contacts K1 1 close energizing compressor B1 2nd Stage Cooling With Low Ambient Kit 14 Se...

Page 67: ...VAC power is routed through freeze stat S50 com preesor monitor S3 high pressure limit S7 and low pressure limit S25 energizing compressor con tactor K2 7 N O contacts K2 1 close energizing compressor...

Page 68: ...limit S24 to energize compressor contactor K1 6 N O Contacts K1 1 close compressor B1 begins operation 2nd Stage Cooling 7 Second stage cooling demand energizes Y2 24VAC power is routed through high p...

Page 69: ...to energize con tactor K15 and relay K9 K15 1 contacts close and K9 1 switches 2 When K15 1 closes heating heating elements HE1 are energized The elements are ar ranged in a Delta configuration for 2...

Page 70: ...5 1 closes heating elements HE1 are energized The elements are arranged in a Del ta configuration for 208 230V operation 3 When K9 1 switches indoor blower contactor K3 is energized When K9 2 switches...

Page 71: ...osition when K3 2 contacts close When K9 2 closes second stage heat is enabled When K9 3 closes control voltage passes through primary limits S15 to energize contactor K15 4 When K15 1 closes heating...

Page 72: ...at is enabled When K9 3 closes control voltage passes through primary limit S15 to energize contactor K15 and time delay DL2 4 When K15 1 closes heating elements HE1 are energized All elements are arr...

Page 73: ...S15 to energize contac tor K15 and relay K9 K15 1 contacts close and K9 1 switches 2 When K15 1 closes heating heating elements HE1 are energized The elements are ar ranged in a Wye configuration for...

Page 74: ...its S15 to energize contac tor K15 and relay K9 K15 1 contacts close and K9 1 switch 2 When K15 1 closes heating elements HE1 and HE2 are both energized The elements are ar ranged in a Wye configurati...

Page 75: ...s heating elements HE1 are energized The elements are arranged in a Wye configuration for 460V or 575V operation 3 When K9 1 switches indoor blower contactor K3 is energized When K9 2 switches time de...

Page 76: ...ing elements HE1 and HE2 are both energized The elements are ar ranged in a Wye configuration for 460V or 575V operation 3 When K9 1 switches indoor blower contactor K3 is energized When K9 2 switches...

Page 77: ...tches and K9 3 closes 3 When K9 1 switches indoor blower contactor K3 is energized and optional power exhaust fan relay K65 is enabled when K3 2 contacts close 4 When K9 3 closes electric heat contact...

Page 78: ...lower contactor K3 is energized and optional power ex haust fan relay K65 is enabled when K3 2 contacts close 4 When K9 3 closes electric heat contactor K15 is energized K15 1 closes 5 When K15 1 clos...

Page 79: ...s enabled when K3 2 contacts close 4 When K9 3 closes electric heat contactor K15 is energized K15 1 closes 5 When K15 1 closes heating elements HE1 are energized All elements are arranged in a Delta...

Page 80: ...both energized K15 1 closes and DL2 begins timing After 30 seconds DL2 closes 5 When K15 1 closes heating elements HE1 are energized All elements are arranged in a Delta configuration for 208 230V op...

Page 81: ...heating elements HE1 are energized All elements are arranged in a Delta configuration for 208 230V operation 6 When DL2 closes contactor K16 is energized 7 When K16 is energized heating elements HE2 a...

Page 82: ...s 3 When K77 1 closes heating pilot relay K9 is energized K9 1 switches and K9 3 closes 4 When K9 1 switches indoor blower contactor K3 is energized and optional power exhaust fan relay K65 is enabled...

Page 83: ...hen K77 1 closes heating pilot relay K9 is energized K9 1 switches and K9 3 closes 4 When K9 1 switches indoor blower contactor K3 is energized and optional power exhaust fan relay K65 is enabled when...

Page 84: ...loses to enable K19 4 When K9 1 switches indoor blower contactor K3 is energized and optional power ex haust fan relay K65 is enabled when K3 2 contacts close 5 When K9 3 closes electric heat contacto...

Page 85: ...o enable K19 4 When K9 1 switches indoor blower contactor K3 is energized and optional power exhaust fan relay K65 is enabled when K3 2 contacts close 5 When K9 3 closes electric heat contactor K15 is...

Page 86: ...ower ex haust fan relay K65 is enabled when K3 2 cotacts close 5 When K9 3 closes electric heat contactor K15 is energized K15 1 closes 6 When K15 1 closes heating elements HE1 and HE2 are both energi...

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