Lennox 90W84 User manual

10/2012 506944-01
*2P102012* *P506944-01*
Page 1
LITHO U.S.A.
506944-01
10/2012
Supersedes 2/2012 HOT WATER HEAT KIT
KITS COMMON TO AIR HANDLERS
INSTALLATION INSTRUCTION FOR HOT WATER HEAT KIT (90W84)
E2012 Lennox Industries Inc.
Dallas, Texas, USA
WARNING
Improper installation, adjustment, alteration, service or
maintenance can cause personal injury, loss of life, or
damage to property.
Installation and service must be performed by a licensed
professional installer (or equivalent) or a service agency.
CAUTION
Physical contact with metal edges and corners while
applying excessive force or rapid motion can result in
personal injury. Be aware of, and use caution when
working near these areas during installation or while
servicing this equipment.
WARNING
Electric Shock Hazard. Can cause injury
or death. Unit must be grounded in
accordance with national and local
codes.
Line voltage is present at all components
when unit is not in operation on units with
single‐pole contactors. Disconnect all
remote electric power supplies before
opening access panel. Unit may have
multiple power supplies.
Shipping and Packing List
Check unit for shipping damage. Consult last carrier
immediately if damage is found.
Catalog
Number Part Names Part Numbers Qty.
90W84
DC Relay, 22VDC 102297-01 1
3PDT Relay 67K6601 1
Delay-On-Make Relay 99P41 1
9-Pin Wiring Harness 609345-01 1
Wiring Diagram 537516-01 1
Field-Provided Supplies
The following field-provided supplies may be required.
S1/4” quick connects
SControl wiring (various lengths)
General
Hot water heat kit (90W84) adapts CBX32MV and
CBX40UHV units for use with a boiler to provide hot water
heating in select applications. When used with an air
conditioner, the hot water provides first-stage heating.
When used with a heat pump, the hot water provides
second-stage heating.
This kit is only approved for use in systems using either the
ComfortSense®7000 thermostat or icomfortt
thermostat. Wiring modifications shown are in addition to
field wiring detailed in the instructions provided with the air
handler.
Thermostat Configuration
HEAT PUMP APPLICATIONS
The ComfortSense®7000 will need to be reconfigured for
use with:
SHeat pump with hot water heat (see figure 7).
SCompressor low balance set point of 40ºF.
Since the hot water coil is downstream of the coil, the heat
pump and boiler can be operated simultaneously. In
emergency heat mode, the blower CFM drops to the lower
heat table CFM setting.
AIR CONDITIONER APPLICATIONS
In applications with condensing units, configure
ComfortSense®7000 for hot water heat (see figure 7).
In icomfortt-enabled systems, see figure 7 for heat
discovery procedures and the icomforttthermostat
installer guide to configure the thermostat.
Kit Installation
This kit can be installed for any of the following variations:
SAir handler - hot water heat and air conditioner
SAir handler - hot water heat and heat pump
FREEZESTAT INSTALLATION
Since the hot water coil is downstream of the indoor a
freezestat will need to be installed to protect the indoor
coil during summer air conditioning operation.
1. All units will require one field-provided properly sized
freezestat (S49) for use with this kit. Order part using
table 1.

Page 2
Table 1. Freezestat Selection (S49)
Tubing
Size
Wire
Length
Wire
Gauge
Lennox
Catalog
Number
Freezestat
Set Points
Open Close
3/8” 90-13/16” 18 93G35 29ºF
(-2ºC)
58ºF
(10ºC)
5/8” 36-1/2” 18 50A93 36ºF
(2ºC)
58ºF
(10ºC)
Installation Method 1 — (Non-Communicating Unit)
This installation method is applicable to systems that use
standard thermostat wiring (see figure 2).
1. A freezestat, sized per table 1 and ordered separately,
must be installed. Install the freezestat on one of the
copper lines between the last hairpins and the suction
manifold (see figure 1) of the indoor coil.
2. The freezestat senses the line temperature and cycles
the compressor off when the line temperature fails
below its setpoint. The freezestat will open and closed
as listed in table 1.
3. Connect freezestat (S49) wires as exampled in figure
2.
CLIP
COPPER
LINE
EXPANSION
VALVE
FREEZESTAT
SUCTION
MANIFOLD
LIQUID LINE
LAST HAIRPINS
COPPER LINES
Figure 1. Typical Freezestat (S49) Installation
(Indoor Coil)
R
C
W1
Y1
O
G
R
C
W1
W2
W3
G
reversing valve
Thermostat Designations
(Some connections may not apply.
Refer to specific thermostat and indoor unit.)
Thermostat Indoor
Unit
R
C
W1
Y1
O
Outdoor
Unit
power power
common common
1st. stage aux. heat 1st. stage aux. heat
indoor blower
compressor
*
*Freezestat
See figure 1. Typical Freezestat (S49)
Installation (Indoor Coil)
Figure 2. S49 Freezestat Wiring
CAUTION
ELECTROSTATIC
DISCHARGE
(ESD)
PRECAUTIONS
AND
PROCEDURES
Electrostatic discharge can affect
electronic components. Take care
during unit installation 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. Touch hand and all tools on an
unpainted unit surface before
performing any service procedure to
neutralize electrostatic charge.

Page 3
Installation Method 2 — (Communicating Unit)
This installation method is applicable to the models listed
below.
Table 2. Method 2 Models
XC17
In communicating mode only.
XP17 and XP17N
XP19-XXX-230-06
XC21-XX-230-04 and later
XP21 and XP21N
1. A freezestat, sized per table 1 and ordered separately,
must be installed. Install the freezestat near last bend
(tube) of the indoor coil before the suction manifold
(see figure 1).
2. The freezestat senses the line temperature and cycles
the compressor off when the line temperature fails
below its setpoint. The freezestat will open and closed
as listed in table 1.
3. Connect freezestat (S49) wires as exampled in the
applicable unit wiring diagrams and figure 3.
OUTDOOR UNIT CONTROL
(A175)
OUTDOOR UNIT LOW
PRESSURE SWITCH (S87)
INDOOR UNIT
FREEZESTAT
(S49)
BLACK
BLACK
NOTE - For communicating systems only,
use a 6-conductor control cable between
the indoor and outdoor units. The freezestat
(S49) two wires will be spliced in series be
tween the outdoor unit low pressure switch
(S87) outdoor control (A175) LO and PS
terminals.
See figure 1. Typical Freezestat (S49)
Installation (Indoor Coil)
Figure 3. Freezestat (S49) Wiring for Communicating Systems

Page 4
OPTION 1 — AIR HANDLER - HOT WATER HEAT AND HEAT PUMP / AIR CONDITIONER WITH ICOMFORT™
THERMOSTAT
SCREWS TO
SECURE
RELAY (2)
AIR
HANDLER
CONTROL
9-PIN CONNECTOR
22V DIRECT CURRENT COIL
30 AMP CONTACT
RATING
NOTE — EVENHEAT MODE CANNOT BE ENABLED WITH HARMONY III DUE
TO EACH CONTROL REQUIRING ITS OWN DISCHARGE AIR SENSOR.
DETAIL B
CONNECT WIRES TO DISCHARGE AIR SENSOR
TERMINAL ON AIR HANDLER CONTROL.
AIR HANDLER CONTROL
PART NO. 50W28 or 65W70
ORANGE
TO BOILER CONTROL
RELAY
Heat discovery must be completed before powering the icomfort™ thermostat, if not, the icomfort™ setup will need to
be performed again after air handler heat discovery. The icomfort™ thermostat will control operation as single-stage
hot water heat.
Heat relay contacts 4 and 2
must be used to control
boiler when configured with
icomfort™ thermostat only.
Refer to icomforttThermostat Installer's System Setup Guide, Setting up Equipment Parame
ters for configuring hot water heating equipment.
1. Press start
2. Navigate to equipment tab.
3. Under system devices, select AIR HANDER and select edit to the right of the box.
4. Select Electric heating Air flow and select edit to the right of the box.
5. Use the UP or DOWN arrows to set the desired CFM. Select save when done.
6. Under Equipment Name, scroll down to Heating Indoor Blower OFF Delay and select edit
to the right of the box.
7. Use the UP or DOWN arrows to set a maximum of 10 seconds. Select save when done
8. Under Equipment Name, scroll down to Heating Indoor Blower ON Delay and select edit
to the right of the box.
9. Use the UP or DOWN arrows to set a maximum of five (5) seconds. Select save when done
10. Toggle to exit
All configurations will use the heat relay terminals 0and 1connected
to pins 1and 3 on the 9-pin connector.
Figure 4. Air Handler - Hot Water Heat and Heat Pump / Air Conditioner with icomfort™ Thermostat

Page 5
OPTION 2 — AIR HANDLER - HOT WATER HEAT AND AIR CONDITIONER WITH COMFORTSENSE®7000
99P41 67K66
TO BOILER
CONTROL
TO W1 ON
THERMOSTAT
DELAY−ON−MAKE
TIME DELAY RELAY
KIT INSTALLATION
1. Remove factory-installed P8 cable assembly.
2. Install provided P8 cable assembly.
3. Initiate air handler control heat discovery
mode (figure 7).
4. install 99P41 and 67K66 as shown.
5. Adjust 99P41 for average water warm-up time.
6. Adjust heat CFM for desired air temperature
rise.
HEAT DEMAND
1. Boiler zone to air handler will start.
2. Air handler blower will start after time delay.
CONTINUOUS FAN CALL
CFM jumper may be set 28%, 38%, 70% or 100%
without interfering with the hot water heating CFM.
HEAT
RELAY
Figure 5. Air handler - hot water heat and air conditioner with ComfortSense®7000
OPTION 3 — AIR HANDLER - HOT WATER HEAT AND HEAT PUMP WITH COMFORTSENSE®7000
99P41 67K66
TO BOILER
CONTROL
TO W1 ON
THERMOSTAT
TO Y1 ON
THERMOSTAT
DELAY−ON−MAKE
TIME DELAY RELAY
KIT INSTALLATION
1. Remove factory-installed P8 cable assembly.
2. Install provided P8 cable assembly.
3. Initiate air handler control heat discovery mode
(figure 7).
4. install 99P41 and 67K66 as shown.
5. Adjust 99P41 for average water warm-up time.
6. Adjust heat CFM for desired air temperature rise.
BACKUP HEAT DEMAND
1. Heat pump will turn off.
2. Boiler zone to air handler will start.
3. Air handler blower will start after time delay.
CONTINUOUS FAN CALL
CFM jumper may be set at 28%, 38%, 70% or 100%
without interfering with hot water heating CFM.
HEAT
RELAY
Figure 6. Air handler - hot water heat and heat pump with ComfortSense®7000

Page 6
Configuring/Detecting Hot Water Heat Section
IMPORTANT — Hot water heat installation
require the air handler control to be manually
configured to detect hot water heat section.
SSet desired Heating Mode Blower Speed jumper pin.
SHot water heat is stage by room thermostat. The air handler control comes with
factory jumper between W1 and W2 and W2 and W3.
SRefer to air handler control checkout flow diagram for operation.
Configuration
Air handler control in
Idle Mode (No heating
cooling or indoor fan
operation)
To enter hot water heat
configuration mode, push and
hold button next to
single-character LED display until
dash symbol (solid bar) appears.
Then, release button.
Turn room thermostat to OFF.
Yes
Solid dash starts blinking
on single character LED
display
Push and hold button until the solid Hsymbol is displayed on the
single-character LED display. Then, release button.
Finished
No
1 Air handler control will start the indoor blower motor to the selected heat jumper speed setting and cycle the hot water heat relay ON to automati
cally detect the hot water heat section.
2 Air handler control waits for maximum of ten seconds to detect the hot water heat 22VDC relay coil is energized:
A If relay coil current is detected within 10 seconds, the air handler control will show a 1 on the single-character LED display indicating that the
first-stage hot water heat has been detected. As each additional heat section is detected, the single-character LED will display that hot
water heat number.
B If relay coil current is not detected within 10 seconds, the air handler control will exit the current active mode and resume operation with hot
water heat disabled.
3 The air handler control will automatically exit current active mode when configuration is completed. To verify that the hot water section detected
matches the installed hot water heat package, the field MUST CONFIRM that the last number the single character LED display before exiting the
configuring/detectionmode matches the hot water heat section. The air handler control stores the hot water heat stage in non-volatile memory.
4 After the detection is finished, unit will continue to operate for an additional 30 seconds.
NOTE — If the air handler control is unable to verify all 22 volt DC hot water heat relay(s) were energized using hot water heater detection after
the air handler control button is pushed, or power to the air handler control is cycled, then the configuration procedure must be repeated.
_
_H
This procedure is for the installation of one hot water heat section. This procedure is typically used to configure hot water heat
which is the same as configuring for electric heat.
Figure 7. Heat Discovery Mode