The HPXA19 is a high efficiency residential split−system
heat pump unit, which features a two−step scroll compressor and R410A refrigerant. HPXA19 units are available in
2, 3 (−036 and −038 models), 4 and 5 ton sizes. The series
includes the HPXA19−038, a 3 ton unit equipped with a variable speed condenser fan motor. The series is designed for
use with an expansion valve only (approved for use with
R410A) in the indoor unit.This manual is divided into sections which discuss the major components, refrigerant system, charging procedure, maintenance and operation sequence.
Information contained in this manual is intended for use by
qualified service technicians only. All specifications are
subject to change.
IMPORTANT
Operating pressures of this R410A unit are higher
than pressures in R22 units. Always use service
equipment rated for R410A.
HPXA19
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal injury or loss of life. Installation and service must
be performed by a qualified installer or service
agency.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting of (CFC’s and HFC’s) as of July 1, 1992. Approved
methods of recovery, recycling or reclaiming must
be followed. Fines and/or incarceration my be levied
for noncompliance.
fore removing access panel.
HPXA19 units use single-pole contactors. Potential exists for electrical
shock resulting in injury or death.
Line voltage exists at all components
(even when unit is not in operation).
All major components (indoor blower and coil) must be
matched according to Lennox recommendations for the
compressor to be covered under warranty. Refer to the Engineering Handbook for approved system matchups. A
misapplied system will cause erratic operation and can result in early compressor failure.
II−Unit Components
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect electronic
components. Take precautions 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. Neutralize electrostatic charge by touching hand and all tools on an
unpainted unit surface before performing any
service procedure.
A−Two−Stage Scroll Compressor (B1)
TWO−STAGE MODULATED SCROLL
slider ring
solenoid actuator coil
FIGURE 1
The scroll compressor design is simple, efficient and requires few moving parts. A cutaway diagram of the scroll
compressor is shown in figure 1.The scrolls are located in
the top of the compressor can and the motor is located just
below. The oil level is immediately below the motor.
The scroll is a simple compression concept centered
around the unique spiral shape of the scroll and its inherent
properties. Figure 2 shows the basic scroll form. Two identical scrolls are mated together forming concentric spiral
shapes (figure 3). One scroll remains stationary, while the
other is allowed to orbit" (figure 4). Note that the orbiting
scroll does not rotate or turn but merely orbits" the stationary scroll.
SCROLL FORM
FIGURE 2
CROSS−SECTION OF SCROLLS
DISCHARGE
PRESSURE
TIPS SEALED BY
DISCHARGE PRESSURE
DISCHARGE
STATIONARY
SCROLL
SUCTION
ORBITING SCROLL
FIGURE 3
The counterclockwise orbiting scroll draws gas into the outer crescent shaped gas pocket created by the two scrolls
(figure 4 − 1). The centrifugal action of the orbiting scroll
seals off the flanks of the scrolls (figure 4 − 2). As the orbiting
motion continues, the gas is forced toward the center of the
scroll and the gas pocket becomes compressed (figure 4
−3). When the compressed gas reaches the center, it is discharged vertically into a chamber and discharge port in the
top of the compressor (figure1). The discharge pressure
forcing down on the top scroll helps seal off the upper and
lower edges (tips) of the scrolls (figure 3). During a single orbit, several pockets of gas are compressed simultaneously
providing smooth continuous compression.
The scroll compressor is tolerant to the effects of liquid return. If liquid enters the scrolls, the orbiting scroll is allowed
to separate from the stationary scroll. The liquid is worked
toward the center of the scroll and is discharged.
Due to its efficiency, the scroll compressor is capable of
drawing a much deeper vacuum than reciprocating compressors. Deep vacuum operation can cause internal fusite
arcing resulting in damaged internal parts and will result in
compressor failure. This type of damage can be detected
and will result in denial of warranty claims. The scroll compressor can be used to pump down refrigerant as long as
the pressure is not reduced below 7 psig.
NOTE − During operation, the head of a scroll compressor
may be hot since it is in constant contact with discharge
gas.
The scroll compressors in all HPXA19 model units are designed for use with R410A refrigerant and operation at high
pressures. Compressors are shipped from the factory with
3MA (32MMMA) P.O.E. oil. See electrical section in this
manual for compressor specifications.
Page 3
TWO−STAGE OPERATION
The two−stage scroll compressor operates like any stan-
dard scroll compressor with the exception the two−stage
compressor modulates between first stage (low capacity
approximately 67%) and second stage (high capacity).
Modulation occurs when gas is bypassed through bypass
ports (figure 5 bypass ports open) in the first suction pock-
et. This bypassing of gas allows the compressor to operate
on first stage (low capacity) if thermostat demand allows.
Indoor thermostat setting will determine first or second
HOW A SCROLL WORKS
MOVEMENT OF ORBIT
SUCTION
ORBITING
SUCTION
POCKET
SCROLL
stage operation. The compressor will operate on first−stage
until demand is satisfied or the indoor temperature reaches
the thermostat set point calling for second−stage.
Second−stage (high capacity) is achieved by blocking the
bypass ports (figure 5 bypass ports closed) with a slider
ring. The slider ring begins in the open position and is controlled by a 24VDC internal solenoid. On a Y2 call the inter-
nal solenoid closes the slider ring, blocking the bypass
ports and bringing the compressor to high capacity. Two−
stage modulation can occur during a single thermostat demand as the motor runs continuously while the compressor
modulates from first−stage to second− stage.
SUCTION
INTERMEDIATE
PRESSURE
GAS
CRESCENT
SHAPED GAS
POCKET
3
12
FLANKS
SUCTION
STATIONARY SCROLL
SEALED BY
CENTRIFUGAL
FORCE
SUCTION
4
HIGH
PRESSURE
GAS
FIGURE 4
TWO−STAGE MODULATION
Bypass Ports
Closed
High Capacity
DISCHARGE
POCKET
Bypass Ports
Open
Low Capacity
FIGURE 5
Page 4
INTERNAL SOLENOID (L34)
Procedure
The internal unloader solenoid controls the two−stage operation of the compressor by shifting a slide ring mechanism to open two by−pass ports in the first compression
pocket of the scrolls in the compressor. The internal solenoid is activated by a 24 volt direct current solenoid coil.
The coil power requires 20VAC. The internal wires from the
solenoid in the compressor are routed to a 2 pin fusite connection on the side of the compressor shell. The external
electrical connection is made to the compressor with a
molded plug assembly. This plug contains a full wave rectifier that converts 24 volt AC into 24 volt DC power to power
the unloader solenoid. Refer to unit diagram for internal circuitry view of plug.
If it is suspect the unloader is not operating properly, check
the following
IMPORTANT
This performance check is ONLY valid on systems
that have clean indoor and outdoor coils, proper airflow over coils, and correct system refrigerant
charge. All components in the system must be functioning proper to correctly perform compressor
modulation operational check. (Accurate measurements are critical to this test as indoor system loading and outdoor ambient can affect variations between low and high capacity readings).
STEP 1 Confirm low to high capacity compressor
operation
Tools required
Refrigeration gauge set
Digital volt/amp meter
Electronic temperature thermometer
On-off toggle switch
1. Turn main power "OFF" to outdoor unit.
2. Adjust room thermostat set point above (heating operation on heat pump) or below (cooling operation) the
room temperature 5ºF.
3. Remove control access panel. Install refrigeration
gauges on unit. Attach the amp meter to the common
(black wire) wire of the compressor harness. Attach
thermometer to discharge line as close as possible to
the compressor.
4. Turn toggle switch "OFF" and install switch in series
with Y2 wire from room thermostat.
5. Cycle main power "ON."
6. Allow pressures and temperatures to stabilize before taking any measured reading (may take up to 10
minutes).
NOTE − Block outdoor coil to maintain a minimum of 375
psig during testing).
7. Record all of the readings for the Y1 demand on
table 1.
8. Close switch to energize Y2 demand.
9. Allow pressures and temperatures to stabilize before taking any measured reading (this may take up to
10 minutes).
10. Record all of the readings of Y2 demand on table
1.
NOTE − On new installations or installations that have
shut down for an extended period of time, if the compressor does not cycle from low stage to high stage on
the first attempt, it may be necessary to recycle the compressor back down to low stage and back up to high
stage a few times in order to get the bypass seals to
properly seat
Compare Y1 readings with Y2 readings in table 1. Some
readings should be higher, lower or the same. If the
readings follow what table 1 specifies, the compressor is
operating and shifting to high capacity as designed. If the
readings do not follow what table 1 specifies, continue to
step 2 to determine if problem is with external solenoid
plug power.
Page 5
TABLE 1
Compressor Operation
Unit Readings
Y1 −
1st-Stage
Expected Results
Compressor
VoltageSame
AmperageHigher
Condenser Fan motor
AmperageSame or Higher
Temperature
AmbientSame
Outdoor Coil Discharge AirHigher in Cooling
STEP 2 Confirm DC voltage output on compressor
solenoid plug
A − Compressor solenoid plug WITH built in full wave−
rectifier (LSOM I) that converts 24 volt AC into 24 volt
DC power. See Table 1 for units equipped with the
LSOM I.
1. Shut power off to outdoor unit.
2. Supply 24 volts AC control voltage to the wire ends
of the full wave rectifier plug. Listen for a click" as the
solenoid is energized. See figure 6.
apply 24vac
meter
compressor
fusite
terminals
rectifier plug leads
solenoid fusite
terminals
compressor
FIGURE 6
3. Unplug the full wave rectifier plug from the fusite
connection on the compressor.
4. Turn the low voltage power back onto the unit. Supply 24VAC to the wires of the full wave rectifier plug. Set
volt meter to DC volts and measure the DC voltage at
the female connector end of the full wave rectifier plug.
The DC voltage reading should be 1.5 to 3 volts lower
than the input voltage to the plug wire leads. (EX: Input
voltage is 24VAC output voltage is 22VDC).
See figure 7.
rectifier plug leads
apply 24vac
compressor
fusite
terminals
compressor
solenoid
fusite
terminals
meter
FIGURE 7
If the above checks verify that the solenoid plug is providing power to cycle into high capacity operation, continue to step 3 to determine if problem is with solenoid
coil in compressor
Page 6
STEP 3 Confirm internal unloader solenoid has proper resistance
1. Shut all power off to unit (main and low voltage)
2. Unplug the molded plug from the compressor solenoid 2−pin fusite.
3. Using a volt meter set on the 200 ohm scale
Replace the Compressor under these conditions:
Bad Solenoid
a. Measure the resistance at the 2−pin fusite. The resistance should be 32 to 60 ohms depending on compressor
temperature. If no resist ancereplace compressor.
b. Measure the resistance from each fusite pin to
ground. There should not be continuity to ground. If solenoid coil is grounded, replace compressor.
Good Solenoid
a. Seals not shifting, replace compressor
b. Slider ring not shifting, replace compressor.
B−Contactor (K1)
The compressor is energized by a contactor located in the
control box. All XP19 units are single phase and use single−
pole contactors.
C−Low Pressure Switch (S87)
The XP19 is equipped with an auto−reset low pressure
switch which is located on the suction line. The switch shuts
off the compressor when the suction pressure falls below
the factory setting. This switch is ignored during the first 90
seconds of compressor start up, during defrost operation,
90 seconds after defrost operation, during test mode and
when the outdoor temperature drops below 15°F.
The switch closes when it is exposed to 55 psig and opens
at 25 psig. It is not adjustable.
D−High Pressure Switch (S4)
E−Capacitor (C12)
The compressor in XP19−024, −036, −048 and −060 units
use a permanent split capacitor (see unit wiring diagram).
The capacitor is located inside the unit control box. Ratings
are on capacitor side.
F−Condenser Fan with
Variable Speed Motor(B4)
The variable speed condenser fan motor (figure 14) used in all
units is a three-phase, electronically controlled d.c. brushless
motor (controller converts single phase a.c. to three phase
d.c.), with a permanent-magnet-type rotor, manufactured by
GE. Because this motor has a permanent magnet rotor it does
not need brushes like conventional D.C. motors. The motors
consist of a control module and motor . Internal components
are shown in figure 15. The stator windings are split into three
poles which are electrically connected to the controller. This ar-
rangement allows motor windings to be turned on and off in
sequence by the controller.
The controller is primarily an a.c. to d.c. converter. Con-
verted d.c. power is used to drive the motor. The control-
ler contains a microprocessor which monitors varying
conditions inside the motor (such as motor workload).
G−Contactor (K1)
The compressor is energized by a contactor located in the
control box. All HPXA19 units are single phase and use single−
pole contactors.
H−Low Pressure Switch (S87)
IMPORTANT
Pressure switch settings for R410A refrigerant will
be significantly higher than units with R22.
An auto-reset, single-pole/single-throw high pressure switch
is located in the liquid line. This switch shuts off the compressor when liquid line pressure rises above the factory setting.
The switch is normally closed and is permanently adjusted to
trip (open) at 640 +
ure 13 for switch location.
10 psi and close at 448 + 10 psi. See fig-
Page 7
The HPXA19 is equipped with an auto−reset low pressure
switch which is located on the suction line. The switch shuts
off the compressor when the suction pressure falls below
the factory setting. This switch is ignored during the first 90
seconds of compressor start up, during defrost operation,
90 seconds after defrost operation, during test mode and
when the outdoor temperature drops below 15°F.
The switch closes when it is exposed to 55 psig and opens
at 25 psig. It is not adjustable.
I−High Pressure Switch (S4)
IMPORTANT
Pressure switch settings for R410A refrigerant will
be significantly higher than units with R22.
An auto-reset, single-pole/single-throw high pressure switch
is located in the liquid line. This switch shuts off the compressor when liquid line pressure rises above the factory setting.
The switch is normally closed and is permanently adjusted to
trip (open) at 640 +
ure 13 for switch location.
J−Low Ambient Thermostat (S23)
Second−stage low ambient thermostat S23 (figure 8) is a
SPST thermostat located in the compressor compartment.
The control uses a cap-tube sensor to monitor the temperature inside the compressor compartment. The cap-tube
sensor is coiled adjacent to the control.
Temperature Sensor
(Cap-Tube)
10 psi and close at 448 + 10 psi. See fig-
(Second−Stage)
Low Ambient Thermostat S23
Regional climatic conditions may require the control to be adjusted to a different setting. The adjustment screw is located
on the control. A hole cut into the bottom shelf of the control
box provides access to the control from the compressor
compartment. See figure 9.
Adjusting Low Ambient Thermostat
Adjustment screw can be
reached by inserting a screwdriver through the slot in control
box.
Turn screw clockwise to increase
switchover temperature.
FIGURE 9
Figure 10 shows the adjustment range of the control. Turn
adjustment screw clockwise to raise the switchover temperature and counterclockwise to lower the switchover
temperature.
Low Ambient Thermostat
49
adjustment
screw
FIGURE 8
S23 continually monitors the temperature inside the compressor compartment. When compressor compartment
temperature drops below the control setpoint, the control
closes. When the control closes, the contacts shunt across
Y1 and Y2 inside the unit. When Y1 heating demand is
present and S23 is closed, the compressor will run in high
capacity. The compressor will operate in high capacity
mode anytime there is a Y1 heating call from indoor thermostat, until the units control box warms and S23 opens.
S23 has field adjustable setpoints. Temperature differential
(difference between cut-in and cut-out) is fixed and cannot
be adjusted. Table 2 shows S23 control setpoints. The control is factory set to close at 40+
and reset at 50+
2°F on a temperature rise.
2°F on a temperature drop
TABLE 2
Control Setpoints
Low Ambient Thermostat
Adjustable Range
Cut-In
(Close on Temperature Drop)
Cut-Out
(Open on Temperature Rise)
Factory
Setting
40+2°F37+2°F 55+2°F
50+2°F47+2°F 65+2°F
Min.Max.
43
*40
37
55
FIGURE 10
K−Reversing Valve (L1)
A refrigerant reversing valve with an electromechanical solenoid is used to reverse refrigerant flow during unit operation. The reversing valve is energized during cooling demand and during defrost.
L−Transformer (T46)
Transformer T46 is located in the control box and is energized any time the compressor is operating.
M−Solenoid Relay (K195)
Relay K195 is N.O. SPDT relay located in the control box.
On a Y2 call K195−1 closes allowing AC voltage from
(T46) to the two pin full wave rectifier plug (D4).
N−Rectifier Plug (D4)
D4 is a molded assembly that plugs into the compressor.
On a Y2 call D4 converts 24 volts AC to 24 volts DC. The
DC voltage energizes solenoid L34, allowing the compressor to operate at full capacity.
Page 8
O−Discharge Line Thermostat (S5)
S5 is an automatic reset SPST N.C. switch which opens on
temperature rise. S5 is located on the discharge line and
wired in series with S4 high pressure switch on the defrost
control board. When discharge line temperature rises to
8°F the switch opens and shuts down the compres-
275° +
sor. The switch resets when discharge line temperature
drops to 225° +
11°F.
P−Dual Capacitor (C12)
The compressor and fan in HPXA19−024, −036, −048 and
−060 units use permanent split capacitor motors. A single
dual" capacitor is used for both the fan motor and the compressor (see unit wiring diagram). The two sides (fan and
compressor) of the capacitor have different mfd ratings and
may change with each compressor. The capacitor is located
inside the unit control box.
Q−Condenser Fan Motor (B4)
HPXA19−024, −036, −048 and −060 units use single−phase
PSC fan motors which require a run capacitor. The FAN"
side of the dual capacitor is used for this purpose. In all
units, the outdoor fan is controlled by the compressor contactor. See ELECTRICAL DATA and SPECIFICATIONS
section for more information. See figure 11 if condenser fan
motor replacement is necessary. Rain shield location is
critical on the condenser fan assembly. Two shields are
used in unison to prevent moisture from entering the motor
bearings. Installing the shields to close to the bearing hub
will create noise and may affect operation. Installing too far
away will allow moisture to enter the bearing, resulting in
motor failure. See figure 12.
"A" SEE TABLE 3
Condenser fan
and motor
FIGURE
11
TABLE 3
HPXA19 UNIT"A" DIM. + 1/8"
−024, −0361 1/16"
−038
−048
−060
RAIN SHIELD LOCATION
(See figure 14 for HPXA19−038)
Critical Dimension
plastic
shield
fiber
shield
FIGURE 12
FAN
GUARD
Wiring
Drip loop
1 3/16"
1/4" (.250)
run capacitor
start capacitor
(−024 unit only)
system
operation monitor
defrost control
charge compensator
(−038 and −048 units)
TXV/check valve
discharge line
compressor terminal plug
vapor line
low pressure switch
discharge temperature
thermostat
HPXA19 PARTS ARRANGEMENT
outdoor fan
(variable speed
on 038 units)
contactor
vapor valve
and
gauge port
two−stage compressor
filter drier
high pressure switch
FIGURE 13
Page 9
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