Lennox XP15, XP15-042, XP15-024, XP15-030, XP15-036 Installation Instructions Manual
...
INSTALLATION
,1,_2008LennoxindustriesInc,
®
Dallas,Texas,USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
X_ WARNING
_, CAUTION
INSTRUCTIONS
Dave Lennox Signature ®
Collection XP15 Units
HEAT PUMP UNITS _-_Technical
505,328M U£[ Publications
04/08 Litho U.S.A.
Supersedes 03/08
XP15 Outdoor Unit ............................ 1
Shipping and Packing List ...................... 1
Unit Dimensions ............................... 2
General Information ........................... 2
Recovering Refrigerant from Existing System ..... 4
Positioning New Outdoor Unit .................. 5
Removing Panel .............................. 6
Electrical Connections ......................... 7
New or Replacement Line Set ................... 9
Brazing Line Set Connections ................... 11
Removing Existing Refrigerant Metering Device . .. 11
Testing for Leaks .............................. 11
Removing Service Valve Port Core .............. 12
Flushing Existing System ....................... 12
Installing New Refrigerant Metering Device ....... 13
Installing Service Valve Port Core ............... 14
Evacuating the System ......................... 14
Start-Up Procedures ........................... 15
System Operations ............................ 19
Lennox System Operation Monitor (LSOM) ....... 19
Defrost System ............................... 21
Maintenance .................................. 26
Homeowner Information ........................ 26
Start-Up and Performance Checklist ............. 28
A IMPORTANT
IMPORTANT
04/08
IIIHIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
The Lennox XP15 outdoor units use HFC-410A
refrigerant, This unit must be installed with a matching
indoor coil and line set as outlined in the Lennox
Engineering Handbook, XP15 series outdoor units are
designed for use in check expansion valve (CTXV)
systems only, and are not designed to be used with other
refrigerant flow control devices. The Lennox Engineering
Handbook lists compatible indoor CTXV kits which are
ordered separately.
1 - Assembled XP15 outdoor unit
1 - Bushing (for low voltage wiring)
2 - Grommets (for liquid and vapor lines)
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
Page 1
505,328M
IIIIIIIIIIIIIIIIIIIIIIHIIIIIIIIIIIIIIIIIIIIIIII
39-1/2 DISCHARGE AIR
(1003) t
35-1/2
(902)
ELECTRICAL IN_ETS __
37 (94O)
[-024 thru -042]
47 (1194)
[-048 and -060]
UNIT SUPPORT
FEET \
Y
16-7/8
(429)
8 -3/4
(2_2)
3-1/8
(79) "-_
BASE WITH ELONGATED LEGS
SIDE VIEW
® ® ®
VAPOR LINE
INLET
LIQUID LINE
/INLET
DEFROST CONTROL
& CONTACTOR
OPERATION MONITOR
VAPOR VALVE AND
26-7/8 GAUGE PORT ..
(6_3) DISCHARGE LINE
3-3/4 (95) VAPOR
_' FILTER
4-5/8
(117)
18!1/2
(470)
SYSTEM
4-7/16.__
(113)
7--
8 (203)
1 (25)
XP15 Parts Arrangement
ACCESS VIEW
FAN
CAPACITOR
COMPRESSOR
DOME
COMPRESSOR
PLUG
LOW PRESSURE
HIGH PRESSURE
SWITCH
WARNING
505328M 04/08
I
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
When servicing or repairing HVAC components, ensure
caps and fasteners are appropriately tightened. Table 1
lists torque values for typical service and repair items.
Table 1. Torque Requirements
Part Recommended Torque
Service valve cap 8 ft.- lb. 11 NM
Sheet metal screws 16 in.- lb. 2 NM
Machine screws #10 28 in.- lb. 3 NM
Compressor bolts 90 in.- lb. 10 NM
Gauge port seal cap 8 ft.- lb. 11 NM
Page 2
USINGMANIFOLD GAUGE SETS
HFC-410A refrigerant manifold gauge sets must be
capable of handling higher system operating pressures.
The gauge set shall be rated for use with pressures of 0 -
800 psig on the high side, and a low side of 30 inches of
vacuum (Hg) to 250 psig, which retards when opened to
500 psig. Gauge hoses must be rated for use up to 800 psig
of pressure with a 4000 psig burst rating,
OPERATING SERVICE VALVES
IMPORTANT
The liquid and vapor lines service valves with gauge ports
as illustrated in figures 2 and 3 are used for removing
refrigerant, flushing, leak testing, evacuating, checking
charge and charging,
Each valve is equipped with a service port which has a
factory-installed valve stem.
1/6 TURN
1/12 TURN
2. Connect gauge to the service port.
3. When testing is completed, replace service port cap and
tighten as follows:
• With Torque Wrench: Finger tighten and then
tighten per table 1 on page 2.
• Without Torque Wrench: Finger tighten and with an
appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 1.
To Open and Close Angle-Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak-free seal.
1, Remove stem cap with a wrench,
2. Use a service wrench with a hex-head extension
(3/16" for liquid-line valve sizes and 5/16" for
vapor-line valve sizes) to back the stem out
counterclockwise as far as it will go.
3. Replace the stem cap and tighten as follows:
• With Torque Wrench: Tighten finger tight and then
tighten per table 1 on page 2.
• Without Torque Wrench: Finger tighten and with an
appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 1,
NOTE -A label with specific torque requirements may be
affixed to the stem cap, If the label is present, use the
specified torque listed,
SERVICE PORT CAP
SERVICE PORT _
CLOSED TO BOTH
INDOOR AND
OUTDOOR UNITS]
VALVE STEM
VALVE IS FRONT-SEATED
o
(CLOSED)
jSERV,CEPORT
,, HHERE
This illustrates how to use a wrench to tighten caps an additional
1/6 or 1/12 turn clockwise.
Figure 1. Cap Tightening Distances
IMPORTANT
Operating Angle-Type Service Valve
To Access Angle-Type Service Port:
A service port cap protects the service port core from
contamination and serves as the primary leak seal.
1. Remove service port cap using an appropriately sized
wrench.
Page 3
FRON%SEATEI_
TO INDOOR
CORE _ _ "i
UNIT
TO OUTDOOR _
UNIT
SERVICE PORT CAP _ _:_ VALVE IS(oPENED)BACK=SEATED
CORE SERVICE PORT
SERVICE PORT _
OPEN TO BOTH
INDOOR AND (VALVE STEM
OUTDOOR UNITS] L _ _ SHOWNOPEN)INSERTHEX
VALVE STEM WRENCH HERE
TO INDOOR
UNIT
BACKED-SEATE_ __
TO OUT
UNIT
Figure 2. Angle -Type Service Valve
XP15 SERIES
Operating Bali-Type Service Valve
To Access Bali-Type Service Port:
A service port cap protects the service port core from
contamination and serves as the primary leak seal,
1, Remove service port cap using an appropriately sized
wrench,
2. Connect gauge to the service port.
3, When testing is completed, replace service port cap and
tighten as follows:
• With Torque Wrench: Finger tighten and then
tighten per table table 1 on page 2.
• Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 1,
To Open and Close Bali-Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak-free seal,
1, Remove stem cap with a wrench,
2, Use an adjustable wrench to open, To open valve,
rotate stem counterclockwise 90°, To close rotate
stem clockwise 90°.
3, Replace the stem cap and tighten as follows:
• With Torque Wrench: Finger tighten and then
tighten per table 1 on page 2.
• Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 1.
NOTE - A label with specific torque requirements may be
affixed to the stem cap. If the label is present, use the
specified valve listed.
Remove existing HCFC-22 refrigerant using one of the
following methods:
METHOD 1:
If the existing outdoor unit is not equipped with shut-off
valves, or if the unit is not operational and you plan to use
the existing HCFC-22 or refrigerant to flush the system:
1, Disconnect all power to the existing outdoor unit,
2, Connect to the existing unit a gauge set, clean
recovery cylinder and a recovery machine. Use the
instructions provided with the recover machine on how
to setup the connections,
3, Remove all HCFC-22 refrigerant from the existing
system, Check gauges after shutdown to confirm that
the entire system is completely void of refrigerant,
4, Disconnect the liquid and vapor lines from the existing
outdoor unit,
5, Remove the existing outdoor unit,
NOTE - Use recovery machine instructions for specific
setup requirements.
Recovery Machine
\
Manifold Gauges
/
To INDOOR UNIT
Open to line set when valve
is closed, to both line set
and unit when valve is open.
Service Port
Service Port
Core
Service Port
Cap
To outdoor unit
Use Adjustable Wrench To open: rotate Stem Counter-Clock-
wise 90°.To close: rotate Stem clockwise 90°.
Figure 3. Bali-Type Service Valve
Ball (Shown Closed)
Valve Stem
t
STEM CAP
Clean Recovery Cylinder
Figure 4. Typical Refrigerant Recovery (Method 1)
METHOD 2:
If the existing outdoor unit is equipped with manual shut-off
valves and you plan to use new HCFC-22 refrigerant to
flush the system -
1, Start the existing HCFC-22 system in the cooling
mode and close the liquid line valve,
2, Pump all of the existing HCFC-22 refrigerant back into
the outdoor unit,
NOTE - It may be necessary to bypass the low pressure
switches to ensure complete refrigerant evacuation.
Outdoor/_Unit
505328M 04/08
Page 4
3.Whenthelowsidesystempressuresreach0 psig,
closethevaporlinevalve,
4. Disconnectall powerto the existingoutdoorunit.
Checkgaugesaftershutdownto confirmthat the
valvesarenotallowingrefrigeranttoflowbackintothe
lowsideofthesystem,
5. Disconnecttheliquidandvaporlinesfromtheexisting
outdoorunit.
6. Removetheexistingoutdoorunit,
CAUTION
See Unit Dimensions on page 2 for sizing mounting slab,
platforms or supports, Refer to figure 5 for mandatory
installation clearance requirements.
Install unit away
from windows
Two 90° elbows installed inline set -
will reduce line set vibration.
Figure 6. Outside Unit Placement
PLACING UNIT ON SLAB
When installing a unit at grade level, the top of the slab
should be high enough above the grade so that water from
higher ground would not collect around the unit as
illustrated in figure 7. Slab may be level or have a slope
tolerance away from the building of not more than two
degrees, or 2 inches per 5 feet (51 mm per 1524 mm).
NOTES:
Service clearance of 30 in, (762 mm) must be maintained on one of
the sides adjacent to the control box,
Clearance to one of the other three sides must be 36 in, (914 mm)
Clearance to one of the remaining two sides may be 12 in. (305
mm) and the final side may be 6 in, (152 mm)
48 in, (1219 ram) clearance required on top of unit,
A clearance of 24 in, (610 mm) must be maintained between two
units
Figure 5. Installation Clearances
POSITIONING CONSIDERATIONS
Some localities are adopting sound ordinances based on
the unit's sound level registered from the adjacent
property, not from the installation property, Install the unit
as far as possible from the property line. When possible,
do not install the unit directly outside a window, Glass has a
very high level of sound transmission. For proper
placement of unit in relation to a window see the provided
illustration in figure 6.
Install unit level or, if on a slope, maintain slope tolerance of 2
degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from
building structure.
Building
Structure
J
7/ Mounting
-T--
Slab
Figure 7. Ground Level Slab Mounting
INSTALLING UNIT ON ROOF
Install the unit a minimum of 6 inches (152 mm) above the
roof surface to avoid ice build-up around the unit. Locate
the unit above a load bearing wall or area of the roof that
can adequately support the unit, Consult local codes for
rooftop applications.
If unit coil cannot be mounted away from prevailing winter
winds, a wind barrier should be constructed as illustrated in
figure 8. Size barrier at least the same height and width as
outdoor unit, Mount barrier 24 inches (610 mm) from the
sides of the unit in the direction of prevailing winds.
Page 5
XP15 SERIES
PREVAILING _.
WINTER WINDS
I WIND BARRIER
INLET AIR ,_
1
2_'_6" 10 ram)
With unit positioned at installation site, remove two side
Iouvered panels to expose the unit base pan. Install the
brackets as illustrated in figure 10 using conventional
practices; replace the panels after installation is complete.
INLETAIR
O INLET AIR
Figure 8. Rooftop Application and Wind Barrier
NOTE - If necessary for stability, anchor unit to slab as
described in Stabilizing Unit on Uneven Surfaces.
ELEVATING THE UNIT
These units are outfitted with elongated-shaped feet as
illustrated in figure 9.
BASE
IMPORTANT
Slab Side Mounting
#101/2" LONG
SELF-DRILLING SHEET
METAL SCREWS
STABILIZING BRACKET
(18 GAUGE METAL - 2"
RW/DTDHi HEIGHT AS _,_1 f, _
#10 1-1/4" LONG HEX
HD SCREW AND
FLATWASHER
PLASTIC ANCHOR - USE IF CONCRETE
(HOLE DRILL 1/4"); NOT IF PLASTIC SLAB
(HOLE DRILL 1/8").
/
LEG DETAIL 2"(50.8MM)
SCH 40
FEMALE
THREADED
ADAPTER
Figure 9. Elevated Slab Mounting using Feet
Extenders (Larger Base Units)
If additional elevation is necessary, raise the unit by
extending the height of the unit support feet. This may be
done with 2" SCH 40 female threaded adapter. The
specified coupling will fit snuggly into the recess portion of
the feet. Use additional 2" SCH 40 male threaded adapters
which can be threaded into the female threaded adapters
to make additional adjustments to the level of the unit.
NOTE - Keep the height of extenders short enough to
ensure a sturdy installation, If it is necessary to extend
further, consider a different type of field-fabricated
framework that is sturdy enough for greater heights.
STABILIZING UNIT ON UNEVEN SURFACES
Mounting
STABILIZING MINIMUM 1
BRACKET (18 PER SIDE
GAUGE METAL - 2"
WIDTH; HEIGHT
AS REQ'D); BEND
TO FORM RIGHT FOR EXTRA
I Deck Top
ANGLE STABILITY
ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY,
TWO BRACKETS PER SIDE, 2" FROM EACH CORNER.
Figure 10. Installing Stabilizer Brackets
CAUTION
To help stabilize an outdoor unit, some installations may
require strapping the unit to the pad using brackets and
anchors commonly available in the marketplace.
505328M 04/08
Page 6
REMOVE4SCREWSTOREMOVEPANELFOR
ACCESSINGCOMPRESSORANDCONTROLS.
_ INSTALLBYPOSITIONINGPANELWITHHOLES
ALIGNED;INSTALLSCREWSANDTIGHTEN.
Figure 11. Access Panel
IMPORTANT! DO NOT ALLOW K-_
PANELS TO HANG ON UNIT BY
TOP TAB. TAB IS FOR ALIGNMENT
ANDNOTDESIGNEDTOSUPPORT
)
WE,GHTOFPANEL
PANEL SHOWN SLIGHTLY _ _
ROTATED TO ALLOW TOP TAB TO _
EXIT (OR ENTER) TOP SLOT FOR _
PANEL.
REMOVING (OR INSTALLING) _
SCREW
L. HOLES......_ _iiii_///l _
ii
Detail A
Detail B -_-_\_
ROTATE IN THIS DIRECTION;
THEN DOWN TO REMOVE PANEL
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT
AS POSSIBLE) WHILE INSTALLING PANEL.
ANGLE MAY BE TOO THE HINGED SIDE TO MAINTAIN
EXTREME FULLY-ENGAGED TABS
PREFERRED ANGLE
FOR INSTALLATION
HOLD DOOR FIRMLY ALONG
Detail D
Figure 13. Removing/Installing Louvered Panels
(Detail D)
ACCESS PANEL
Removal and reinstallation of the access panel is
illustrated in figure 11,
LOUVERED PANELS
Remove the Iouvered panels as follows:
1, Remove two screws, allowing the panel to swing open
slightly.
U
2, Hold the panel firmly throughout this procedure.
Rotate bottom corner of panel away from hinged
corner post until lower three tabs clear the slots as
illustrated in figure 12, detail B.
t_
3, Move panel down until lip of upper tab clears the top
slot in corner post as illustrated in figure 12, detail A,
Position and Install Panel--Position the panel almost
parallel with the unit as illustrated in figure 13, detail D with
the screw side as close to the unit as possible. Then, in a
continuous motion:
• Slightly rotate and guide the lip of top tab inward as
illustrated in figure 12, details A and C; then upward
into the top slot of the hinge corner post.
• Rotate panel to vertical to fully engage all tabs,
• Holding the panel's hinged side firmly in place, close
the right-hand side of the panel, aligning the screw
holes.
When panel is correctly positioned and aligned, insert the
screws and tighten.
Figure 12. Removing/Installing Louvered Panels
(Detail A, B and C)
A'kWARNING
In the U,S.A., wiring must conform with current local codes
and the current National Electric Code (NEC). In Canada,
wiring must conform with current local codes and the current
Canadian Electrical Code (CEC),
ELECTRICAL AND CONTROL CONNECTIONS
Refer to the furnace or blower coil installation instructions
for additional wiring application diagrams and refer to unit
nameplate for minimum circuit ampacity and maximum
overcurrent protection size.
NOTE - Connect conduit to the unit using a proper conduit
fitting. Units are approved for use only with copper
conductors. A complete unit wiring diagram is located on
the back side of the unit's access panel.
NOTE - For proper voltages, select thermostat wire gauge
per the following chart:
Page 7
XP15 SERIES
Table 2. Wire Run Length
Wire Run Length AWG # Insulation Type
less than 100' (30m) 18 color-coded, temperature
more than 100' (30m) 16 rating 35°C minimum
1. Install room thermostat (ordered separately) on an
inside wall approximately in the center of the area and
5 feet (1.5 m) from the floor. Do not installon an outside
wall or where sunlight, drafts or vibrations affect it.
2. Install low voltage wiring from outdoor to indoor unit
and from thermostat to indoor unit as illustrated in
figure 14.
3. Install line voltage power supply to unit from a properly
sized disconnect switch as illustrated in figure 15.
4. Ground unit from ground lug as illustrated in figure 15
to unit disconnect switch, or to an earth ground.
LI _._
z_
RTI$
AMBIENT
SENSOR
@
R721 DEFROST
COIL SENSOR
S4HIGH
PRESSURE
SWITCH
$87 LOW
PRESSURE
SWITCH
©
LI
REVERSING
VALVE
©
LZ_
CONTACTOR
OMPRESSOR
54O
AI32
HRI
A
AI32
A
EQUIPMENT
GROUND
COMPRESSOR
CONTACTOR
BLACK
CB31MV
TBI
CBX32MV
A2 SIGNATURE
81M2B
TWISTEO
PAIR
(W5_
(W8
"-(v _
G
BI
©
@
A NOTE
FOR USE WITH COPPER CONDUCTORS ONLY.
w
• I
REFER TO UNIT RATING PLATE FOR
MINIMUM CIRCUIT AMPACITY AND
MAXIMUM OVER CURRENT PROTECTION SIZE
A REFER TO COMPRESSOR N UNIT
FOR ACTUAL TERMINAL mRmANGEMENT.
Z_ WARNING
ELECTRIC SHOCK HAZARD,CAN CAUSE INJURY
OR DEATH.UNIT MUST BE GROUNDED IN
ACCOROANCE WITH NATIONAL AND LOCAL CODES.
A RTI4 SENSOR, OUTDOOR TEMP (OPTIONAL)
LINE VOLTAGE FIELD INSTALLED
CLASS II VOLTAGE FIELD INSTALLED
Figure 14. Typical Low-Voltage Field Wiring
GROUNDLUG
CONTACTOR
DEFROST CONTROL
GROUND
208-230/60/1 L1
L2
-''_/ L_)NNNTOoXRt LYs'<oTE_ OPERATION
"__ _[3_/ _ CAPACITOR
K1-1 COMPRESSOR CONTACTOR
BOARD (DCB)
WARNING! - ELECTRIC SHOCK HAZARD. Can cause INJURY or DEATH. Unit must be grounded in accordance with national and local codes.
NOTE - For use with copper conductors only. Refer to unit rating plate for minimum circuit ampacity and maximum over-current protection size.
CONTROLBOX _'-
Figure 15. Typical High-Voltage Field Wiring (Unit Panel)
505328M 04/08
Page 8
This sectionprovidesinformationon installationor
replacementofexistinglinesets.Iflinesetsarenotbeing
installedorreplace,thenproceedtoBrazing Connections
on page 11.
If refrigerant lines are routed through a wall, seal and
isolate the opening so vibration is not transmitted to the
building, Pay close attention to line set isolation during
installation of any HVAC system. When properly isolated
from building structures (walls, ceilings, floors), the
refrigerant lines will not create unnecessary vibration and
subsequent sounds.
REFRIGERANT LINE SET
Field refrigerant piping consists of liquid and vapor lines
from the outdoor unit (sweat connections) to the indoor unit
coil (flare or sweat connections). Use Lennox L15 (sweat,
non41are) series line sets, or use field-fabricated
refrigerant lines as listed in table 3.
MATCHING WITH NEW OR EXISTING INDOOR COIL
AND LINE SET
IMPORTANT
Line sets for heat pump applications can not be installed
underground. For more information see the Lennox
Refrigerant Piping Design and Fabrication Guidelines, or
contact Lennox Technical Support Product Applications
for assistance.
Table 3. Refrigerant Line Sets
Valve Sizes Recommended Line Set
Model Liquid Vapor Liquid Vapor L15
Line Line Line Line LineSets
-024
-030 (10mm) (19mm) (10mm) (19mm) 15-50ft.
-- (5 - 15 m)
-036
-042 3/8 in. 7/8 in 3/8 in. 7/Sin L15-65
-060 (10 ram) (29 ram) (10 ram) (29 ram) Fabricated
3/8 in. 3/4 in. 3/8 in 3/4 in. L15-41
15 - 50 ft.
(10mm) (22mm) (10mm) (22mm) (5-15m)
3/8 in. 1-1/8 in, 3/8 in. 1-1/8 in, Field
INSTALLING LINE SET
Line Set Isolation--This reference illustrates
procedures, which ensure proper refrigerant line set
isolation:
• Installation of line sets on horizontal runs is
illustrated in figure 16.
• Installation of line sets on vertical runs is illustrated
in figure 17 on page 10.
• Installation of a transition from horizontal to
vertical is illustrated in figure 18 on page 10.
When installing refrigerant lines longer than 50 feet, see
the Lennox Refrigerant Piping Design and Fabrication
Guidelines, or contact Lennox Technical Support Product
Applications for assistance. To obtain the correct
information from Lennox, be sure to communicate the
following points:
Model (XP15) and size (e.g. -060) of unit.
Line set diameters for the unit being installed (from
table 3)
Number of elbows and if there is a rise or drop of the
piping.
TO HANG LINE SET FROM JOIST OR RAFTER,
USE EITHER METAL STRAPPING MATERIAL OR
ANCHORED HEAVY NYLON WIRE TIES.
STRAPPING MATERIAL
(AROUND VAPOR LINE
ONLY)
METAL JOIST OR RAFTER AT 8 FEET
TAPE OR LIQUID LINE TO THE VAPOR LINE.
FLOOR JOIST OR _ _ _%
ROOF RAFTER _-
SLEEVE INTERVALS THEN STRAP THE
STRAP THE VAPOR LINE TO THE
WIRE TIE (AROUND
VAPOR LINE ONLY
8 FEET TAPE OR
_._ I1
Figure 16. Refrigerant Line Sets: Installing
Horizontal Runs
WIRE TIE
Page 9
XP15 SERIES
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