Lennox XP21, XP21−024, XP21−036, XP21−048, XP21−060 Installation Instructions Manual

Download

Page 1

INSTALLATION

E20 Lennox Industries Inc.

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.

NOTICE TO INSTALLER

It is critical for proper unit operation to place outdoor unit on an elevated surface as described in Unit Placement section on page 7.

It is critical for proper defrost operation to set the defrost termination pins (E47) on the heat pump control prior to starting system. See Defrost System section on page 33 for further details.

BRAZING LINE SET TO SERVICE VALVES

It is imperative to follow the brazing technique illustrated starting on page 13 to avoid damaging the service valve’s internal seals.

UNIT PLACEMENT

DEFROST OPERATION

NOTICE

A thermostat is not included and must be ordered separately.

D The Lennox icomfort Touch® thermostat must be used

in communicating application

D In non−icomfortt applications, the Lennox

ComfortSense® 7000 thermostat may be used, as well as other non−communicating thermostats.

In all cases, setup is critical to ensure proper system operation.

Field wiring examples for non−icomforttapplications begin on page 25.

See the icomfort Touch® thermostat Quick Start Guide for communicating and partial communicating field wiring connections.

INSTRUCTIONS

Dave Lennox Signature Collection XP21 System

HEAT PUMPS 506601−01 06/11 Supersedes 05/11

TABLE OF CONTENTS

General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Number Identification 2. . . . . . . . . . . . . . . . . . . .

Typical Unit Parts Arrangement 3. . . . . . . . . . . . . . . . .

Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . .

Using Manifold Gauge Set 4. . . . . . . . . . . . . . . . . . . . . .

Operating Service Valves 4. . . . . . . . . . . . . . . . . . . . . . .

Recovering Refrigerant from Existing System 6. . . . .

Unit Placement 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and Installing Panels 9. . . . . . . . . . . . . . . . .

New or Replacement Line Set 11. . . . . . . . . . . . . . . . . . .

Brazing Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Line Set and Indoor Coil 16. . . . . . . . . . . . . . . .

Installing Indoor Expansion Valve 17. . . . . . . . . . . . . . . .

Leak Test Line Set and Indoor Coil 18. . . . . . . . . . . . . . .

Evacuating Line Set and Indoor Coil 18. . . . . . . . . . . . .

Electrical 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat Pump Control (A175) Jumpers and Terminals 23

Field Control Wiring 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Unit Delivered Void of Charge 27. . . . . . . . . .

Unit Start−Up 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Refrigerant 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Handler / Coil Match up and Targeted

Subcooling Values 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating and Temperature Pressures 31. . . . . . . . . . .

System Operations 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defrost System 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Status, Fault and Lockout LED Codes 43. . . . .

Field Component Configuration and Testing 48. . . . . . .

Maintenance (Dealer and Homeowner) 55. . . . . . . . . . .

SunSource® Home Energy System 57. . . . . . . . . . . . . .

Checklists 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General

This outdoor unit is designed for use with HFC−410A refrigerant only. This unit must be installed with an approved indoor air handler or coil. See the Lennox XP21 Engineering Handbook for approved indoor component match ups.

Litho U.S.A.

06/11 506601−01

*2P0611* *P506601-01*

Page 1

Page 2

Unit Dimensions −− Inches (mm)

39−1/2 (1003)

DISCHARGE AIR

37 (940) (−024 AND −036)

47 (1194) (−048 AND −060)

SUCTION LINE INLET

4−1/2 (114)

35−1/2

(902)

ELECTRICAL INLET (HIGH VOLTAGE)

ELECTRICAL INLET (CONTROL WIRING − LOW VOLTAGE)

SIDE VIEW

UNIT SUPPORT

FEET

16−7/8

(429)

8−3/4 (222)

3−1/8

(79)

LIQUID LINE INLET

30−3/4

(781)

18−1/2

(470)

8 (203)

1 (25)

BASE WITH ELONGATED LEGS

SOLAR MODULE WIRING

ACCESS VIEW

26−7/8

(683)

3−3/4 (95)

4−5/8 (117)

Model Number Identification

Refrigerant Type

X = R−410A

Unit Type

P = Heat Pump

Series

506601−01

P 21 036− −

230

−2

Nominal Cooling Capacity

024 = 2 tons 036 = 3 tons 048 = 4 tons 060 = 5 tons

Page 2

Minor Revision Number

Voltage

230 = 208/230V−1ph−60hz

Page 3

Typical Unit Parts Arrangement

WIRE TIE

OUTDOOR AMBIENT

TEMPERATURE SENSOR (RT13)

DISCHARGE LINE

TEMPERATURE SENSOR

MUFFLER

(RT28)

COMPRESSOR

GROUND LUGS

CONTACTOR  1 POLE (K1−1)

HIGH VOLTAGE FIELD

CONNECTIONS

CHECK

EXPANSION VALVE

FAN MOTOR CONTROL (A177)

HEAT PUMP CONTROL

(A175)

COIL TEMPERATURE SENSOR (RT21) 

ON RETURN BEND, 12 TUBES UP FROM

BOTTOM (11.50’ UP)

CAPACITOR (C12)

XP21−024 AND −036

REVERSING

VALV E

VAPOR VALVE

AND GAUGE

PORT

LIQUID VALVE AND

GAUGE PORT

TRUE SUCTION LINE

LIQUID LINE BI−FLOW

FILTER DRIER

PORT

CRANKCASE HEATER (HR1) (BELLY BAND)

CRANKCASE HEATER THERMOSTAT (S40)

HIGH PRESSURE

SWITCH (S4)

LOW PRESSURE

SWITCH (S87)

Figure 1. Plumbing, Switches and Sensor Components

COIL TEMPERATURE

SENSOR (RT21)  ON

RETURN BEND, 24

TUBES UP FROM

BOTTOM (23.50’ UP)

DISTRIBUTOR

XP21−048 AND −060

Page 3

XP21 SERIES

Page 4

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.

1  Bushing (for low voltage wiring) 2  Isolation grommets for liquid and suction lines

Using Manifold Gauge Set

When checking the system charge, only use a manifold gauge set that features low−loss anti−blow back fittings.

IMPORTANT

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.

IMPORTANT

The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFCs, HCFCs AND HFCs) as of July 1,

1992. Approved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarceration may be levied for noncompliance.

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.

To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening.

Manifold gauge set used with HFC−410A refrigerant systems must be capable of handling higher system operating pressures. The gauges should be rated for use with pressures of 0 − 800 psig on the high side and a low side of 30" vacuum to 250 psig with dampened speed to 500 psi. Gauge hoses must be rated for use at or up to 800 psig of pressure with a 4000 psig burst rating.

Table 1. Torque Requirements

Parts 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

Operating Service Valves

The liquid and vapor line service valves are used for removing refrigerant, flushing, leak testing, evacuating, verifying charge and charging.

Each valve is equipped with a service port which has a factory−installed valve stem. Figure 2 provides information on how to access and operating both angle and ball service valves.

IMPORTANT

This model is designed for use in check expansion valve systems only. An indoor expansion valve approved for use with HFC−410A refrigerant must be ordered separately, and installed prior to operating the system.

Shipping and Packing List

Check unit for shipping damage. Consult last carrier immediately if damage is found.

1  Assembled outdoor unit.

1  Bag assembly which includes the following:

506601−01

IMPORTANT

Only use Allen wrenches of sufficient hardness (50Rc − Rockwell Harness Scale minimum). Fully insert the wrench into the valve stem recess.

Service valve stems are factory−torqued (from 9 ft−lbs for small valves, to 25 ft−lbs for large valves) to prevent refrigerant loss during shipping and handling. Using an Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench, or stripping the valve stem recess.

See the Lennox Service and Application Notes #C−08−1 for further details and information.

Page 4

Page 5

SERVICE VALVES

ANGLE AND BALL

Operating Angle Type Service Valve:

1. Remove stem cap with an appropriately sized 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.

SERVICE PORT CAP

SERVICE PORT CORE

(VALVE STEM SHOWN CLOSED) INSERT HEX WRENCH HERE

TO INDOOR

UNIT

(VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE

STEM CAP

TO OUTDOOR UNIT

ANGLE−TYPE SERVICE VALVE

(BACK−SEATED OPENED)

When service valve is OPEN, the service port is open to linE set, indoor and outdoor unit.

Operating Ball Type Service Valve:

1. Remove stem cap with an appropriately sized wrench.

2. Use an appropriately sized wrenched to open. To open valve, rotate stem counterclockwise 90°. To close, rotate stem clockwise 90°.

TO INDOOR UNIT

TO OPEN ROTATE STEM COUNTERCLOCKWISE 90°.

TO CLOSE ROTATE STEM CLOCKWISE 90°.

SERVICE PORT

CORE

CAP

TO OUTDOOR

UNIT

BALL (SHOWN CLOSED)

VALV E STEM

STEM CAP

ANGLE−TYPE SERVICE VALVE

(FRONT−SEATED CLOSED)

WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN TO

THE LINE SET AND INDOOR UNIT.

To Access 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 with an appropriately sized wrench.

2. Connect gauge set to service port.

3. When testing is completed, replace service port cap and tighten as follows:

1/6 TURN

1/12 TURN

S With torque wrench: Finger tighten and

torque cap per table 1.

S Without torque wrench: Finger tighten and

use an appropriately sized wrench to turn an additional 1/6 turn clockwise.

Reinstall Stem Cap:

Stem cap protects the valve stem from damage and serves as the primary seal. Replace the stem cap and tighten as follows:

S With Torque Wrench: Finger tighten and then

torque cap per table 1.

S Without Torque Wrench: Finger tighten and use

an appropriately sized wrench to turn an additional 1/12 turn clockwise.

NOTE  A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.

Figure 2. Angle and Ball Service Valves

Page 5

XP21 SERIES

Page 6

Recovering Refrigerant from Existing System

DISCONNECT POWER

Disconnect all power to the existing outdoor unit at the disconnect

switch or main fuse box/breaker panel.

SERVICE DISCONNECT

SWITCH

CONNECT MANIFOLD GAUGE SET

Connect a gauge set, clean recovery cylinder and a recovery

machine to the service ports of the existing unit. Use the instruction provided with the recovery machine to make the connections.

MANIFOLD GAUGES

RECOVERY MACHINE

LOW

HIGH

RECOVERING REFRIGERANT

Remove existing HCFC−22 refrigerant using one of the following methods

below:

IMPORTANT  Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes, and/or long line sets.

CLEAN RECOVERY CYLINDER

OUTDOOR UNIT

METHOD 1:

Us this method 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 to flush the system.

Remove all HCFC−22 refrigerant from the existing system. Check gauges after shutdown to confirm that the entire system is completely void of refrigerant.

METHOD 2:

Use this method 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.

The following devices could prevent full system charge recovery into the outdoor unit:

S Outdoor unit’s high or low−pressure switches (if applicable) when tripped can cycle the compressor OFF.

S Compressor can stop pumping due to tripped internal pressure relief valve.

S Compressor has internal vacuum protection that is designed to unload the scrolls (compressor stops pumping) when the pressure ratio meets

a certain value or when the suction pressure is as high as 20 psig. (Compressor suction pressures should never be allowed to go into a vacuum. Prolonged operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips, drive bearings and internal seals.)

Once the compressor can not pump down to a lower pressure due to one of the above system conditions, shut off the vapor valve. Turn OFF the main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set.

Perform the following task:

A Start the existing HCFC−22 system in the cooling mode and close the liquid line valve.

B Use the compressor to pump as much of the existing HCFC−22 refrigerant into the outdoor unit until the outdoor system is full (high pressure

switch will trip and shut the compressor off). Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system.

NOTE  It may be necessary to bypass the low pressure switch (if equipped) to ensure complete refrigerant evacuation.

C When the low side system pressures reach 0 psig, close the vapor line valve.

D Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system.

Figure 3. Refrigerant Recovery Procedure

Page 6

506601−01

Page 7

CLEARANCE ON ALL SIDES  INCHES (MILLIMETERS)

MINIMUM CLEARANCE

ABOVE UNIT

12 (305)

6 (152)

36 (914)

ACCESS PANEL

CONTROL PANEL

ACCESS

LOCATION

30 (762)

LINE SET CONNECTIONS

MINIMUM CLEARANCE BETWEEN

TWO UNITS

24 (610)

Figure 4. Mandatory Installation Clearances

NOTES:

S Clearance to one of the other three

sides must be 36 inches (914mm).

S Clearance to one of the remaining

two sides may be 12 inches (305mm) and the final side may be 6 inches (152mm).

ACCESS PANEL

LINE SET

CONNECTIONS

48 (1219)

REAR VIEW OF UNIT

Unit Placement

CAUTION

In order to avoid injury, take proper precaution when lifting heavy objects.

See Unit Dimensions on page 3 for sizing mounting slab, platforms or supports. Refer to figure 4 for mandatory installation clearance requirements.

POSITIONING CONSIDERATIONS

Consider the following when positioning the unit:

S Some localities are adopting sound ordinances based

on the unit’s sound level registered from the adjacent property and not from the installation property. Install the unit as far as possible from the property line.

S 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 5, detail A.

PLACING UNIT ON SLAB

When installing unit at grade level, the top of the slab should be high enough above grade so that water from higher ground will not collect around the unit. The slab should have a slope tolerance as described in figure 5, detail B.

NOTE  If necessary for stability, anchor unit to slab as described in figure 5, detail D.

ELEVATING THE UNIT

Units are outfitted with elongated support feet as illustrated in figure 5, detail C.

If additional elevation is necessary, raise the unit by extending the height of the unit support feet. This may be achieved by using a 2−inch (50.8mm) Schedule 40 female threaded adapter.

The specified coupling will fit snuggly into the recessed portion of the feet. Use additional 2−inch (50.8mm) Schedule 40 male threaded adaptors which can be threaded into the female threaded adaptors 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.

Page 7

XP21 SERIES

Page 8

DETAIL A

Install unit away from windows.

 Outside Unit Placement

DETAIL B

Install unit level or, if on a slope, maintain slope tolerance of two (2) degrees (or two inches per five feet [50 mm per 1.5 m]) away from building structure.

 Slab Mounting at Ground Level

BUILDING

STRUCTURE

MOUNTING SLAB

TWO 90° ELBOWS INSTALLED IN LINE SET WILL

REDUCE LINE SET VIBRATION.

DETAIL C

 Elevated Slab Mounting

using Feet Extenders

LEG DETAIL

2" (50.8MM) SCH 40

FEMALE THREADED

ADAPTER

BASE

GROUND LEVEL

STABILIZING UNIT ON UNEVEN SURFACES

DETAIL D

#10 1/2" LONG SELF−DRILLING

SHEET METAL SCREWS

STABILIZING BRACKET (18 GAUGE

METAL  2" WIDTH; HEIGHT AS

#10 1−1/4" LONG HEX HD SCREW

Concrete slab  use two plastic anchors (hole drill 1/4")

Wood or plastic slab  no plastic anchor (hole drill 1/8")

DETAIL E

Stabilizing bracket (18 gauge metal  2" (50.8mm) width; height as required); bend to form right angle as exampled below.

 Slab Side Mounting

REQUIRED)

AND FLAT WASHER

 Deck Top Mounting

MINIMUM ONE

PER SIDE

COIL

BASE PAN

CORNER POST

2" (50.8MM) SCH 40

MALE THREADED

ADAPTER

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.

IMPORTANT  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.

Figure 5. Placement and Slab Mounting

506601−01

SAME FASTENERS AS SLAB SIDE MOUNTING.

One bracket per side (minimum). For extra stability, two brackets per side, two inches (51mm) from each corner.

FOR EXTRA

STABILITY

Page 8

Page 9

STABILIZING UNIT ON UNEVEN SURFACES

IMPORTANT

Unit Stabilizer Bracket Use (field−provided):

Always use stabilizers when unit is raised above the factory height. (Elevated units could become unstable in gusty wind conditions).

Stabilizers may be used on factory height units when mounted on unstable an uneven surface.

1. Remove two side louvered panels to expose the unit base.

2. Install the brackets as illustrated in figure 5, details D or E using conventional practices.

3. Replace the panels after installation is complete.

ROOF MOUNTING

Install the unit a minimum of six (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. 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.

PREVAILING WINTER

WINDS

WIND BARRIER

INLET AIR

24"

(610)

NOTICE

Roof Damage! This system contains both refrigerant and oil. Some

rubber roofing material may absorbed oil and cause the rubber to swell when it comes into contact with oil. The rubber will then bubble and could cause leaks. Protect the roof surface to avoid exposure to refrigerant and oil during service and installation. Failure to follow this notice could result in damage to roof surface.

Removing and Installing Panels

IMPORTANT

Do not allow panels to hang on unit by top tab. Tab is for alignment and not designed to support weight of panel.

IMPORTANT

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.

WARNING

To prevent personal injury, or damage to panels, unit or structure, be sure to observe the following:

While installing or servicing this unit, carefully stow all removed panels out of the way, so that the panels will not cause injury to personnel, nor cause damage to objects or structures nearby, nor will the panels be subjected to damage (e.g., being bent or scratched).

While handling or stowing the panels, consider any weather conditions, especially windy conditions, that may cause panels to be blown around and battered.

INLET AIR

Figure 6. Rooftop Application and Wind Barrier

Page 9

XP21 SERIES

Page 10

REMOVING AND INSTALLING PANELS

Panel shown slightly rotated to allow top tab to exit (or enter) top slot for removing (or installing) panel.

LOUVERED PANEL REMOVAL

Remove the louvered panels as follows:

LOUVERED PANEL INSTALLATION

Position the panel almost parallel with the unit as illustrated in detail D with the screw side as close to the unit as possible. Then, in a continuous motion:

Detail C

WARNING

1. Remove two screws, allowing the panel to swing open slightly.

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 detail B.

3. Move panel down until lip of upper tab clears the top slot in corner post as illustrated

in detail A.

1. Slightly rotate and guide the lip of top tab inward as illustrated in detail A and C; then

upward into the top slot of the hinge corner post.

2. Rotate panel to vertical to fully engage all tabs.

3. Holding the panel’s hinged side firmly in place, close the right−hand side of the panel, aligning the screw holes.

4. When panel is correctly positioned and aligned, insert the screws and tighten.

Detail A

LIP

SCREW

HOLES

REMOVE 4 SCREWS TO REMOVE PANEL FOR ACCESSING COMPRESSOR AND CONTROLS.

Position panel with holes aligned; install screws and tighten.

Detail D

ANGLE MAY BE TOO EXTREME

PREFERRED ANGLE FOR INSTALLATION

Maintain minimum panel angle (as close to parallel with the unit as possible) while installing panel.

HOLD DOOR FIRMLY ALONG

THE HINGED SIDE TO MAINTAIN

FULLY−ENGAGED TABS

Figure 7. Removing and Installing Panels

Detail B

ROTATE IN THIS DIRECTION; THEN

DOWN TO REMOVE PANEL

506601−01

Page 10

Page 11

New or Replacement Line Set

REFRIGERANT LINE SET

This section provides information on installation or replacement of existing line set. If new or replacement line set is not being installed then proceed to Brazing

Connections on page 13.

NOTE  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 information:

S Model (XP21) and size of unit (e.g. −036).

IMPORTANT

Lennox highly recommends changing line set when converting the existing system from HCFC−22 to HFC−410A. If that is not possible and the line set is the proper size as reference in table 2, use the procedure outlined under Flushing the System on page 16.

If refrigerant lines are routed through a wall, then 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. See figure 8 for recommended installation practices. Also, consider the following when placing and installing a high−efficiency outdoor unit.

IMPORTANT

Refrigerant lines must not contact structure.

Liquid lines that meter the refrigerant, such as RFC1 liquid lines, must not be used in this application. Existing line set of proper size as listed in table 2 may be reused. If system was previously charged with HCFC−22 refrigerant, then existing line set must be flushed (see Flushing the System on page 16).

Field refrigerant piping consists of liquid and vapor lines from the outdoor unit to the indoor unit coil (braze connections). Use Lennox L15 (sweat, non−flare) series line set, or field−fabricated refrigerant line sizes as listed in table 2.

Table 2. Refrigerant Line Set

Models Liquid

Line

−024, −036 and−048

−060 3/8 (10) 1−1/8 (29) Field Fabricated

NOTE  Some applications may required a field−provided 7/8" to 1−1/8" adapter.

3/8 (10) 7/8 (22) L15 line set sizes are

Vapor/ Suction Line

L15 Line Set

dependent on unit match up. See XP21 Engineering Handbook to determine correct line set sizes.

S Line set diameters for the unit being installed as listed

in table 2 and total length of installation.

S Number of elbows vertical rise or drop in the piping.

The compressor is charged with sufficient Polyol Ester oil (POE) for line set lengths up to 50 feet. Recommend adding oil to system based on the amount of refrigerant charge in the system. Systems with 20 pounds or less of refrigerant required no oil to be added.

For systems over 20 pounds − add one ounce for every five (5) pounds of HFC−410A refrigerant.

Recommended POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATEt RL32CF.

IMPORTANT

If this unit is being matched with an approved line set or indoor unit coil which was previously charged with mineral oil, or if it is being matched with a coil which was manufactured before January of 1999, the coil and line set must be flushed prior to installation. Take care to empty all existing traps. Polyol ester (POE) oils are used in Lennox units charged with HFC−410A refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the expansion device, and reduce the system performance and capacity. Failure to properly flush the system per the instructions below will void the warranty.

WARNING

Polyol Ester (POE) oils used with HFC−410A refrigerant absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as possible. DO NOT remove line set caps or service valve stub caps until you are ready to make connections.

IMPORTANT

Mineral oils are not compatible with HFC−410A. If oil

must be added, it must be a Polyol Ester oil.

Page 11

XP21 SERIES

Page 12

Line Set Isolation  The following illustrations are examples of proper refrigerant line set isolation:

REFRIGERANT LINE SET  TRANSITION

FROM VERTICAL TO HORIZONTAL

ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE

MUFFLER-TYPE HANGER

WALL

STUD

NON−CORROSIVE

METAL SLEEVE

AUTOMOTIVE

MUFFLER-TYPE HANGER

STRAP LIQUID LINE TO VAPOR LINE

LIQUID LINE

VAPOR LINE − WRAPPED IN ARMAFLEX

REFRIGERANT LINE SET  INSTALLING

HORIZONTAL RUNS

To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties.

WIRE TIE (AROUND VAPOR LINE ONLY)

8 FEET (2.43 METERS)

STRAPPING

MATERIAL (AROUND

VAPOR LINE ONLY)

TAPE OR WIRE TIE

FLOOR JOIST OR

ROOF RAFTER

8 FEET (2.43 METERS)

NON−CORROSIVE METAL SLEEVE

STRAP THE VAPOR LINE TO THE JOIST OR RAFTER AT 8 FEET (2.43 METERS) INTERVALS THEN STRAP THE LIQUID LINE TO THE VAPOR LINE.

TAPE OR WIRE TIE

REFRIGERANT LINE SET  INSTALLING

VERTICAL RUNS (NEW CONSTRUCTION SHOWN)

NOTE  Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig.

OUTSIDE WALL

WOOD BLOCK

BETWEEN STUDS

VAPOR LINE WRAPPED

WITH ARMAFLEX

OUTSIDE

WALL

PVC

PIPE

FIBERGLASS

INSULATION

VAPOR LINE

SLEEVE

CAULK

LIQUID LINE

NOTE  Similar installation practices should be used if line set is to be installed on exterior of outside wall.

LIQUID LINE

WIRE TIE

INSIDE WALL

STRAP

NON−CORROSIVE METAL SLEEVE

WIRE TIE

WOOD BLOCK

WIRE TIE

STRAP

FLOOR JOIST OR

ROOF RAFTER

506601−01

Figure 8. Line Set Installation

Page 12

Page 13

Brazing Connections

Use the procedures outline in figures 9 and 10 for brazing line set connections to service valves.

WARNING

Danger of fire. Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing. Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture − Check the high and low pressures before applying heat.

IMPORTANT

Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve.

IMPORTANT

Allow braze joint to cool before removing the wet rag from the service valve. Temperatures above 250ºF can damage valve seals.

WARNING

When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).

CAUTION

Brazing alloys and flux contain materials which are hazardous to your health.

Avoid breathing vapors or fumes from brazing operations. Perform operations only in well−ventilated areas.

Wear gloves and protective goggles or face shield to protect against burns.

Wash hands with soap and water after handling brazing alloys and flux.

IMPORTANT

Use silver alloy brazing rods with 5% minimum silver alloy for copper−to−copper brazing. Use 45% minimum alloy for copper−to−brass and copper−to−steel brazing.

WARNING

Fire, Explosion and Personal Safety Hazard.

Failure to follow this warning could result in damage, personal injury or death.

Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when exposed to a spark or open flame, can cause fire and/or an explosion, that could result in property damage, personal injury or death.

Page 13

XP21 SERIES

Page 14

PIPING PANEL REMOVAL AND PREPARING LINE SET

Remove piping panel for easier access to service valves. Cut ends of the refrigerant lines square (free from nicks or dents) and debur the ends. The pipe must remain round. Do not crimp end of the line.

CUT AND DEBUR

LINE SET SIZE MATCHES

SERVICE VALVE CONNECTION

SERVICE VALVE

COPPER TUBE

REDUCER

STUB

CONNECTION

LINE SET SIZE IS SMALLER

THAN CONNECTION

CAP AND CORE REMOVAL

Remove service cap and core from both the suction / vapor and

liquid line service ports.

SERVICE PORT CAP

SERVICE PORT CORE

LIQUID LINE SERVICE VALVE

REFRIGERANT LINE

DO NOT CRIMP SERVICE VALVE

CONNECTOR WHEN PIPE IS

SMALLER THAN CONNECTION

ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE VALVES

A Connect gauge set low pressure side to liquid line

service valve (service port).

B Connect gauge set center port to bottle of nitrogen with

regulator.

C With valve core removed from the suction / vapor line

service port, nitrogen flow will have an exit point.

ATTACH

GAUGES

SUCTION / VAPOR SERVICE PORT MUST BE

OPEN AND SERVICE PORT CORE REMOVED

TO ALLOW EXIT POINT FOR NITROGEN FLOW

SUCTION / VAPOR

LINE

INDOOR

UNIT

SUCTION /

VAPOR LINE

SERVICE

VALV E

SUCTION / VAPOR LINE

SERVICE VALVE

HIGHLOW

OUTDOOR

UNIT

SERVICE PORT CORE

SERVICE PORT CAP

LIQUID LINE

506601−01

LIQUID LINE SERVICE

VALV E

Figure 9. Brazing Procedures

Page 14

NITROGEN

Page 15

WRAP SERVICE VALVES

To help protect service valve seals during brazing, wrap water saturated cloths around service valve bodies and copper tube stubs. Use

additional water saturated cloths underneath the valve body to protect the base paint.

FLOW NITROGEN

Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration

gauge set into the valve stem port connection on the liquid service valve and out of the suction / vapor valve stem port. See steps 3A, 3B and 3C on previous page and below for manifold gauge setup.

BRAZE LINE SET

Water saturated cloths must remain water saturated throughout

the brazing and cool−down process.

A Braze liquid line to liquid line service valve.

B Braze suction / vapor line to suction / vapor service

valve.

1. FIRE, PERSONAL INJURY, OR PROPERTY DAMAGE will result if you do not wrap a water saturated cloth around both liquid and suction line service valve bodies and copper tube stub while brazing in the line set! The braze, when complete, must be quenched with water to absorb any residual heat.

2. Do not open service valves until refrigerant lines and indoor coil have been leak−tested and evacuated. Refer to procedures provided in this supplement.

WHEN BRAZING LINE SET TO

SERVICE VALVES, POINT FLAME AWAY

FROM SERVICE VALVE.

WARNING

SUCTION / VAPOR LINE

WATER SATURATED CLOTHS

IMPORTANT  Allow braze joint to cool. Apply

additional water saturated cloths to help cool brazed joints. Do not remove water saturated cloths until piping has cooled. Temperatures above 250ºF will damage valve seals.

SUCTION / VAPOR SERVICE PORT

MUST BE OPEN AND SERVICE PORT

CORE REMOVED TO ALLOW EXIT

POINT FOR NITROGEN FLOW

LIQUID LINE

WATER SATURATED

PREPARATION FOR NEXT STEP

After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water saturated cloths to both services

valves to cool piping. Once piping is cool, remove all water saturated cloths. Refer to the unit installation instructions for the next step in preparing the unit.

CLOTHS

Figure 10. Brazing Procedures (Continued)

Page 15

XP21 SERIES

Page 16

Flushing Line Set and Indoor Coil

The following procedure should not be performed on a system which contain contaminants (i.e., compressor burn out).

TYPICAL EXISTING FIXED ORIFICE

DISTRIBUTOR

ASSEMBLY

A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps holding the liquid line and distributor as-

sembly.

C Using two wrenches, disconnect liquid line from liquid line orifice hous-

ing. Take care not to twist or damage distributor tubes during this process.

D Remove and discard fixed orifice, valve stem assembly if present and

Teflon® washer as illustrated above.

E Use a field−provided fitting to temporary reconnect the liquid line to the

indoor unit’s liquid line orifice housing.

COIL SHOWN)

DISTRIBUTOR TUBES

LIQUID LINE ORIFICE HOUSING

REMOVE AND DISCARD

WHITE TEFLON

(IF PRESENT)

TEFLON® RING

FIXED ORIFICE

SEAL

LIQUID LINE ASSEMBLY

(INCLUDES STRAINER)

REMOVAL PROCEDURE (UNCASED

BRASS NUT

TWO PIECE PATCH PLATE

(UNCASED COIL ONLY)

CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE

INVERTED HCFC−22 CYLINDER CONTAINS CLEAN HCFC−22 TO BE USED FOR FLUSHING.

VAPOR LINE

SERVICE VALVE

EXISTING

INDOOR

UNIT

LIQUID LINE SERVICE

VALV E

VAPOR

LIQUID

RECOVERY

CYLINDER

A Inverted HCFC−22 cylinder with clean refrigerant to the vapor service

valve.

B HCFC−22 gauge set (low side) to the liquid line valve. C HCFC−22 gauge set center port to inlet on the recovery machine with an

empty recovery tank to the gauge set.

D Connect recovery tank to recovery machines per machine instructions.

OUTDOOR

NEW

UNIT

OPENED

RECOVERY MACHINE

GAUGE

MANIFOLD

LOW HIGH

CLOSED

TANK RETURN

INLET

DISCHARGE

TYPICAL EXISTING EXPANSION VALVE REMOVAL PROCEDURE (UNCASED COIL SHOWN)

ORIFICE

HOUSING

EQUALIZER LINE

STUB END

TEFLON RING

VAPOR

CHECK

EXPANSION

VALV E

LIQUID LINE

ASSEMBLY WITH

BRASS NUT

LINE

TEFLON

RING

SENSING

LINE

LIQUID

LINE

LIQUID LINE

DISTRIBUTOR

TUBES

DISTRIBUTOR

ASSEMBLY

MALE EQUALIZER

LINE FITTING

SENSING BULB

A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps holding the liquid line and distributor

assembly.

C Disconnect the equalizer line from the check expansion valve

equalizer line fitting on the vapor line.

D Remove the vapor line sensing bulb. E Disconnect the liquid line from the check expansion valve at the liquid

line assembly.

F Disconnect the check expansion valve from the liquid line orifice

housing. Take care not to twist or damage distributor tubes during this process.

G Remove and discard check expansion valve and the two Teflon® rings. H Use a field−provided fitting to temporary reconnect the liquid line to the

indoor unit’s liquid line orifice housing.

FLUSHING LINE SET

The line set and indoor unit coil must be flushed with at least the

same amount of clean refrigerant that previously charged the system. Check the charge in the flushing cylinder before proceeding.

A Set the recovery machine for liquid recovery and start the

recovery machine. Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line

set and indoor unit coil.

B Invert the cylinder of clean HCFC−22 and open its valve to allow

liquid refrigerant to flow into the system through the vapor line valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine.

C After all of the liquid refrigerant has been recovered, switch the

recovery machine to vapor recovery so that all of the HCFC−22 vapor is recovered. Allow the recovery machine to pull down to 0 the system.

D Close the valve on the inverted HCFC−22 drum and the gauge

set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off.

Figure 11. Flushing Line Set and Indoor Coil

506601−01

Page 16

Page 17

Installing Indoor Expansion Valve

This outdoor unit is designed for use in systems that use check expansion valve metering device. See the Lennox XP21 Engineering Handbook for approved check expansion valve kit match−ups and application information. The check

expansion valve unit can be installed internal or external to the indoor coil. In applications where an uncased coil is being installed in a field−provided plenum, install the check expansion valve in a manner that will provide access for field servicing of the check expansion valve. Refer to below illustration for reference during installation of check expansion valve unit.

INDOOR EXPANSION VALVE INSTALLATION

TWO PIECE

PATCH PLATE

(UNCASED

COIL ONLY)

DISTRIBUTOR

TUBES

DISTRIBUTOR

ASSEMBLY

MALE EQUALIZER LINE

FITTING (SEE

EQUALIZER LINE INSTALLATION FOR FURTHER DETAILS)

(Uncased Coil Shown)

LIQUID LINE

ORIFICE

HOUSING

STUB

END

TEFLON RING

EQUALIZER LINE

VAPOR

CHECK

EXPANSION

VALV E

ASSEMBLY WITH

LINE

TEFLON

RING

SENSING

LIQUID LINE

BRASS NUT

LIQUID LINE

Sensing bulb insulation is required if mounted external to the coil casing. sensing bulb installation for bulb positioning.

EQUALIZER LINE INSTALLATION

A Remove and discard either the flare seal cap or flare nut

with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right.

B Remove and discard either the flare seal cap or flare nut

with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right.

LINE

A Remove the field−provided fitting that temporary

reconnected the liquid line to the indoor unit’s distributor assembly.

B Install one of the provided Teflon® rings around the

stubbed end of the check expansion valve and lightly lubricate the connector threads and expose surface of the Teflon® ring with refrigerant oil.

C Attach the stubbed end of the check expansion valve to

the liquid line orifice housing. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above, or 20 ft−lb.

D Place the remaining Teflon® washer around the other

end of the check expansion valve. Lightly lubricate connector threads and expose surface of the Teflon ring with refrigerant oil.

E Attach the liquid line assembly to the check expansion

valve. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or 20 ft−lb.

SENSING BULB INSTALLATION

A Attach the vapor line sensing bulb in the proper

orientation as illustrated to the right using the clamp and screws provided.

NOTE  Confirm proper thermal contact between vapor line and check expansion bulb before insulating the sensing bulb once installed.

B Connect the equalizer line from the check expansion

valve to the equalizer vapor port on the vapor line. Finger tighten the flare nut plus 1/8 turn (7 ft−lbs) as illustrated below.

VAPOR LINE

BULB

ON LINES SMALLER THAN 7/8", MOUNT SENSING BULB AT EITHER THE 3 OR 9 O’CLOCK POSITION.

BULB

1/2 Turn

1/8 Turn

FLARE SEAL CAP

Figure 12. Installing Indoor Expansion Valve

FLARE NUT

COPPER FLARE SEAL BONNET

MALE BRASS EQUALIZER LINE FITTING

VAPOR LINE

Page 17

VAPOR LINE

BULB

NOTE  NEVER MOUNT ON BOTTOM OF LINE.

ON 7/8" AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 4 OR 8 O’CLOCK POSITION. NEVER MOUNT ON BOTTOM OF LINE.

BULB

XP21 SERIES

Page 18

IMPORTANT

Leak Test Line Set and Indoor Coil

The Environmental Protection Agency (EPA) prohibits the intentional venting of HFC refrigerants during maintenance, service, repair and disposal of appliance. Approved methods of recovery, recycling or reclaiming must be followed.

IMPORTANT

CONNECT GAUGE SET

A Connect an HFC−410A manifold gauge set high pressure hose to

the vapor valve service port.

NOTE  Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the vapor port better protects the manifold gauge set from high pressure damage.

B With both manifold valves closed, connect the cylinder of

HFC−410A refrigerant to the center port of the manifold gauge set.

NOTE  Later in the procedure, the HFC−410A container will be replaced by the nitrogen container.

IMPORTANT

Leak detector must be capable of sensing HFC refrigerant.

WARNING

When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).

WARNING

Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly.

Failure to follow this warning may result in personal injury or death.

HIGHLOW

MANIFOLD GAUGE SET

OUTDOOR UNIT

TO VAPOR

SERVICE VALVE

NITROGEN

HFC−410A

TEST FOR LEAKS

After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the

following procedure to test for leaks:

A With both manifold valves closed, connect the cylinder of HFC−410A refrigerant to the center port of the manifold gauge set. Open the valve

on the HFC−410A cylinder (vapor only).

B Open the high pressure side of the manifold to allow HFC−410A into the line set and indoor unit. Weigh in a trace amount of HFC−410A. [A

trace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kPa) pressure]. Close the valve on the HFC−410A cylinder

and the valve on the high pressure side of the manifold gauge set. Disconnect the HFC−410A cylinder.

C Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set.

D Adjust dry nitrogen pressure to 150 psig (1034 kPa). Open the valve on the high side of the manifold gauge set in order to pressurize the line set

and the indoor unit.

E After a few minutes, open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak

detector.

F After leak testing disconnect gauges from service ports.

Figure 13. Leak Test

506601−01

Page 18

Page 19

Evacuating Line Set and Indoor Coil

CONNECT GAUGE SET

NOTE  Remove cores from service valves (if not already done).

A Connect low side of manifold gauge set

with 1/4 SAE in−line tee to vapor line service valve

B Connect high side of manifold gauge

set to liquid line service valve

C Connect micron gauge available

connector on the 1/4 SAE in−line tee.

D Connect the vacuum pump (with

vacuum gauge) to the center port of the manifold gauge set. The center port line will be used later for both the HFC−410A and nitrogen containers.

NITROGEN

HFC−410A

VACUUM PUMP

OUTDOOR

UNIT

A34000 1/4 SAE TEE WITH SWIVEL COUPLER

500

MICRON

GAUGE

GAUGE SET

SERVICE VALVE

TO LIQUID LINE SERVICE VALVE

LOW

MANIFOLD

TO VAPOR

EVACUATE THE SYSTEM

A Open both manifold valves and start the vacuum pump.

B Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury).

NOTE  During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once. A rapid rise in pressure indicates a relatively large leak. If this occurs, repeat the leak testing procedure.

NOTE  The term absolute pressure means the total actual pressure within a given volume or system, above the absolute zero of pressure. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure.

C When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), perform the following:

S Close manifold gauge valves S Close valve on vacuum pump S Turn off vacuum pump S Disconnect manifold gauge center port hose from vacuum pump S Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose. S Open manifold gauge valves to break the vacuum in the line set and indoor unit. S Close manifold gauge valves.

D Shut off the dry nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the

dry nitrogen from the line set and indoor unit.

E Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and indoor unit until the

absolute pressure does not rise above 500 microns (29.9 inches of mercury) within a 20−minute period after shutting off the vacuum pump and closing the manifold gauge valves.

F When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to an

upright cylinder of HFC−410A refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit.

G Perform the following:

S Close manifold gauge valves. S Shut off HFC−410A cylinder. S Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core

tool while maintaining a positive system pressure.

S Replace stem caps and secure finger tight, then tighten an additional one−sixth (1/6) of a turn as illustrated.

RECOMMEND

MINIMUM 3/8" HOSE

1/6 TURN

HIGH

Figure 14. Evacuating System

Page 19

XP21 SERIES

Page 20

IMPORTANT

Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns.

WARNING

Danger of Equipment Damage. Avoid deep vacuum operation. Do not use compressors to evacuate a system. Extremely low vacuums can cause internal arcing and compressor failure. Damage caused by deep vacuum operation will void warranty.

Evacuating the system of non−condensables is critical for proper operation of the unit. Non−condensables are defined as any gas that will not condense under

temperatures and pressures present during operation of an air conditioning system. Non−condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts.

Electrical

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).

Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size.

24VAC TRANSFORMER

Use the transformer provided with the furnace or air handler for low-voltage control power (24VAC − 40 VA minimum)

SIZE CIRCUIT AND INSTALL DISCONNECT SWITCH

Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR per NEC). Install power wiring and properly sized disconnect switch.

SERVICE

DISCONNECT

SWITCH

NOTE  Units are approved for use only with copper conductors. Ground unit at disconnect switch or to an earth ground.

WARNING

Electric Shock Hazard. Can cause injury or death. Unit must be grounded in accordance with national and local codes.

INSTALL THERMOSTAT

Install room thermostat (ordered separately) on an inside wall

approximately in the center of the conditioned area and 5 feet (1.5m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight or drafts.

THERMOSTAT

5 FEET

(1.5M)

NOTE  24VAC, Class II circuit connections are made in the control box.

CAUTION

ELECTROSTATIC DISCHARGE

(ESD)

Precautions and Procedures

506601−01

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

Page 20

Page 21

A. ROUTE CONTROL WIRES  NON−COMMUNICATING

Install low voltage control wiring from outdoor to indoor unit and from

thermostat to indoor unit.

A Run 24VAC control wires through hole with grommet.

B Make 24VAC control wire connections to heat pump control (A175) .

NOTE  Do not bundle any excess 24VAC control wires inside control box.

NOTE  Wire tie provides low voltage wire strain relief and to maintain

separation of field installed low and high voltage circuits.

NOTE  For proper voltages, select control wires gauge per table below.

WIRE RUN LENGTH AWG# INSULATION TYPE

LESS THAN 100’ (30 METERS) 18 TEMPERATURE RATING

MORE THAN 100’ (30 METERS) 16 35ºC MINIMUM.

CONTROL (A175)

B. ROUTE CONTROL WIRES  COMMUNICATING

Maximum length of wiring (18 gauge) for all connections on the RSBus is limited to 1500 feet (457 meters). Color−coded, temperature rating 95ºF (35ºC) minimum, solid core. (Class II Rated Wiring)

HEAT PUMP

HOLE

CONTROL BOX

ROUTE HIGH VOLTAGE AND GROUND WIRES

Any excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring. To facilitate a conduit, a

cutout is located in the bottom of the control box. Connect conduit to the control box using a proper conduit fitting.

HIGH VOLTAGE

CONDUIT HOLE

WATERTIGHT

CONDUIT

FITTING

WATERTIGHT

FLEXIBLE

CONDUIT

TO SERVICE

DISCONNECT BOX

PIPING PANEL

GROUND LUG

CONTACTOR

CONTROL BOX

ELECTRICAL INLET

(HIGH VOLTAGE)

WIRING ENTRY POINTS

ELECTRICAL INLET (CONTROL WIRING  LOW VOLTAGE). USE BUSHING PROVIDED IN BAG ASSEMBLY HERE.

ACCESS VIEW

Page 21

XP21 SERIES

Page 22

506601−01

Figure 15. Typical XP21 Wiring

Page 22

Page 23

Heat Pump Control (A175) Jumpers and Terminals

HEAT PUMP CONTROL  TWO STAGE

Table 3 on page 24 provides additional information concerning jumpers, links, and connections for the heat pump control.

DS11 and DS14

LED ALERT CODES

E37

*30

SECOND DELAY

COMPRESSOR SHIFT DELAY

E33

TEST PINS (SEE FIGURE 28 FOR DESCRIPTION OF VARIOUS FUNCTIONS)

DS13 and DS15

LED ALERT CODES

E48

DEGREE TARGET

50 DEGREE TARGET

DEGREE

TARGET

40 DEGREE TARGET

*NO JUMPER

E34

SECOND−STAGE LOCK−IN TEMPERATURE

JUMPER REMOVED − NO SECOND STAGE LOCK−IN TEMPERATURE.

NOTE  Earlier produce units will have a default factory setting (jumper present) for 40ºF. Later produce units will have no jumper by default present on E48.

E47

100

DEGREE TARGET

100

90 DEGREE TARGET

100

70 DEGREE TARGET

100

*50 DEGREE TARGET

100

DEFROST TERMINATION TEMPERATURE

DS12

INDICATES RS−BUS DATA COMMUNICATION IS ACTIVE. (COMMUNICATION MODE ONLY)

CUT FOR HUMIDITROL APPLICATION (TWO−STAGE UNITS ONLY)

Figure 16. Heat Pump Control Connections, Jumper Settings and LED Locations

Page 23

XP21 SERIES

Page 24

Table 3. Heat Pump Control (A175) Jumper and Terminal Descriptions

Control ID Label Description

E12 PSC Fan 240VAC output connection for outdoor fan.

E16 PSC Fan 240VAC input connection for outdoor fan.

W 24VAC output for defrost auxiliary heat output.

L Thermostat service light connection.

Y2 24VAC thermostat input/output for second stage operation of the unit.

Y1 24VAC thermostat input for first stage operation of the unit.

E18

E19 and E20 O OUT 24VAC output connection for reversing valve.

E21 and E22 LO−PS Connection for low−pressure switch (2.4 milliamps @ 18VAC)

E31 and E32 Y1 OUT 24VAC common output, switched for enabling compressor contactor.

E24 and E25 HS−PS Connection for high−pressure switch.

E26 FAN 1 First−stage basic and precision dehumidification ECM fan motor 24VDC output connection 1.

E27 FAN 2 Second−stage basic and precision dehumidification ECM fan motor 24VDC output connection 2.

E28 FAN C ECM common connection for ECM fan.

E30

E33 Field Test

E34 Y2 SOLENOID Keyed plug header used for second−stage compressor output.

E37 Comp Shift Delay

E47

E48

W1 DS To R

* Factory default setting

O 24VAC thermostat input for reversing valve operation

DS Humiditrol Input

C 24VAC system common

i− Input/Output − RSBus data low. Used in communicating mode only with compatible indoor thermostat.

i+ Input/Output − RSBus data high. Used in communicating mode only with compatible indoor thermostat.

R 24VAC system power input

Six position square pin header. P4 provides connections for the temperature sensors.

DIS (YELLOW) PINS 5 and 6 (RT28)

AMB (BLACK) Pins 3 and 4 (RT13)

COIL (BROWN) Pins 1 and 2 (RT21)

50*

100

NO JUMPER*

DIS 5  Discharge line temperature sensor supply.

DIS 6  Discharge line temperature sensor return.

Range is −35ºF to +310ºF. Sensor is clipped on a 1/2" copper tube.

AMB 3  Outdoor ambient temperature sensor supply.

AMB 4  Outdoor ambient temperature return.

Range is −40ºF to +140ºF

COIL 1  Outdoor coil temperature sensor supply.

COIL 2  Outdoor coil temperature sensor return

Range is −40ºF to +140ºF. Sensor is clipped on a 5/16" copper return bend.

This jumper allows service personnel to defeat the timed−off control, initiate or terminate a defrost cycle, and field programming of unit capacity feature.

Two position square pin header. When jumper is installed, a 30−second compressor shift delay is implemented. It de−energizes the compressor contactor, second−stage solenoid (if on) and the ECM fan outputs. After the timer expires, the compressor contactor and ECM fan outputs are energized. If no jumper is installed, it changes the reversing valve direction and de−energizing the outputs immediately.

Seven position square pin header. Provides selection of the defrost terminate temperature based on the position of the selection jumper. The defrost termination temperature is measured by the coil temperature sensor (RT21). The jumper termination pin is factory set at 50°F (10°C). If the temperature jumper is not installed, the default termination temperature is 90°F (32°C).

Five position square pin header. If the first−stage compressor output is active in heating mode and the outdoor ambient temperature is below the selected compressor lock−in temperature, the second−stage compressor solenoid outputs will be energized without the Y2 input. Factory default is no jumper present on E48, which sets the control to no second stage lock−in.

NOTE  Earlier produce units will have a default factory setting (jumper present) for 40ºF. Later produce units will have no jumper by default present on E48.

Cut for Humiditrol (EDA) application. This sets the outdoor fan speed to predefined speed. See table 15 for set speed based on unit size. Use only in two−stage units.

506601−01

Page 24

Page 25

Field Control Wiring

The following two illustrations provide examples on how to install control wiring using a non−communicating thermostat. For

examples of how to install control wiring in complete or partial communicating systems, see the icomfort Touch

thermostat

Quick Start Guide which is provided with the thermostat.

AIR HANDLER

CONTROL

HEAT PUMP

CONTROL (A175)

INDOOR

THERMOSTAT (S1)

On−board link

Low voltage thermostat wiring

Flat metal jumper

1. Thermostat T terminals are used for outdoor sensor input. Use for thermostat’s outdoor temperature display (optional).

2. R to L connection is required for this model when using the ComfortSense

required and ordered separately.

3. Air handler control ships from factory with metal jumpers installed across W1, W2 and W3. For one−stage electric heat, do not remove factory installed

metal jumpers.

4. Air handler control ships from factory with metal jumpers installed across W1, W2 and W3. For two−stage electric heat, remove factory installed metal jumper between W1 to W2. Then connect thermostat wire between the air handler control’s W2 and the thermostat’s W2 terminal.

5. Cut on−board link (clippable wire) from R−O HEAT PUMP for heat pump applications.

6. Cut on−board link (clippable wire) from Y1−Y2 2 STAGE COMPR for two−stage compressor and two−speed fan operation.

7. Cut loop jumper (clippable wire) DS to R on two−stage units for Humiditrol® whole−home dehumidication system applications. This will slow the outdoor unit’s fan speed to a specific RPM. A wire must be installed between the DS terminals on the furnace and outdoor unit controls. See table 15 for fan speed based on unit capacity.

8. Cut on−board link (clippable wire) DS−R for Humiditrol slow the indoor blower motor to the lowest speed setting. See furnace installation instruction or engineering handbook for lowest fan speed information.

whole−home dehumidication system or Harmony IIIt zoning system applications. This will

7000 − catalog number Y0349 only. Resistor Kit (catalog number 47W97)

Figure 17. ComfortSense® 7000 Series Thermostat  Air Hander/Two−Stage Heat Pump

Page 25

XP21 SERIES

Page 26

INTEGRATED

FURNACE CONTROL

(A95)

INDOOR

THERMOSTAT (S1)

HEAT PUMP

CONTROL (A175)

On−board link

Low voltage thermostat wiring

1. Thermostat T terminals are used for outdoor sensor input. Use for thermostat’s outdoor temperature display (optional).

2. R to L connection is required for this model when using the ComfortSense

47W97) required and ordered separately.

3. Cut on−board link W951 (clippable wire) from R−O HEAT PUMP for heat pump applications.

4. Cut on−board link W915 (clippable wire) for two−stage operation.

5. Cut loop jumper (clippable wire) DS to R on two−stage units for Humiditrol® whole−home dehumidication system applications. This will slow the outdoor unit’s fan speed to a specific RPM. A wire must be installed between the DS terminals on the furnace and outdoor unit controls. See table 15 for fan speed based on unit capacity.

6. Cut on−board link (clippable wire) DS−R for Humiditrol will slow the indoor blower motor to the lowest speed setting. See furnace installation instruction or engineering handbook for lowest fan speed information.

NOTE − For defrost temper with furnace, the optional 67M41 temper kit would be wired between W of from the heat pump control (A175) to the W1 of the furnace control. The kit allows for the furnace to cycle on and off during a defrost. It protects the compressor from high refrigeration pressures during defrost.

whole−home dehumidication system or Harmony IIIt zoning system applications. This

7000 − catalog number Y0349 only. Resistor kit (catalog number

Figure 18. ComfortSense® 7000 Series Thermostat  Furnace/Two−Stage Heat Pump

Page 26

506601−01

Page 27

Servicing Units Delivered Void of Charge

If the outdoor unit is void of refrigerant, clean the system using the procedure described below.

1. Leak check system using procedure outlined on page

18.

2. Evacuate the system using procedure outlined on page .

3. Use nitrogen to break the vacuum and install a new filter drier in the system.

4. Evacuate the system again using procedure outlined on page .

5. Weigh in refrigerant using procedure outlined in figure

21.

6. Monitor the system to determine the amount of moisture remaining in the oil. It may be necessary to replace the filter drier several times to achieve the required dryness level. If system dryness is not

verified, the compressor will fail in the future.

3. After evacuation is complete, open both the liquid and vapor line service valves to release the refrigerant charge contained in outdoor unit into the system.

4. Replace the stem caps and tighten to the value listed in table 1.

5. Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit’s nameplate. If not, do not start the equipment until you have consulted with the power company and the voltage condition has been corrected.

6. Set the thermostat for a cooling demand. Turn on power to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit.

7. Recheck voltage while the unit is running. Power must be within range shown on the nameplate.

8. Check system for sufficient refrigerant by using the procedures listed under System Refrigerant.

Unit Start−Up

IMPORTANT

If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start−up to prevent compressor damage as a result of slugging.

1. Rotate fan to check for binding.

2. Inspect all factory− and field−installed wiring for loose connections.

GAUGE SET

CONNECTIONS FOR TESTING AND CHARGING

TRUE SUCTION PORT

CONNECTION

REFRIGERANT TANK

CHARGE IN

LIQUID PHASE

System Refrigerant

This section outlines procedures for:

1. Connecting gauge set for testing and charging as illustrated in figure 19.

2. Checking and adjusting indoor airflow as described in figure 20.

3. Add or remove refrigerant using the weigh in method provided in figure 21, and verifying charge using subcooling method described in figure 22.

MANIFOLD GAUGE SET

LOW

HIGH

OUTDOOR UNIT

INSIDE OUTDOOR UNIT

TEMPERATURE

SENSOR

AClose manifold gauge set valves and connect the center hose to a cylinder of HFC−410A. Set for liquid phase charging.

BConnect the manifold gauge set’s low pressure side to the true suction port.

CConnect the manifold gauge set’s high pressure side to the liquid line service port.

DPosition temperature sensor on liquid line near liquid line service port.

DIGITAL SCALE

TO LIQUID

LINE SERVICE

VALV E

Figure 19. Gauge Set Connections

Page 27

TEMPERATURE SENSOR

(LIQUID LINE)

XP21 SERIES

Page 28

ADDING OR REMOVING REFRIGERANT

This system uses HFC−410A refrigerant which operates at much higher pressures than HCFC−22. The pre−installed liquid line filter drier is approved for use with HFC−410A only. Do not replace it with components designed for use with HCFC−22.

COOLING MODE INDOOR AIRFLOW CHECK

Check airflow using the Delta−T (

DT) process using the

illustration in figure 20.

HEATING MODE INDOOR AIRFLOW CHECK

Blower airflow cubic feet per minute (CFM) may be calculated by energizing electric heat and measuring:

S Temperature rise between the return air and supply air

temperatures at the indoor coil blower unit,

S Measuring voltage supplied to the unit,

S Measuring amperage being drawn by the heat unit(s).

Then, apply the measurements taken in following formula to determine CFM:

CFM =

Amps x Volts x 3.41

1.08 x Temperature rise (F)

AIRFLOW

DRY

BULB

53º

All temperatures are expressed in ºF

DROP

19º

INDOOR COIL

TEMPERATURE OF AIR ENTERING INDOOR COIL ºF

WET−BULB ºF

80 24 24 24 23 23 22 22 22 20 19 18 17 16 15 78 23 23 23 22 22 21 21 20 19 18 17 16 15 14 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13 74 21 21 21 20 19 19 18 17 16 16 15 14 13 12

DRY−BULB

72 20 20 19 18 17 17 16 15 15 14 13 12 11 10 70 19 19 18 18 17 17 16 15 15 14 13 12 11 10

57 58 59 60 61 62 63 64 65 66 67 68 69 70

AIR FLOWAIR FLOW

64º

INDOOR COIL

72º

DRY BULB

WET BULB

Use the following procedure to adjust for optimal air flow across the indoor coil:

1. Determine the desired DT  Measure entering air temperature using dry bulb (A) and wet bulb (B). DT is the intersecting value of A and B in the

table (see triangle).

2. Find temperature drop across coil  Measure the coil’s dry bulb entering and leaving air temperatures (A and C). Temperature Drop Formula:

) = A minus C.

Drop

3. Determine if fan needs adjustment  If the difference between the measured T

is needed. See example below:

ASSUME DT = 15 AND A TEMP. = 72º, THESE C TEMPERATURES WOULD NECESSITATE STATED ACTIONS:

Cº T

53º 19 – 15 = 4 INCREASE THE AIRFLOW 58º 14 – 15 = −1 (WITHIN +3º RANGE) NO CHANGE 62º 10 – 15 = −5 DECREASE THE AIRFLOW

4. ADJUST THE FAN SPEED  See indoor unit instructions to increase/decrease fan speed.

– DT = ºF ACTION

DROP

Figure 20. Checking Indoor Airflow over Evaporator Coil using Delta−T Chart

506601−01

and the desired DT (T

Drop

Changing air flow affects all temperatures; recheck temperatures to confirm that the temperature drop and DT are within +3º.

–DT) is within +3º, no adjustment

Drop

Page 28

Page 29

Use WEIGH IN method for adding initial refrigerant charge, and then use SUBCOOLING method for for verifying refrigerant charge.

WEIGH IN

CHARGING METHOD

CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE

If the system is void of refrigerant, first, locate and repair any leaks and then weigh in the refrigerant charge into the unit. To calculate the total refrigerant charge:

Amount specified on

nameplate

Adjust amount. for variation in line set

length listed on line set length table below.

Additional charge specified per indoor

unit match−ups starting on page 30.

Total Charge

Refrigerant Charge per Line Set Length

LIQUID LINE SET DIAMETER

3/8" (9.5 MM)

*If line length is greater than 15 ft. (4.6 m), add this amount. If line length is less than 15 ft. (4.6 m), subtract this amount.

NOTE  The above nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information.

OUNCES PER 5 FEET (G PER 1.5 M) ADJUST FROM 15 FEET (4.6 M)

3 OUNCE PER 5’ (85 G PER 1.5 M)

LINE SET*

Figure 21. Using HFC−410A Weigh In Method

SUBCOOLING

1. Check the airflow as illustrated in figure 20 to be sure the indoor airflow is as required. (Make any air flow adjustments before continuing with the following procedure.)

2. Measure outdoor ambient temperature; determine whether to use cooling mode or heating mode to check charge.

3. Connect gauge set.

4. Check liquid and vapor line pressures. Compare pressures with either heat or cooling mode normal operating pressures in table 8, Normal Operating Pressures, High Stage.

NOTE  The reference table is a general guide. Expect minor pressure variations. Significant differences may mean improper charge or other system problem.

5. Set thermostat for heat/cool demand, depending on mode being used:

USING COOLING MODE  When the outdoor ambient temperature is 60°F (15°C) and above. Target

subcooling values (second stage − high capacity) in table 8 are based on 70 to 80°F (21−27°C) indoor return air temperature; if necessary, operate heating to reach that temperature range; then set thermostat to cooling mode set point to 68ºF (20ºC) which should call for second−stage (high stage) cooling. When pressures have stabilized, continue with Step 6.

USING HEATING MODE  When the outdoor ambient temperature is below 60°F (15°C). Target subcooling

values (second−stage − high capacity) in table 8 are based on 65−75°F (18−24°C) indoor return air temperature; if necessary, operate cooling to reach that temperature range; then set thermostat to heating mode set point to 77ºF (25ºC) which should call for second−stage (high stage) heating. When pressures have stabilized, continue with Step 6.

6. Read the liquid line temperature; record in the LIQº space.

7. Read the liquid line pressure; then find its corresponding temperature in the temperature/ pressure chart listed in table 9 and record it in the SATº space.

8. Subtract LIQº temperature from SATº temperature to determine subcooling; record it in SCº space.

9. Compare SCº results with tables 4 through 7, being sure to note any additional charge for line set and/or match− up.

10. If subcooling value is greater than shown in tables 4 through 7 for the applicable unit, remove refrigerant; if less than shown, add refrigerant.

11. If refrigerant is added or removed, repeat steps 5 through 6 to verify charge.

12. Disconnect gauge set and re−install both the liquid and suction service valve caps.

SATº LIQº – SCº =

USE

COOLING

MODE

60ºF

(15ºC)

USE

HEATING

MODE

CHARGING METHOD

Figure 22. Using HFC−410A Subcooling Method  High Stage (High Capacity)

Page 29

XP21 SERIES

Page 30

Air Handler / Coil Match ups and Targeted Subcooling Values

Listed below are the targeted subcooling and charging values for approved indoor unit air handler / coil match ups. This information is also listed on the unit charging sticker located on the access panel.

* Indicates amount of charge required in additional to charge shown on unit nameplate. Remember to consider line set length differences.

Table 4  XP21−024

Target SC

Model Number

CB(X)27UH−024 15 4 0 0

CB(X)27UH−030 22 7 1 10

CBX32M−036 and CBX32MV−036 22 7 1 10

CBX32M−030 and CBX32MV−24/30 15 4 0 0

CBX40UHV−024 22 7 1 10

CBX40UHV−030 22 7 1 10

CBX40UHV−036 22 7 1 10

CH23−51 18 4 0 10

CH33−31 18 4 0 10

CH33−42 18 4 0 10

CR33−48 32 4 0 0

CR33−50/60C 14 7 1 10

CX34−31 27 4 0 10

CX34−34/48B 22 5 1 3

CX34−38 25 6 1 7

Heat

(+5ºF)

Cool

(+1º)

Add

Charge*

lb. oz.

Table 5  XP21−036

Target SC

Model Number

CB(X)27UH−036 17 5 0 0

CB(X)27UH−042 12 5 1 10

CBX32M−036 and CBX32MV−036 17 5 0 0

CBX32M−048 and CBX32MV−048 12 5 1 10

CBX40UHV−036 17 5 0 0

CBX40UHV−042 12 5 1 10

CBX40UHV−048 12 5 1 10

CH23−51 19 7 0 0

CH33−43 11 5 0 7

CH33−44/48B 11 5 0 7

CH33−48C 11 5 0 7

CH33−50/60C 12 7 1 6

CR33−48 32 4 0 7

CR33−50/60C 11 4 1 8

CX34−38 15 5 0 7

CX34−43 11 5 0 7

CX34−44/48B 19 4 0 10

CX34−49 10 10 1 10

CX34−50/60C 11 5 0 7

Heat

(+5ºF)

Cool

(+1º)

Add

Charge*

lb. oz.

Model Number

CB(X)27UH−048 24 4 1 0

CB(X)27UH−060 14 4 1 6

CBX32M−048 and CBX32MV−048 24 4 1 0

CBX32M−060 and CBX32MV−060 21 4 1 14

CBX32MV−068 14 4 1 0

CBX40UHV−048 24 4 1 0

CBX40UHV−060 21 4 1 14

CH23−68 14 4 1 6

CH33−49C 21 4 1 14

CH33−50/60C 21 4 1 14

CH33−62D 20 4 1 7

CR33−50/60 32 4 0 0

CR33−60D 32 4 0 0

CX34−49 21 5 0 10

CX34−62C 11 4 1 5

CX34−62D 11 4 1 5

Model Number

CB(X)27UH−060 7 6 0 10

CBX32M−060 and CBX32MV−060 10 4 0 0

CBX32MV−068 9 4 0 10

CBX40UHV−060 10 4 0 0

CH23−68 10 4 0 10

CH33−49C 7 5 0 0

CH33−50/60C 7 5 0 0

CH33−62D 9 4 0 7

CR33−50/60 22 5 0 4

CR33−60D 22 5 0 4

CX34−49 10 5 0 4

CX34−62C 7 5 0 0

CX34−62D 7 5 0 0

Table 6  XP21−048

Target SC

Heat

(+5ºF)

Table 7  XP21−060

Target SC

Heat

(+5ºF)

Cool

(+1º)

Cool

(+1º)

Add

Charge*

lb. oz.

Add

Charge*

lb. oz.

506601−01

Page 30

Page 31

Operating and Temperature Pressures

Minor variations in these pressures may be expected due to differences in installations. Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system.

Table 8. Normal Operating Pressure − Liquid +10 and Vapor +5 PSIG*

XP21−024 XP21−036 XP21−048 XP21−060

5F (5C)**

40 (4) 319 104 307 99 367 92 322 96 50 (10) 345 122 331 117 385 11 3 352 115 60 (16) 380 144 350 137 415 130 371 132

65 (18) 224 149 224 145 229 142 227 139 70 (21) 241 149 241 147 247 142 244 141 75 (24) 260 150 261 148 266 143 263 142 80 (27) 281 150 282 149 288 144 284 143 85 (29) 303 151 303 150 311 145 305 144 90 (32) 325 152 326 151 334 146 328 146 95 (35) 348 154 350 152 358 147 352 147

100 (38) 372 155 374 153 383 149 376 148 105 (41) 397 156 400 154 410 150 402 150

110 (43) 425 159 427 155 438 151 429 151 115 (46) 453 155 456 157 468 152 458 153

20 (−7) 312 67 293 62 326 63 305 62 30 (−1) 351 82 309 76 353 76 320 72

40 (4) 364 98 322 90 375 93 347 90 50 (10) 390 117 341 109 405 11 0 366 105 60 (16) 420 140 357 129 437 127 387 120

65 (18) 231 144 237 140 240 138 236 134 70 (21) 250 145 254 141 259 139 252 135 75 (24) 270 146 275 142 279 140 272 136 80 (27) 291 147 294 143 299 140 294 137 85 (29) 312 148 315 146 323 142 316 139 90 (32) 336 149 338 147 346 143 339 140 95 (35) 360 150 363 148 371 144 364 141

100 (38) 387 151 389 150 397 145 389 142 105 (41) 411 152 415 151 423 146 416 144

110 (43) 438 153 443 152 451 147 445 145 115 (46) 467 154 473 153 481 149 475 146

Liq Vap Liq Vap Liq Vap Liq Va p

Low Stage  Heating Operation

Low Stage  Cooling Operation

High Stage  Heating Operation

High Stage  Cooling Operation

Page 31

XP21 SERIES

Page 32

Table 9. HFC−410A Temperature (°F) − Pressure (Psig)

°F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig

32 100.8 48 137.1 63 178.5 79 231.6 94 290.8 110 365.0

33 102.9 49 139.6 64 181.6 80 235.3 95 295.1 111 370.0 126 451.8 142 552.3

34 105.0 50 142.2 65 184.3 81 239.0 96 299.4 112 375.1 127 457.6 143 559.1

35 107.1 51 144.8 66 187.7 82 242.7 97 303.8 113 380.2 128 463.5 144 565.9

36 109.2 52 147.4 67 190.9 83 246.5 98 308.2 114 385.4 129 469.5 145 572.8

37 111.4 53 150.1 68 194.1 84 250.3 99 312.7 115 390.7 130 475.6 146 579.8

38 113.6 54 152.8 69 197.3 85 254.1 100 317.2 11 6 396.0 131 481.6 147 586.8

39 115.8 55 155.5 70 200.6 86 258.0 101 321.8 11 7 401.3 132 487.8 148 593.8

40 118.0 56 158.2 71 203.9 87 262.0 102 326.4 11 8 406.7 133 494.0 149 601.0

41 120.3 57 161.0 72 207.2 88 266.0 103 331.0 11 9 412.2 134 500.2 150 608.1

42 122.6 58 163.9 73 210.6 89 270.0 104 335.7 120 417.7 135 506.5 151 615.4

43 125.0 59 166.7 74 214.0 90 274.1 105 340.5 121 423.2 136 512.9 152 622.7

44 127.3 60 169.6 75 217.4 91 278.2 106 345.3 122 428.8 137 519.3 153 630.1

45 129.7 61 172.6 76 220.9 92 282.3 107 350.1 123 434.5 138 525.8 154 637.5

46 132.2 62 175.4 77 224.4 93 286.5 108 355.0 124 440.2 139 532.4 155 645.0

47 134.6 78 228.0 109 360.0 140 539.0

125 445.9

141 545.6

INSTALLING ISOLATION GROMMETS

Locate the isolation grommets (provided). Slide grommets onto vapor and liquid lines. Insert grommets into piping panel to isolate refrigerant lines from sheet metal edges.

SUCTION LINE

LIQUID LINE

TWO ISOLATION GROMMETS ARE PROVIDE FOR THE LIQUID AND SUCTION LINE PIPE PANEL PASS THROUGH.

REAR VIEW OF UNIT EXTERIOR

PIPING PANEL

Figure 23. Isolation Grommets

System Operations

IMPORTANT

Some scroll compressor have internal vacuum protector that will unload scrolls when suction pressure goes below 20 psig. A hissing sound will be heard when the compressor is running unloaded. Protector will reset when low pressure in system is raised above 40 psig. DO NOT REPLACE COMPRESSOR.

The heat pump control (A175) provides the following functions:

S Demand defrost algorithm

S Field−selectable defrost termination temperatures

S Internal switching of outputs S Compressor anti−short−cycle delay.

S Five−strikes lockout safety function

S High (S4) and low (S87) pressure switches

S Ambient (RT13), coil (RT21) and discharge line

(RT28) temperatures monitoring and protection.

COMPRESSOR PROTECTION  ANTI−SHORT CYCLE DELAY

The heat pump control protects the compressor from:

S Short cycling (five minutes) when there is initial power

S Interruption in power to the unit

S Pressure or sensor trips

S Delay after Y1 demand is removed.

In non−communicating systems the delay is set for 300 seconds (five minutes) and can not be changed. To override timer when active or inactive, place a jumper on the field test pins between 1 and 2 seconds.

In communicating system, the icomfort Touch® thermostat has a separate built−in 5−minute non−adjustable short cycle protection.

506601−01

Page 32

Page 33

HIGH (S4) AND LOW (S87) PRESSURE SWITCHES

The unit’s pressure switches (LO PS − S87 and HI PS − S4) are factory−wired into the control on the LO−PS and HI−PS terminals, respectively.

Low Pressure Switch (LO−PS)  See figure 29 for low pressure switch sequence of operation.

High Pressure Switch (HI−PS)  See figure 30 for high pressure switch sequence of operation.

Pressure Switch Event Settings

The following pressures are the auto reset event value triggers for low and high pressure thresholds:

S High Pressure (auto reset) − trip at 590 psig; reset at

418.

S Low Pressure (auto reset) − trip at 25 psig; reset at 40.

COMPRESSOR PROTECTION  FIVE−STRIKE LOCKOUT SAFETY FUNCTION

The five−strike lockout safety function is designed to protect the unit’s compressor from damage. The five−strike feature is used for high pressure (S4) and low (S87) pressure switch trips, high discharge temperature (RT28) sensor input and W input fault or miswire.

Resetting Five−Strike Lockout

Once the condition has been rectified, power to the heat pump control’s R terminal must be cycled OFF, or a jumper placed on the FIELD TEST pins between 1− to 2−seconds to reset the heat pump control.

Defrost System

The heat pump control (A175) measures differential temperatures to detect when the system is performing poorly because of ice build−up on the outdoor coil. The heat pump control self−calibrates (see figure 27) when the defrost system starts and after each system defrost cycle. The heat pump control monitors ambient temperature, outdoor coil temperature, and total run−time to determine when a defrost cycle is required. The coil temperature sensor is designed with a spring clip to allow mounting to the outside coil tubing. The location of the coil sensor is important for proper defrost operation (see figure 1 for location of coil sensor).

NOTE − The heat pump control accurately measures the performance of the system as frost accumulates on the outdoor coil. This typically will translate into longer running time between defrost cycles as more frost accumulates on the outdoor coil before the heat pump control initiates defrost cycles.

DEFROST OPERATING MODES

The heat pump control has three operational modes which are:

S Defrost calibration and operation (see figure 27) S Defrost test (see figure 28)

DEFROST TERMINATION TEMPERATURES (E47)

The heat pump control selections are: 50, 70, 90, and 100°F (10, 21, 32 and 38°C). The jumper termination pin is factory set at 50°F (10°C).

If the temperature jumper is not installed, the default termination temperature is 90°F (32°C). See figure 27 for on how this settings affects defrost calibration and defrost modes.

NOTE − Colder climates could require a high discharge termination temperature setting to maintain a clear coil.

IF JUMPER IS NOT INSTALLED (90ºF)

FACTORY DEFAULT (50ºF)

100

DEGREE TARGET

70 DEGREE TARGET

100

DEGREE

TARGET

DEGREE

TARGET

100

Figure 24. Defrost Termination Temperature

Settings

UNIT SENSORS

Sensors connect to the heat pump control through a field-replaceable harness assembly that plugs into the control. Through the sensors, the control detects outdoor ambient, coil, and discharge temperature fault conditions. As the detected temperature changes, the resistance across the sensor changes. Tables 11 and 12 shows how the resistance varies as the temperature changes for both type of sensors. Sensor resistance values can be checked by ohming across pins shown in table 10.

NOTE  When checking the ohms across a sensor, be aware that a sensor showing a resistance value that is not within the range shown in table 10, may be performing as designed. However, if a shorted or open circuit is detected, then the sensor may be faulty and the sensor harness will need to be replaced.

Ambient Temperature Sensor (RT13)

See table 10 for sensor range. If the ambient sensor is detected as being open, shorted or out of the temperature range of the sensor, the control will not perform demand defrost operation. The control will revert to time/temperature defrost operation and will display the appropriate alert code. Heating and cooling operation will be allowed in this fault condition.

Coil Temperature Sensor (RT21)

See table 10 for sensor range. If the defrost coil sensor is open, shorted or out of the temperature range of the sensor, the heat pump control will not perform demand or time/temperature defrost operation and will display the appropriate fault code. Heating and cooling operation will be allowed in this fault condition.

Page 33

XP21 SERIES

Page 34

High Discharge Line Temperature Sensor (RT28)

See table 10 for sensor range. The high discharge line temperature sensor (location shown in figure 1 monitors temperature range and open/short conditions. See figure 31 for the high discharge line temperature sensor sequence of operation.

Table 10. Sensor Temperature / Resistance Range

Temperature

Sensor

Discharge (RT28)

Outdoor (Ambient) (RT13)

Coil (RT21) −40 (−40) to 140

NOTE  Sensor resistance decreases as sensed temperature increases (see tables 11 and 12).

Range °F (°C)

−35 (−37) to 310 (154)

−40 (−40) to 140 (60)

(60)

Resistance values range (ohms)

41,000 to 103 1 and 2

280,000 to 3750 3 and 4

280,000 to 3750 5 and 6

Pins/Wire Color

(Yellow)

(Black)

(Brown)

W Input Fault or Miswire

In case of a W input fault or possible miswire, the system will function as listed in the sequence of operation in figure

32.

SECOND−STAGE OPERATION

If the control receives a call for second−stage compressor operation Y2 in heating or cooling mode and the first-stage compressor output is active, the second-stage compressor solenoid output will be energized by the heat pump control system operation function.

NOTE  Figure 15 illustrates the correct Y2 field wiring configuration.

NOTE  The heat pump control system operation monitor has a five second delay between Y2 being powered and the solenoid energizing.

Second Stage Lock−in (E48)

If first-stage compressor output is active in heating mode and the outdoor ambient temperature is below the selected compressor lock−in temperature, the second-stage compressor solenoid output will be energized even without a Y2 room thermostat input.

If the jumper is not connected to one of the temperature selection pins on E48 (40, 45, 50, 55°F), the second stage lock−in feature is inactive. Factory default is no jumper present.

DEGREE TARGET

DEGREE

TARGET

DEGREE

TARGET

DEGREE

TARGET

FACTORY DEFAULT IS NOT JUMPER − SECOND STAGE LOCK−IN INACTIVE.

NOTE  Earlier produce units will have a default factory setting (jumper present) for 40ºF. Later produce units will have no jumper by default present on E48.

Figure 25. Second Stage Lock−in (E48) Settings

The heat pump control de−energizes the second-stage compressor solenoid output immediately when the Y2 signal is removed or the outdoor ambient temperature is 5°F above the selected compressor lock−in temperature, or the first-stage compressor output is de−energized for any reason.

Shift Delay (E37)

The heat pump control has a field−selectable function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode. When a jumper is installed on the DELAY pins (E37), the compressor will be cycled off for 30 seconds going in and out of the defrost mode. Units are shipped with jumper installed on DELAY pins.

*30

SECOND DELAY

FACTORY DEFAULT OR WHEN JUMPER IS MISSING

Figure 26. Shift Delay Settings

506601−01

Page 34

Page 35

Heat pump control monitors mode of operation through outdoor ambient temperature (RT13), outdoor coil temperature (RT21) and compressor run−time to determine when a defrost cycle is required.

NOTE  No system alert codes can be active for defrost calibration to be achieved.

100

DEGREE TARGET

DEGREE

TARGET

70 DEGREE TARGET

*50 DEGREE TARGET

100

E47

*Heat Pump Control (A175)

Defrost Termination (E47) Pins (Factory Default is 50ºF)

Defrost Calibration

Coil sensor (RT21) detects temperature below 35°F {2°C} during either initial power−up, after loss of power or after cooling mode, a sacrificial defrost will be used to ensure there is a clear coil before attempting calibration.

Coil sensor

below 35°F {2°C}

YES

Accumulate compressor run−time while outdoor coil temperature sensor input (RT21) is below 35°F (2°C)

30−35 minutes

compressor

run−time

YES

No attempt to calibrate.

Continue to accumulate run time.

Demand Mode

After the initial calibration, the heat pump control disables the defrost mode for 30−34 minutes in order to avoid unnecessary defrosts. Beyond this timing period, both the ambient (RT13) and coil (RT21) sensors are continuously monitored. If the coil temperature is below 35°F (2°C) and the calibration delta is reached or accumulated compressor run−time is more than six (6) hours, a defrost is to be initiated.

Initiate a defrost and monitor coil temperature sensor input (RT21) and accumulate defrost time.

Coil temperature sensor input (RT21) reached specified defrost termination temperature as set on heat pump control E47 pins*.

Calibration Attempted

(Unit Running in Heat Mode)

Defrost Mode

How did defrost

terminate?

Defrosted for 14 minutes without the coil temperature sensor input (RT21) reaching defrost termination temperature as set on heat pump control E47 pins*.

YES

Figure 27. Defrost Calibration Sequence of Operations

Calibration

Page 35

XP21 SERIES

Page 36

MULTI−FUNCTION TEST PINS (E33)

Placing the jumper on the field test pins (E33) using a specific sequence allows the technician to:

S Clear short cycle lockout S Clear five−strike fault lockout S Cycle the unit in and out of defrost mode S Manually place the unit in defrost mode to clear the coil

When Y1 is energized and 24V power is being applied to the heat pump control (A175), a test cycle can be initiated by placing a jumper on the heat pump control’s TEST pins for 2 to 5 seconds. If the jumper remains on the TEST pins (E33) for longer than five seconds, the heat pump control will ignore the jumpered TEST pins and revert to normal operation.

The heat pump control will initiate one test event each time a jumper is placed on the TEST pins. For each TEST the jumper must be removed for at least one second and then reapplied.

Y1 Active

Place a jumper on TEST pins for

longer than one second but less than two seconds.

Clears any short cycle lockout and five strike fault lockout function, if applicable. No other functions will be executed and unit will continue in the mode it was operating.

If in COOLING Mode

No further test mode operation will be executed until the jumper is removed from the TEST pins and reapplied.

Place a jumper on TEST pins for

more than two seconds.

Clears any short cycle lockout and five strike fault lockout function, if applicable.

ACTIVE

O Line Status

If in DEFROST Mode

The unit will terminate defrost and enter HEAT MODE un−calibrated with defrost timer set for a maximum 34 minute test.

INACTIVE

If in HEATING Mode

If no ambient or coil sensor fault exist, unit will go into DEFROST MODE. If ambient or coil faults exist (open or shorted), unit will remain in HEAT MODE.

NOTE  Heat pump control cannot be force into defrost mode when the ambient temperature input from the RT13 sensor is above 65ºF (18ºC).

NOTE  If ambient or coil fault is detected, the board will not execute the TEST mode.

Figure 28. Heat Pump Control’s Multi−Function Test Pins (E33)

506601−01

If jumper on TEST pins remains in place for more than five seconds.

The unit will return to HEAT MODE un−calibrated with defrost timer set for 34 minutes.

Page 36

If jumper on TEST pins is removed before a maximum of five seconds.

The unit will remain in DEFROST MODE until termination on time or

temperature.

Page 37

Y1 DEMAND

LOW

PRESSURE

SWITCH (S87)

CLOSED

COMPRESSOR

CONTACTOR

ENERGIZED

INITIAL TRIP

SWITCH IS

IGNORED FOR

90 SECONDS

OPEN

COMPRESSOR

CONTACTOR

DE−ENERGIZED

COMPRESSOR

ANTI−SHORT

CYCLE TIMER

BEGINS

INCREMENT

5−STRIKE

COUNTER

LED ALERT CODE / OR

MODERATE

ALERT 410

DISPLAYED

LOW

PRESSURE

SWITCH (S87)

If 5−strike counter has four or less strikes when Y1 demand is

CLOSED

terminated or satisfied, the strike counter will reset to zero. In a icomfort Touch® thermostat enabled setup, the thermostat will terminate demand when the compressor contactor is de−energized. If demand is satisfied when alarm is not active, the 5−strike counter will reset.

Lockouts can be reset by either cycling power off to the heat pump

control’s (A175) R terminal, or placing a jumper on the field test pins (E33) between 1 to 2 seconds.

5−STRIKE

COUNTER

REACHES 5

WITHIN A SINGLE

Y1 DEMAND

LOW

PRESSURE

SWITCH (S87)

LOCKOUT

SWITCH IS CLOSED OR OUTDOOR

AMBIENT TEMPERATURE IS 15ºF

OR BELOW

SERVICE

REQUIRED

OPEN

ANTI−SHORT

CYCLE TIMER

ENDS

LED ALERT CODE / OR

CRITICAL

ALERT 411

SERVICE

REQUIRED

DISPLAYED

COMPRESSOR

CONTACTOR

ENERGIZED

LOW

PRESSURE

SWITCH (S87)

CLOSED

LED ALERT CODE / OR

MODERATE

ALERT 410

NORMAL

OPERATION

DISPLAYED

WAITING FOR

PRESSURE SWITCH TO

CLOSED

Figure 29. Low Pressure Switch (S87) Sequence of Operation

Page 37

XP21 SERIES

Page 38

Y1 DEMAND

OPEN

HIGH

PRESSURE

SWITCH (S4)

OPEN

COMPRESSOR

CONTACTOR

DE−ENERGIZED

COMPRESSOR

ANTI−SHORT

CYCLE TIMER

BEGINS

INCREMENT

5−STRIKE

COUNTER

CLOSED

COMPRESSOR

CONTACTOR

ENERGIZED

HIGH

PRESSURE

SWITCH (S4)

If 5−strike counter has four or less strikes when Y1 demand is terminated

CLOSED

or satisfied, the strike counter will reset to zero. In a icomfort Touch thermostat enabled setup, the thermostat will terminate demand when the compressor contactor is de−energized. If demand is satisfied when alarm is not active, the 5−strike counter will reset.

Lockouts can be reset by either cycling power off to the heat pump con-

trol’s (A175) R terminal, or placing a jumper on the field test pins (E33) between 1 to 2 seconds.

5−STRIKE

COUNTER

REACHES 5

WITHIN A SINGLE

Y1 DEMAND

SERVICE

REQUIRED

OPEN

LED ALERT CODE / OR

MODERATE

ALERT 412

DISPLAYED

ANTI−SHORT

CYCLE TIMER

ENDS

COMPRESSOR

CONTACTOR

ENERGIZED

HIGH

PRESSURE

SWITCH (S4)

WAITING FOR

PRESSURE SWITCH TO

CLOSED

HIGH

PRESSURE

SWITCH (S4)

LOCKOUT

LED ALERT

CODE / OR

CRITICAL

ALERT 413

CLEARED

LED ALERT

CODE / OR

MODERATE

ALERT 412

DISPLAYED

SERVICE

REQUIRED

NORMAL

OPERATION

Figure 30. High Pressure Switch (S4) Sequence of Operation

506601−01

Page 38

Page 39

If temperature is at or above 279ºF.

Y1 DEMAND

OPEN

DISCHARGE

SENSOR

(RT28)*

OPEN

COMPRESSOR

CONTACTOR

DE−ENERGIZED

COMPRESSOR

ANTI−SHORT

CYCLE TIMER

BEGINS

INCREMENT

5−STRIKE

COUNTER

CLOSED

COMPRESSOR

CONTACTOR

ENERGIZED

HIGH

PRESSURE

SWITCH (S4)

If 5−strike counter has four or less strikes when Y1 demand is

CLOSED

Lockouts can be reset by either cycling power off to the heat pump

control’s (A175) R terminal, or placing a jumper on the field test pins (E33) between 1 to 2 seconds.

5−STRIKE

COUNTER

REACHES 5

WITHIN A SINGLE

Y1 DEMAND

DISCHARGE

SENSOR (RT28)

IS AT OR

BELOW 225ºF

LED ALERT

CODE / OR

MODERATE

ALERT 414

DISPLAYED

ANTI−SHORT

CYCLE TIMER

ENDS

YES

COMPRESSOR

CONTACTOR

ENERGIZED

WAITING FOR

TEMPERATURE

DROP TO OR BELOW 225ºF

DISCHARGE

SENSOR (RT28)

LOCKOUT

LED ALERT

CODE / OR

CRITICAL

ALERT 415

CLEARED

LED ALERT

CODE / OR

MODERATE

ALERT 414

CLEARED

SERVICE

REQUIRED

NORMAL

OPERATION

Figure 31. High Discharge Temperature Sensor (RT28) Sequence of Operation

Page 39

XP21 SERIES

Page 40

Y1 DEMAND

COMPRESSOR

CONTACTOR

ENERGIZED

YES

COMPRESSOR

CONTACTOR

DE−ENERGIZED

W OUTPUT

ACTIVE)

INITIAL TRIP

SWITCH IS

IGNORED FOR

90 SECONDS

NORMAL

OPERATION

W OUTPUT

ACTIVE)

COMPRESSOR

ANTI−SHORT

CYCLE TIMER

BEGINS

INCREMENT

5−STRIKE

COUNTER

LED ALERT

CODE / OR

MODERATE

ALERT 418

DISPLAYED

YES

COMPRESSOR

ANTI−SHORT

CYCLE TIMER

BEGINS

5−STRIKE

COUNTER

REACHES 5

WITHIN A SINGLE

Y1 DEMAND

W OUTPUT

HARDWARE

FAULT

LOCKOUT

LED ALERT

CODE / OR

MODERATE

ALERT 418

DISPLAYED

ANTI−SHORT

CYCLE TIMER

ENDS

W OUTPUT

ACTIVE)

YES

WAITING FOR

W OUTPUT TO

DEACTIVATE

LED ALERT CODE / OR

MODERATE

ALERT 418

CLEARED

ANTI−SHORT

CYCLE TIMER

ENDS

LED ALERT

CODE / OR

MODERATE

ALERT 418

CLEARED

If 5−strike counter has four or less strikes when Y1 demand is terminated or satisfied, the strike counter will reset to zero. In a icomfort Touch® thermostat enabled setup, the thermostat will terminate demand when the compressor contactor is de−energized. If demand is satisfied when alarm is not active, the 5−strike counter will reset.

Lockouts can be reset by either cycling power off to the heat pump control’s (A175) R terminal, or placing

a jumper on the field test pins (E33) between 1 to 2 seconds.

Figure 32. W Input Fault or Miswire Sequence of Operation

506601−01

LED ALERT CODE / OR

CRITICAL

ALERT 419

DISPLAYED

Page 40

SERVICE

REQUIRED

Page 41

Table 11. Ambient (RT13) and Coil (RT21) Sensors Temperature / Resistance Range

Degrees

Fahrenheit

136.3 2680 56.8 16657 21.6 44154 −11.3 123152

133.1 2859 56.0 16973 21.0 44851 −11.9 125787

130.1 3040 55.3 17293 20.5 45560 −12.6 128508

127.3 3223 54.6 17616 20.0 46281 −13.2 131320

124.7 3407 53.9 17942 19.4 47014 −13.9 134227

122.1 3592 53.2 18273 18.9 47759 −14.5 137234

119.7 3779 52.5 18607 18.4 48517 −15.2 140347

117.5 3968 51.9 18945 17.8 49289 −15.9 143571

115.3 4159 51.2 19287 17.3 50074 −16.5 146913

113.2 4351 50.5 19633 16.8 50873 −17.2 150378

111.2 4544 49.9 19982 16.3 51686 −17.9 153974

109.3 4740 49.2 20336 15.7 52514 −18.6 157708

107.4 4937 48.5 20695 15.2 53356 −19.3 161588

105.6 5136 47.9 21057 14.7 54215 −20.1 165624

103.9 5336 47.3 21424 14.1 55089 −20.8 169824

102.3 5539 46.6 21795 13.6 55979 −21.5 174200

100.6 5743 46.0 22171 13.1 56887 −22.3 178762

99.1 5949 45.4 22551 12.5 57811 −23.0 183522

97.6 6157 44.7 22936 12.0 58754 −23.8 188493

96.1 6367 44.1 23326 11.5 59715 −24.6 193691

94.7 6578 43.5 23720 11.0 60694 −25.4 199130

93.3 6792 42.9 24120 10.4 61693 −26.2 204829

92.0 7007 42.3 24525 9.9 62712 −27.0 210805

90.6 7225 41.7 24934 9.3 63752 −27.8 217080

89.4 7444 41.1 25349 8.8 64812 −28.7 223677

88.1 7666 40.5 25769 8.3 65895 −29.5 230621

86.9 7890 39.9 26195 7.7 67000 −30.4 237941

85.7 8115 39.3 26626 7.2 68128 −31.3 245667

84.5 8343 38.7 27063 6.7 69281 −32.2 253834

83.4 8573 38.1 27505 6.1 70458 −33.2 262482

82.3 8806 37.5 27954 5.6 71661 −34.1 271655

81.2 9040 37.0 28408 5.0 72890 −35.1 281400

80.1 9277 36.4 28868 4.5 74147 −36.1 291774

79.0 9516 35.8 29335 3.9 75431 −37.1 302840

78.0 9757 35.2 29808 3.4 76745 −38.2 314669

77.0 10001 34.7 30288 2.8 78090 −39.2 327343

76.0 10247 34.1 30774 2.3 79465

75.0 10496 33.5 31267 1.7 80873

74.1 10747 33.0 31766 1.2 82314

73.1 11000 32.4 32273 0.6 83790

72.2 11256 31.9 32787 0.0 85302

71.3 11515 31.3 33309 −0.5 86852

70.4 11776 30.7 33837 −1.1 88440

69.5 12040 30.2 34374 −1.7 90068

68.6 12306 29.6 34918 −2.2 91738

67.7 12575 29.1 35471 −2.8 93452

66.9 12847 28.6 36031 −3.4 95211

66.0 13122 28.0 36600 −4.0 97016

65.2 13400 27.5 37177 −4.6 98870

64.4 13681 26.9 37764 −5.2 100775

63.6 13964 26.4 38359 −5.7 102733

62.8 14251 25.8 38963 −6.3 104746

62.0 14540 25.3 39577 −6.9 106817

61.2 14833 24.8 40200 −7.5 108948

60.5 15129 24.2 40833 −8.2 11114 1

59.7 15428 23.7 41476 −8.8 113400

59.0 15730 23.2 42130 −9.4 115727

58.2 16036 22.6 42794 −10.0 118126

57.5 16345 22.1 43468 −10.6 120600

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

Page 41

XP21 SERIES

Page 42

Table 12. High Discharge Sensor (RT28) Temperature / Resistance Range

Degrees

Fahrenheit

303.1 183 186.1 1052 136.8 2656 94.5 6613

298.1 195 185.0 1072 136.0 2698 93.6 6739

293.4 207 183.9 1093 135.2 2740 92.8 6869

289.0 220 182.8 1114 134.5 2783 92.0 7002

284.8 232 181.8 1135 133.7 2827 91.2 7139

280.9 245 180.7 1157 132.9 2872 90.3 7281

277.1 258 179.6 1179 132.2 2917 89.5 7426

273.6 270 178.6 1201 131.4 2963 88.6 7575

270.2 283 177.6 1223 130.6 3010 87.8 7729

267.0 297 176.6 1245 129.9 3057 86.9 7888

263.9 310 175.5 1268 129.1 3105 86.0 8051

260.9 323 174.6 1291 128.4 3154 85.2 8220

258.1 336 173.6 1315 127.6 3204 84.3 8394

255.3 350 172.6 1338 126.8 3255 83.4 8574

252.7 364 171.6 1362 126.1 3307 82.5 8759

250.1 378 170.6 1386 125.3 3359 81.6 8951

247.7 391 169.7 1411 124.6 3413 80.7 9149

245.3 405 168.7 1435 123.8 3467 79.8 9354

243.0 420 167.8 1460 123.1 3523 78.8 9566

240.8 434 166.9 1486 122.3 3579 77.9 9786

238.6 448 165.9 1511 121.6 3637 76.9 10013

236.5 463 165.0 1537 120.8 3695 76.0 10250

234.4 478 164.1 1563 120.1 3755 75.0 10495

232.4 492 163.2 1590 119.3 3816 74.1 10749

230.5 507 162.3 1617 118.5 3877 73.1 11014

228.6 523 161.4 1644 117.8 3940 72.1 11289

226.7 538 160.5 1672 117.0 4005 71.1 11575

224.9 553 159.7 1699 116.3 4070 70.0 11873

223.2 569 158.8 1728 115.5 4137 69.0 12184

221.5 584 157.9 1756 114.8 4205 68.0 12509

219.8 600 157.1 1785 114.0 4274 66.9 12848

218.1 616 156.2 1815 113.2 4345 65.8 13202

216.5 632 155.3 1845 112.5 4418 64.7 13573

214.9 649 154.5 1875 111.7 4491 63.6 13961

213.4 665 153.6 1905 111.0 4567 62.5 14368

211.9 682 152.8 1936 110.2 4644 61.3 14796

210.4 698 152.0 1968 109.4 4722 60.2 15246

208.9 715 151.1 1999 108.7 4802 59.0 15719

207.5 732 150.3 2032 107.9 4884 57.8 16218

206.0 750 149.5 2064 107.1 4968 56.6 16744

204.6 767 148.7 2098 106.4 5054 55.3 17301

203.3 785 147.9 2131 105.6 5141 54.0 17891

201.9 803 147.1 2165 104.8 5231 52.7 18516

200.6 821 146.2 2200 104.0 5323 51.4 19180

199.3 839 145.4 2235 103.3 5416 50.0 19887

198.0 857 144.6 2270 102.5 5512 48.6 20641

196.8 876 143.8 2306 101.7 5610 47.2 21448

195.5 894 143.0 2343 100.9 5711 45.7 22311

194.3 913 142.3 2380 100.1 5814

193.1 932 141.5 2418 99.3 5920

191.9 952 140.7 2456 98.5 6028

190.7 971 139.9 2495 97.7 6139

189.5 991 139.1 2534 96.9 6253

188.4 1011 138.3 2574 96.1 6370

187.2 1031 137.6 2615 95.3 6489

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

506601−01

Page 42

Page 43

System Status, Fault and Lockout LED Codes

LED codes are displayed via various LEDs located on the heat pump control (A175). See figure 16 for location of heat pump control LEDs.

DS15 and DS13 compressor LED fault and lockout codes do not provide safety protection. The is a monitoring function only and cannot control or shut down other devices.

IMPORTANT

DS11 AND DS14  SYSTEM STATUS, FAULT AND LOCKOUT LED CODES

DS11 (Green) and DS14 (Red) LEDs indicate non−communicating mode diagnostics conditions that are listed in table 13.

These LEDs display fault conditions in system cooling or heating modes, dehumidification mode, anti−short cycle lockout, high and low pressures, discharge line temperature, outdoor temperature, and discharge sensor failures.

RESETTING FAULT AND LOCKOUT LED CODES

All LED fault and lockout codes can be reset manually or automatically.

1. Manual Reset

Manual reset can be achieve by one of the following methods:

S Disconnecting R wire from the heat pump control’s

R terminal. DS15 AND DS13  COMPRESSOR FAULT AND LOCKOUT LED CODES

DS15 (yellow) and DS13 (red) LEDs indicate non−communicating mode diagnostics conditions that are listed in table 13.

These LEDs display the most common fault conditions in the system. When an abnormal condition is detected, this function communicates the specific condition through the system LED codes. The feature is capable of detecting both mechanical and electrical system problems.

S Turning the indoor unit off an on again

After power up, existing code will display for 60 seconds and then clear.

2. Automatic Reset

After a fault or lockout is detected, the heat pump control continues to monitor the compressor and outdoor unit. When/if conditions return to normal, the fault or lockout LED code is turned off automatically.

Table 13. System Status, Fault and Lockout LED Codes and Related icomfort Touch® Thermostat Alert Codes

System fault and lockout LED (DS11 / DS14) alarm codes takes precedence over system status LED codes (cooling, heating stages or defrost/dehumidification). Only the latest active LED fault or lockout alarm code if present will be displayed. If no fault or lockout codes are active, then system status LEDs are routinely displayed. See notes 1 and 2 in table below for duration of fast / slow flashes and pause.

Heat Pump Control

LEDs

DS11

Green

DS14 Red

icomfort

Touch

Thermostat

Display

Condition Possible Cause(s) Solution

SYSTEM STATUS

Off Off

Simultaneous slow flash

Alternating slow flash

Simultaneous fast

flashes

Alternating fast flash

On On

Not

applicable

Not

applicable

Not

applicable

Moderate /

Critical Alert

Code 180

Moderate /

Critical Alert

Code 417

Not

applicable

1. No power (24V) to heat pump control terminal’s

Power problem

Normal operation Unit operating normally or in standby mode.

5−minute

anti−short cycle

delay

Ambient sensor

problem

Coil sensor

problem

Heat pump

control failure

R and C or heat pump control failure.

2. Heat pump control failure.

Initial power up, safety trip, end of room thermostat demand.

If sensor detects an open, shorted or out−of−temperature range. heat pump control will revert to time/temperature defrost operation. System will still heat or cool.

If the outdoor coil temperature sensor is detected as being open or shorted, the heat pump control will not perform defrost operations.

Indicates that heat pump control has an internal component failure. Cycle 24 volt power to heat pump control. If code does not clear, replace the heat pump control.

Check control transformer power (24V).

If power is available to control and LED(s) do not light, replace the heat pump control.

None required (Jumper FIELD TEST (E33) pins to override)

Page 43

XP21 SERIES

Page 44

Heat Pump Control

LEDs

DS11

Green

Off

DS14 Red

1 fast flash then pause

icomfort

Touch

Thermostat

Display

Not

applicable

First−stage

compressor

heating

SolutionPossible Cause(s)Condition

Off

1 fast flash

then pause

2 fast

flashes

then pause

2 fast

flashes

then pause

None

2 fast

flashes

2 fast

flashes

Off

Not

applicable

Not

applicable

Not

applicable

Not

applicable

Not

applicable

Moderate

Alert Code

105

Moderate

Alert Code

120

Critical Alert

Code 124

Second−stage

compressor

heating

Defrost

First−stage

compressor

cooling

Second−stage

compressor

cooling

Dehumidification

mode

Device

communication

failure

Unresponsive

device

Active subnet

controller missing

for 180 seconds

These are codes that show status of operation whether the system is operating in either in first or second stage heating or cooling operation, defrost or in the dehumidification modes.

ALERT STATUS

Equipment is unable to communicate. Indicates numerous message errors. In most cases errors are related to electrical noise. Make sure high voltage power is separated from RSBus. Check for mis−wired and/or loose connections between the stat, indoor unit and outdoor unit. Check for a high voltage source of noise close to the system. Fault clears after communication is restored.

Usually caused by delay in outdoor unit responding to indoor unit poling. Recycle power. Check all wiring connections. Cleared after unresponsive device responds to any inquiry.

Equipment lost communication with the thermostat. Check four wiring connections, ohm wires and cycle power at the thermostat. Alert stops all services and waits for heartbeat message from thermostat (subnet controller). Cleared after valid thermostat (subnet controller) message is received.

None

Off

Slow flash

Off On

Slow flash Off

506601−01

Critical Alert

Code 125

Moderate /

Critical Alert

Code 126

Critical Alert

Code 131

Critical Alert

Code 132

Moderate

Alert Code

410

Critical Alert

Code 411

Moderate

Alert Code

412

Hardware Failure

Internal control communication

failure

Corrupted control

parameters

Failed flash CRC

check.

Low pressure

fault

Low pressure

switch lockout

High pressure

fault

Hardware problem on the control. Cycle power on control. Replace if problem prevents service and is persistent. Cleared 300 seconds after fault recovered.

Internal communication on heat pump control. Alert will clear 300 seconds after fault has recovered.

Reconfigure the system. Replace control if heating or cooling is not available. Only applicable in the communicating mode, not in start up. Exit from Commissioning and Execute ´Set Factory Default mode´. Control will still operate on default parameter settings.

Recycle power. If failure re−occurs, replace control. System reset is required to recover.

Unit pressures below the lower limit. System is shut down. Clears after pressure switch closes.

Open low pressure switch error count reached 5 strikes. Check system charge using approach and subcooling temperatures. Reset by putting outdoor unit control in test mode or resetting low voltage power.

Unit pressure is above the upper limit. System is shut down. Check system operating pressures and compare to unit charging charts. Clears when pressure switch closes.

Page 44

Page 45

Heat Pump Control

LEDs

DS11

Green

DS14 Red

icomfort

Touch

Thermostat

Display

SolutionPossible Cause(s)Condition

Open high pressure switch error count reached 5 strikes. Check system charge using

On Off

Critical Alert

Code 413

High pressure switch lockout

approach and subcooling temperatures. Check outdoor fan operation. Check for dirt or debris blocking air flow to outdoor unit. Reset by putting outdoor unit control in test mode or resetting low voltage power.

Slow flash On

Fast flash On

Off Fast flash

3 fast

flashes

then pause

3 fast

flashes

then pause

3 fast

Off

flashes

then pause

Simultaneous fast

flashes then pause

Off

Moderate

Alert Code

414

Critical Alert

Code 415

Critical Alert

Code 416

Moderate /

Critical Alert

Code 417

Moderate /

Critical Alert

Code 418

Moderate /

Critical Alert

Code 419

Critical Alert

Code 421

None

Discharge line

temperature fault

High Discharge

Line Temperature

Strikes Lockout

Outdoor Coil

Sensor Faulty

Discharge sensor

fault

W output

hardware fault

W output

hardware fault

lockout

W external

miswire fault

Second−stage

heat lock−in

Discharge line temperature is > 279ºF. Check system operating pressures and compare to unit charging charts in installation manual. Clears after discharge temperature is < 225ºF.

Discharge line high temperature error count reached 5 strikes. Check system charge using approach and subcooling temperatures. Reset by putting outdoor board in test mode or resetting low voltage power.

Sensor being detected open or shorted, or temperature is out of sensor range. Outdoor unit control will not perform demand or time/temperature defrost operation. (System will still heat or cool.) Clears when outdoor unit control detects proper sensor readings.

Outdoor unit control detects open or shorted sensor, or temperature that is out of sensor range. Critical Alert after 10 minutes. Reset by replacing sensor. This fault is detected by allowing the unit to run for 90 seconds before checking sensor resistance. If the sensor resistance is not within range after 90 seconds, the board will count one fault. After 5 faults, the board will lock out. Check for proper sensor reading and attachment to line. Replace if out−of−spec.

When auxiliary heat output is detected as active. Fault in the heat pump control. Replace heat pump control. See figure 32 for further details.

If heat pump control recognizes five output hardware fault events during a single cooling demand, the heat pump control will initiate a lockout. See figure 32 for further details.

When auxiliary heat output is detected as active after compressor has been de−energized. See figure 32 for further details.

If the unit is in non−communicating mode and it goes to second stage due to ambient temperature being below second stage lock−in setting (E48).

Fast simultaneous flashing of DS11,

DS13, DS14 and DS15

1. Pause duration is two (2) seconds.

2. Fast flash duration is 1/2 second. Slow flash duration is one (1) second.

OEM mode Factory test mode.

Page 45

XP21 SERIES

Page 46

Table 14. Compressor Fault and Alarm LED Codes and Related icomfort Touch® Thermostat Alert Codes

NOTE  See notes 1 and 2 in table below for duration of fast / slow flashes and pause.

Heat Pump Control

LEDs

DS15 Yellow

DS13

Red

Off On

1 flash then pause

2 flashes then pause

Off

icomfort

Touch

Thermostat

Display

Moderate/

Critical3 Alert

Code 400

Critical Alert

Code 401

Critical Alert

Code 402

Condition

Compressor

internal

overload trip

Long run time.

System

pressure trip

Possible Cause(s)

Thermostat demand signal Y1 is present, but compressor not running

Compressor is running extremely long run cycles.

Indicates the compressor protector is open or missing supply power to the compressor.

Solution

Compressor protector is open.

S Check for high head pressure S Check compressor supply voltage

Outdoor unit power disconnect is open.

Compressor circuit breaker or fuse(s) is open.

Broken wire or connector is not making contact.

Low or high pressure switch open if present in the system.

Compressor contactor has failed to close.

Low refrigerant charge.

Evaporator blower is not running.

S Check blower relay coil and contacts S Check blower motor capacitor S Check blower motor for failure or blockage S Check evaporator blower wiring and connec-

tors

S Check indoor blower control S Check thermostat wiring for open circuit

Evaporator coil is frozen.

S Check for low suction pressure S Check for excessively low thermostat setting S Check evaporator airflow (coil blockages or re-

turn air filter)

S Check ductwork or registers for blockage.

Faulty metering device.

S Check TXV bulb installation (size, location and

contact)

S Check if TXV/fixed orifice is stuck closed or de-

fective

Condenser coil is dirty

Liquid line restriction (filter drier blocked if present)

Thermostat is malfunctioning

S Check thermostat sub−base or wiring for short

circuit

S Check thermostat installation (location and lev-

el)

High head pressure.

S Check high pressure switch if present in sys-

tem

S Check if system is overcharged with refrigerant S Check for non−condensable in system

Condenser coil poor air circulation (dirty, blocked, damaged).

Condenser fan is not running.

S Check fan capacitor S Check fan wiring and connectors S Check fan motor for failure or blockage

Return air duct has substantial leakage.

Clearing Status

Clears the error after current is sensed in the run and start winding for two seconds, service removed or power reset.

Clears the error after 30 consecutive normal run cycles, or after power reset.

Clears after four consecutive normal compressor run cycles, or after power reset.

3 flashes then pause

506601−01

Off

Moderate

Alert Code

403

Short cycling

Compressor is running less than three minutes.

Page 46

Thermostat demand signal is intermittent.

Time delay relay or heat pump control is defective.

If high pressure switch is present, see flash code 2 information.

Clears after four consecutive normal compressor run cycles, or after power reset.

Page 47

Heat Pump Control

LEDs

DS15 Yellow

4 flashes then pause

5 flashes then pause

6 flashes then pause

7 flashes then pause

DS13

Red

Off

icomfort

Touch

Thermostat

Display

Critical Alert

Code 404

Critical Alert

Code 405

Critical Alert

Code 406

Critical Alert

Code 407

Condition

Locked rotor

Open circuit

Open start

circuit

Open run

circuit

Possible

Possible Cause(s)

Cause(s)

Compressor has a locked out due to run capacitor short, bearings are seized, excessive liquid refrigerant.

Compressor has an open circuit due to power disconnection, fuse is open or other similar conditions.

Current not sensed by Start transformer.

Current not sensed by run transformer.

Solution

Run capacitor has failed.

Low line voltage (contact utility if voltage at disconnect is low).

S Check wiring connections

Excessive liquid refrigerant in the compressor.

Compressor bearings are seized.

Outdoor unit power disconnect is open.

Unit circuit breaker or fuse(s) is open.

Unit contactor has failed to close.

S Check compressor contactor wiring and

connectors

S Check for compressor contactor failure

(burned, pitted or open)

S Check wiring and connectors between supply

and compressor

S Check for low pilot voltage at compressor

contactor coil

High pressure switch is open and requires manual reset.

Open circuit in compressor supply wiring or connections.

Unusually long compressor protector reset time due to extreme ambient temperature.

Compressor windings are damaged.

S Check compressor motor winding resistance

Run capacitor has failed.

Open circuit in compressor start wiring or connections.

S Check wiring and connectors between supply

and the compressor S terminal

Compressor start winding is damaged.

S Check compressor motor winding resistance

Open circuit in compressor start wiring or connections.

S Check wiring and connectors between supply

and the compressor R terminal

Compressor start winding is damaged.

S Check compressor motor winding resistance

Clearing Status

Clears after power reset or four normal compressor cycles.

Clears after one normal compressor run cycle or power reset.

Clears when amperage is detected in RUN and START sensors, or after power reset.

8 flashes then pause

9 flashes then pause

Off

Fast simultaneous flashing of DS11,

Critical Alert

Code 408

Moderate/

Critical Alert

Code 409

Welded

contactor

Secondary low

voltage

OEM Mode Factory test mode.

DS13, DS14 and DS15

1. Pause duration is two (2) seconds.

2. Fast flash duration is 1/2 second. Slow flash duration is one (1) second.

3. Initially a moderate status is displayed and is escalated to critical if alarm exists for more than 10 minutes.

Compressor always runs

24VAC is below 18VAC.

Page 47

Compressor contactor failed to open.

Thermostat demand signal not connected to module.

Control circuit transformer is overloaded.

Low line voltage (contact utility if voltage at disconnect is low).

S Check wiring connections

Clears after one normal compressor run cycle or after power reset.

Clears after voltage is higher than 20VAC for two seconds, or after power reset.

XP21 SERIES

Page 48

Field Component Configuration and Testing

This section provides procedures for configuring, adjusting and testing various components of this unit.

S Fan motor (B4) test procedure S Fan motor control (A177) configuration and testing S Top grille and fan motor mounting adjustment (fan

clearance)

S Heat pump control (A175) unit nominal capacity code

configuration

FAN MOTOR (B4) TEST PROCEDURE

The following procedure can be used to test the fan motor operation. A fully charged 9V battery will be required for this procedure. See figure 33 for complete test procedure.

This is a test that will verify that the motor does operate.

1. Verify main (240 volt) power if OFF to unit.

2. Remove both wires (brown and black) from the J2 terminal on the fan motor control (A177).

3. Room thermostat should be in OFF position (unit in idle mode − no heating or cooling demands)

4. Turn main power (240 volt) ON to unit.

5. Connect 9 Volt battery to fan motor plugs as noted in picture below.

6. Fan motor should run at a reduced fan speed.

7. If fan motor does not run, then replace fan motor assembly.

FAN MOTOR CONTROL (A177) OPERATION, AND TROUBLESHOOTING

This section provides information concerning operation and testing of the fan control.

Fan Motor Control Sequence of Operation

During start up, the following sequence is followed:

1. Display error conditions (see table 16), if present.

2. If no errors are detected, the LED code indicating stage operation (see table 17) will display the applicable code and then a long pause.

3. The fan motor speed / RPM (revolutions per minute) indicator is displayed next (see table 15).

4. There is a short pause.

The above sequence will continue to repeat if a thermostat demand is present. See figure 34 for LED sequence and table 17 for description of flash and pause durations.

REMOVE BOTH LEADS

FROM J2 TERMINALS

BLACK LEAD

BROWN LEAD

COM

PARK

FAN PWM OUT

FAN MOTOR CONTROL

BLACK LEAD

CONNECT B4 FAN

MOTOR BLACK COMMON

WIRE TO 9V BATTERY

NEGATIVE TERMINAL

FULLY CHARGED

9V BATTERY

BLACK LEAD

BROWN LEAD

CONNECT B4 FAN MOTOR WIRE TO 9V BATTERY

POSITIVE TERMINAL

506601−01

Figure 33. Fan Motor (B4) Test

Page 48

Page 49

Table 15. Fan Motor Control RPM, LED Code and DC Voltage Output

CFM Profile Pin Select

Application

4 3 2 1 RPM

XP21−024 ON ON OFF ON 425 6 13.6 500 7 16.0 200 3 6.3

XP21−036 ON OFF ON ON 525 7 16.8 600 8 19.2 225 3 7.0

XP21−048 ON OFF OFF ON 600 8 19.2 675 9 21.6 225 3 7.0

XP21−060 ON OFF OFF OFF 625 8 20.0 700 10 22.5 225 3 7.0

* LED Code indicates Fan Motor Control LED flash sequence. For example, LED Code 9 indicates 9 slow flashes and pause.

Low Stage  ECM1/Y1

Only

LED

Code

DC Volt RPM

High Stage  ECM1/Y1

and ECM2/Y2

LED

Code

DC Volt RPM

EDA Operation 

ECM2/Y2 Only

LED

Code

DC Volt

Table 16. Fan Motor Control Error/Fault LED Codes

Unit Status Motor Control LED Possible Cause

Mismatched RPM

CRC Failure Constant ON.

Fast flash with no

pause

Internal feedback, PWM does not match target

Microcontroller CRC failure

During start up, the fan motor control LED will display any error conditions. If error conditions exist then no other codes will display. If no error conditions are present, then the stage status and and RPM indicator are displayed in sequence. Two−stage units have

various fan motor speed operations available (see table

Verify LED Status Codes

15).

Table 17. Fan Motor Control Stage LED Indicator

Codes

Unit Status Unit Status Motor Control LED

Two Stage Operation

Low Stage  ECM1/Y1 ONLY

High Stage  ECM1/Y1 and ECM2/Y2

EDA Operation  ECM2/Y2 ONLY

One slow flash, then short pause

Two slow flash, then short pause

Three slow flash, then short pause

Table 18. Fan Motor Control Flash and Pause

Durations

Flash or Pause State Duration

Flash Flash Three flashes per second

Slow Flash One flash per second

Short Pause Two seconds of OFF time

Long Pause Five seconds of OFF time

The following three methods can be used to determine whether the fan motor (B4) is operating at the correct RPMs based on unit size.

1. Use the information provided in table 15 to verify that all

2. Verify that the fan motor speed / RPM indicator is

3. Test DC voltage output on the fan motor control’s J2

4. If no voltage is detected at the J2 terminals, verify there

If there is a demand, proceed to the next section for further testing.

Verify Correct DC Output Voltage (J2)

four jumper terminals are set correctly for the specific unit.

displaying the correct flash sequence for the specific unit (see table table 15).

terminals (see figure 35) while under full load. The actual voltage tested should match the voltage listed in table 15 for the specific unit.

is a Y1 demand at the thermostat.

Verify Correct Input Voltage  (ECM/Y1, ECM/Y2,

Testing

Use the following information to verify and test the fan motor control (A177).

Verify Jumper Settings (J2)

The unit is shipped from the factory with the default fan motor speed setting (in RPMs) required for each model. Use table 15 to verify that jumpers are set correctly for the unit being installed.

Use a voltmeter to check voltages on the following fan motor control inputs, using table 19. Voltage will only be present during a thermostat demand. See figure 36 for test example.

If correct voltages are detected at the applicable inputs during a demand, and no voltage is present at the J2 terminals, then the fan motor control should be replaced.

ECM C AND EXT ECM/R) Terminals

Table 19. Fan Motor Control Voltage Inputs

Input Thermostat Demand Voltage Present

ECM/Y1 and ECM C (Low Stage)

ECM/Y1 − ECM/Y2 and ECM C (High Stage)

ECM/Y2 and ECM C (EDA Operation)

EXT ECM/R and ECM C

YES Between 24VDC and 32 VDC

NO NONE

YES Between 24VDC and 32 VDC at each input

NO NONE at each input

YES Between 24VDC and 32 VDC

NO NONE

YES 24VAC

NO NONE

Page 49

XP21 SERIES

Page 50

DEMAND

BEGINS

MISMATCHED

RPM

DEFAULT

FAN MOTOR

SPEED USED

LED CONTINUOUS FAST

FLASH

REPLACE FAN MOTOR

CONTROL BOARD

CRC

FAILURE

ONE STAGE

(LOW)

DEMAND

ENDED

TWO STAGE

(HIGH)

DEMAND

ENDED

YES

DEFAULT FAN

MOTOR

SPEED USED

ECM1/Y1

ONLY

ECM1/Y1

ONLY AND

EMC2/Y2

FAN MOTOR

RPM SET PER

JUMPER

SETTINGS

FAN MOTOR

RPM SET PER

JUMPER

SETTINGS

LED CONSTANT ON

LED STAGE INDICATOR: ONE SLOW FLASH AND ONE SHORT PAUSE

REPLACE FAN MOTOR

CONTROL BOARD

LED RPM INDICATOR: EXAMPLE: (2−TON) – 5 SLOW FLASHES AND LONG PAUSE

LED STAGE INDICATOR: TWO SLOW FLASHES AND ONE SHORT PAUSE

LED RPM INDICATOR: EXAMPLE: (2−TON) – 5 SLOW FLASHES AND LONG PAUSE

YES

EDA

OPERATION

DEMAND

ENDED

YES

ECM2/Y2

ONLY

FAN MOTOR

RPM SET PER

JUMPER

SETTINGS

LED STAGE INDICATOR: THREE SLOW FLASHES AND ONE SHORT PAUSE

LED RPM INDICATOR: EXAMPLE: (2−TON – 3 SLOW FLASHES AND LONG PAUSE

Figure 34. Fan Motor Control (A177) One/Two Stage and EDA LED Sequence of Operation

506601−01

Page 50

Page 51

FAN MOTOR CONTROL (A177) 

PULSE−WIDTH MODULATION (PWM)

CFM Profile Pin Select

HEAT PUMP

CONTROL (A175)

CONTROL BOX

Verify DC voltage output using fan pwm out and com terminals. see table 15 for optimal DC voltage based on CFM profile used.

COM

PARK

JUMPER

OFF

JUMPER

LED

GREEN

FAN PWM OUT

RED

YELLOW

HIGH PRESSURE SWITCH (S4)

YELLOW

BLUE

BLACK

YELLOW

FAN MOTOR

CONTROL

HEAT PUMP CONTROL

Figure 35. Fan Motor Control, Wiring, Jumper Settings, Testing and LED Location

GREEN

RED RED

B4 FAN

MOTOR

BLACK

BROWN

SEE TABLE 15 FOR CFM PROFILE SELECTION OPTIONS.

Page 51

XP21 SERIES

Page 52

FAN MOTOR CONTROL (A177) 

PULSE−WIDTH MODULATION (PWM)

CONTROL BOX

INPUT VOLTAGES DURING DEMAND

ECM/Y1 ONLY − 24VDC BOTH ECM/Y1 AND ECM/Y2 − 24VDC AT EACH INPUT ECM/Y2 ONLY − 24VDC

HEAT PUMP

CONTROL (A175)

BLUE WIRE

BLACK WIRE

VDC

VAC

ONE YELLOW WIRE FROM PS (E24) TERMINAL ON HEAT PUMP

CONTROL. AND SECOND YELLOW WIRES ON PIGGYBACK

TERMINALS GOES TO S4 HIGH PRESSURE SWITCH.

GREEN

RED

YELLOW

S4 HIGH PRESSURE SWITCH

YELLOW

YELLOW WIRE

EXT PWR/R (24VAC INPUT

DURING DEMAND ONLY)

YELLOW

BLUE

BLACK

YELLOW

FAN MOTOR

CONTROL

GREEN

RED RED

B4 FAN

BLACK

BROWN

SEE TABLE 15 FOR CFM PROFILE SELECTION OPTIONS.

MOTOR

Figure 36. Testing for External Power to Fan Motor Control (A177)

506601−01

HEAT PUMP CONTROL

Page 52

Page 53

TOP GRILLE OR FAN MOTOR MOUNT ADJUSTMENT FOR FAN CLEARANCE

Sometimes during shipping, either the fan motor mounting or top grille may become out of alignment. This may cause the fan motor blade to not clear the orifice ring. If this situation occurs, simply adjust either or both the fan motor mount or top grille positions to allow proper clearance. The top grille four fastener insertion points to the plastic top and motor mount locations are larger than the fasteners used to secure the grille and fan motor mounts. Use the procedures provided in figure 37 to adjust for fan clearance.

PUSH

FORWARD

GRILLE MOUNTING

POINTS

PUSH

FORWARD

FASTENER INSERTION POINT

FAN MOTOR MOUNTING POINTS

The four mounting point holes that secure the top grille to the plastic top are larger than the fasteners used to secure the grille. this is also true for the four fasteners securing the fan motor to the top grille. To provide more clearance, preform either or both of the following procedures.

GRILLE MOUNTING POINTS

Figure 37. Fan Blade Clearance Adjustment

TOP GRILLE ADJUSTMENT

loosen the four grille mounting fasteners and push the grille forward. tighten mounting hardware. if there is still insufficient clearance proceed to Fan Motor Position Adjustment.

FAN MOTOR POSITION ADJUSTMENT

Loosen the four fan motor grille mounting fasteners and push the fan motor forward. tighten mounting hardware.

ORIFICE RING

Page 53

XP21 SERIES

Page 54

HEAT PUMP CONTROL (A175) UNIT NOMINAL CAPACITY CODE CONFIGURATION

In a communicating system, if the room thermostat is indicating either a error code 313, indoor and outdoor unit capacity mismatch error code, or error code 34, must program unit capacity for outdoor unit (see figure 38).

Set room thermostat

Go to control terminal

Remove R wire

from control (24 volt

AC power)

icomfort

enabled 

Remove control

wires from i+ and

i− terminals

START

to OFF

strip

Non − icomfort

enabled 

Remove control

wire from Y1

terminal

DS14 (Red)

DS11 (Green)

Field Test

(E33)

DS12

Communicating

Status Indicator

TERMINAL STRIP

Sensor harness must be attached to air conditioner control.

FINISH

Connect R wire to

control (24 volt AC

power)

Reconnect any control

wiring previously

removed.

Remove R wire from

air conditioner control

(24 volt AC power)

Place jumper on

FIELD TEST

(E33 pins)

Connect R wire to control

(24 volt AC power)

Status LED lights DS11 and DS14 will blink and then on continuously. Once both LEDs are on continuously then remove jumper immediately from E33.

If jumper is not removed immediately from E33, then DS11 and DS14 LEDs will resume blinking again.

YES

successfully

Remove R wire

from control (24 volt

AC power)

Jumper

removed

Place jumper on FIELD

TEST (E33 pins) within 2 to 4

seconds after removal

The control´s DS11 and DS14 LEDs will start blinking the Unit Nominal Code at three (3) second intervals starting at 1−ton through to 6−ton. If a code is not selected, the control will cycle one more time through the codes before defaulting back to the idle mode (simultaneous slow flash).

Long blink ON red LED (DS14) to indicate tonnage and solid ON green LED (DS11) to indicate ½ tonnage.

When the required Unit Capacity Code is displaying on the LEDs, remove FIELD TEST jumper from pins (E33). LEDs will continue to display the selected unit capacity code for two (2) minutes before defaulting back to the idle mode {simultaneous slow flash}, or until the 24 volt

power is cycled to the air conditioner control.

Model

−012

−018

−024

−030

−036

−042

−048

−054

−060

−066

−072

Size

1−ton

1.5−ton

2−ton

2.5−ton

3−ton

3.5−ton

4−ton

4.5−ton

5−ton

5.5−ton

6.0−ton

DS11 Green LED

OFF

DS14 Red LED

1 long flash

2 long flashes

3 long flashes

4 long flashes

5 long flashes

6 long flashes

Figure 38. Heat Pump Control (A175) Unit Nominal Capacity Code Configuration

506601−01

Page 54

Page 55

Maintenance

WARNING

This product and/or the indoor unit it is matched with may contain fiberglass wool.

Disturbing the insulation during installation, maintenance, or repair will expose you to fiberglass wool dust. Breathing this may cause lung cancer. (Fiberglass wool is known to the State of California to cause cancer.)

Fiberglass wool may also cause respiratory, skin, and eye irritation.

To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor.

Lennox Industries Inc. P.O. Box 799900 Dallas, TX 75379−9900

DEALER

Outdoor Unit

Maintenance and service must be performed by a qualified installer or service agency. At the beginning of each cooling season, the system should be checked as follows:

1. Clean and inspect outdoor coil (may be flushed with a water hose). Ensure power is off before cleaning.

2. Outdoor unit fan motor is pre−lubricated and sealed. No further lubrication is needed.

3. Visually inspect all connecting lines, joints and coils for evidence of oil leaks.

4. Check all wiring for loose connections.

5. Check for correct voltage at unit (unit operating).

6. Check amp draw on outdoor fan motor. Motor Nameplate:_________ Actual:__________.

7. Inspect drain holes in coil compartment base and clean if necessary.

NOTE - If insufficient heating or cooling occurs, the unit should be gauged and refrigerant charge should be checked.

S Outdoor Coil (Sea Coast)  Moist air in ocean

locations can carry salt, which is corrosive to most metal. Units that are located near the ocean require frequent inspections and maintenance. These inspections will determine the necessary need to wash the unit including the outdoor coil. Consult your installing contractor for proper intervals/procedures for your geographic area or service contract.

INDOOR UNIT MAINTENANCE

Indoor Unit

1. Clean or change filters.

2. Lennox blower motors are prelubricated and permanently sealed. No more lubrication is needed.

3. Adjust blower speed for cooling. Measure the pressure drop over the coil to determine the correct blower CFM. Refer to the unit information service manual for pressure drop tables and procedure.

4. Belt Drive Blowers − Check belt for wear and proper tension.

5. Check all wiring for loose connections.

6. Check for correct voltage at unit. (blower operating)

7. Check amp draw on blower motor.

Motor Nameplate:_________ Actual:__________.

Indoor Coil

1. Clean coil if necessary.

2. Check connecting lines, joints and coil for evidence of oil leaks.

3. Check condensate line and clean if necessary.

Locations with Possibility of Heavy Snow or

Freezing Rain Accumulation

Heavy snow and/or freezing rain can interfere with the performance of the outdoor fan assembly. Lennox recommends use of the optional snow guard (X8782) in these areas.

Outdoor Coil

It may be necessary to flush the outdoor coil more frequently if it is exposed to substances which are corrosive or which block airflow across the coil (e.g., pet urine, cottonwood seeds, fertilizers, fluids that may contain high levels of corrosive chemicals such as salts)

S Outdoor Coil  The outdoor coil may be flushed with

a water hose.

Figure 39. Snow Guard Top Cover  X8782

Page 55

XP21 SERIES

Page 56

HOMEOWNER

Cleaning of the outdoor unit’s coil should be performed by a trained service technician. Contact your dealer and set up a schedule (preferably twice a year, but at least once a year) to inspect and service your outdoor unit. The following maintenance may be performed by the homeowner.

IMPORTANT

Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to the outdoor unit by treated water. Prolonged exposure of the unit to treated water (i.e., sprinkler systems, soakers, waste water, etc.) will corrode the surface of steel and aluminum parts and diminish performance and longevity of the unit.

Outdoor Coil

The outdoor unit must be properly maintained to ensure its proper operation.

S Please contact your dealer to schedule proper

inspection and maintenance for your equipment.

S Make sure no obstructions restrict airflow to the

outdoor unit.

S Grass clippings, leaves, or shrubs crowding the unit

can cause the unit to work harder and use more energy.

S Keep shrubbery trimmed away from the unit and

periodically check for debris which collects around the unit.

Routine Maintenance

In order to ensure peak performance, your system must be properly maintained. Clogged filters and blocked airflow prevent your unit from operating at its most efficient level.

1. Air Filter  Ask your Lennox dealer to show you

where your indoor unit’s filter is located. It will be either at the indoor unit (installed internal or external to the cabinet) or behind a return air grille in the wall or ceiling. Check the filter monthly and clean or replace it as needed.

2. Disposable Filter  Disposable filters should be

replaced with a filter of the same type and size.

NOTE  If you are unsure about the filter required for your system, call your Lennox dealer for assistance.

3. Reusable Filter  Many indoor units are equipped

with reusable foam filters. Clean foam filters with a mild soap and water solution; rinse thoroughly; allow filter to dry completely before returning it to the unit or grille.

NOTE  The filter and all access panels must be in place any time the unit is in operation.

4. Lennox Branded Air Filters  are designed to

remove airborne particles from the air passing through the filter.

5. Indoor Unit  The indoor unit’s evaporator coil is

equipped with a drain pan to collect condensate formed as your system removes humidity from the

506601−01

Page 56

inside air. Have your dealer show you the location of the drain line and how to check for obstructions. (This would also apply to an auxiliary drain, if installed.)

Thermostat Operation

See the ComfortSense® 7000 or icomfort Touch thermostat homeowner manual for instructions on how to operate your thermostat.

Heat Pump Operation

Your new Lennox heat pump has several characteristics that you should be aware of:

S Heat pumps satisfy heating demand by delivering

large amounts of warm air into the living space. This is quite different from gas- or oil-fired furnaces or an electric furnace which deliver lower volumes of considerably hotter air to heat the space.

S Do not be alarmed if you notice frost on the outdoor coil

in the winter months. Frost develops on the outdoor coil during the heating cycle when temperatures are below 45F (7C). The heat pump control activates a defrost cycle lasting 5 to 15 minutes at preset intervals to clear the outdoor coil of the frost.

S During the defrost cycle, you may notice steam rising

from the outdoor unit. This is a normal occurrence. The thermostat may engage auxiliary heat during the defrost cycle to satisfy a heating demand; however, the unit will return to normal operation at the conclusion of the defrost cycle.

Extended Power Outage

The heat pump is equipped with a compressor crankcase heater which protects the compressor from refrigerant slugging during cold weather operation.

If power to your unit has been interrupted for several hours or more, set the room thermostat selector to the EMERGENCY HEAT setting to obtain temporary heat without the risk of serious damage to the heat pump.

In EMERGENCY HEAT mode, all heating demand is satisfied by auxiliary heat; heat pump operation is locked out. After a six-hour compressor crankcase warm-up period, the thermostat can be switched to the HEAT setting and normal heat pump operation may resume.

Preservice Check

If your system fails to operate, check the following before calling for service:

S Verify room thermostat settings are correct. S Verify that all electrical disconnect switches are ON. S Check for any blown fuses or tripped circuit breakers. S Verify unit access panels are in place. S Verify air filter is clean. S If service is needed, locate and write down the unit

model number and have it handy before calling.

Accessories

For update−to−date information, see any of the following publications:

S Lennox XP21 Engineering Handbook S Lennox Product Catalog S Lennox Price Book

Page 57

SunSource® Home Energy System

This Dave Lennox Signature® Collection heat pump is factory−equipped with components that make it SunSource with solar modules and other optional equipment so that they can become part of a SunSource® Home Energy System.

Units can be upgraded for use with solar equipment at the time of installation or in the future.

Solar energy is first used to meet cooling/heating demands. When the outdoor unit is not operating, the system powers lighting, appliances and other electronic devices in the home. Any surplus power is sent back to the utility company for a possible credit (check with your local utility company for availability).

The SolarSynct package consists of the following components:

S Lennox

Signature

unit.

solar−ready. These units can be matched

Solar Subpanel installed in a Dave Lennox

Collection air conditioner or heat pump

S Solar modules (1 to 15 may be used to vary the

amount of electricity generated).

S Envoy Communications Gateway monitors solar

power performance.

All components must be ordered separately. See the Lennox XP21 Engineering Handbook for SunSource Home Energy System component ordering.

Wiring runs from the roof−mounted solar modules to the outdoor unit. From there, power travels to the home electrical service panel using the existing outdoor unit power wiring.

Checklists

TWO  STAGE COMPRESSOR CHECKOUT

Use this check-out procedure to verify part- and full-load capacity operation of two-stage modulation compressor.

TOOLS REQUIRED

S Refrigeration gauge set

S Digital volt/amp meter

S Electronic temperature thermometer

S On-off toggle switch

PROCEDURE

1. Turn main power OFF to outdoor unit.

2. Adjust room thermostat set point 5ºF above (heating operation) or 5ºF below (cooling operation) the room temperature.

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. Install switch in series with Y2 wire from room thermostat (see note ** in the Field Operational Checklist on page 58).

5. Cycle main power ON.

6. Allow pressures and temperatures to stabilize before taking any measured reading (may take up to 10 minutes).

7. Record all of the readings for the Y1 demand.

8. Close switch to energize Y2 demand. Verify power is going to compressor solenoid (see note ** in the Field Operational Checklist on page 58).

9. Allow pressures and temperatures to stabilize before taking any measured reading (this may take up to 10 minutes).

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).

10. Record all of the readings with the Y1 and Y2 demand.

11. If temperatures and pressures change in the direction noted in chart, the compressor is properly modulating from low to high capacity. (If no amperage, pressures or temperature readings change when this test is performed, the compressor is not switching between low and high capacity and replacement is necessary).

12. After testing is complete, return unit to original set up.

Page 57

XP21 SERIES

Page 58

XP21 Field Operational Checklist

Cooling*** Heating***

Unit Readings

Compressor

Voltage Same Same

Amperage Higher Higher

Condenser Fan motor

Amperage Same or Higher Same or Higher

Temperature

Ambient Same Same

Outdoor Coil Discharge Air Higher Lower

Compressor Discharge Line Higher Higher

Indoor Return Air Same Same

Indoor Coil Discharge Air Lower Higher

Pressures

First

Stage

Expected results

during Y2 demand

(Toggle switch On)

Second

Stage

First Stage

Expected results

during Y2 demand

(Toggle switch On)

Y2 Second

Stage

Suction (Vapor) Lower Down

Liquid Higher Higher

Note − Heat pump may have a low ambient control or control that locks in second−stage below its set point. It may be necessary to remove a wire from

the control when performing this check out. ** On the XP21 units, the System Operation Monitor controls the second−stage solenoid coil in compressor. *** Cooling Mode Operation − Block outdoor coil to maintain a minimum of 375 psig during testing.

Heating Mode Operation − Block indoor coil to maintain a minimum of 375 psig during testing.

506601−01

Page 58

Page 59

XP21 Start−Up and Performance Checklist

Customer Address

Indoor Unit Model Serial

Outdoor Unit Model Serial

Solar Module Mfg and Model Serial

Notes:

START−UP CHECKS

Refrigerant Type:

Rated Load Amps Actual Amps Rated Volts Actual Volts

Condenser Fan Full Load Amps Actual Amps:

COOLING MODE

Vapor Pressure: Liquid Pressure:

Supply Air Temperature: Ambient Temperature: Return Air Temperature:

HEATING MODE

Vapor Pressure: Liquid Pressure:

Supply Air Temperature: Ambient Temperature: Return Air Temperature:

System Refrigerant Charge (Refer to manufacturer’s information on unit or installation instructions for required subcooling and approach temperatures.)

Subcooling:

Saturated Condensing Temperature (A)

minus Liquid Line Temperature (B)

Approach:

Liquid Line Temperature (A)

minus Outdoor Air Temperature (B)

Indoor Coil Temp. Drop (18 to 22°F)

Return Air Temperature (A)

minus Supply Air Temperature (B)

A  B = SUBCOOLING

A  B = APPROACH

A  B = COIL TEMP DROP

Page 59

XP21 SERIES

Lennox XP21, XP21−024, XP21−036, XP21−048, XP21−060 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual