Lennox XP25-024-230-01, XP25-036-230-01, XP25-048-230-01, XP25-060-230-01 Installation And Service Procedure
INSTALLATION AND SERVICE
PROCEDURE
Service Literature
July 24, 2013 (Revised on Dec. 11, 2014)
Dave Lennox Signature
Corp. 1252-L11
IMPORTANT
This unit has refrigerant piping requirements that are
unique to this this model. Size and install the refrigerant
piping per table 2 (page 14) to ensure proper unit operation.
IMPORTANT: Before applying any power (main, solar or low
voltage) to the outdoor unit, confirm iComfort Wi-Fi
has Version 2.1 or higher software. (Reference iComfort Wi-Fi
thermostat manual.)
This unit is an integral component of a system that requires an
iComfort Wi-Fi
or furnace.
XP25 Heat
Pump
®
thermostat and iComfort®-enabled air handler
iComfort Wi-Fi
Thermostat
iComfort
™
-enabled
air handler or
furnace
®
thermostat
®
®
®
Collection XP25 Series Units
TABLE OF CONTENTS
I. OVERVIEW
Model Number Identification 2....................
Typical Serial Number Identification 2..............
Specifications 2.................................
Electrical Data 3................................
Unit Dimensions 4..............................
Typical Unit Parts Arrangement 5.................
General 7......................................
Operating Service Valves 7.......................
II. INSTALLATION
Unit Placement 9...............................
Removing and Installing Panels 12.................
New or Replacement Line Set 13..................
Brazing Connections 16...........................
Flushing the System 19...........................
Leak Testing the System 21.......................
Evacuating the System 21.........................
Electrical 24.....................................
Servicing Unit Delivered Void of Charge 29..........
Unit Start-Up 29.................................
III. SYSTEM OPERATION AND SERVICE
7-Segment Alert and System Status Codes 30.......
Outdoor Control Push-Button Operation 38..........
Configuring Unit 42...............................
Reconfiguring Outdoor Control using iComfort Wi-Fi
Thermostat 43...................................
System Overview 43.............................
Diagnostic Information 43.........................
Defrost Function 43..............................
Outdoor Temperature Operational Range 44.........
Maintenance 45..................................
SunSource
Unit Wiring Diagrams 46..........................
Factory Wiring Diagrams 49.......................
Unit Sequence of Operations 51...................
Component Testing 56............................
System Refrigerant 85............................
®
Home Energy System 45..............
XP25
®
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.
Page 1
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.
2013 Lennox Industries Inc.
Model Number identification
I. OVERVIEW
X
Refrigerant Type
X = R-410A
Unit Type
P = Heat Pump
230 -02P 25 XXX- -
Minor Revision Number
Voltage
230 = 208/230V-1ph-60hz
Nominal Cooling Capacity
024 = 2 tons
Series
036 = 3 tons
048 = 4 tons
060 = 5 tons
Typical Serial Number Identification
Location Code
19 = Saltillo, Mexico
58 = Marshalltown, IA
Year Code
08 = 2008
09 = 2009
10 = 2010
09 C
8
5
05716
5 (or 6) Digit Unique Number
Month Code
A = January
B = February
C = March
Specifications
Unit Outdoor Fan
Model Number
XP25-024-230-01 68 58 11 lbs., 5 oz. 3 26
Sound Rating Number (dB)
Maximum Minimum
1
Factory Refrigerant
Charge
2
Number of Blades Diameter - inches.
Unit Outdoor Fan
Model Number
XP25-036-230-01 73 58 11 lbs., 8 oz. 3 26
Model Number
XP25-048-230-01 74 64 13 lbs., 14 oz. 3 26
Model Number
XP25-060-230-01 74 64 13 lbs., 0 oz. 3 26
1
Tested according to AHRI Standard 270-2008 test conditions.
2
Factory charge is sufficient for refrigerant line lengths up to 15 feet.
Sound Rating Number (dB)
Maximum Minimum
Sound Rating Number (dB)
Maximum Minimum
Sound Rating Number (dB)
Maximum Minimum
1
Unit Outdoor Fan
1
Unit Outdoor Fan
1
Factory Refrigerant
Factory Refrigerant
Factory Refrigerant
Charge
Charge
Charge
2
2
2
Number of Blades Diameter - inches.
Number of Blades Diameter - inches.
Number of Blades Diameter - inches.
Page 2
XP25
Electrical Data
208/230V-60 Hz-1 Ph
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Model Number
Over-
current
Protection
(amps)
1
Minimum
Circuity
Ampacity
Maximum
XP25-024-230-01 25 15.7 10.30 18.00 1/3 2580 1845 723 515 70 32 2.80
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Model Number
Over-
current
Protection
(amps)
1
Minimum
Circuity
Ampacity
Maximum
XP25-036-230-01 25 20.3 14.00 18.00 1/3 4130 1865 850 390 214 40 2.80
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Model Number
Over-
current
Protection
(amps)
1
Minimum
Circuity
Ampacity
Maximum
XP25-048-230-01 40 33.7 24.70 29.00 1/3 4040 3315 805 658 172 98 2.80
Rated
Load
Amps
2
(RLA)
Locked
Rotor
Amps
(LRA)
Motor
HP
CFM RPM WATTS
MAX MIN MAX MIN MAX MIN
Full
Load
Amps
(FLA)
208/230V-60 Hz-1 Ph
Rated
Load
Amps
2
(RLA)
Locked
Rotor
Amps
(LRA)
Motor
HP
CFM RPM WATTS
MAX MIN MAX MIN MAX MIN
Full
Load
Amps
(FLA)
208/230V-60 Hz-1 Ph
Rated
Load
Amps
2
(RLA)
Locked
Rotor
Amps
(LRA)
Motor
HP
CFM RPM WATTS
MAX MIN MAX MIN MAX MIN
Full
Load
Amps
(FLA)
208/230V-60 Hz-1 Ph
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Model Number
Maximum
Over-
current
Protection
(amps)
1
Minimum
Circuity
Ampacity
Rated
Load
Amps
2
(RLA)
Locked
Rotor
Amps
(LRA)
Motor
HP
CFM RPM WATTS
MAX MIN MAX MIN MAX MIN
Load
Amps
(FLA)
XP25-060-230-01 40 34.9 25.70 29.00 1/3 4240 3025 845 600 198 76 2.80
1
HACR type circuit breaker or fuse.
2
Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.
Full
Page 3
XP25
Unit Dimensions -- Inches (mm)
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.
UNIT SUPPORT
16-7/8
(429)
8-3/4
(222)
3-1/8
(79)
FEET
30-3/4
(781)
26-7/8
(683)
3-3/4 (95)
4-5/8
(117)
BASE WITH ELONGATED LEGS
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 nearby these areas during installation or while
servicing this equipment.
WARNING
Electrical Hazard
High Voltage
Wait 5 Minutes
Electrical components may hold charge. Do
not remove this panel or service this area for
5 minutes after the power has been
removed.
XP25
Page 4
Typical Unit Parts Arrangement
GROUND LUGS
CONTROL PANEL FOR
XP25-024 AND -036
CONTACTOR-SPST
(25FLA/35RES)
INVERTER REACTOR,
GROUND LUGS
230V, 4KW
OUTDOOR
CONTROL
CONTROL PANEL FOR
XP25-048 AND -060
VARIABLE-CAPACITY
INVERTER CONTROL
INVERTER NOISE FILTER FOR
6KW INVERTER (208/240V, 60HZ,
CURRENT RANGE 30A MAXIMUM,
INDUCTANCE 4.3MH
CONTACTOR-SPST
(35FLA/40RES)
OUTDOOR CONTROL
Figure 1. Control Panel Components
Page 5
INVERTER REACTOR,
230V, 6KW
VARIABLE-CAPACITY
INVERTER CONTROL
XP25
VAPOR VALVE
AND GAUGE
PORT
LIQUID VALVE AND
GAUGE PORT
Typical Plumbing Components (-024 and -048)
COMPRESSOR TOP CAP
SWITCH (THERMAL)
MUFFLER
REVERSING
VALV E
VARIABLE-CAPACITY
COMPRESSOR SPEED - HFC-410A,
3-PHASE
CHARGE
C0MPENSATOR
(INTERNAL VOLUME
30.0 CUBIC INCHES)
CHECK EXPANSION
VALVE - (HFC-410A)
HR1 CRANKCASE
HEATER (40W, 240VAC)
TRUE SUCTION LINE
LIQUID LINE SENSOR
LIQUID LINE BI-FLOW
LOW PRESSURE SWITCH - NORMALLY OPEN, SWITCH CLOSES
PORT
FILTER DRIER
(HFC-410A)
WHEN SYSTEM PRESSURES GO ABOVE 40±5 PSIG. OPENS
WHEN SYSTEM PRESSURES GO BELOW 25±5 PSIG
Typical Plumbing Components (-036 and -060)
COMPRESSOR TOP CAP SWITCH (THERMAL)
DISCHARGE LINE
MUFFLER
REVERSING
VALV E
VAPOR VALVE
AND GAUGE
PORT
EXPANSION VALVE SENSING
BULB
CRANKCASE HEATER
THERMOSTAT (S40) OPENS AT
70ºF, CLOSES AT 50ºF
HIGH PRESSURE SWITCH - NORMALLY CLOSED, SWITCH OPENS
WHEN SYSTEM PRESSURES REACH 590+
WHEN PRESSURES DROP BELOW 418+
15 PSIG, CLOSES
15 PSIG
VARIABLE-CAPACITY
COMPRESSOR SPEED - HFC-410A,
60HZ, 3-PHASE
CHECK EXPANSION
VALVE - (HFC-410A)
LIQUID VALVE AND
GAUGE PORT
TRUE SUCTION LINE
LIQUID LINE SENSOR
LIQUID LINE BI-FLOW
LOW PRESSURE SWITCH - NORMALLY OPEN, SWITCH CLOSES
PORT
FILTER DRIER
WHEN SYSTEM PRESSURES GO ABOVE 40±5 PSIG. OPENS
WHEN SYSTEM PRESSURES DROP BELOW 25±5 PSIG
Figure 2. Plumbing (Component Locations and Specifications)
HR1 CRANKCASE HEATER (40W,
240VAC)
CRANKCASE HEATER THERMOSTAT
CHECK EXPANSION VALVE SENSING BLUB
HIGH PRESSURE SWITCH - NORMALLY CLOSED, SWITCH
OPENS WHEN SYSTEM PRESSURES REACH 590+
CLOSES WHEN PRESSURES DROP BELOW 418+
Page 6
15 PSIG,
15 PSIG
XP25
IMPORTANT
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox Product Specification bulletin. Coils
previously charged with HCFC-22 must be flushed.
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 nearby these areas during installation or while
servicing this equipment.
WARNING
Electric Shock Hazard. Can cause injury or
death. Unit must be grounded in
accordance with national and local codes.
Line voltage is present at all components
when unit is not in operation on units with
single‐pole contactors. Disconnect all
remote electric power supplies before
opening access panel. Unit may have
multiple power supplies.
WARNING
The State of California has determined that this product
may contain or produce a chemical or chemicals, in very
low doses, which may cause serious illness or death. It
may also cause cancer, birth defects, or reproductive
harm.
General
The XP25 is a high-efficiency residential split-system heat
pump unit, which features a variable-capacity scroll
compressor and HFC-410A refrigerant. Units are available
in 2, 3, 4 and 5-ton sizes. The series is designed for use with
a check expansion valve (approved for use with HFC-410A)
in the indoor unit only.
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
TORQUE REQUIREMENTS
When servicing or repairing HVAC components, ensure the
fasteners are appropriately tightened. Table 1 lists torque
values for fasteners.
Only use hex 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 a hex
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.
IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted
snugly over the cap before tightening.
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
USING MANIFOLD GAUGE SET
When checking the system charge, only use a manifold
gauge set that features low loss anti-blow back fittings.
Manifold gauge sets 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.
Operating Service Valves
The liquid and vapor line service valves are used for
removing refrigerant, flushing, leak testing, evacuating,
checking charge and charging.
Each valve is equipped with a service port which has a
factory-installed valve stem. Figure 3 provides information
on how to access and operate both angle and ball-type
service valves.
Page 7
XP25
SERVICE VALVES
ANGLE AND BALL-TYPE
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
SERVICE PORT
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:
11
7
12
6
1/6 TURN
1
2
4
5
1/12 TURN
• With torque wrench: Finger tighten and
torque cap per table 1.
• 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:
10
9
8
• With torque wrench: Finger tighten and then
torque cap per table 1.
• Without torque wrench: Finger tighten and use
an appropriately sized wrench to turn an addi
tional 1/12 turn clockwise.
10
9
12
11
8
1
5
7
6
3
2
3
4
NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
Figure 3. Angle- and Ball-Type Service Valves
Page 8
XP25
II. INSTALLATION
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:
• Some localities are adopting sound ordinances based
on the unit sound level registered from the adjacent
property, not from the installation property. Install the
unit as far as possible from the property line.
• When possible, do not install the unit directly outside a
window. Glass has a very high level of sound
transmission. For proper placement of unit in relation to
a window see figure 6, 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 6, detail B.
NOTE - If necessary for stability, anchor unit to slab as
described in figure 6, detail D.
Elevating the Unit
Units are outfitted with elongated support feet as illustrated
in figure 6, detail C.
If additional elevation is necessary, raise the unit by
extending the height of the unit support feet. Use a 2-inch
(50.8mm) Schedule 40 female threaded adapter to raise the
height of the unit.
The specified coupling fits snugly 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 the
height further than what is stable, consider a different type
of field-fabricated framework that is sturdy enough for
greater heights.
CLEARANCE ON ALL SIDES — INCHES (MILLIMETERS)
6 (152)
12 (305)
36 (914)
ACCESS PANEL
CONTROL PANEL
ACCESS
LOCATION
30 (762)
LINE SET
CONNECTIONS
Note - Dimensions are not to scale.
NOTES:
• CLEARANCE TO ONE OF THE THREE
SIDES MUST BE 36 INCHES (914MM).
• CLEARANCE TO ONE OF THE
REMAINING TWO SIDES MAY BE 12
INCHES (305MM) AND THE FINAL
SIDE MAY BE 6 INCHES (152MM).
MINIMUM CLEARANCE BETWEEN
TWO UNITS
24 (610)
ACCESS PANEL
LINE SET
CONNECTIONS
MINIMUM CLEARANCE
ABOVE UNIT
48 (1219)
REAR VIEW OF UNIT
Figure 4. Installation Clearances
Page 9
XP25
STABILIZING UNIT ON UNEVEN SURFACES
IMPORTANT
unit above a load-bearing wall or area of the roof that can
adequately support the unit. Consult local codes for rooftop
applications.
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 the louvered panel from each side to expose
the unit base.
2. Install the brackets as illustrated in figure 6, detail D
using conventional practices.
3. Replace the panels after installation is complete.
ROOF MOUNTING
NOTICE
Roof Damage!
This system contains both refrigerant and oil. Some
rubber roofing material may absorb 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.
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
INLET AIR
INLET AIR
24”
(610)
Install the unit a minimum of six inches (152 mm) above the
roof surface to avoid ice build-up around the unit. Locate the
Figure 5. Wind Barrier
(Rooftop or Ground Application)
Page 10
XP25
DETAIL A DETAIL B
INSTALL UNIT AWAY FROM WINDOWS
TWO 90° ELBOWS INSTALLED IN LINE SET
REDUCES LINE SET VIBRATION.
Outside Unit Placement
INSTALL UNIT LEVEL OR, IF ON A SLOPE, MAINTAIN SLOPE
TOLERANCE OF 2 DEGREES (OR 2 INCHES PER 5 FEET [50 MM PER 1.5
M]) AWAY FROM BUILDING STRUCTURE.
GROUND LEVEL
Slab Mounting at Ground Level
BUILDING
STRUCTURE
MOUNTING
SLAB
DETAIL C
BASE
LEG DETAIL
2” (50.8MM) SCH 40
FEMALE THREADED
USE ADDITIONAL 2” SCH 40 MALE THREADED ADAPT
ERS WHICH CAN BE THREADED INTO THE FEMALE
THREADED ADAPTERS TO MAKE ADDITIONAL AD
JUSTMENTS TO THE LEVEL OF THE UNIT.
Elevated Slab Mounting using Feet
ADAPTER
2” (50.8MM) SCH 40
MALE THREADED
ADAPTER
Extenders
DETAIL D
Slab Side Mounting
#10 1/2” LONG SELF-DRILLING
SHEET METAL SCREWS
STABILIZING BRACKET (18 GAUGE
METAL — 2” WIDTH; HEIGHT AS
#10 1-1/4” LONG HEX HEAD
SCREW AND FLAT WASHER
CONCRETE SLAB — USE TWO PLASTIC
ANCHORS (HOLE DRILL 1/4”)
WOOD OR PLASTIC SLAB — NO PLASTIC ANCHOR
(HOLE DRILL 1/8”)
REQUIRED)
CORNER POST
MINIMUM ONE
Deck Top Mounting
STABILIZING BRACKET (18 GAUGE METAL
— 2” (50.8MM) WIDTH; HEIGHT AS
REQUIRED); BEND TO FORM RIGHT ANGLE
SAME FASTENERS AS
SLAB SIDE MOUNTING.
ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY, TWO
BRACKETS PER SIDE, 2” (50.8MM) FROM EACH CORNER.
PER SIDE
FOR EXTRA
STABILITY
Stabilizing Unit on Uneven Surfaces
IMPORTANT - To help stabilize an outdoor unit, some installations may require strap
ping the unit to the pad using brackets and anchors commonly available in the
marketplace.
COIL
BASE PAN
Figure 6. Placement and Slab Mounting
Page 11
XP25
Removing and Installing Panels
ACCESS PANEL REMOVAL
PANELS
ACCESS AND LOUVERED
REMOVE AND INSTALL THE ACCESS PANEL
AS ILLUSTRATED.
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.
IMPORTANT - Do not allow panels to hang on unit by top tab. Tab
is for alignment and not designed to support weight of panel.
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:
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.
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:
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 C
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT AS
POSSIBLE) WHILE INSTALLING PANEL.
Detail D
Detail A
LIP
SCREW
HOLES
Detail B
REMOVE 4 SCREWS TO
REMOVE PANEL FOR
ACCESSING COMPRESSOR
AND CONTROLS.
ALIGN PANEL WITH SCREW
HOLES. INSTALL SCREWS
AND TIGHTEN.
ROTATE IN THIS DIRECTION; THEN
DOWN TO REMOVE PANEL
ANGLE MAY BE TOO EXTREME
PREFERRED ANGLE FOR INSTALLATION
Figure 7. Removing and Installing Panels
Page 12
HOLD DOOR FIRMLY ALONG
THE HINGED SIDE TO MAINTAIN
FULLY-ENGAGED TABS
XP25
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 16.
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 19.
IMPORTANT
If this unit is being matched with an approved line set or
indoor unit coil that 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
system performance and capacity.
Failure to properly flush the system per the XP25
Installation and Service Procedures will void the warranty.
If refrigerant lines are routed through a wall, seal and isolate
the opening so vibration is not transmitted to the building. Pay
close attention to line set isolation during installation of any
HVAC system. When properly isolated from building
structures (walls, ceilings, floors), the refrigerant lines will
not create unnecessary vibration and subsequent sounds.
See figure 8 for recommended installation practices. Also,
consider the following when placing and installing a
high-efficiency outdoor unit.
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 3) may be reused. If system
was previously charged with HCFC-22 refrigerant, the
existing line set must be flushed (see Flushing the System
on page 19).
IMPORTANT
Mineral oils are not compatible with HFC-410A. If oil must
be added, it must be a Polyol ester oil.
Recommended topping-off POE oils are Mobil EAL ARCTIC
22 CC or ICI EMKARATEt RL32CF.
WARNING
Danger of fire. Bleeding the refrigerant
charge from only the high side may result
in the low side shell and suction tubing
being pressurized. Application of a brazing
torch while pressurized may result in
ignition of the refrigerant and oil mixture check the high and low pressures before
unbrazing.
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.
WARNING
Fire, Explosion and Personal Safety Haz
ard. Failure to follow this warning could re
sult 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.
WARNING
When using a high pressure gas such as
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).
IMPORTANT
Some scroll compressors have an 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 XP25 is a variable-capacity cooling and heat pump
system utilizing variable-speed compressor technology.
With the variable-speed compressor and variable pumping
capacity, additional consideration must be given to
refrigerant piping sizing and application. The following
guidelines are to be used exclusively for the XP25 systems.
Page 13
XP25
COOLING SYSTEM (HFC-410A)
• Total equivalent length equals 180 feet (piping and all
fittings included).
NOTE - This is a general guide. Lengths may be more or
less, depending on remaining system design factors.
• Maximum linear (actual) length = 150 feet.
• Maximum linear liquid lift = 60 feet.
NOTE - Maximum lifts are dependent on total length,
number of elbows, and other factors that contribute to total
pressure drop.
• Maximum linear length of vapor riser = 60 feet.
• Size vertical vapor riser per table 3.
• Line set lengths up to 50 linear feet: Use rated line
sizes listed in table 2.
• Line set lengths between 51 150 linear feet:
Crankcase heater and nonbleed port TXV
factory-installed. No additional components required.
Table 2. Standard Refrigerant Line Set — Up to 50 Linear Feet
Inches (mm)
Valve Size Connections Recommended Line Sets
Model Number (-xx*)
XP25-024-230-XX
XP25-036-230-XX
XP25-048-230-XX
XP25-060-230-XX 3/8” (10 mm) 1-1/8” (29 mm) ** Field-fabricated
* Applicable to all minor revision numbers unless otherwise specified.
** Some applications may require a field-provided 1-1/8” to 7/8” adapter.
Liquid Line Suction Line
3/8” (10 mm) 7/8” (22 mm)
L15 Line Set
Model
L15-65-30 30 feet (9.1 m) 89J60
L15-65-40 40 feet (12.2 m) 89J61
L15-65-50 50 feet (15.2 m) 89J62
Vertical vapor riser must be sized per table 3 on systems
with line sets longer than 51 feet. Use tables 3 and 4 to
determine the correct liquid and vapor line sizes.
NOTE - See figure 65 on page 87 to calculate required
refrigerant charge.
• Line set lengths over 150 linear feet: Not
recommended.
• Additional oil is not required for systems with line lengths
up to 150 feet except for the XP25-048 and XP25-060.
These units require 2 ounces of oil for every 10 feet
beyond 100 feet.
NOTE - Recommended POE oils are Mobil EAL ARCTIC 22
CC or ICI EMKARATE
SUCTION TRAPS
In systems with the outdoor unit 5 to 60 feet above the
indoor unit, one trap must be installed at the bottom of the
suction riser.
®
RL32CF.
Line Set Length
Catalog
Number
Table 3. XP25 Piping Guidelines
Model
024 180 150 60 60 7/8” 5/8”
036 180 150 60 60 7/8” 3/4”
048 180 150 60 60 7/8” 7/8”
060 180 150 60 60 7/8” 7/8”
Maximum Total
Equivalent Length (ft)
Maximum Linear
(actual) Length (ft)
Maximum Vapor
Riser (ft)
Maximum
Linear Liquid
Lift (ft)
Preferred Vapor Line
Sizes for Horizontal
Runs
Required Vapor
Riser Size
Table 4. Liquid Line Diameter Selection Table
Total Linear Length (feet)
Unit
024
036
048
060
Note Shaded rows indicate rated liquid line size.
1. Find your unit on the left side of the table.
2. Start with the rated liquid line size (shaded row) for the outdoor unit.
3. Select the actual total linear length of your system shown at the top of
the table.
Line Size
5/16”
3/8” 25 50 60 60 60 60
3/8” 25 50 60 56 51 45
1/2” 25 50 60 60 60 60
3/8” 25 50 50 41 31 22
1/2” 25 50 60 60 60 60
3/8” 25 50 36 22 8 NR
1/2”
25 50 75 100 125 150
25
25
50 55 48 40 33
50 60 60 60 59
4. The elevation listed in the table is the maximum allowed for the liquid
line listed.
5. Consider the larger liquid line size shown in the table if the elevation
does not meet your requirements.
Max. Elevation
(ft)
XP25
Page 14
LINE SET
INSTALLATION
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
AUTOMOTIVE
MUFFLER‐TYPE HANGER
IMPORTANT - Refrigerant lines must not contact structure.
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.
IMPORTANT - Refrigerant lines must not contact
wall
OUTSIDE WALL
VAPOR LINE
LIQUID LINE
WALL
STUD
STRAP LIQUID LINE TO
VAPOR LINE
LIQUID LINE
NON-CORROSIVE
METAL SLEEVE
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)
FLOOR JOIST OR
ROOF RAFTER
NON-CORROSIVE
METAL SLEEVE
TAPE OR
WIRE TIE
8 FEET (2.43 METERS)
WOOD BLOCK
BETWEEN
STUDS
SLEEVE
VAPOR LINE WRAPPED
WITH ARMAFLEX
OUTSIDE
WALL
PVC
PIPE
FIBERGLASS
INSULATION
CAULK
WIRE TIE
INSIDE WALL
STRAP
NON-CORROSIVE
METAL SLEEVE
WIRE TIE
WOOD BLOCK
WIRE TIE
STRAP
LIQUID
LINE
TAPE OR
WIRE TIE
FLOOR JOIST OR
ROOF RAFTER
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.
Figure 8. Line Set Installation
NOTE - SIMILAR INSTALLATION PRACTICES SHOULD BE USED IF
LINE SET IS TO BE INSTALLED ON EXTERIOR OF OUTSIDE WALL.
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.
Page 15
XP25
Brazing Connections
Use the procedures outlined in figures 9 and 10 for brazing
line set connections to service valves.
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.
WARNING
Fire, Explosion and Personal Safety Haz
ard.
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 a fire
and/or an explosion, that could result in
property damage, personal injury or death.
Page 16
XP25
PIPING PANEL REMOVAL AND LINE SET
PREPARATION
1
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 and
2
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 LINE SERVICE VALVES
3
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 Remove the valve core from the suction line to
provide an exit point for the nitrogen flow.
SUCTION SERVICE PORT MUST BE OPEN AND
SERVICE PORT CORE REMOVED TO ALLOW
EXIT POINT FOR NITROGEN FLOW
SUCTION LINE
INDOOR
UNIT
C
SERVICE VALVE
SUCTION LINE SERVICE
LOW
ATTACH
GAUGES
SUCTION LINE
VALV E
B
HIGH
OUTDOOR
UNIT
SERVICE
PORT CORE
SERVICE
PORT CAP
LIQUID LINE
LIQUID LINE SERVICE
VALV E
A
Figure 9. Brazing Procedures
Page 17
NITROGEN
XP25
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.
4
FLOW NITROGEN
Flow regulated nitrogen (at 1 to 2 psig) through the
5
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
Cloths must remain water-saturated throughout the
6
brazing and cool-down process.
A Braze liquid line to liquid line service valve.
B Braze suction / vapor line to suction / vapor
service valve.
IMPORTANT !
Use silver alloy brazing rods with 5%
minimum silver alloy for copper-to-copper
brazing and 45% alloy for copper-to-brass
or copper-to-steel brazing.
6B
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
SUCTION / VAPOR SERVICE PORT
MUST BE OPEN AND SERVICE PORT
CORE REMOVED TO ALLOW EXIT
POINT FOR NITROGEN FLOW
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.
6A
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
7
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 18
XP25
Flushing the System
LINE SET AND INDOOR COIL (1 OF 2)
1B
TWO PIECE PATCH PLATE
TYPICAL EXISTING FIXED ORIFICE
1A
DISTRIBUTOR
ASSEMBLY
A ON FULLY CASED COILS, REMOVE THE COIL ACCESS AND PLUMBING
PANELS.
B REMOVE ANY SHIPPING CLAMPS HOLDING THE LIQUID LINE AND DIS
TRIBUTOR ASSEMBLY.
C USING TWO WRENCHES, DISCONNECT LIQUID LINE FROM LIQUID LINE
ORIFICE HOUSING. TAKE CARE NOT TO TWIST OR DAMAGE DISTRIBU
TOR TUBES DURING THIS PROCESS.
D REMOVE AND DISCARD FIXED ORIFICE, VALVE STEM ASSEMBLY (IF
PRESENT) AND TEFLON
E USE A FIELD-PROVIDED FITTING TO TEMPORARILY RECONNECT THE
LIQUID LINE TO THE INDOOR UNIT'S LIQUID LINE ORIFICE HOUSING.
CONNECT GAUGES AND EQUIPMENT FOR
FLUSHING PROCEDURE
2
VAPOR LINE
SERVICE VALVE
EXISTING
INDOOR
LIQUID LINE SERVICE
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.
REMOVAL PROCEDURE
(UNCASED COIL SHOWN)
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
REMOVE AND DISCARD
WHITE TEFLON
(IF PRESENT)
®
WASHER AS ILLUSTRATED ABOVE.
INV ERT ED HCFC-22
CYLINDER CONTAINS
CLE AN HCFC-22 TO B E
USED FOR FLUSHING.
A
1
UNIT
VALV E
VAPOR
LIQUID
B
D
TEFLON® RING
FIXED ORIFICE
®
SEAL
NEW
OUTDOOR
UNIT
C
BRASS NUT
LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
GAUGE
MANIFOLD
LOW
OPENED
TANK
RETURN
INLET
DISCHARGE
RECOVERY MACHINE
CLOSED
HIGH
TYPICAL EXISTING EXPANSION VALVE
REMOVAL PROCEDURE (UNCASED COIL
SHOWN)
(UNCASED COIL ONLY)
DISTRIBUTOR
TUBES
OR
A ON FULLY CASED COILS, REMOVE THE COIL ACCESS AND PLUMBING
B REMOVE ANY SHIPPING CLAMPS HOLDING THE LIQUID LINE AND DIS
C DISCONNECT THE EQUALIZER LINE FROM THE CHECK EXPANSION
D REMOVE THE VAPOR LINE SENSING BULB.
E DISCONNECT THE LIQUID LINE FROM THE CHECK EXPANSION VALVE
F DISCONNECT THE CHECK EXPANSION VALVE FROM THE LIQUID LINE
G REMOVE AND DISCARD CHECK EXPANSION VALVE AND THE TWO TEF
H USE A FIELD-PROVIDED FITTING TO TEMPORARILY RECONNECT THE
DISTRIBUTOR
ASSEMBLY
MALE EQUALIZER
LINE FITTING
PANELS.
TRIBUTOR ASSEMBLY.
VALVE EQUALIZER LINE FITTING ON THE VAPOR LINE.
AT THE LIQUID LINE ASSEMBLY.
ORIFICE HOUSING. TAKE CARE NOT TO TWIST OR DAMAGE DISTRIBU
TOR TUBES DURING THIS PROCESS.
®
RINGS.
LON
LIQUID LINE TO THE INDOOR UNIT'S LIQUID LINE ORIFICE HOUSING.
LIQUID LINE
SENSING BULB
ORIFICE
HOUSING
EQUALIZER
LINE
STUB END
TEFLON
RING
VAPOR
CHECK
EXPANSION
VALV E
®
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
LINE
TEFLON
RING
SENSING
FLUSHING LINE SET
3
CAUTION - This procedure should not be performed on sys
tems which contain contaminants (Example, compressor burn
out).
THE LINE SET AND INDOOR UNIT COIL MUST BE FLUSHED WITH AT
LEAST THE SAME AMOUNT OF CLEAN REFRIGERANT THAT PRE
VIOUSLY CHARGED THE SYSTEM. CHECK THE CHARGE IN THE
B
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 VACU
UM 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 RECOV
ERED, SWITCH THE RECOVERY MACHINE TO VAPOR RECOVERY
SO THAT ALL OF THE HCFC-22 VAPOR IS RECOVERED. ALLOW
THE RECOVERY MACHINE TO PULL SYSTEM DOWN TO 0.
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 OFF THE MACHINE.
®
LINE
LIQUID
LINE
Page 19
XP25
FLUSHING LINE SET AND INDOOR COIL (2 OF 2)
TYPICAL NEW CHECK EXPANSION VALVE INSTALLATION PROCEDURE
THIS OUTDOOR UNIT IS DESIGNED FOR USE IN SYSTEMS THAT USE A CHECK EXPANSION VALVE METERING DEVICE. SEE THE LENNOX XP25
PRODUCT SPECIFICATION FOR APPROVED EXPANSION VALVE KIT MATCH-UPS AND APPLICATION INFORMATION.
4
THE EXPANSION VALVE UNIT CAN BE INSTALLED INTERNAL OR
EXTERNAL TO THE INDOOR COIL. IN APPLICATIONS WHERE AN
TWO PIECE
PATCH PLATE
(UNCASED
COIL ONLY)
DISTRIBUTOR
TUBES
DISTRIBUTOR
ASSEMBLY
MALE EQUALIZER LINE
FITTING (SEE
EQUALIZER LINE
INSTALLATION FOR
FURTHER DETAILS)
SENSING BULB INSULATION IS REQUIRED
IF MOUNTED EXTERNAL TO THE COIL
CASING. SEE SENSING BULB
INSTALLATION FOR BULB POSITIONING.
(Uncased Coil Shown)
LIQUID LINE
ORIFICE
HOUSING
STUB
END
TEFLON
RING
EQUALIZER
LINE
EXPANSION
VALV E
®
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
VAPOR
LINE
UNCASED COIL IS BEING INSTALLED IN A FIELD-PROVIDED
PLENUM, INSTALL THE CHECK EXPANSION VALVE IN A MANNER
WHICH PROVIDES ACCESS FOR FIELD SERVICING OF THE
EXPANSION VALVE. REFER TO BELOW ILLUSTRATION FOR
REFERENCE DURING INSTALLATION OF EXPANSION VALVE
UNIT.
®
TEFLON
RING
A REMOVE THE FIELD-PROVIDED FITTING THAT TEMPORARILY RECON
NECTED THE LIQUID LINE TO THE INDOOR UNIT'S DISTRIBUTOR AS
SENSING
LINE
LIQUID LINE
SEMBLY.
B INSTALL ONE OF THE PROVIDED TEFLON
STUBBED END OF THE 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 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 IL
LUSTRATED IN THE FIGURE ABOVE, OR 20 FT-LB.
D PLACE THE REMAINING TEFLON
OF THE EXPANSION VALVE. LIGHTLY LUBRICATE CONNECTOR
THREADS AND EXPOSE SURFACE OF THE TEFLON
FRIGERANT OIL.
E ATTACH THE LIQUID LINE ASSEMBLY TO THE EXPANSION VALVE. FIN
GER 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.
9 O'CLOCK TO
3 O'CLOCK
BULB
12
®
BULB
9
WASHER AROUND THE OTHER END
12
11
10
8
7
6
®
RINGS AROUND THE
®
ON LINES SMALLER THAN
7/8”, MOUNT SENSING
BULB BETWEEN THE 9
AND 3 O'CLOCK
POSITIONS.
SENSING BULB INSTALLATION
VAPOR LINE
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 VA
POR LINE AND CHECK EXPANSION BULB BEFORE INSULATING
THE SENSING BULB ONCE INSTALLED.
B CONNECT THE EQUALIZER LINE
FROM THE EXPANSION VALVE TO
THE EQUALIZER VAPOR PORT ON
THE VAPOR LINE. FINGER
TIGHTEN THE FLARE NUT PLUS
1/8 TURN (7 FT-LBS) AS ILLUS
TRATED BELOW.
9
10
11
12
1
8
7
5
6
1/8 TURN
2
3
4
VAPOR LINE
BULB
FLARE SEAL CAP
ON 7/8” AND LARGER LINES,
MOUNT SENSING BULB AT
EITHER THE 4 OR 8 O'CLOCK
POSITION. NEVER MOUNT
12
BULB
NOTE - NEVER MOUNT THE SENSING BULB ON
BOTTOM OF LINE.
THE SENSING BULB ON
BOTTOM OF LINE.
FLARE NUT
1/2 TURN
1
2
3
4
5
®
RING WITH RE
EQUALIZER LINE INSTALLATION
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.
Page 20
OR
COPPER FLARE
SEAL BONNET
MALE BRASS EQUALIZER
LINE FITTING
VAPOR LINE
XP25
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.
PIPING PANEL
SUCTION LINE
Leak Testing the System
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).
LIQUID LINE
TWO ISOLATION GROMMETS
ARE PROVIDED FOR THE
LIQUID AND SUCTION LINE PIPE
PANEL PASS THROUGH.
REAR VIEW OF UNIT EXTERIOR
Figure 11. Isolation Grommets
IMPORTANT
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
Leak detector must be capable of sensing HFC
refrigerant.
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
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.
Page 21
XP25
LEAK TEST
LINE SET AND INDOOR COIL
CONNECT GAUGE SET
1
A CONNECT AN HFC-410A MANIFOLD GAUGE SET
HIGH PRESSURE HOSE TO THE VAPOR VALVE
SERVICE PORT.
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 IS REPLACED BY THE NITROGEN
CONTAINER.
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.
LOW
HIGH
MANIFOLD GAUGE SET
OUTDOOR UNIT
A
NITROGEN
HFC-410A
B
TO VAPOR
SERVICE VALVE
TEST FOR LEAKS
AFTER THE LINE SET HAS BEEN CONNECTED TO THE INDOOR AND OUTDOOR UNITS, CHECK THE LINE SET CON
2
NECTIONS 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 12. System Leak Test
Page 22
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Evacuating the System
LINE SET AND INDOOR COIL
CONNECT GAUGE SET
1
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 TO AN
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 IS USED LATER
FOR BOTH THE HFC-410A AND
NITROGEN CONTAINERS.
OUTDOOR
UNIT
A
A34000 1/4 SAE TEE WITH
SWIVEL COUPLER
500
C
MICRON
GAUGE
LOW
TO VAPOR
SERVICE VALVE
MANIFOLD
GAUGE SET
HIGH
HFC-410A
B
TO LIQUID LINE
SERVICE VALVE
VACUUM PUMP
NITROGEN
EVACUATE THE SYSTEM
A OPEN BOTH MANIFOLD VALVES AND START THE VACUUM PUMP.
2
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 REFERS TO THE TOTAL ACTUAL PRESSURE (ABOVE ABSOLUTE ZERO) WITHIN A GIVEN VOLUME OR
SYSTEM. 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), CLOSE THE MANIFOLD GAUGE VALVES, TURN
OFF THE VACUUM PUMP AND DISCONNECT THE MANIFOLD GAUGE CENTER PORT HOSE FROM VACUUM PUMP. ATTACH THE MANIFOLD
CENTER PORT HOSE TO A DRY NITROGEN CYLINDER WITH PRESSURE REGULATOR SET TO 150 PSIG (1034 KPA) AND PURGE THE HOSE.
OPEN THE MANIFOLD GAUGE VALVES TO BREAK THE VACUUM IN THE LINE SET AND INDOOR UNIT. CLOSE THE 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 IN
DOOR 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:
D
RECOMMEND
MINIMUM 3/8” HOSE
1/6 TURN
1. Close manifold gauge valves.
2. Shut off HFC-410A cylinder.
3. Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with
core tool while maintaining a positive system pressure.
4. Replace the stem caps and secure finger tight, then tighten an additional one-sixth (1/6) of a turn as
illustrated.
Figure 13. System Evacuation
Page 23
9
10
8
11
12
1
2
3
4
7
5
6
XP25
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 combined 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. See unit nameplate
for minimum circuit ampacity and maximum over-current
protection size.
24VAC TRANSFORMER
Use the transformer provided with the furnace or air handler
for low‐voltage control power (24VAC - 40 VA minimum).
LOAD SHEDDING
Utility Load Shedding Mode ACTIVATED – The normally
closed set of contacts in the utility load shedding control
receiver OPEN. This removes 24VAC from the coil of the
field-provided relay (catalog # 69J79). The relay contacts
close (terminal 7 to terminal 2), completing the circuit
between terminals R and L on the outdoor control. The
24VAC input to terminal L activates the load shedding mode
in the outdoor control, cycling the outdoor unit OFF. The
7-Segment display on the outdoor control displays a load
shedding alert code (E600) and an alert appears on the
display of the iComfort Wi-Fi
receives email notifications when the alert occurs, if the
option to receive notifications is selected.
Utility Load Shedding Mode DEACTIVATED
(Normal Equipment Operation) – When load shedding is
not required, the contacts in the utility load control receiver
are closed. This provides 24VAC to the coil of the
field-provided relay (catalog # 69J79).The relay contacts
OPEN (terminal 7 to terminal 2) removing 24VAC from the L
terminal on the outdoor control. This deactivates the load
shedding mode in the outdoor control. The outdoor unit
returns to normal operation and alert code clears once load
shedding mode is deactivated.
For more information, see the Load Shedding Feature
Wiring Diagram on page 48.
®
thermostat. The customer
SIZE CIRCUIT AND INSTALL DISCONNECT
SWITCH
1
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.
Figure 14. Electrical
INSTALL THERMOSTAT
INSTALL ROOM THERMOSTAT (ORDERED SEPARATELY) ON AN
INSIDE WALL APPROXIMATELY IN THE CENTER OF THE
2
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 CON
TROL BOX.
Page 24
XP25
ROUTE CONTROL WIRES
Maximum length of wiring (18 gauge) for all connections on
3
the RSBus is 1500 feet (457 meters). Wires should be col
or-coded, with a temperature rating of 95
mum, and solid-core (Class II Rated Wiring). All low volt
age wiring must enter unit through the provided fieldinstalled busing installed in the electrical inlet.
The iComfort Wi-Fi
wires between the thermostat and the furnace / air handler
iComfort
and the furnace/air handler iComfort® control. When a
thermostat cable with more than four wires is used, the ex
tra wires must be properly connected to avoid electrical
noise (see below).
Use a wire nut to bundle the four unused wires at each end
of the cable. Each bundle should also include an additional
wire that should be connected on each end to the C termi
nal as shown in the figure below.
Provided Rast
6-PIN Connector
®
control and four wires between the outdoor unit
®
thermostat requires four thermostat
Outdoor Control
º
F (35ºC) mini
ELECTRICAL (CONTROL WIRING)
AND LINE SET INLETS USE
BUSHING AND GROMMETS
PROVIDED IN BAG
BUSHING
GROMMETS
Indoor Control
TYPICAL CONTROL BOX
CONTROL WIRING
ROUTE (LOW VOLTAGE)
OUTDOOR CONTROL
iComfort Wi-Fi
thermostat
®
Single Wire To
C Terminal
Unused Wires
ROUTE HIGH VOLTAGE AND GROUND WIRES
4
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 side panel of
the control box. Connect conduit to the control box using a proper conduit fitting.
ELECTRICAL INLET
(HIGH VOLTAGE)
WATERTIGHT
FLEXIBLE CONDUIT
Single Wire To C Terminal
Unused Wires
GROUND LUGS
CONTACTOR
TO SERVICE
DISCONNECT BOX
Figure 15. Electrical (Continued)
XP25
Page 25
ELECTRICAL (Continued) -- Outdoor Unit Control
CAUTION
Electrostatic discharge can affect electronic components. Take precautions
ELECTROSTATIC DISCHARGE
(ESD)
Precautions and Procedures
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
NOTE - The green LED located on the outdoor control
flashes when communication occurs between the outdoor
control and either the thermostat or the inverter.
Figure 16. Outdoor Unit Control
Page 26
7-SEGMENT
DISPLAY
PUSH
BUTTON
PUMP DOWN - WHEN UNIT IS IN PUMP DOWN MODE, IS
SHOWN ON THE 7-SEGMENT DISPLAY.
TO ACTIVATE MODE, REFER TO PUMP DOWN CYCLE
SEQUENCE ON PAGE 39.
XP25
TABLE 5
Outdoor Control Terminal Designations and Input /Outputs (see figure 16 for terminal locations)
Designator Description Input Output Common
O OUT Reversing valve switched output N/A
O Reversing valve return N/A N/A 24VAC common
LO PS Low Pressure switch N/A 5ma @18VAC N/A
LO PS
Hi PS High Pressure switch N/A 24VAC nominal N/A
Hi PS
TP
TP
Cntctr
Cntctr Contactor common N/A 24VAC common
Fan PWM PWM fan output N/A
COM PWM Fan common connection N/A N/A Fan PWM common
Fan Park
P2 Terminals
O O (reversing valve) emergency input
Y1 Y1 emergency input
C 24VAC nominal power return. N/A N/A 24VAC common
i Low data line. Data Data N/A
i+ High data line. Data Data N/A
R 24VAC nominal power input.
DF Factory test N/A N/A N/A
TOUT
TST
Low Pressure switch sensing con
nection
High pressure switch sensing con
nection
Top cap thermostat switch (in series
with the HI PS)
Top Cap thermostat switch sensing
connection
Control (Inverter power) contactor
switched output (in series with the HI
PS and TC)
PWM Fan Parking spot for unused
terminal, not connected.
26Vdc transistor output to Lennox
factory OEM tester
Factory test pin.
In each terminal box:
P2 Terminal 1 TEST
P2 Terminal 2 TOUT
P2 Terminal 3 DF
P2 Terminal 4 R
5ma @18VAC N/A N/A
24VAC nominal N/A N/A
N/A 24VAC nominal N/A
24VAC nominal N/A N/A
N/A
N/A N/A N/A
24VAC nominal from
thermostat and loaded to
draw 17ma at 30VAC
24VAC nominal from
thermostat and loaded to
draw 17ma at 30VAC
24VAC nominal board
main power input.
N/A N/A N/A
24VAC nominal 17ma @
30VAC
Switched 24VAC
nominal
Switched 24VAC
Nominal
1097% duty cycle,
1923 VDC peak
N/A N/A
N/A N/A
N/A N/A
N/A N/A
N/A
N/A
N/A
Page 27
XP25
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