Lenox P506640-01, XP16 User Manual

Page 1

INSTALLATION

E20 Lennox Industries Inc.

Dallas, Texas, USA

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

RETAIN THESE INSTRUCTIONS FOR FUTURE

REFERENCE

NOTICE TO INSTALLER

BRAZING LINE SET TO SERVICE VALVES

It is imperative to follow the brazing technique illustrated starting on page 11 to avoid damaging the service valve’s internal seals.

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.

IMPORTANT

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

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

INSTRUCTIONS

Elite® Series XP16 Units

HEAT PUMPS

506640−01 12/10 Supersedes 11/10

TABLE OF CONTENTS

Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Caps and Fasteners Torque Requirements 3. . . . . . . .

Operating Gauge Set and Service Valves 3. . . . . . . . .

Recovering Refrigerant from Existing System 5. . . . .

New Outdoor Unit Placement 6. . . . . . . . . . . . . . . . . . .

Removing and Installing Panels 8. . . . . . . . . . . . . . . . .

Line Set Requirements 9. . . . . . . . . . . . . . . . . . . . . . . . .

Brazing Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Indoor Refrigerant Metering Device Removal and

Flushing Line Set and Indoor Coil 14. . . . . . . . . . . . . . . .

Installing New Indoor Metering Device 15. . . . . . . . . . . .

Leak Test Line Set and Indoor Coil 16. . . . . . . . . . . . . . .

Evacuating Line Set and Indoor Coil 17. . . . . . . . . . . . .

Electrical Connections 18. . . . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing and Weighing In Refrigerant for Units

Delivered Void of Charge 24. . . . . . . . . . . . . . . . . . . . . . .

Optimizing System Refrigerant Charge 26. . . . . . . . . . .

System Operation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defrost System 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two−Stage Modulation Compressors Checks 40. . . . . .

Maintenance 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checklists 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Litho U.S.A.

IMPORTANT

This unit must be matched with an indoor coil as specified in Lennox XP16 Engineering Handbook. 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 near these areas during installation or while servicing this equipment.

12/10 506640−01

Page 1

Shipping and Packing List

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

1 − Assembled outdoor unit

General

The XP16 outdoor unit uses HFC−410A refrigerant. This unit must be installed with a matching indoor blower coil and line set as outlined in the XP16 Lennox Engineering Handbook. Elite® Series outdoor units are designed for use in check / expansion valve (CTXV) systems only and are not to be used with other refrigerant flow control devices. An indoor coil check / expansion valve approved for use with HFC−410A must be ordered separately and installed prior to operating the unit.

*2P1210* *P506640-01*

Page 2

Model Number Identification

Refrigerant Type

X = R−410A

Unit Type

P = Heat Pump

Series

Unit Dimensions − inches (mm)

DISCHARGE AIR

P 16 036− −

X −05

230

Nominal Cooling Capacity

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

LIQUID LINE CONNECTION

ELECTRICAL INLETS

VAPOR LINE CONNECTION

4−3/4

4−1/4

(121)

(108)

Minor Revision Number

Voltage

230 = 208/230V−1ph−60hz

2 (51)

1 (25)

SIDE VIEW

XP16 BASE WITH LEGS

UNIT SUPPORT

FEET

8−1/2 (216)

8−3/4 (222)

SIDE VIEW

5−1/2 (140)

13−1/2

(343)

XP16−024 BASE SECTION

9−1/2 (241)

8−1/4 (210)

UNIT SUPPORT FEET

Mode Number A B C D E F G H J K

XP16−024−230 35 (889) 27 (686) 28 (711) − − − − − − −

XP16−036−230 39 (991) 30−1/2 (775) 35 (889) 13−7/8 (352) 7−3/4 (197) 3−1/4 (83) 27−1/8 (689) 3−5/8 (92) 4−1/2 (114) 20−5/8 (524)

XP16−048−230 35 (889) 35−1/2 (902)

39−1/2 (1003)

16−7/8 (429) 8−3/4 (222) 3−1/8 (79) 30−3/4 (781) 4−5/8 (117) 3−3/4 (95) 26−7/8 (683)

XP16−060−230 45 (1143 35−1/2 (902)

39−1/2 (1003)

Page 2

Page 3

Typical Unit Parts Arrangement

FOR COIL SENSOR (RT21)

LOCATION SEE DETAIL A

GROUND

SINGLE POLE

LUG AMBIENT

CONTACTOR

(K1)

TEMPERATURE SENSOR (RT13)

DETAIL A

DUAL RUN CAPACITOR (C12) (−024, −036 AND −048 ONLY)

SINGLE RUN CAPACITOR (C1) (−060 ONLY)

DEMAND DEFROST CONTROL (A108)

DISCHARGE LINE

SENSOR (RT28)

REVERSING

VALVE (L1)

TRUE SUCTION

PORT

HIGH PRESSURE

SWITCH (S4)

EXPANSION VALVE

SENSING BULB

LIQUID VALVE AND GAUGE

PORT / LIQUID LINE

CONNECTIONS

VAPOR VALVE AND GAUGE PORT /

SUCTION LINE CONNECTIONS

COMPRESSOR

CHECK / EXPANSION VALV E

LIQUID LINE BI−FLOW FILTER DRIER

LOW PRESSURE SWITCH (S87)

XP16−036

COIL SENSOR − NINTH HAIRPIN UP FROM THE BOTTOM ON INSIDE ROW.

XP16−024

COIL SENSOR −THIRD HAIRPIN DOWN FROM THE TOP ON INSIDE ROW.

Figure 1. Unit Parts Arrangement

Caps and Fasteners Torque Requirements

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 Corp.0807−L5 (C−08−1) for further details and information.

XP16−048

COIL SENSOR − EIGHT HAIRPIN UP FROM THE BOTTOM ON INSIDE ROW.

XP16−060

COIL SENSOR − SIXTH HAIRPIN UP FROM THE BOTTOM

ON INSIDE ROW.

When servicing or repairing HVAC equipment and components, ensure the fasteners are appropriately tightened. Table 1 list torque values for various caps and fasteners.

Table 1. Torque Requirements

Parts Recommended Torque

Service valve cap 8 ft.− lb. 11 N M

Sheet metal screws 16 in.− lb. 2 NM

Machine screws #10 28 in.− lb. 3 NM

Compressor bolts 90 in.− lb. 10 NM

Gauge port seal cap 8 ft.− lb. 11 NM

Page 3

XP16 SERIES

Page 4

Operating Gauge Set and Service Valves

USING MANIFOLD GAUGE SET

IMPORTANT

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

OPERATING SERVICE VALVES

The liquid and vapor line service valves are used for refrigerant recovery, flushing, leak testing, evacuating, weighing in refrigerant and optimizing system charge.

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

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 to open the service valve.

SERVICE PORT

CORE

SERVICE PORT CAP

SERVICE PORT CORE

(VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE

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

Manifold gauge set used for HFC−410A refrigerant systems must be capable of handling the higher system operating pressures. The manifold gauges should be rated for:

S High side  Pressure range of 0 − 800 pound−force per

square inch gauge (psig)

S Low side  Use with 30" vacuum to 250 psig with

dampened speed to 500 psig

S Manifold gauge set hoses must be rated for use to 800

psig of pressure with a 4000 psig burst rating.

TO INDOOR

UNIT

TO OUTDOOR

UNIT

VALVE STEM

SHOWN

CLOSED

INSERT HEX−HEAD

EXTENSION HERE

TO INDOOR

UNIT

TO OUTDOOR UNIT

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

STEM CAP

Operating Ball−Type Service Valve:

1. Remove stem cap with an appropriately sized wrench.

2. Use an appropriately sized wrenched to open.

ATo open rotate stem

counterclockwise 90°.

BTo close rotate stem

clockwise 90°.

SERVICE PORT

SERVICE PORT CORE

SERVICE PORT CAP

TO OUTDOOR UNIT

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

TO INDOOR UNIT

BALL (SHOWN CLOSED)

VALVE STEM

REMOVE

STEM CAP

When service valve stem is in the CLOSED position, 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:

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.

REMOVE STEM CAP

1/6 TURN

1/12 TURN

Figure 2. Angle and Ball−Type Service Valves

Page 4

Page 5

Recovering Refrigerant from Existing System

DISCONNECT POWER

Disconnect all power to the existing outdoor unit at the disconnect

switch and/or main fuse box/breaker panel.

MAIN FUSE

BOX/BREAKER

PANEL

DISCONNECT

SWITCH

RECOVERING REFRIGERANT

Remove existing HCFC−22 refrigerant using one of the following procedures:

METHOD 1:

Use Method 1 if the existing outdoor unit is not equipped with shut−off valves, or if the unit is not operational and you plan to use the existing HCFC−22 to flush the system.

Recover all HCFC−22 refrigerant from the existing system using a recovery machine and clean recovery cylinder. Check gauges after shutdown to confirm that the entire system is completely void of refrigerant.

METHOD 2:

Use Method 2 if the existing outdoor unit is equipped with manual shut−off valves, and you plan to use new HCFC−22 refrigerant to flush the system.

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. 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 switches (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.

CONNECT MANIFOLD GAUGE SET

Connect a manifold gauge set, clean recovery cylinder and a

recovery machine to the service ports of the existing unit..

NOTE  Use the recovery machine instructions to make the correct manifold gauge set connections for recovery refrigerant. The illustration below is a typical connection.

MANIFOLD GAUGES

RECOVERY MACHINE

LOW

CLEAN RECOVERY CYLINDER

OUTDOOR UNIT

METHOD 2 LIMITATIONS

NOTE  When using Method 2, the listed devices below 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 any of the above mentioned 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.

HIGH

Figure 3. Refrigerant Recovery

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.

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 5

XP16 SERIES

Page 6

New Outdoor Unit Placement

CAUTION

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

Remove existing outdoor unit prior to placement of new outdoor unit. See Unit Dimensions on page 2 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, 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.

ROOF MOUNTING

Install the unit a minimum of 6 inches (152 mm) above the roof surface to avoid ice build−up around the unit. Locate the unit above a load bearing wall or area of the roof that can adequately support the unit. Consult local codes for rooftop applications. See figure 5, detail F for other roof top mounting considerations.

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.

CLEARANCE ON ALL SIDES  INCHES (MILLIMETERS)

6 (152)

12 (305)

36 (914)

ACCESS PANEL

CONTROL PANEL

ACCESS

LOCATION

30 (762)

LINE SET CONNECTIONS

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).

MINIMUM CLEARANCE BETWEEN TWO UNITS

(610)

Figure 4. Installation Clearances

MINIMUM CLEARANCE

ABOVE UNIT

48 (1219)

Page 6

Page 7

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.

Elevated Slab Mounting

DETAIL C

LEG DETAIL

2" (50.8MM) SCH 40

FEMALE THREADED

2" (50.8MM) SCH 40

MALE THREADED

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.

DETAIL E



using Feet Extenders

ADAPTER

 Deck Top Mounting

BASE

GROUND LEVEL

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")

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

DETAIL F

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 as illustrated.

 Slab Side Mounting

COIL

BASE PAN

REQUIRED)

AND FLAT WASHER

CORNER POST

 Roof Top Mounting

PREVAILING WINTER WINDS

WIND BARRIER

INLET AIR

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

SAME FASTENERS AS SLAB SIDE MOUNTING.

Figure 5. Placement, Slab Mounting and Stabilizing Unit

MINIMUM ONE

PER SIDE

FOR EXTRA

STABILITY

Page 7

INLET AIR

XP16 SERIES

Page 8

Removing and Installing Panels

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

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.

SCREW

LIP

HOLES

Detail A

Detail B

ROTATE IN THIS DIRECTION;

ANGLE MAY BE TOO EXTREME

THEN DOWN TO REMOVE

HOLD DOOR FIRMLY TO THE HINGED

PANEL

SIDE TO MAINTAIN

FULLY−ENGAGED TABS

PREFERRED ANGLE FOR INSTALLATION

Detail D

MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT AS POSSIBLE) WHILE INSTALLING PANEL.

Figure 6. Removing and Installing Panels

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.

Page 8

Page 9

Line Set Requirements

This section provides information on: installation of new or replacement line set.

S Adding Polyol ester oil requirements S New or replacement line set installation S Using existing line set.

ADDING POLYOL ESTER OIL REQUIREMENTS

IMPORTANT

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

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

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 topping−off POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATEt RL32CF.

NEW OR REPLACEMENT LINE SET INSTALLATION

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

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 7 for recommended installation practices.

NOTE  When installing refrigerant lines longer than 50 feet, see the Lennox Refrigerant Piping Design and Fabrication Guidelines, CORP. 9351−L9, or contact Lennox Technical Support Product Applications for assistance. To obtain the correct information from Lennox, be sure to communicate the following information:

Table 2. Refrigerant Line Set  Inches (mm)

Model

XP16−024−230 3/8" (10 mm) 3/4" (19 mm) 3/8" (10 mm) 3/4" (19 mm) L15−41  15 ft. − 50 ft. (4.6m − 15 m)

XP16−036−230

XP16−048−230

XP16−060−230 3/8" (10 mm) 1−1/8" (29 mm) 3/8" (10 mm) 1−1/8" (29 mm) Field Fabricated

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

Liquid Line Suction Line Liquid Line Suction Line L15 Line Set

3/8" (10 mm) 7/8" (22 mm) 3/8" (10 mm) 7/8" (22 mm) L15−65  15 ft. − 50 ft. (4.6 m − 15 m)

Field Connections Recommended Line Set

S Model (XP16) and size of unit (e.g. −036).

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.

USING EXISTING LINE SET

Things to consider:

S Liquid line that meter the refrigerant, such as RFC1

liquid line, must not be used in this application.

S Existing line set of proper size as listed in table 2 may

be reused.

S If system was previously charged with HCFC−22

refrigerant, then existing line set must be flushed (see Flushing Line Set and Indoor Coil on page 14).

If existing line set is being used, then proceed to Brazing Connections on page 11.

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 Line Set and Indoor Coil on page

13.

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.

Page 9

XP16 SERIES

Page 10

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

Figure 7. Line Set Installation

Page 10

Page 11

Brazing Connections

Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves.

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.

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.

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).

IMPORTANT

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

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.

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.

Page 11

XP16 SERIES

Page 12

CUT AND DEBUR

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

CONNECTION

STUB

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

VALV E

SERVICE

PORT

CORE

SERVICE PORT CAP

SUCTION / VAPOR LINE

SERVICE VALVE

LINE SET SIZE IS SMALLER

THAN CONNECTION

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

Flow regulated nitrogen (at 1 to 2 psig) through the low−side refrigeration gauge set into the liquid line service port valve, and out of the suction / vapor line service port valve.

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 core from valve in suction / vapor

line service port to allow nitrogen to escape.

SUCTION / VAPOR SERVICE PORT MUST BE

OPEN TO ALLOW EXIT POINT FOR NITROGEN

VAPOR LINE

INDOOR

UNIT

LIQUID LINE

ATTACH

GAUGES

LIQUID LINE SERVICE

SUCTION /

VAPOR LINE

SERVICE

VALV E

HIGHLOW

OUTDOOR

UNIT

WHEN BRAZING LINE SET TO

SERVICE VALVES, POINT FLAME

AWAY FROM SERVICE VALVE.

USE REGULATOR TO FLOW

NITROGEN AT 1 TO 2 PSIG.

NITROGEN

Figure 8. Brazing Procedures

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).

Page 12

Page 13

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 manifold gauge set connections

BRAZE LINE SET

Wrap both service valves with water saturated cloths as illustrated here and as mentioned in step 4, before brazing to line set. Water

saturated cloths must remain water saturated throughout the brazing and cool−down process.

LIQUID LINE SERVICE VALVE

WHEN BRAZING LINE SET TO

SERVICE VALVES, POINT FLAME

AWAY FROM SERVICE VALVE.

IMPORTANT  Allow braze joint to cool. Apply

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

LIQUID LINE

WATER SATURATED CLOTH

WARNING

1. FIRE, PERSONAL INJURY, OR PROPERTY DAMAGE may 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.

SUCTION / VAPOR LINE

PREPARATION FOR NEXT STEP

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

service valves to cool piping. Once piping is cool, remove all water saturated cloths.

SUCTION / VAPOR LINE

SERVICE VALVE

WATER SATURATED CLOTH

WHEN BRAZING LINE SET TO

SERVICE VALVES, POINT FLAME

AWAY FROM SERVICE VALVE.

Figure 9. Brazing Procedures (continued)

Page 13

XP16 SERIES

Page 14

Indoor Refrigerant Metering Device Removal and Flushing Line Set and Indoor Coil

Flushing is only required when the existing system used HCFC−22 refrigerant. If the existing system used HFC−410a, then remove the original indoor coil metering device and proceed to Installing New Indoor Metering Device on page 15.

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

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

RECOVERY

CYLINDER

LIQUID

VAPOR

OUTDOOR

NEW

UNIT

OPENED

RECOVERY MACHINE

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.

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

(UNCASED COIL ONLY)

DISTRIBUTOR

TUBES

DISTRIBUTOR

ASSEMBLY

MALE EQUALIZER

LINE FITTING

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.

LIQUID LINE

SENSING BULB

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.

LINE

Figure 10. Removing Indoor Refrigerate Metering Device and Flushing Procedures

Page 14

Page 15

Installing New Indoor Metering Device

This outdoor unit is designed for use in HFC−410A systems that use a check / expansion valve metering device (purchased separately) at the indoor coil.

See the Lennox XP16 Engineering Handbook for approved check / expansion valve kit match−ups. The check / expansion valve device can be installed either 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 (see figure 11).

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

LIQUID LINE

ASSEMBLY WITH

LINE

TEFLON

RING

SENSING

BRASS NUT

LIQUID LINE

Sensing bulb insulation is required if mounted external to the coil casing.

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.

LINE

A Remove the field−provided fitting that temporarily

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 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 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

FLARE NUT

COPPER FLARE SEAL BONNET

MALE BRASS EQUALIZER LINE FITTING

VAPOR LINE

BULB

NOTE  NEVER MOUNT ON BOTTOM OF LINE.

Figure 11. Installing Indoor Check / Expansion Valve

Page 15

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

XP16 SERIES

Page 16

Leak Test Line Set and Indoor Coil

IMPORTANT

Leak detector must be capable of sensing HFC refrigerant.

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.

HIGHLOW

MANIFOLD GAUGE SET

OUTDOOR UNIT

NITROGEN

Figure 12. Manifold Gauge Set Connections for Leak Testing

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:

1. 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).

2. 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

HFC−410A

TO VAPOR

SERVICE VALVE

side of the manifold gauge set. Disconnect the HFC−410A cylinder.

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

4. 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.

5. 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.

6. After leak testing disconnect gauges from service ports.

Page 16

Page 17

Evacuating Line Set and Indoor Coil

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.

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

MANIFOLD

GAUGE SET

TO VAPOR

SERVICE VALVE

TO LIQUID LINE SERVICE VALVE

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 and 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

HIGHLOW

Figure 13. Evacuating Line Set and Indoor Coil

Page 17

XP16 SERIES

Page 18

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.

Electrical Connections

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.

MAIN FUSE BOX/ BREAKER PANEL

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.

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.

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 panel.

Page 18

Page 19

LOW VOLTAGE CONNECTIONS

WIRE RUN LENGTH AWG# INSULATION TYPE

LESS THAN 100’ (30 METERS) 18 TEMPERATURE RATING

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

NOTE − For proper voltages, select thermostat wire (control wires) gauge per table above.

CUTOUT WITH

Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated. See figures 14 and 15 for typical field connections when connecting unit to either a CBX32MV or CBX40UHV in non−communicating mode. For connections to other Lennox air handlers or furnaces, see the ComfortSense® 7000 installation instruction for further match component wiring illustrations.

GROMMET

24V CONTROL WIRES

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

A Run 24VAC control wires through cutout with grommet. B Run 24VAC control wires through wire tie. C Make 24VAC control wire connections. D Tighten wire tie to security 24V control wiring.

NOTE − Wire tie provides low voltage wire strain relief and to maintain separation of field installed low and high voltage circuits.

TIGHTEN WIRE TIE

HIGH VOLTAGE FIELD WIRING

LOW VOLTAGE (24V) FIELD WIRING

HIGH VOLTAGE POWER SUPPLY CONNECTIONS

GROUND

NOTE − Any excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring.

NOTE − 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.

OUTDOOR UNIT

CONTROL BOX

CONDUIT

CUTOUT

CONDUIT

Page 19

XP16 SERIES

Page 20

HEAT PUMP UNIT

(TWO−STAGE)

OUT

CBX32MV

CBX40UHV

W1 W1

Figure 14. Typical Field Wiring  Heat Pump Application with CBX32MV or CBX40UHV

COMFORTSENSET

7000

O. D.

SENSOR

(X2658)

Y2Y2

X2658 OUTDOOR SENSOR IS REQUIRED FOR OUTDOOR TEMPERATURE DISPLAY, DEW POINT CONTROL, HEAT PUMP AND

DUAL FUEL BALANCE POINTS.

CONNECTED ON UNIT WITH LSOM. RESISTOR KIT (CAT # 47W97)

IS REQUIRED WHEN CONNECTING THE COMFORTSENSE 7000 WITH THE LSOM 2.

FIELD PROVIDED JUMPER BETWEEN Y2 OUT BL ON HEAT PUMP TO Y2 ON CBX40UHV.

IMPORTANT − USE CARE WHEN CUTTING LINKS TO

PREVENT DAMAGE TO CONTROL. SEE CBX40UHV

INSTALLATION INSTRUCTION FOR FURTHER DETAILS.

CUT ON−BOARD LINK Y1−Y2 FOR TWO−STAGE HP

CUT ON−BOARD LINK R −O.

CUT ON−BOARD LINK R−DS WHEN DEHUMIDIFICATION TERMINAL IS USED.

AIR HANDLER CONTROL

Y1−Y2

2−STAGE

COMPR

R−O

HEAT

PUMP

R−DS

DEHUM

HARMONY

CUT FOR OPTION

OUTDOOR UNIT

RED

FAN RELAY (NOT REQUIRED WITH SINGLE−SPEED OUTDOOR FAN)

PURPLE

BLACK

YELLOW

BLUE

BROWN (NOT USED FOR APPLICATIONS WITHOUT LSOM

BLUE (NOT REQUIRED FOR SINGLE STAGE)

RESISTOR KIT (CAT # 47W97) IS REQUIRED WHEN CONNECTING THE COMFORTSENSE 7000 WITH THE LSOM 2.

CBX32MV OR

CBX40UHV

RED

BLACK

PURPLE

IMPORTANT − USE CARE WHEN CUTTING LINKS TO

PREVENT DAMAGE TO CONTROL. SEE CBX40UHV

INSTALLATION INSTRUCTION FOR FURTHER DETAILS.

CUT ON−BOARD LINK Y1−Y2 FOR TWO−STAGE A/C ONLY

CUT ON−BOARD LINK R−DS WHEN DEHUMIDIFICATION

COMFORTSENSEt 7000 THERMOSTAT

CUT ON−BOARD LINK R −O.

TERMINAL IS USED.

OUTDOOR

SENSOR

(X2658)

AIR HANDLER CONTROL

Y1−Y2

2−STAGE

COMPR

PUMP

DEHUM

HARMONY

R−O

HEAT

R−DS

CUT FOR OPTION

Figure 15. Heat Pump Application  Humiditrol

CBX32MV or CBX40UHV

Page 20

and Second−Stage Outdoor Fan Relay Wiring with

Page 21

Figure 16. Typical Unit Wiring Diagram (−024, −036 and −048 Only)

Page 21

XP16 SERIES

Page 22

Figure 17. Typical Unit Wiring Diagram (−060 Only)

Page 22

Page 23

Figure 18. Typical Factory Wiring Diagram (No Field Modifications)

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.

UNIT START−UP

1. Rotate fan to check for binding.

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

3. Verify that the manifold gauge set is connected as illustrated in figure 21. Use a temperature sensor positioned near the liquid line service port as illustrated in figure 21 which will be required later when using the subcooling method for optimizing the system refrigerant charge.

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. Open both the liquid and vapor line service valves to release the refrigerant charge contained in outdoor unit into the system.

7. Use figure 19 to determine next step in system preparation.

OPEN BOTH VAPOR AND LIQUID SERVICE

VALVE STEMS TO RELEASE

REFRIGERANT FROM OUTDOOR UNIT TO

GO TO SERVICE AND WEIGH

IN REFRIGERANT CHARGE

FOR OUTDOOR UNITS

DELIVERED VOID OF CHARGE

ON PAGE 24.

SYSTEM.

REFRIGERANT

PRESENT

YESNO

GO TO OPTIMIZING SYSTEM REFRIGERANT CHARGE ON

PAGE 26.

Figure 19. Outdoor Unit Factory Charge

Page 23

XP16 SERIES

Page 24

Service and Weigh In Refrigerant for Outdoor Units Delivered Void of Charge

The following procedures are only required if it has been determine that the new outdoor unit is void of charge. Skip to the next section if refrigerant charge is present.

LEAK CHECK, REPAIR AND EVACUATE

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

1. Leak check system using procedures provided on page 16. Repair any leaks discovered during leak test.

2. Evacuate the system using procedure provided in figure 13.

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

4. Evacuate the system again using procedure in figure

12.

CONNECT MANIFOLD GAUGE SET AND WEIGH IN CHARGE

After the evacuation procedure, reconnect the manifold gauge set as illustrated in figure 21.

NOTE − Temperature sensor illustrated in figure 21 is not required for initial system weigh in charging.

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

2. Connect the manifold gauge set’s low pressure side to

the true suction port.

3. Connect the manifold gauge set’s high pressure side

to the liquid line service port.

4. Connect the center hose of the gauge set to a cylinder of HFC−410A and purge the hose. Then, place the cylinder upside down on a scale.

5. Check that fan rotates freely.

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

7. Open the high side manifold gauge valve and weigh in liquid refrigerant. Use figure 20 in calculating the correct weigh−in charge.

8. Close manifold gauge valves.

9. Monitor the system to determine the amount of moisture remaining in the oil. It may be necessary to replace the bi−flow filter drier several times to achieve the required dryness level. If system dryness is not verified, the compressor will fail in the future.

10. Continue to Optimizing System Refrigerant Charge

on page 26 to optimize the system charge using subcooling method.

WEIGH−IN CHARGING

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.

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

Figure 20. Using HFC−410A Weigh In Method

Additional charge specified per indoor

unit match listed on page 28.

(4.6 M) LINE SET*

3 OUNCE PER 5’ (85 G PER 1.5 M)

Total Charge

Page 24

Page 25

MANIFOLD GAUGE SET

GAUGE SET

CONNECTIONS FOR OPTIMIZING SYSTEM CHARGE

TRUE SUCTION PORT

CONNECTION

NOTE  Refrigerant tank should be turned right−side−up to deliver vapor during charge optimizing procedure.

CHARGE IN

LIQUID PHASE

DIGITAL SCALE

INSIDE OUTDOOR UNIT

TEMPERATURE SENSOR (USE FOR

SUBCOOLING METHOD)

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

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

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

D Position temperature sensor on liquid line near liquid line service port (use only for subcooling method).

LOW

REFRIGERANT

TANK

TO LIQUID

LINE SERVICE

VALV E

HIGH

TEMPERATURE SENSOR

(LIQUID LINE)

OUTDOOR UNIT

Figure 21. Gauge Set Connections for Adding Refrigerant

OUTDOOR UNIT

CHECK / EXPANSION

VALV E

BI−FLOW FILTER / DRIER

LIQUID LINE

SERVICE PORT

MUFFLER

NOTE − Use gauge ports on vapor line valve and liquid valve for evacuating refrigerant lines and indoor coil. Use true suction port to measure vapor pressure during charging.

DISTRIBUTOR

OUTDOOR

COIL

COMPRESSOR

REVERSING VALVE

TRUE SUCTION PORT

VAPOR

SERVICE

PORT

CHECK / EXPANSION VALVE

Figure 22. Heat Pump Cooling Cycle

NOTE − ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW

INDOOR UNIT

INDOOR

COIL

Page 25

XP16 SERIES

Page 26

Optimizing System Refrigerant Charge

This section provides instructions on optimizing the system charge. This section includes:

S Optimizing procedure S Adjusting indoor airflow S Using subcooling method S Approved matched components, targeted subcooling

(SC) values and add charge values

S Normal operating pressures S Temperature pressures

OPTIMIZING PROCEDURE

1. Move the low−side manifold gauge hose from the vapor line service valve to the true suction port (see figure 21).

2. Set the thermostat for either cooling or heating demand. Turn on power to the indoor unit and close the outdoor unit disconnect switch to start the unit.

3. Allow unit to run for five minutes to allow pressures to stabilize.

4. Check the airflow as instructed under Adjusting Indoor Airflow to verify or adjust indoor airflow for maximum

efficiency. Make any air flow adjustments before continuing with the optimizing procedure.

5. Use subcooling method to optimize the system

charge (see figure 24). Adjust charge as necessary.

ADJUSTING INDOOR AIRFLOW

Heating Mode Indoor Airflow Check

(Only use when indoor unit has electric heat)

Indoor blower airflow (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 the following formula to determine CFM:

CFM =

Check airflow using the Delta−T (DT) process using figure

23.

Amps x Volts x 3.41

1.08 x Temperature rise (F)

Cooling Mode Indoor Airflow Check

Temp. of air entering indoor coil ºF

Wet−bulb ºF

53º

DRY

BULB

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

Drop

19º

All temperatures are expressed in ºF

ADJUSTING INDOOR AIRFLOW

72º

air flowair flow

INDOOR COIL

64º

WET

BULB

DRY

BULB

Figure 23. Checking Airflow over Indoor Coil Using Delta−T Formula

1. Determine the desired DTMeasure entering air temper-

ature 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: (T

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

the measured T +

3º, no adjustment is needed. See examples: Assume DT =

and the desired DT (T

Drop

) = A minus C.

Drop

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 in-

– DT = ºF ACTION

Drop

crease/decrease fan speed.

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

3º.

–DT) is within

Drop

Page 26

Page 27

OPTIMIZE CHARGE USING SUBCOOLING METHOD

1. Check liquid and vapor line pressures. Compare pressures with either second−stage heat or cooling mode normal operating pressures listed in table 7. Table 7 is a general guide and expect minor pressures variations. Significant pressure differences may indicate improper charge or other system problem.

USE

COOLING

MODE

60ºF

(15ºC)

USE

HEATING

MODE

2. Decide whether to use cooling or heating mode based on current outdoor ambient temperature:

A Use COOLING MODE when:

S Outdoor ambient temperature is 60°F (15.5°C) and above. S Indoor return air temperature range is between 70 to 80°F (21−27°C). This

temperature range is what the target subcooling values are base upon in tables 3 through 6.

If indoor return air temperature is not within reference range, set thermostat to cooling mode and a setpoint of 68ºF (20ºC). This should place the outdoor unit into second−stage (high−capacity) cooling mode. When operating and temperature pressures have stabilized, continue to step 3.

B Use HEATING MODE when:

S Outdoor ambient temperature is 59°F (15.0°C) and below. S Indoor return air temperature range is between 65−75°F (18−24°C). This

temperature range is what the target subcooling values are base upon in tables 3 through 6.

If indoor return air temperature is not within reference range, set thermostat to heating mode and a setpoint of 77ºF (25ºC). This should place the outdoor unit into second−stage (high−capacity) heating mode. When operating and temperature pressures have stabilized, continue to step 3.

3. Read the liquid line pressure; then find its corresponding temperature pressure listed in table 8 and record it in the SATº space to the left.

SATº

LIQº –

SCº =

4. Read the liquid line temperature; record in the LIQº space to the left.

5. Subtract LIQº temperature from SATº temperature to determine subcooling; record it in SCº space to the left..

6. Compare SCº results with tables 3 through 6 (either Heating or Cooling mode column), also consider any additional charge required for line set lengths longer than 15 feet and/or unit matched component combinations (Add Charge column).

7. If subcooling value is:

A GREATER than shown for the applicable unit match component, REMOVE

refrigerant;

B LESS than shown for the applicable unit match component, ADD refrigerant.

8. If refrigerant is added or removed, repeat steps 3 through 6 to verify charge.

9. Close all manifold gauge set valves and disconnect gauge set from outdoor unit.

10. Replace the stem and service port caps and tighten as specified in Operating Service Valves on page 2.

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

Figure 24. Using HFC−410A Subcooling Method  Second Stage (High Capacity)

Page 27

XP16 SERIES

Page 28

APPROVED MATCHED SYSTEM COMPONENTS, TARGETED SUBCOOLING (SC) VALUES AND

ADD CHARGE VALUES

Listed below are the approved matched system components (air handlers and indoor coils), targeted subcooling and add charge values for the XP16. This information is also listed on the unit charging sticker located on the outdoor unit

access panel.

Subcooling values listed in the following tables are based on outdoor ambient air temperature of:

S 60°F (15.5°C) and above for cooling mode S 59°F (15.0°C) and below for heating mode.

Table 3. XP16−024−230

Heating

Indoor Air Handers and Coils

CBX26UH−024 45 6 0 15

CBX27UH−024−230 20 7 0 9

CBX27UH−030−230 17 7 1 3

CBX32MV−024/030 20 7 0 9

CBX32MV−036 17 7 1 3

CBX40UHV−024 17 7 1 3

CBX40UHV−030 17 7 1 3

CBX40UHV−036 17 7 1 3

CH33−31B 31 8 1 12

CR33−30/36A/B/C 45 4 0 0

CX34−31A/B 24 7 1 11

CX34−38A/B 18 8 1 10

Mode

+5ºF

Subcooling lb. oz.

Table 4. XP16−036−230

Heating

Indoor Air Handers and Coils

CBX26UH−036 50 5 0 0

CBX27UH−036−230 22 7 0 9

CBX27UH−042−230 24 11 3 0

CBX32M−036 22 7 0 9

CBX32MV−036 22 7 0 9

CBX32MV−048 24 11 3 0

CBX40UHV−030 22 7 0 9

CBX40UHV−036 22 7 0 9

CBX40UHV−042 24 11 3 0

CBX40UHV−048 24 11 3 0

CH33−43B 13 10 2 7

CH33−48C 37 11 2 11

CH33−43C 37 11 2 11

CR33−48B/C 49 7 0 9

CX34−43B/C 29 9 2 11

CX34−50/60C 29 9 2 11

Mode

+5ºF

Subcooling lbs. oz.

Cooling

Mode

+1ºF

Cooling

Mode

+1ºF

*Add Charge

Indoor Air Handers and Coils

CBX26UH−048−230 10 8 1 4

CBX27UH−048−230 19 9 1 4

CBX27UH−060−230 13 14 3 3

CBX32M−048 19 9 1 4

CBX32M−060 14 9 1 11

CBX32MV−048 19 9 1 4

CBX32MV−060 14 9 1 11

CBX32MV−068 9 8 1 11

CBX40UHV−048 19 9 1 4

CBX40UHV−060 14 9 1 11

CH23−68 24 10 1 12

CH33−49C 19 9 2 5

CH33−50/60C 19 9 2 5

CH33−60D 13 8 0 0

CH33−62D 11 9 1 4

CR33−50/60C 15 7 0 10

CR33−60D 15 7 0 10

CX34−60D 14 8 1 0

CX34−62D 9 9 1 6

CX34−62C 8 9 1 9

Indoor Air Handers and Coils

CBX26UH−060 20 9 4 13

CBX27UH−060−230 10 6 2 3

CBX32M−060 17 6 1 12

CBX32MV−060 17 6 1 12

CBX32MV−068 15 7 2 1

CBX40UHV−060 17 6 1 12

CH23−682 37 9 2 10

CH33−50/60C 33 8 1 0

CH33−62D 15 7 1 4

CR33−50/60C 24 7 0 0

CR33−60D 24 7 0 0

CX34−62C 21 9 2 16

CX34−62D 13 7 1 4

*Amount of charge required in additional to charge shown on unit nameplate. (Remember to consider line set length difference.)

Table 5. XP16−048−230

Heating

Mode

+5ºF

Subcooling lbs. oz.

Cooling

Mode

+1ºF

Table 6. XP16−060−230

Heating

Mode

+5ºF

Subcooling lbs. oz.

Cooling

Mode

+1ºF

*Add Charge

Page 28

Page 29

NORMAL OPERATING PRESSURES

Use the following tables to perform maintenance checks; it is not a procedure for charging the system. Minor variations in these pressures may be due to differences in installations. Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system.

Typical pressures only, expressed in psig (liquid +/− 10 and vapor +/− 5 psig); matched indoor component (air handler or coil), indoor air quality, and indoor load will cause the pressures to vary.

Table 7. Normal Operating Pressures*

Normal Operating Pressures − Cooling

XP16 −024 −036 −048 −060

F

(C)**

(18.3)

(23.9)

(29.4)

(35.0)

105

(40.6)

115

(46.1)

(18.3)

(23.9)

(29.4)

(35.0)

105

(40.6)

115

(46.1)

(10)

(15.5)

(−7.0)

(−1.0)

(4.4)

(10)

(15.5)

** Temperature of air entering outdoor coil.

Liq Vap Liq Vap Liq Vap Liq Vap

First Stage (Low Capacity) Pressure

226 144 220 141 224 143 230 137

260 145 254 144 259 143 267 139

301 148 295 148 302 147 311 141

346 151 340 150 346 149 357 144

396 153 389 153 396 152 398 147

451 156 444 156 450 155 453 149

Second Stage (High Capacity) Pressure

241 140 232 129 238 138 232 131

279 142 269 136 278 140 276 133

321 144 312 140 321 142 320 136

369 146 346 142 372 144 367 138

421 148 409 145 424 147 421 141

480 151 465 148 481 149 479 144

Normal Operating Pressures − Heating

First Stage (Low Capacity) Pressure

312 112 350 115 336 114 385 108

330 130 372 136 363 135 414 126

Second Stage (High Capacity) Pressure

299 64 321 61 289 57 332 59

312 79 347 74 294 69 349 67

325 93 367 90 321 80 361 75

344 110 387 110 341 110 383 85

358 128 395 131 361 128 425 122

TEMPERATURE PRESSURES

Compute subcooling by determining saturated condensing temperature from temperature pressure chart. Subtract from liquid temperature entering TXV.

Table 8. HFC−410A Temperature (°F) −

Pressure (Psig)

°F Psig °F Psig °F Psig °F Psig

32 100.8 63 178.5 94 290.8 125 445.9

33 102.9 64 181.6 95 295.1 126 451.8

34 105.0 65 184.3 96 299.4 127 457.6

35 107.1 66 187.7 97 303.8 128 463.5

36 109.2 67 190.9 98 308.2 129 469.5

37 111.4 68 194.1 99 312.7 130 475.6

38 113.6 69 197.3 100 317.2 131 481.6

39 115.8 70 200.6 101 321.8 132 487.8

40 118.0 71 203.9 102 326.4 133 494.0

41 120.3 72 207.2 103 331.0 134 500.2

42 122.6 73 210.6 104 335.7 135 506.5

43 125.0 74 214.0 105 340.5 136 512.9

44 127.3 75 217.4 106 345.3 137 519.3

45 129.7 76 220.9 107 350.1 138 525.8

46 132.2 77 224.4 108 355.0 139 532.4

47 134.6 78 228.0 109 360.0 140 539.0

48 137.1 79 231.6 110 365.0 141 545.6

49 139.6 80 235.3 111 370.0 142 552.3

50 142.2 81 239.0 112 375.1 143 559.1

51 144.8 82 242.7 113 380.2 144 565.9

52 147.4 83 246.5 114 385.4 145 572.8

53 150.1 84 250.3 115 390.7 146 579.8

54 152.8 85 254.1 116 396.0 147 586.8

55 155.5 86 258.0 117 401.3 148 593.8

56 158.2 87 262.0 118 406.7 149 601.0

57 161.0 88 266.0 119 412.2 150 608.1

58 163.9 89 270.0 120 417.7 151 615.4

59 166.7 90 274.1 121 423.2 152 622.7

60 169.6 91 278.2 122 428.8 153 630.1

61 172.6 92 282.3 123 434.5 154 637.5

62 175.4 93 286.5 124 440.2 155 645.0

Page 29

XP16 SERIES

Page 30

System Operation

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.

This section addresses:

S Unit components (sensors, temperature switch,

pressure switches and demand defrost control)

S Second−stage operation

TEST PINS (P1)

DEFROST TERMINATION

PIN SETTINGS (P1)

SENSOR PLUG IN

(COIL AND

AMBIENT

SENSORS) (P4)

UNIT COMPONENTS

Demand Defrost Control (A108)

The demand defrost control measures differential temperatures to detect when the system is performing poorly because of ice build−up on the outdoor coil. The controller self−calibrates when the defrost system starts and after each system defrost cycle. The demand defrost control’s: components are shown in figure 25.

S Demand defrost control connections, jumpers and

LED locations are shown in figure 25.

S Demand defrost control connections, jumpers and

LED descriptions are listed on table 9.

S Demand defrost control status, fault and lockout LEDs

are listed in table 10.

LOW AMBIENT THERMOSTAT PINS (P3)

DELAY PINS

(P5)

REVERSING VALVE

(O OUT)

PRESSURE SWITCH

CIRCUIT

CONNECTIONS

DIAGNOSTIC LEDS (DS1 AND DS2)

24V TERMINAL STRIP CONNECTIONS (P2)

Note − Component locations vary by board manufacturer.

Figure 25. Demand Defrost Control (A108)

Page 30

Page 31

Table 9. Demand Defrost Control (A108) Inputs, Outputs and Configurable Settings

Control Locations

P1 TEST Test Mode See Test Mode on page 39 for further details.

P1 50, 70, 90, 100

P3 55, 50, 45, 40

P5 DELAY Delay Mode

P6 TST, PS DF, C, R, O, Y1, Y2 Factory Test Connectors No field use.

DS1 RED LED

DS2 GREEN LED

FAN TWO CONNECTORS Condenser Fan Operation These two connections provide power for the condenser fan.

O OUT O OUT 24 VAC output 24 VAC output connection for reversing valve.

LO−PS LO−PS Low−Pressure Switch

Control Label or Description

C 24VAC Common 24VAC common

L Thermostat Service Light Thermostat service light connection.

R 24VAC 24VAC

Y2 Thermostat Input Controls the second stage operation of the unit.

O Thermostat Input Reversing valve solenoid.

Y1 Thermostat Input Controls the operation of the unit.

DIS−YEL Coil Sensor

AMB−BLACK Ambient Sensor

COIL−BROWN Discharge Sensor No discharge sensor is used; replaced by 10K resistor.

Purpose Function

Defrost Temperature Termination Shunt (Jumper) Pins

24VAC Thermostat Input / Output

Low Ambient Thermostat Pins

Diagnostic LED

The demand defrost control as illustrated in figure 25 has valid selections which are: 50, 70, 90, and 100°F (10, 21, 32 and 38°C). The shunt termination pin is factory set at 50°F (10°C). If the temperature shunt is not installed, the default termination temperature is 90°F (32°C).

24VAC input / output from indoor thermostat to indoor unit.

Provides selection of the Y2 compressor lock−in temperature. Valid options are 40, 45, 50 and 55 degrees Fahrenheit.

(P4−5) Ground connection for outdoor coil temperature sensor. (P4−6) Connection for outdoor coil temperature sensor.

(P4−3) Ground connection for outdoor ambient temperature sensor. (P4−4) Connection for outdoor ambient temperature sensor.

The demand defrost 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, 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.

NOTE − The 30 second off cycle is NOT functional when TEST pins on P1 are jumpered.

Valid states for demand defrost control two LEDs are OFF, ON and FLASHING which indicate diagnostics conditions that are described in table 10.

When the low pressure switch trips, the demand defrost control will cycle off the compressor, and the strike counter in the demand defrost control will count one strike. The low pressure switch is ignored under the following conditions:

S during the defrost cycle and 90 seconds after the termination of

defrost

S when the average ambient sensor temperature is below 0°F (−18°C) S for 90 seconds following the start up of the compressor S during TEST mode

Y2 OUT Y2 OUT 24 VAC Output 24 VAC output for second stage compressor solenoid.

Y1 OUT Y1 OUT 24 VAC Common Output 24 VAC common output, switched for enabling compressor contactor.

When the high pressure switch trips, the demand defrost control will cycle

HS−PS HS−PS High−Pressure Switch

L L Service Light Output 24VAC service light output.

24V 24V 24 Volt output

off the compressor, and the strike counter in the demand defrost control will count one strike.

24VAC typically used to supply power to the Lennox System Operation Monitor (LSOM). Not used in this system.

Page 31

XP16 SERIES

Page 32

DEMAND DEFROST CONTROL (A108) DIAGNOSTIC LEDS

The state (Off, On, Flashing) of two LEDs on the demand defrost control (DS1 [Red] and DS2 [Green]) indicate diagnostics conditions that are described in table 10.

Table 10. Demand Defrost Control (A108) Diagnostic LEDs

DS1 and DS2 System Status, Fault and Lockout Codes

DS2 Green

DS1 Red

Type

Condition/Code Possible Cause(s) Solution

OFF OFF Status Power problem

Simultaneous SLOW Flash

Alternating SLOW Flash

Simultaneous FAST Flash

Alternating FAST Flash

ON ON Fault

OFF

SLOW Flash

Status Normal operation

Status 5−minute anti−short cycle delay

Fault Ambient Sensor Problem

Fault Coil Sensor Problem

Demand Defrost Control Failure

Fault Low Pressure Fault

OFF ON Lockout Low Pressure Lockout

SLOW Flash

OFF Fault High Pressure Fault

ON OFF Lockout High Pressure Lockout

No power (24V) to demand defrost control terminals R and C or demand defrost control failure.

Unit operating normally or in standby mode.

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

Check control transformer power (24V).

If power is available to demand defrost control and LED(s) do not light, replace demand defrost control.

None required.

None required (jumper TEST pins to override)

Sensor being detected open or shorted or out of temperature range. Demand defrost control will revert to time/temperature defrost operation. (System will still heat or cool).

Sensor being detected open or shorted or out of temperature range. Demand defrost control will not perform demand or time/temperature defrost operation. (System will still heat or cool).

Indicates that demand defrost control has internal component failure. Cycle 24VAC power to demand defrost control. If code does not clear, replace demand defrost control.

Restricted air flow over indoor or outdoor coil.

Improper refrigerant charge in system.

Improper metering device installed or incorrect operation of metering device.

Incorrect or improper sensor location or connection to system.

Remove any blockages or restrictions from coils and/or fans. Check indoor and outdoor fan motor for proper current draws.

Check system charge using subcooling method.

Check system operating pressures and compare to unit subcooling tables in this instruction or located on unit access panel.

Make sure all pressure switches and sensors have secure connections to system to prevent refrigerant leaks or errors in pressure and temperature measurements.

SLOW Flash

ON Fault

Discharge Line Temperature Fault

This code detects shorted sensor or high discharge temperatures. If the discharge line temperature exceeds a temperature of 285ºF (140ºC) during compressor

operation, the demand defrost control will de−energize the compressor contactor FAST Flash

OFF

ON Lockout

Fast Flash

Fault Discharge Sensor Fault

Discharge Line Temperature Lockout

output (and the defrost output if active). The compressor will remain off until the

discharge temperature has dropped below 225ºF (107ºC).

The demand defrost control detects open sensor or out of temperature sensor range.

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 Fast Flash

OFF Lockout

Discharge Sensor Lockout

demand defrost control will count one fault. After 5 faults, the demand defrost control

will lockout.

(Each fault adds 1 strike to that code’s counter; 5 strikes per code = LOCKOUT)

Page 32

Page 33

High Pressure Switch (S4)

When the high pressure switch trips, the demand defrost control will cycle off the compressor, and the strike counter in the demand defrost control will count one strike. High Pressure (auto reset) − trip at 590 psig, reset at 418.

Low Pressure Switch (S87)

When the low pressure switch trips, the demand defrost control will cycle off the compressor, and the strike counter in the demand defrost control will count one strike. Low pressure switch (auto reset) − trip at 25 psig, reset at 40 psig.

The low pressure switch is ignored under the following conditions:

S During the defrost cycle and 90 seconds after the

termination of defrost

S When the average ambient sensor temperature is

below 15° F (−9°C)

S For 90 seconds following the start up of the

compressor

S During test mode

Ambient Sensor (RT13)

The ambient sensor considers outdoor temperatures below −35°F (−37°C) or above 120°F (48°C) as a fault. If the ambient sensor is detected as being open, shorted or out of the temperature range of the sensor, the demand defrost control will not perform demand defrost operation. The demand defrost control will revert to time/temperature defrost operation and will display the appropriate fault code. Heating and cooling operation will be allowed in this fault condition.

Coil Sensor (RT21)

Coil SensorThe coil temperature sensor considers

outdoor temperatures below −35°F (−37°C) or above 120°F (48°C) as a fault. If the coil temperature sensor is detected as being open, shorted or out of the temperature range of the sensor, the demand defrost 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.

High Discharge Temperature Sensor (RT28)

If the discharge line temperature exceeds a temperature of 285°F (140°C) during compressor operation, the demand defrost control will de−energize the compressor contactor output (and the defrost output, if active). The compressor will remain off until the discharge temperature has dropped below 225°F (107°C) and the 5-minute anti−short cycle delay has been satisfied. This sensor has two fault and lockout codes:

1. If the demand defrost control recognizes five high discharge line temperature faults during a single (Y1) compressor demand, it reverts to a lockout mode and displays the appropriate code. This code detects shorted sensor or high discharge temperatures. Code on demand defrost control is Discharge Line Temperature Fault and Lockout.

2. If the demand defrost control recognizes five temperature sensor range faults during a single (Y1) compressor demand, it reverts to a lockout mode and displays the appropriate code. The demand defrost control detects open sensor or out-of-temperature sensor range. 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 demand defrost control will count one fault. After five faults, the demand defrost control will lockout. Code on demand defrost control is Discharge Sensor Fault and Lockout.

The discharge line sensor, which covers a range of 150°F (65°C) to 350°F (176°C), is designed to mount on a ½" refrigerant discharge line.

NOTE − Within a single room thermostat demand, if 5−strikes occur, the demand defrost control will lockout the unit. demand defrost control 24 volt power R must be cycled OFF or the TEST pins on demand defrost control must be shorted between 1 to 2 seconds to reset the demand defrost control.

Crankcase Heater (HR1) and Crankcase Thermostat

Switch (S40)

The reference models are equipped with a 70 watt, belly band type crankcase heater. HR1 prevents liquid from accumulating in the compressor. HR1 is controlled by a thermostat located on the liquid line. When liquid line temperature drops below 50° F the thermostat closes energizing HR1. The thermostat will open, de−energizing HR1 once liquid line temperature reaches 70° F .

Liquid Line Bi−Flow Filter Drier

The unit is equipped with a large−capacity biflow filter drier which keeps the system clean and dry. If replacement is necessary, order another of like design and capacity. The replacement filter drier must be suitable for use with HFC−410A refrigerant.

The replacement filter drier must be suitable for use with HFC−410A refrigerant.

SECOND−STAGE OPERATION

If the demand defrost control (A108) 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.

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 without the Y2 input. If the jumper is not connected to one of the temperature selection pins on P3 (40, 45, 50, 55°F), the default lock−in temperature of 40°F (4.5°C) will be used.

The demand defrost 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.

Page 33

XP16 SERIES

Page 34

Defrost System

This section addresses:

S Emergency Heat S Defrost System Overview S Defrost Control Connections, Jumper Settings and

Features

S Operational Mode Overview (Calibration, Normal and

Defrost)

S Defrost Cycle Actuation

EMERGENCY HEAT (AMBER LIGHT)

An emergency heat function is designed into some room thermostats. This feature is applicable when isolation of the outdoor unit is required, or when auxiliary electric heat is staged by outdoor thermostats. When the room thermostat is placed in the emergency heat position, the outdoor unit control circuit is isolated from power and field-provided relays bypass the outdoor thermostats. An amber indicating light simultaneously comes on to remind the homeowner that he is operating in the emergency heat mode.

Emergency heat is usually used during an outdoor unit shutdown, but it should also be used following a power outage if power has been off for over an hour and the outdoor temperature is below 50°F (10°C). System should be left in the emergency heat mode at least six hours to allow the crankcase heater sufficient time to prevent compressor slugging.

DEFROST SYSTEM OVERVIEW

The control monitors ambient temperature, outdoor coil temperature, and total run time to determine when a defrost cycle is required. The coil temperature probe 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.

NOTE − The demand defrost 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 demand defrost control initiates defrost cycles.

DEFROST CONTROL CONNECTIONS, JUMPERS SETTINGS AND FEATURES

Pressure Switch 5−Strike Lockout

The internal control logic of the demand defrost control counts the pressure switch trips only while the Y1 (Input) line is active. If a pressure switch opens and closes four times during a Y1 (Input), the control logic will reset the pressure switch trip counter to zero at the end of the Y1 (Input). If the pressure switch opens for a fifth time during the current Y1 (Input), the control will enter a lockout condition.

The 5−strike pressure switch lockout condition can be reset by cycling OFF the 24−volt power to the demand defrost control or by shorting the TEST pins between 1 to 2 seconds. All timer functions (run times) will also be reset.

If a pressure switch opens while the Y1 Out line is engaged, a 5−minute short cycle will occur after the switch closes.

Demand Defrost Control Pressure Switch

Connections

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

Demand Defrost Control Sensors

Sensors connect to the demand defrost control through a field-replaceable harness assembly that plugs into the demand defrost control as illustrated in figure 1. Through the sensors, the demand defrost control detects outdoor ambient, coil, and discharge temperature fault conditions. As the detected temperature changes, the resistance across the sensor changes.

Testing Demand Defrost Control Sensors

Sensor resistance values can be checked by ohming across pins shown in table 11.

Table 11. Sensor Temperature /Resistance Range

Temperature

Sensor

Outdoor −35 (−37) to 120 (48) 280,000 to 3750 3 & 4

Coil −35 (−37) to 120 (48) 280,000 to 3750 5 & 6

Discharge (if applicable)

Note: Sensor resistance increases as sensed temperature decreases.

Range °F (°C)

24 (−4) to 350 (176) 41,000 to 103 1 & 2

Resistance values range (ohms)

Pins/W ire Color

(Black)

(Brown)

(Yellow)

Tables 12 and 13 shows how the resistance varies as the temperature changes for various types of sensors.

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 11, 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.

Defrost Temperature Termination Jumper

Settings (P1)

The demand defrost control selections are: 50, 70, 90, and 100°F (10, 21, 32 and 38°C). The shunt termination pin is factory set at 50°F (10°C). If temperature shunt is not installed, default termination temperature is 90°F (32°C).

Test Pins (P1) Function

Placing the jumper on the field test pins (P1) 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 Place the unit in defrost mode to clear the coil

See figure 27 for flowchart of test pin (P1) operations.

Page 34

Page 35

Compressor Delay Mode (P5)

NOTE − The 30 second off cycle is NOT functional when jumpering the TEST pins.

OPERATIONAL MODE OVERVIEW

The demand defrost control has three basic operational modes. Those modes are:

1. Calibration Mode  The demand defrost control is

considered uncalibrated when power is applied to the demand defrost control, after cool mode operation, or if the coil temperature exceeds the termination temperature when it is in heat mode (see figure 26 for further details).

2. Normal Mode  The demand defrost control monitors the O line, to determine the system operating mode (heat/cool), outdoor ambient temperature, coil temperature (outdoor coil) and compressor run time to determine when a defrost cycle is required.

Calibration of the demand defrost control occurs after a defrost cycle to ensure that there is no ice on the coil. During calibration, the temperature of both the coil and the ambient sensor are measured to establish the temperature differential which is required to allow a defrost cycle.

3. Defrost Mode  The following paragraphs provide a detailed description of the defrost system operation.

DEFROST CYCLE ACTUATION

The demand defrost control initiates a defrost cycle based on either frost detection or time.

1. Frost Detection  If the compressor runs longer than

30 minutes and the actual difference between the clear coil and frosted coil temperatures exceeds the maximum difference allowed by the demand defrost control, a defrost cycle will be initiated.

2. Time  If six hours of heating mode compressor run

time has elapsed since the last defrost cycle while the coil temperature remains below 35°F (2°C), the demand defrost control will initiate a defrost cycle.

Actuation

When the reversing valve is de−energized, the Y1 circuit is energized, and the coil temperature is below 35°F (2°C), the demand defrost control logs the compressor run time. If the demand defrost control is not calibrated, a defrost cycle will be initiated after 30 minutes of heating mode compressor run time. The control will attempt to self−calibrate after this (and all other) defrost cycle(s).

Calibration success depends on stable system temperatures during the 20−minute calibration period. If the demand defrost control fails to calibrate, another defrost cycle will be initiated after 45 minutes of heating mode compressor run time. Once the demand defrost control is calibrated, it initiates a demand defrost cycle when the difference between the clear coil and frosted coil temperatures exceeds the maximum difference allowed by the control or after six hours of heating mode compressor run time has been logged since the last defrost cycle.

Termination

The defrost cycle ends when the coil temperature exceeds the termination temperature or after 14 minutes of defrost operation. If the defrost is terminated by the 14−minute timer, another defrost cycle will be initiated after 30 minutes of run time.

Page 35

XP16 SERIES

Page 36

DEFROST CONTROL (A108) CALIBRATION MODE SEQUENCE

Occurs after power up and cooling operation, or if the coil temperature exceeds

Demand defrost control defaults to 30 minute  Time / Temperature Mode

Reset Compressor Runtime / Reset Three / Five Strike Counter

DEMAND MODE

Accumulate compressor runtime of more than 30 minutes while coil temperature is below 35° F (2°C). When the accumulated compressor time exceeds six (6) hours or if the coil sensor indicates frost is present on coil, go to Defrost.

the termination temperature while in Heat Mode.

THIRTY (30) MINUTE TIME /

TEMPERATURE MODE

Accumulate compressor runtime while coil temperature is below 35° F (2°C). When the accumulated compressor time exceeds 30 minutes go to Defrost.

DEFROST

S Outdoor Fan OFF S Reversing Valve ON S W1 line ON

Monitor coil temperature and

time in defrost mode.

TIME/TEMPERATURE MODE

45 MINUTE

Accumulate compressor runtime while coil temperature is below 35° F (2°C). When the accumulated compressor time exceeds 45 minutes go to Defrost.

HOW DID DEFROST TERMINATE?

Coil temperature was above 35°F (2°C) for four (4) minutes. of the 14−minute defrost OR reached defrost termination temperature.

DEFROST TERMINATION

S Compressor runtime counter RESET S Outdoor Fan ON S Reversing Valve OFF S W1 line OFF

Attempt to Calibration  Temperature measurements are not taken for the first few minutes of each heat demand. This is to allow coil temperatures to stabilize. demand defrost control has a maximum of 20 minutes of accumulated compressor runtime in heat mode to calibrate demand defrost control This may involve more than one heating demand.

YES  Calibration occurred

Was stable coil temperature attained within 20 minutes?

Defrosted for 14−minute without the coil temperature going above 35°F (2°C) for four (4) minutes and coil did not reach termination temperature.

DEFROST TERMINATION

S Compressor runtime counter RESET S Outdoor Fan ON S Reversing Valve OFF S W1 line OFF

NO  Demand defrost control reverts to 45 minute time / temperature.

Figure 26. Defrost Calibration

Page 36

Page 37

Table 12. 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 111141

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 37

XP16 SERIES

Page 38

Table 13. 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

Page 38

Page 39

TEST

Placing the jumper on the field test pins (P1) 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 Place the unit in defrost mode to clear the coil

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

The 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 uncalibrated with defrost timer set for 45 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  Placing a jumper on the TEST pins will not bring the unit out of inactive mode. The only way manually activate the heat pump from an inactive mode is to cycle the 24VAC power to the Control.

Figure 27. Test Pin (P1) Functions

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 39

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.

XP16 SERIES

Page 40

Two−Stage Modulation Compressors Checks

Use this checklist on page 42 to verify part-load and full-load capacity operation of two-stage modulation compressors.

TOOLS REQUIRED

S Refrigeration gauge set S Digital volt/amp meter S Electronic temperature thermometer S On-off toggle switch

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).

PROCEDURE

NOTE − Block outdoor coil to maintain a minimum of 375 psig during testing).

1. Turn main power OFF to outdoor unit.

2. Adjust room thermostat set point 5ºF above 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 and install switch in series with Y2 wire from room thermostat.

5. Cycle main power ON.

6. Allow pressures and temperatures to stabilize before taking measurements (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.

9. Allow pressures and temperatures to stabilize before taking measurements (may take up to 10 minutes).

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

11. If temperatures and pressures change in the direction noted in Two−Stage Modulation Compressor Field Operational Checklist on page 42, 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 modulating between low and high capacity and replacement is necessary).

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

Maintenance

DEALER

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:

Outdoor Unit

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.

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.

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

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:__________.

Page 40

Page 41

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.

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. 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 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 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). An electronic 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.

Page 41

XP16 SERIES

Page 42

Accessories

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

S Lennox XP16 Engineering Handbook S Lennox Product Catalog S Lennox Price Book

Checklists

Two−Stage Modulation Compressors Field Operational Checklist

Unit Readings Y1 − First-Stage

Expected results during Y2 demand

COMPRESSOR

Voltage Same

Amperage Higher

OUTDOOR UNIT FAN MOTOR

Amperage Same or Higher

TEMPERATURE

Ambient Same

Outdoor Coil Discharge Air Higher

(Toggle switch On)

Y2 − Second-Stage

Compressor Discharge Line Higher

Indoor Return Air Same

Indoor Coil Discharge Air Lower

PRESSURES

Suction (Vapor) Lower

Liquid Higher

Page 42

Page 43

XP16 Start−Up and Performance

Customer Address

Indoor Unit Model Serial

Outdoor Unit Model Serial

Notes:

START UP CHECKS

Refrigerant Type:

1st Stage: Rated Load Amps Actual Amps Rated Volts Actual Volts

2nd Stage: Rated Load Amps Actual Amps Rated Volts Actual Volts

Outdoor Unit Fan Full Load Amps Actual Amps: 1st Stage 2nd Stage

COOLING MODE

Suction Pressure: 1st Stage: 2nd Stage:

Liquid Pressure: 1st Stage: 2nd Stage:

Supply Air Temperature: 1st Stage: 2nd Stage:

Temperature: Ambient: Return Air:

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 Temperature Drop (18 to 22°F)

Return Air Temperature (A) minus Supply Air

Temperature (B)

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SUBCOOLING

APPROACH

COIL TEMP DROP

Page 43

XP16 SERIES

Lenox P506640-01, XP16 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual