LENNOX Air Conditioner/heat Pump(outside Unit) Manual L0806540

User Manual: LENNOX LENNOX Air conditioner/heat pump(outside unit) Manual LENNOX Air conditioner/heat pump(outside unit) Owner's Manual, LENNOX Air conditioner/heat pump(outside unit) installation guides

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Page Count: 28

®

,1,_2008LennoxindustriesInc,

Dallas,Texas,USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

X_ WARNING

_, CAUTION

INSTALLATION

INSTRUCTIONS

Dave Lennox Signature ®

Collection XP15 Units

HEAT PUMP UNITS _-_Technical

505,328M U£[ Publications

04/08 Litho U.S.A.

Supersedes 03/08

XP15 Outdoor Unit ............................ 1

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

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

General Information ........................... 2

Recovering Refrigerant from Existing System ..... 4

Positioning New Outdoor Unit .................. 5

Removing Panel .............................. 6

Electrical Connections ......................... 7

New or Replacement Line Set ................... 9

Brazing Line Set Connections ................... 11

Removing Existing Refrigerant Metering Device . .. 11

Testing for Leaks .............................. 11

Removing Service Valve Port Core .............. 12

Flushing Existing System ....................... 12

Installing New Refrigerant Metering Device ....... 13

Installing Service Valve Port Core ............... 14

Evacuating the System ......................... 14

Start-Up Procedures ........................... 15

System Operations ............................ 19

Lennox System Operation Monitor (LSOM) ....... 19

Defrost System ............................... 21

Maintenance .................................. 26

Homeowner Information ........................ 26

Start-Up and Performance Checklist ............. 28

AIMPORTANT

IMPORTANT

The Lennox XP15 outdoor units use HFC-410A

refrigerant, This unit must be installed with a matching

indoor coil and line set as outlined in the Lennox

Engineering Handbook, XP15 series outdoor units are

designed for use in check expansion valve (CTXV)

systems only, and are not designed to be used with other

refrigerant flow control devices. The Lennox Engineering

Handbook lists compatible indoor CTXV kits which are

ordered separately.

1 - Assembled XP15 outdoor unit

1 - Bushing (for low voltage wiring)

2 - Grommets (for liquid and vapor lines)

Check equipment for shipping damage. If you find any

damage, immediately contact the last carrier.

04/08

IIIHIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII Page 1 505,328M

IIIIIIIIIIIIIIIIIIIIIIHIIIIIIIIIIIIIIIIIIIIIIII

39-1/2 DISCHARGE AIR

(1003) t

UNIT SUPPORT

FEET \

Y

16-7/8

(429)

8 -3/4

(2_2)

3-1/8

(79) "-_

SIDE VIEW

®®®

ELECTRICAL IN_ETS __

37 (94O)

[-024 thru -042]

47 (1194)

[-048 and -060]

VAPOR LINE

INLET

LIQUID LINE

/INLET

4-7/16.__

(113)

18!1/2

(470) 7--

8 (203)

&CONTACTOR

DEFROST CONTROL

SYSTEM

OPERATION MONITOR

VAPOR VALVE AND

26-7/8 GAUGE PORT ..

(6_3) DISCHARGE LINE

3-3/4 (95) VAPOR

_' FILTER

4-5/8

(117)

BASE WITH ELONGATED LEGS

WARNING I

1 (25)

35-1/2

(902)

ACCESS VIEW

FAN

CAPACITOR

COMPRESSOR

DOME

COMPRESSOR

PLUG

LOW PRESSURE

HIGH PRESSURE

SWITCH

XP15 Parts Arrangement

These instructions are intended as a general guide and do

not supersede local codes in any way. Consult authorities

who have jurisdiction before installation.

When servicing or repairing HVAC components, ensure

caps and fasteners are appropriately tightened. Table 1

lists torque values for typical service and repair items.

Table 1. Torque Requirements

Part Recommended Torque

Service valve cap 8 ft.- lb. 11 NM

Sheet metal screws 16 in.- lb. 2 NM

Machine screws #10 28 in.- lb. 3 NM

Compressor bolts 90 in.- lb. 10 NM

Gauge port seal cap 8 ft.- lb. 11 NM

505328M 04/08

Page 2

USINGMANIFOLD GAUGE SETS

HFC-410A refrigerant manifold gauge sets must be

capable of handling higher system operating pressures.

The gauge set shall be rated for use with pressures of 0 -

800 psig on the high side, and a low side of 30 inches of

vacuum (Hg) to 250 psig, which retards when opened to

500 psig. Gauge hoses must be rated for use up to 800 psig

of pressure with a 4000 psig burst rating,

OPERATING SERVICE VALVES

IMPORTANT

The liquid and vapor lines service valves with gauge ports

as illustrated in figures 2 and 3 are used for removing

refrigerant, flushing, leak testing, evacuating, checking

charge and charging,

Each valve is equipped with a service port which has a

factory-installed valve stem.

1/6 TURN 1/12 TURN

This illustrates how to use a wrench to tighten caps an additional

1/6 or 1/12 turn clockwise.

Figure 1. Cap Tightening Distances

IMPORTANT

Operating Angle-Type Service Valve

To Access Angle-Type Service Port:

A service port cap protects the service port core from

contamination and serves as the primary leak seal.

1. Remove service port cap using an appropriately sized

wrench.

2. Connect gauge to the service port.

3. When testing is completed, replace service port cap and

tighten as follows:

•With Torque Wrench: Finger tighten and then

tighten per table 1 on page 2.

• Without Torque Wrench: Finger tighten and with an

appropriately sized wrench to turn an additional

1/6 turn clockwise as illustrated in figure 1.

To Open and Close Angle-Type Service Valve:

A valve stem cap protects the valve stem from

contamination and assures a leak-free seal.

1, Remove stem cap with a wrench,

2. Use a service wrench with a hex-head extension

(3/16" for liquid-line valve sizes and 5/16" for

vapor-line valve sizes) to back the stem out

counterclockwise as far as it will go.

3. Replace the stem cap and tighten as follows:

• With Torque Wrench: Tighten finger tight and then

tighten per table 1 on page 2.

• Without Torque Wrench: Finger tighten and with an

appropriately sized wrench to turn an additional

1/12 turn clockwise as illustrated in figure 1,

NOTE -A label with specific torque requirements may be

affixed to the stem cap, If the label is present, use the

specified torque listed,

SERVICE PORT CAP o

SERVICE PORT _

CORE _ _ "i

CLOSED TO BOTH

INDOOR AND

OUTDOOR UNITS]

VALVE STEM

FRON%SEATEI_

TO INDOOR

UNIT

TO OUTDOOR _

UNIT

VALVE IS FRONT-SEATED

(CLOSED)

jSERV,CEPORT

,, HHERE

SERVICE PORT CAP _ _:_ VALVE IS(oPENED)BACK=SEATED

SERVICE PORT _

CORE SERVICE PORT

OPEN TO BOTH

INDOOR AND (VALVE STEM

OUTDOOR UNITS] L _ _ SHOWNOPEN)INSERTHEX

VALVE STEM WRENCH HERE

BACKED-SEATE_ __

TO INDOOR

UNIT

TO OUT

UNIT

Figure 2. Angle -Type Service Valve

Page 3

XP15 SERIES

Operating Bali-Type Service Valve

To Access Bali-Type Service Port:

A service port cap protects the service port core from

contamination and serves as the primary leak seal,

1, Remove service port cap using an appropriately sized

wrench,

2. Connect gauge to the service port.

3, When testing is completed, replace service port cap and

tighten as follows:

•With Torque Wrench: Finger tighten and then

tighten per table table 1 on page 2.

• Without Torque Wrench: Finger tighten and use an

appropriately sized wrench to turn an additional

1/6 turn clockwise as illustrated in figure 1,

To Open and Close Bali-Type Service Valve:

A valve stem cap protects the valve stem from

contamination and assures a leak-free seal,

1, Remove stem cap with a wrench,

2, Use an adjustable wrench to open, To open valve,

rotate stem counterclockwise 90°, To close rotate

stem clockwise 90° .

3, Replace the stem cap and tighten as follows:

• With Torque Wrench: Finger tighten and then

tighten per table 1 on page 2.

• Without Torque Wrench: Finger tighten and use an

appropriately sized wrench to turn an additional

1/12 turn clockwise as illustrated in figure 1.

NOTE -A label with specific torque requirements may be

affixed to the stem cap. If the label is present, use the

specified valve listed.

To INDOOR UNIT

Open to line set when valve

is closed, to both line set

and unit when valve is open. Ball (Shown Closed)

Valve Stem

Service Port

Service Port

Core

Service Port

Cap

To outdoor unit

t

STEM CAP

Use Adjustable Wrench To open: rotate Stem Counter-Clock-

wise 90 °.To close: rotate Stem clockwise 90 °.

Figure 3. Bali-Type Service Valve

Remove existing HCFC-22 refrigerant using one of the

following methods:

METHOD 1:

If the existing outdoor unit is not equipped with shut-off

valves, or if the unit is not operational and you plan to use

the existing HCFC-22 or refrigerant to flush the system:

1, Disconnect all power to the existing outdoor unit,

2, Connect to the existing unit a gauge set, clean

recovery cylinder and a recovery machine. Use the

instructions provided with the recover machine on how

to setup the connections,

3, Remove all HCFC-22 refrigerant from the existing

system, Check gauges after shutdown to confirm that

the entire system is completely void of refrigerant,

4, Disconnect the liquid and vapor lines from the existing

outdoor unit,

5, Remove the existing outdoor unit,

NOTE -Use recovery machine instructions for specific

setup requirements.

Recovery Machine

\

Clean Recovery Cylinder

Manifold Gauges

/

Outdoor/_Unit

Figure 4. Typical Refrigerant Recovery (Method 1)

METHOD 2:

If the existing outdoor unit is equipped with manual shut-off

valves and you plan to use new HCFC-22 refrigerant to

flush the system -

1, Start the existing HCFC-22 system in the cooling

mode and close the liquid line valve,

2, Pump all of the existing HCFC-22 refrigerant back into

the outdoor unit,

NOTE -It may be necessary to bypass the low pressure

switches to ensure complete refrigerant evacuation.

505328M 04/08

Page 4

3. Whenthelowsidesystempressuresreach0 psig,

closethevaporlinevalve,

4. Disconnectall powerto the existingoutdoorunit.

Checkgaugesafter shutdownto confirmthat the

valvesarenotallowingrefrigeranttoflowbackintothe

lowsideofthesystem,

5. Disconnecttheliquidandvaporlinesfromtheexisting

outdoorunit.

6. Removetheexistingoutdoorunit,

CAUTION

See Unit Dimensions on page 2 for sizing mounting slab,

platforms or supports, Refer to figure 5 for mandatory

installation clearance requirements.

NOTES:

Service clearance of 30 in, (762 mm) must be maintained on one of

the sides adjacent to the control box,

Clearance to one of the other three sides must be 36 in, (914 mm)

Clearance to one of the remaining two sides may be 12 in. (305

mm) and the final side may be 6 in, (152 mm)

48 in, (1219 ram) clearance required on top of unit,

A clearance of 24 in, (610 mm) must be maintained between two

units

Figure 5. Installation Clearances

POSITIONING CONSIDERATIONS

Some localities are adopting sound ordinances based on

the unit's sound level registered from the adjacent

property, not from the installation property, Install the unit

as far as possible from the property line. When possible,

do not install the unit directly outside a window, Glass has a

very high level of sound transmission. For proper

placement of unit in relation to a window see the provided

illustration in figure 6.

Install unit away

from windows

Two 90 ° elbows installed in line set -

will reduce line set vibration.

Figure 6. Outside Unit Placement

PLACING UNIT ON SLAB

When installing a unit at grade level, the top of the slab

should be high enough above the grade so that water from

higher ground would not collect around the unit as

illustrated in figure 7. Slab may be level or have a slope

tolerance away from the building of not more than two

degrees, or 2 inches per 5 feet (51 mm per 1524 mm).

Install unit level or, if on a slope, maintain slope tolerance of 2

degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from

building structure.

Building

Structure

J

7/ Mounting

Slab

-T--

Figure 7. Ground Level Slab Mounting

INSTALLING UNIT ON ROOF

Install the unit a minimum of 6 inches (152 mm) above the

roof surface to avoid ice build-up around the unit. Locate

the unit above a load bearing wall or area of the roof that

can adequately support the unit, Consult local codes for

rooftop applications.

If unit coil cannot be mounted away from prevailing winter

winds, a wind barrier should be constructed as illustrated in

figure 8. Size barrier at least the same height and width as

outdoor unit, Mount barrier 24 inches (610 mm) from the

sides of the unit in the direction of prevailing winds.

Page 5

XP15 SERIES

PREVAILING _.

WINTER WINDS

I WIND BARRIER

INLET AIR ,_

INLETAIR

O INLET AIR

1

2_'_6" 10 ram)

With unit positioned at installation site, remove two side

Iouvered panels to expose the unit base pan. Install the

brackets as illustrated in figure 10 using conventional

practices; replace the panels after installation is complete.

IMPORTANT

Figure 8. Rooftop Application and Wind Barrier

NOTE -If necessary for stability, anchor unit to slab as

described in Stabilizing Unit on Uneven Surfaces.

ELEVATING THE UNIT

These units are outfitted with elongated-shaped feet as

illustrated in figure 9.

BASE

LEG DETAIL 2"(50.8MM)

SCH 40

FEMALE

THREADED

ADAPTER

Figure 9. Elevated Slab Mounting using Feet

Extenders (Larger Base Units)

If additional elevation is necessary, raise the unit by

extending the height of the unit support feet. This may be

done with 2" SCH 40 female threaded adapter. The

specified coupling will fit snuggly into the recess portion of

the feet. Use additional 2" SCH 40 male threaded adapters

which can be threaded into the female threaded adapters

to make additional adjustments to the level of the unit.

NOTE -Keep the height of extenders short enough to

ensure a sturdy installation, If it is necessary to extend

further, consider a different type of field-fabricated

framework that is sturdy enough for greater heights.

STABILIZING UNIT ON UNEVEN SURFACES

To help stabilize an outdoor unit, some installations may

require strapping the unit to the pad using brackets and

anchors commonly available in the marketplace.

Page 6

Slab Side Mounting

#101/2" LONG

SELF-DRILLING SHEET

METAL SCREWS /

STABILIZING BRACKET

(18 GAUGE METAL - 2"

RW/DTDHi HEIGHT AS _,_1 f, _

#10 1-1/4" LONG HEX

HD SCREW AND

FLATWASHER

PLASTIC ANCHOR - USE IF CONCRETE

(HOLE DRILL 1/4"); NOT IF PLASTIC SLAB

(HOLE DRILL 1/8").

IDeck Top

Mounting

STABILIZING MINIMUM 1

BRACKET (18 PER SIDE

GAUGE METAL - 2"

WIDTH; HEIGHT

AS REQ'D); BEND

TO FORM RIGHT FOR EXTRA

ANGLE STABILITY

ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY,

TWO BRACKETS PER SIDE, 2" FROM EACH CORNER.

Figure 10. Installing Stabilizer Brackets

CAUTION

505328M 04/08

REMOVE4SCREWSTOREMOVEPANELFOR

ACCESSINGCOMPRESSORANDCONTROLS.

_ INSTALLBYPOSITIONINGPANELWITHHOLES

ALIGNED;INSTALLSCREWSANDTIGHTEN.

Figure 11. Access Panel

IMPORTANT! DO NOT ALLOW K-_

PANELS TO HANG ON UNIT BY

TOP TAB. TAB IS FOR ALIGNMENT )

ANDNOTDESIGNEDTOSUPPORT

WE,GHTOFPANEL

PANEL SHOWN SLIGHTLY _ _

ROTATED TO ALLOW TOP TAB TO _

EXIT (OR ENTER) TOP SLOT FOR _

REMOVING (OR INSTALLING) _

PANEL.

SCREW

L. HOLES......_ _iiii_///l _

U

ii t_

Detail A

Detail B -_-_\_

ROTATE IN THIS DIRECTION;

THEN DOWN TO REMOVE PANEL

MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT

AS POSSIBLE) WHILE INSTALLING PANEL.

HOLD DOOR FIRMLY ALONG

ANGLE MAY BE TOO THE HINGED SIDE TO MAINTAIN

EXTREME FULLY-ENGAGED TABS

PREFERRED ANGLE

FOR INSTALLATION

Detail D

Figure 13. Removing/Installing Louvered Panels

(Detail D)

ACCESS PANEL

Removal and reinstallation of the access panel is

illustrated in figure 11,

LOUVERED PANELS

Remove the Iouvered panels as follows:

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

slightly.

2, Hold the panel firmly throughout this procedure.

Rotate bottom corner of panel away from hinged

corner post until lower three tabs clear the slots as

illustrated in figure 12, detail B.

3, Move panel down until lip of upper tab clears the top

slot in corner post as illustrated in figure 12, detail A,

Position and Install Panel--Position the panel almost

parallel with the unit as illustrated in figure 13, detail D with

the screw side as close to the unit as possible. Then, in a

continuous motion:

• Slightly rotate and guide the lip of top tab inward as

illustrated in figure 12, details A and C; then upward

into the top slot of the hinge corner post.

• Rotate panel to vertical to fully engage all tabs,

• Holding the panel's hinged side firmly in place, close

the right-hand side of the panel, aligning the screw

holes.

When panel is correctly positioned and aligned, insert the

screws and tighten.

Figure 12. Removing/Installing Louvered Panels

(Detail A, B and C)

A'kWARNING

In the U,S.A., wiring must conform with current local codes

and the current National Electric Code (NEC). In Canada,

wiring must conform with current local codes and the current

Canadian Electrical Code (CEC),

ELECTRICAL AND CONTROL CONNECTIONS

Refer to the furnace or blower coil installation instructions

for additional wiring application diagrams and refer to unit

nameplate for minimum circuit ampacity and maximum

overcurrent protection size.

NOTE -Connect conduit to the unit using a proper conduit

fitting. Units are approved for use only with copper

conductors. A complete unit wiring diagram is located on

the back side of the unit's access panel.

NOTE -For proper voltages, select thermostat wire gauge

per the following chart:

Page 7

XP15 SERIES

Table 2. Wire Run Length

Wire Run Length AWG # Insulation Type

less than 100' (30m) 18 color-coded, temperature

more than 100' (30m) 16 rating 35°C minimum

1. Install room thermostat (ordered separately) on an

inside wall approximately in the center of the area and

5 feet (1.5 m) from the floor. Do not install on an outside

wall or where sunlight, drafts or vibrations affect it.

2. Install low voltage wiring from outdoor to indoor unit

and from thermostat to indoor unit as illustrated in

figure 14.

3. Install line voltage power supply to unit from a properly

sized disconnect switch as illustrated in figure 15.

4. Ground unit from ground lug as illustrated in figure 15

to unit disconnect switch, or to an earth ground.

LI _._

z_

RTI$

AMBIENT

SENSOR

@

R721 DEFROST

COIL SENSOR

S4HIGH

PRESSURE

SWITCH

$87 LOW

PRESSURE

SWITCH

©

LI

REVERSING

VALVE

©

LZ_

OMPRESSOR

CONTACTOR

54O

AI32

BI

HRI

A

w

AI32

A

EQUIPMENT

GROUND

COMPRESSOR

CONTACTOR

BLACK TBI

(W5_

(W8

"-(v _

G

©

@

CB31MV

CBX32MV A2 SIGNATURE

81M2B

TWISTEO

PAIR

•I

A NOTE

FOR USE WITH COPPER CONDUCTORS ONLY.

REFER TO UNIT RATING PLATE FOR

MINIMUM CIRCUIT AMPACITY AND

MAXIMUM OVER CURRENT PROTECTION SIZE

A REFER TO COMPRESSOR N UNIT

FOR ACTUAL TERMINAL mRmANGEMENT.

Z_ WARNING

ELECTRIC SHOCK HAZARD,CAN CAUSE INJURY

OR DEATH.UNIT MUST BE GROUNDED IN

ACCOROANCE WITH NATIONAL AND LOCAL CODES.

A RTI4 SENSOR, OUTDOOR TEMP (OPTIONAL)

LINE VOLTAGE FIELD INSTALLED

CLASS II VOLTAGE FIELD INSTALLED

Figure 14. Typical Low-Voltage Field Wiring

GROUND

208-230/60/1 L1

L2

K1-1 COMPRESSOR CONTACTOR

GROUNDLUG CONTROLBOX _'-

CONTACTOR

DEFROST CONTROL

BOARD (DCB)

-''_/ L_)NNNTOoXRt LYs'<oTE_ OPERATION

"__ _[3_/ _ CAPACITOR

WARNING! - ELECTRIC SHOCK HAZARD. Can cause INJURY or DEATH. Unit must be grounded in accordance with national and local codes.

NOTE - For use with copper conductors only. Refer to unit rating plate for minimum circuit ampacity and maximum over-current protection size.

Figure 15. Typical High-Voltage Field Wiring (Unit Panel)

505328M 04/08

Page 8

This section providesinformationon installationor

replacementofexistinglinesets.Iflinesetsarenotbeing

installedorreplace,thenproceedtoBrazing Connections

on page 11.

If refrigerant lines are routed through a wall, seal and

isolate the opening so vibration is not transmitted to the

building, Pay close attention to line set isolation during

installation of any HVAC system. When properly isolated

from building structures (walls, ceilings, floors), the

refrigerant lines will not create unnecessary vibration and

subsequent sounds.

REFRIGERANT LINE SET

Field refrigerant piping consists of liquid and vapor lines

from the outdoor unit (sweat connections) to the indoor unit

coil (flare or sweat connections). Use Lennox L15 (sweat,

non41are) series line sets, or use field-fabricated

refrigerant lines as listed in table 3.

MATCHING WITH NEW OR EXISTING INDOOR COIL

AND LINE SET

IMPORTANT

When installing refrigerant lines longer than 50 feet, see

the Lennox Refrigerant Piping Design and Fabrication

Guidelines, or contact Lennox Technical Support Product

Applications for assistance. To obtain the correct

information from Lennox, be sure to communicate the

following points:

Model (XP15) and size (e.g. -060) of unit.

Line set diameters for the unit being installed (from

table 3)

Number of elbows and if there is a rise or drop of the

piping.

Line sets for heat pump applications can not be installed

underground. For more information see the Lennox

Refrigerant Piping Design and Fabrication Guidelines, or

contact Lennox Technical Support Product Applications

for assistance.

Table 3. Refrigerant Line Sets

Valve Sizes Recommended Line Set

Model Liquid Vapor Liquid Vapor L15

Line Line Line Line LineSets

-024 3/8 in. 3/4 in. 3/8 in 3/4 in. L15-41

-030 (10mm) (19mm) (10mm) (19mm) 15-50ft.

-- (5 - 15 m)

-036

-042 3/8 in. 7/8 in 3/8 in. 7/Sin L15-65

15 - 50 ft.

(10mm) (22mm) (10mm) (22mm) (5-15m)

3/8 in. 1-1/8 in, 3/8 in. 1-1/8 in, Field

-060 (10 ram) (29 ram) (10 ram) (29 ram) Fabricated

INSTALLING LINE SET

Line Set Isolation--This reference illustrates

procedures, which ensure proper refrigerant line set

isolation:

• Installation of line sets on horizontal runs is

illustrated in figure 16.

• Installation of line sets on vertical runs is illustrated

in figure 17 on page 10.

• Installation of a transition from horizontal to

vertical is illustrated in figure 18 on page 10.

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

STRAPPING MATERIAL

(AROUND VAPOR LINE

ONLY)

8 FEET TAPE OR

WIRE TIE

STRAP THE VAPOR LINE TO THE

METAL JOIST OR RAFTER AT 8 FEET

SLEEVE INTERVALS THEN STRAP THE

TAPE OR LIQUID LINE TO THE VAPOR LINE.

FLOOR JOIST OR _ _ _%

ROOF RAFTER _-

_._ I1

Figure 16. Refrigerant Line Sets: Installing

Horizontal Runs

Page 9

XP15 SERIES

IMPORTANT-

OUTSIDEWALLREFRIGERANTLINESMUST

NOTCONTACTWALL.VAPORLINELIQUIDLINE

NOTE-SIMILAR

INSTALLATION

PRACTICESSHOULDBE

USEDIFLINESETISTO

BEINSTALLEDON

EXTERIOROFOUTSIDE

WALL.

VAPORLINEWRAPPED

WITHARMAFLEX

PVC_ CAULK

PIPE FIBERGLASS

INSULATION

IMPORTANT!

REFRIGERANTLINES

MUSTNOTCONTACT

STRUCTURE.

ANCHOREDHEAVY

NYLONWIRETIE

WALL

STUD

METALSLEEVE

AUTOMOTIVE

MUFFLER-TYPEHANGER

WALL

STUD

STRAPLIQUIDLINE

TOVAPORLINE

JIDLINE

VAPORLINE-WRAPPED

INARMAFLEX

IUIDLINE

TOVAPORLINE

LIQUID

LINE

VAPORLINEWRAPPED

METALSLEEVE INARMAFLEX

Figure 17. Refrigerant Line Sets: Installing Vertical

Runs (New Construction Shown) Figure 18. Refrigerant Line Sets: Transition from

Vertical to Horizontal

1

CUT AND DEBUR

INSTALL CORE ONLY FOR

3OTH SERVICE PORTS after they

have coolED.

INDOOR UNIT

REMOVE CAP AND CORE FROM

BOTH LIQUID AND SUCTION

SERVICE PORTS

outdoor

UNIT

SERVICE PORT MUST BE

OPEN TO ALLOW EXIT

POINT FOR NITROGEN SERVICE

j SUCTION LINE _/VALVE

_QU_DUNE SERV_CEJ

VALVE

Figure 19. Brazing Connections

Page 10

505328M 04/08

ISOLATION GROMMETS

Locate the provided isolation grommets Slide grommets

onto vapor and liquid lines Insert grommets into mullion to

isolate refrigerant lines from sheet metal edges

Use the following procedure to braze the line set to the new

outdoor unit Figure 19 is provided as a general guide for

preparing to braze the line sets to the outdoor unit

Before brazing, remove the access panel as illustrated in

figure 11; then remove the narrow piping panel to prevent

burning off the paint as illustrated in figure 20

REMOVE TWO SCREWS

AND REMOVE PANEL

BEFORE BRAZING

LINE SET

CONNECTION

POINTS

Figure 20. Piping Panel Removal

WARNING

_WARNING

underneath the valve body to protect the base paint,

Also, shield the light maroon R-410A sticker.

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

refrigeration gauge set into the valve stem port

connection on the liquid line service valve and out of

the valve stem port connection on the vapor service

valve. The CTXV metering device at the indoor unit

coil will allow low pressure nitrogen to flow through the

system,)

Note: Use silver alloy brazing rods with five or six percent

minimum silver alloy for copper-to-copper brazing or 45

percent silver alloy for copper-to-brass or copper-to-steel

brazing,

6. Braze the line set to the liquid line service valve. Turn

off nitrogen flow, Repeat procedure starting at

paragraph 4 for brazing the vapor line set to service

valve,

After brazing the vapor line set to the service valve,

disconnect gauge from service port, remove wrapping and

replace service port cores.

Remove the existing HCFC-22 refrigerant flow control

orifice or thermal expansion valve from the indoor coil.

Existing devices are not approved for use with HFC-410A

refrigerant and may prevent proper flushing. Use a

field-provided fitting to reconnect lines, See figure 23 on

page 13 for disassembly and typical removal instructions.

After the line set has been connected to both the indoor

and outdoor units, check the line set connections at both

the indoor and outdoor units unit for leaks. Use the

following procedure to test for leaks:

IMPORTANT

WARNING

1. Cut ends of the refrigerant lines square (free from

nicks or dents). Debur the ends. The pipe must remain

round, do not pinch end of the line.

2. Remove service cap and core from both the vapor and

liquid line service ports.

3. Connect gauge low pressure side to liquid line service

valve,

4. To protect components during brazing, wrap a wet

cloth around the liquid line service valve body and

copper tube stub and use another wet cloth

Page 11

AWARNING

XP15 SERIES

WARNING I OUTOOORO.,T

SERVICE VALVE

1 Connect an HFC410A manifold gauge set high

pressure hose to the vapor valve service port

(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.)

2 With both manifold valves closed connect the cylinder

of HFC410A refrigerant to the center port of the

manifold gauge set Open the valve on the HFC 410A

cylinder (vapor only)

3 Open the high pressure side of the manifold to allow

HFC 410A into the line set and indoor unit

4 Weigh in a trace amount of HFC410A [,4 trace

amount is a maximum of two ounces (57 g) refrigerant

or three pounds (31 kPa) pressure].

5, Close the valve on the HFC-410A cylinder and the

valve on the high pressure side of the manifold gauge

set.

6. Disconnect the HFC-410A cylinder,

7, Connect a cylinder of dry nitrogen with a pressure

regulating valve to the center port of the manifold

gauge set,

8, Adjust dry nitrogen pressure to 150 psig (1034 kPa),

9, Open the valve on the high side of the manifold gauge

set in order to pressurize the line set and the indoor unit,

10, 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,

11, After leak testing disconnect gauges from service

ports,

REMOVE SERVICE

PORT CAP

REMOVE PORT CORE

Figure 21. Typical Service Valve Port Core Removal

AIMPORTANT

A IMPORTANT

ACAUTION

AIMPORTANT

Remove both of the outdoor unit's service port cores (liquid

and vapor) as illustrated in figure 21,

If new lines are used then proceed to Installing New

Refrigerant Metering Device. Otherwise proceed with the

following procedure,

505328M 04/08

Page 12

REQUIRED EQUIPMENT

Equipment required to flush the existing line set and indoor

unit coil:

• Two clean HCFC-22 recovery bottles,

• Oilless recovery machine with pump-down feature,

• Two gauge sets (one for HCFC-22; one for

HFC-410A),

RECOVERY MACHINE

NOTE -The inverted HCFC-22 cylinder must contain at least the same

amount of refrigerant as was recovered from the existing system.

Figure 22. Typical Flushing Connection

PROCEDURE

1, Verify that the existing HCFC-22 refrigerant flow

control device has been removed before continuing

with flushing procedures. Existing devices are not

approved for use with HFC-410A refrigerant and may

prevent proper flushing.

2, Connect an HCFC-22 cylinder with clean refrigerant to

the vapor service valve. Connect the HCFC-22 gauge

set to the liquid line valve. Connect a recovery

machine with an empty recovery tank to the gauge set

as illustrated in figure 22.

3, 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.

4, 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,

5, 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 a vacuum on the system,

NOTE -A single system flush should remove all of the

mineral oil from the existing refrigerant lines and indoor

unit coil. A second flushing may be done (using clean

refrigerant) if insufficient amounts of mineral oil were

removed during the first flush. Each time the system is

flushed, you must allow the recovery machine to pull a

vacuum on the system at the end of the procedure.

Page1

6, 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.

XP15 units are used in check thermal expansion valve

(CTXV) systems only, See the indoor unit coil installation

instructions and the Lennox Engineering Handbook for

approved CTXV match-ups and application information.

Table 3 on page 9 lists liquid and vapor line sizes and

corresponding line sets,

(Uncased Coil Shown)_ -

TWO PIECE PATCH

I EXPA )RI FIC E _""_

PLATE(UNCASED OR

COIL ONLY) ORIFICE NSION VALVE

HOUSING I (SEE NOTE)

TUBES

ACCESS FITTING

(NO VALVE CORE)

On smaller vapor lines, bulb may be

mounted on top or side-mounted (prefer-

ably at 3 o'clock position).

On 518"and larger lines, mount bulb

approximately at the 4 or 8 o'clock posi-

tions; never mount on bottom of line.

o@clock

NOTE - If necessary, remove HCFC-22 flow control device (fixed

orifice/check expansion valve) from existing line set before instal-

ling HFC-410A approved expansion valve and o-ring.

Figure 23. Typical Metering Device Installation

The thermostatic expansion valve or check /thermostatic

expansion valve, can be installed internal or external to the

indoor coil. In applications where an uncased coil is being

installed in a field provided plenum, install the CTXV and

provide an access for field servicing of the CTXV. Refer to

Figure 23 for reference during installation of CTXV,

XP15 SERIES

1, On fully cased coils, remove the coil access and

plumbing panels,

2, Remove any shipping clamps holding the liquid line

and distributor assembly,

3. Using two wrenches, disconnect liquid line from

distributor. Take care not to twist or damage distributor

tubes during this process,

4, Remove and discard RFC bullet and Teflon washer,

5. Remove and discard cap from the equalizer line port

on the vapor line. Check for valve core in port fitting

and if installed, remove from port.

6. Install one of the provided Teflon washers around the

stubbed end of the CTXV,

7. Attach the stubbed end of the kit valve to the distributor

assembly.

8. Place the remaining Teflon washer around the other

end of the CTXV.

9. Attach the liquid line to the CTXV.

10. Attach the sensing bulb of the CTXV in the proper

orientation to the vapor line using the clamp an screws

provided with the CTXV,

11. Connect the equalizer line from the CTXV to the

equalizer vapor port on the vapor line.

12. To prevent against any possibility of water damage,

properly insulate all parts of the CTXV assemble that

may sweat due to temperature differences between

the valve and its surrounding ambient temperatures.

13. The expansion/check valve can be installed internally

in coil blowers, or external or internal to indoor coil only

applications,

Expansion valves equipped with Chatleff type fittings are

available from Lennox, Refer to the Engineering

Handbook for CTXV kits for use with specific match-ups.

Table 4. Indoor CTXV Kits

Model Kit Number

XP15-024 and -036 49L24

XP15-048 and -060 91M02

AIMPORTANT

If the indoor unit being installed came with a fixed orifice

type metering device, remove that orifice and install the

CTXV as illustrated in figure 23.

Re-install both of the outdoor unit's service port cores

(liquid and vapor) as illustrated in figure 24.

O TOOO .

LIQUID AND VAPOR

SERVICE VALVES DO NOT INSTALL

CAPS AT THIS TIME

INSTALL SERVICE

PORT CORES

Figure 24. Typical Service Valve Port Core

Installation

WARNING

AIMPORTANT

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

vapor combine with refrigerant to produce substances that

corrode copper piping and compressor parts.

1. Connect manifold gauge set to the service valve ports

as follows:

• low pressure gauge to vapor line service valve

• high pressure gauge to liquid line service valve

2. Connect micron gauge.

3. Connect the vacuum pump (with vacuum gauge) to

the center port of the manifold gauge set,

4. Open both manifold valves and start the vacuum

pump.

5. 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 to

determine if there is a rapid rise in sure 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,

6. When the absolute pressure reaches 23,000 microns

(29.01 inches of mercury), close the manifold gauge

505328M 04_8

Page 14

valves,turnoffthevacuumpumpanddisconnectthe

manifoldgaugecenterporthosefromvacuumpump.

Attachthemanifoldcenterporthosetoadrynitrogen

cylinderwithpressureregulatorsetto 150psig(1034

kPa)andpurgethehose.Openthemanifoldgauge

valvestobreakthevacuuminthelinesetandindoor

unit.Closethemanifoldgaugevalves,

7, Shutoff the dry nitrogencylinderand removethe

manifoldgaugehosefromthe cylinder.Openthe

manifoldgaugevalvestoreleasethedrynitrogenfrom

thelinesetandindoorunit,

8, Reconnectthemanifoldgaugeto thevacuumpump,

turnthepumpon,andcontinuetoevacuatethelineset

andindoorunituntiltheabsolutepressuredoesnot

riseabove500microns(29.9inchesofmercury)within

a 20-minuteperiodaftershuttingoffthevacuumpump

andclosingthemanifoldgaugevalves.

9, Whentheabsolutepressurerequirementabovehas

beenmet,disconnectthe manifoldhosefrom the

vacuumpumpandconnectit to anuprightcylinderof

HFC-410Arefrigerant,Openthemanifoldgaugevalve

1to2 psiginordertoreleasethevacuuminthelineset

andindoorunit,

10,Close manifoldgauge valvesand shut off the

HFC-410Acylinderandremovethe manifoldgauge

set,

SERVICINGUNITSDELIVEREDVOIDOFCHARGE

Ifthesystemisvoidofrefrigerant,cleanthesystemusing

theproceduredescribedbelow,

1, Usenitrogentopressurizethesystemandcheckfor

leaks,Repairallleaks,

2, Evacuatethe systemto removeas muchof the

moistureaspossible,

3, Usenitrogento breakthevacuumandinstalla new

filterdrierinthesystem.

4, Evacuatethe system again. Then, weigh the

appropriateamountof HFC-410Arefrigerantaslisted

onunitnameplateintothesystem.

5, Monitorthe systemto determinethe amountof

moistureremainingintheoil.Itmaybenecessaryto

replacethefilterdrierseveraltimesto achievethe

requireddrynesslevel.If systemdryness is not

verified,thecompressorwill fail in thefuture.

IMPORTANT

1. Rotate fan to check for frozen bearings or binding.

2, Inspect all factory- and field-installed wiring for loose

connections.

3, After evacuation is complete, open the liquid line and

vapor line service valves to release the refrigerant

charge (contained in outdoor unit) into the system,

4, Replace the stem caps and tighten as specified in

Operating Service Valves on page 3.

5, Check voltage supply at the disconnect switch. The

voltage must be within the range listed on the unit's

nameplate. If not, do not start the equipment until you

have consulted with the power company and the

voltage condition has been corrected,

6, Set the thermostat for a cooling demand. Turn on

power to the indoor indoor unit and close the outdoor

unit disconnect switch to start the unit.

7, Recheck voltage while the unit is running. Power must

be within range shown on the nameplate,

8, Check system for sufficient refrigerant by using the

procedures listed under Testing and Charging

System,

TESTING AND CHARGING SYSTEM

This system uses HFC-410A refrigerant which operates at

much higher pressures than HCFC-22. The pre-installed

liquid line filter drier is approved for use with HFC-410A

only, Do not replace liquid line filter drier with components

designed for use with HCFC-22,

NOTE - This unit is NOT approved for use with coils which

use capillary tubes as a refrigerant metering device,

SETTING UP TO CHECK CHARGE

1. Close manifold gauge set valves. Connect the center

manifold hose to an upright cylinder of HFC-410A.

2. Connect the manifold gauge set to the unit's service

ports as illustrated in figure 25,

•low pressure gauge to vapor service port

• high pressure gauge to liquid service port

COOLING MODE INDOOR AIRFLOW CHECK

Check airflow using the Delta-T (DT) process as illustrated

in figure 26 on page 16.

HEATING MODE INDOOR AIRFLOW CHECK

Blower airflow (CFM) may be calculated by energizing

electric heat and measuring:

• temperature rise between the return air and supply air

temperatures at the indoor coil blower unit,

• voltage supplied to the unit,

• amperage being drawn by the heat unit(s),

Then, apply the measurements taken in following formula

to determine CFM:

CFM = Amps x Volts x 3.41

1.08 x Temperature rise (F)

CALCULATING 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:

Additional charge

Amount Adjust amount for specified per

specified variation in indoor unit

on line set length match-up Total

nameplate (table in figure 27) (tables 6 through 11) charge

+ + =

Page15

XP15 SERIES

CHECK

EXPANSIONVALVE

LOW HIGH [

PRESSUREPRESSURE

_:[tGAUGEMANIFO%D1]:_

HFC-410 LINEI

ADRUM VALVE COMPRESSOF

J2

DISTRIBUTOR

DRIER OUTDOOR

CO,L

MUFFLER

NOTE- Use gauge ports on vapor line valve and liquid valve for evacuating refrigerant

lines and indoor coil. Use vapor gauge port to measure vapor pressure during charging,

OUTDOOR UNIT

REVERSING VALVE

VAPOR LINE

VALVE

CHECK EXPANSION VALVE --

NOTE -ARROWS INDICATE

DIRECTION OF REFRIGERANT FLOW

INDOOR UNIT

INDOOR

COIL

Figure 25. XP15 Cooling Cycle (Showing Gauge Manifold Connections)

Temp. l

of air I 80 24

I

entering,_ I 78 23

indoor _ I== 22

coil °F _'?1tu

"- 17421

I

72 20

70 19

Wet-bulb °F 57

DT

24 24 23 23 22 22 22 20 19 18 17 16 15

23 23 22 22 21 21 20 19 18 17 16 15 14

22 22 21 21 20 19 19 18 17 16 15 14 13

21 21 20 19 19 18 17 16 16 15 14 13 12

20 19 18 17 17 161L55_15 14 13 12 11 10

19 18 18 17 17 16 15 15 14 13 12 11 10

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

n$

19°

iNDOOR WET

All temperatures are COiL BULB

expressed in °F 6

DRY

BULB

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

ature using dry bulb (A) and wet bulb (B). DT is the intersect-

ing 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). Tem-

perature Drop Formula: (TDrop) = A minus C.

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

the measured TDrop and the desired DT (TDrop-DT) is within

+_3°, no adjustment is needed. See examples: Assume DT =

15 and A temp. = 72 °, these C temperatures would necessi-

LEILI9 _LaL_d EI(3LIUII_:

C°TDrop- DT =°F ACTION

53°19 - 15 = 4 Increase the airflow

58°14 - 15 = -1 (within +3° range) no change

62 °10 - 15 = -5 Decrease the airflow

4. Adjust the fan speed--See indoor unit instructions to in-

crease/decrease fan speed.

Changing air flow affects all temperatures; recheck tempera-

tures to confirm that the temperature drop and DT are within

+_30.

Figure 26. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart

WEIGH

Refrigerant Charge per Line Set Length

Liquid Line Ounces per 5 feet (g per 1.5 m)

Set Diameter adjust from 15 feet (4.6 m) line set*

3t8" (9.5 mm) 3 ounce per 5' (85 g per 1.5 m)

NOTE - *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.

L_NNOX

HIHIIIJI|I[I

@:L,

1. Check Liquid and suction line pressures

2. Compare unit pressures with table 5,

Normal Operating Pressures,

3. Conduct leak check; evacuate as

previously outlined.

4. Weigh in the unit nameplate charge plus

any charge required for line set differences

over feet,

This nameplate is for illustration purposes

only. Go to actual nameplate on outdoor

unit for charge information.

Figure 27. Using Weigh In Method

505328M 04/08

Page 16

8UBCOOLING 1

USE COOLING

MODE

60°F (15 °) --

USE HEATING

MODE

2

3

4

%

SATo

LIQ o -

SC o =

Check the airflow as illustrated in figure 26 to be sure the indoor airflow is as

required. (Make any air flow adjustments before continuing with the following

procedure.)

Measure outdoor ambient temperature; determine whether to use cooling mode

or heating mode to check charge.

Connect gauge set.

Check Liquid and Vapor line pressures. Compare pressures with Normal

Operating Pressures table 5, (The reference table is a general guide. Expect

minor pressure variations. Significant differences may mean improper charge or

other system problem. )

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

Using cooling mode--When the outdoor ambient temperature is 60°F (15°C) and

above. Target subcooling values in table below are based on 70 to 80°F (21-27°C)

indoor return air temperature; if necessary, operate heating to reach that

temperature range; then set thermostat to cooling mode setpoint to 68°F (20°C).

When pressures have stabilized, continue with step 6.

Using heating mode--When the outdoor ambient temperature is below 60°F (15°C).

Target subcooling values in table below are based on 65-75°F (18-24°C) indoor

return air temperature; if necessary, operate cooling to reach that temperature range;

then set thermostat to heating mode setpoint to 77°F (25°C). When pressures have

stabilized, continue with step 6.

6 Read the liquid line temperature; record in the LIQ ° space.

7 Read the liquid line pressure; then find its corresponding temperature in the

temperature/pressure chart listed in table 12 and record it in the SAT° space.

8 Subtract LIQ° temp. from SAT° temp. to determine subcooling; record it in SC° space.

9 Compare SC° results with table below, being sure to note any additional charge for

line set and/or match-up.

10 If subcooling value is greater than shown in tables 6 through 11 for the applicable unit,

remove refrigerant; if less than shown, add refrigerant.

11 If refrigerant is added or removed, repeat steps 6 through 10 to verify charge.

Figure 28. Using Subcooling Method

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

IMPORTANT

|lliiliTo]ilv/_-I IP.|l[[o]i[-.lllilllii['4-"[_]l)i] I[:t-$"]!ll':-.t-lliiL.]Iv|i[_ :--,).-4i[:[_rlrl_irilrlll_l_-41[-4i[_-4.111i!11i1,¢ _-"ll .F'[|[o]i[..'!ll_-'l[i-']'_ilil i,_.]i|l[ill_l[q 1['4i[_:t-11

""""'"" il"""T II

XP15-024 XP15-030 XP15-036 XP15-042 XP15-048 XP15-060

..aidIvo o. Ivo o. Ivo o...aidIVo o. IVo o. IVo o.

HEATINGOPERATION

20 (-7.0) 315 65 308 62 284 59 293 58 312 62 349 61

30 (-1.0) 340 81 317 76 296 71 312 71 332 76 375 74

40 (4.4) 364 97 339 89 313 87 321 82 353 92 384 88

50 (10) 394 115 359 107 326 106 337 103 374 110 406 107

COOLING OPERATION

65 (18.3) 237 141 250 141 260 139 265 141 242 139 255 136

75 (23.9) 274 143 292 143 298 141 309 144 279 140 297 138

85 (29.4) 319 145 336 145 344 143 360 147 322 142 343 140

95 (35.0) 364 147 385 147 393 145 408 149 370 144 392 142

105 (40.6) 415 149 438 148 446 148 462 151 423 147 447 145

115 (49.0) 469 152 497 151 506 150 522 154 479 149 510 148

*These are most-popular-match-up pressure& Indoor match up, indoor air quality, and indoor load cause pressures to vary.

**Temperature of the air entering the outdoor coi!.

Page 17

XP15 SERIES

Table 6. XP15-024

Target *Add

Subcooling charge

INDOOR MATCHUPS Heat Cool

(+5OF) (+1OF) Ib oz

CH23-51 14 6 0 14

CBX27UH-030-230 13 6 2 4

CB3OU-31 15 5 O 1

CBX32M-030 15 5 O 1

CBX32M-036 13 6 2 4

CBX32MV-024/030 15 5 O O

CBX32MV-036 13 6 2 4

CH33-42 14 6 O 14

CR33-48 38 7 3 1

CX34-31 15 5 0 1

CX34-38 SN# 6007 and after 6 6 1 15

CX34-38 before SN# 6007 13 6 1 15

Table 7. XP15-030

Target *Add

Subcooling charge

INDOOR MATCHUPS Heat Cool

(+5OF) (+1OF) Ib oz

CH23-51 13 5 0 4

CBX27UH-030-230 12 5 0 10

CBX27UH-036-230 13 5 0 8

CB30U-31 14 5 0 0

CB30U-41/46 12 5 0 10

CBX32M-030 14 5 0 0

CBX32M-036 12 5 0 10

CBX32MV-024/030 14 5 0 0

CBX32MV-036 12 5 0 10

CR33-48 31 4 0 13

CX34-38 SN# 6007 and after 5 5 0 8

CX34-38 before SN# 6007 13 5 0 8

CX34-43 9 5 1 4

CX34-49 6 5 2 0

CX34-50/60C 9 5 1 4

Table 8. XP15-036

Target *Add

Subcooling charge

INDOOR MATCHUPS Heat Cool

(+5OF) (+1OF) Ib oz

CBX27UH-036-230 13 4 0 3

CBX27UH-042-230 5 5 O 12

CB3OU-41/46 13 4 O 3

CB3OU-51 5 5 O 12

CBX32M-042 13 4 O 3

CBX32M-048 5 5 O 12

CBX32MV-036 13 4 O 3

CBX32MV-048 5 5 O 12

C33-44C 13 4 O 3

CH33-42 14 4 O 1

CH33-44/48B 9 4 O 7

CH33-48C 7 5 O 7

CH33-49C 5 5 O 12

CH33-62D 5 7 O 14

CR33-48C 37 4 O 5

CR33-50/60 32 5 O 10

CX34-31 15 4 O O

CX34-38 SN# 6007 and after 4 4 O 3

CX34-38 before SN# 6007 13 4 O 3

CX34-43 7 5 O 7

CX34-44/48 13 4 O 3

CX34-49 6 5 O 11

Table 9. XP15-042

Target *Add

Subcooling charge

INDOOR MATCHUPS Heat Cool

(+5OF) (+1OF) Ib oz

CH33-62D 7 7 0 13

CBX27UH-042-230 9 4 O 11

CBX27UH-048-230 9 4 O 11

CB3OU-51*P 9 4 O 11

CBX32M-048 9 4 O 11

CBX32MV-048 9 4 O 11

C33-44C 13 4 O O

CH33-44/48B, -48C 12 4 O 5

CH33-49C 9 4 O 12

CR33-48 35 3 O 2

CX34-38 SN# 6007 and after 4 4 O O

CX34-38 before SN# 6007 13 4 O O

CX34-43 12 4 O 5

CX34-44/48B 13 4 O O

CX34-50/60C 12 4 O 5

Table 10. XP1 _-048

Target *Add

Subcooling charge

INDOOR MATCHUPS Heat Cool

(+5OF) (+1OF) Ib oz

CH23-68 21 4 0 12

CBX27UH-048-230 22 4 O 3

CBX27UH-060-230 12 4 O 11

CB3OU-51*P 22 4 O 3

CB3OU-65*P 12 4 O 3

CBX32M-048 22 4 O 3

CBX32M-060 12 4 O 3

CBX32MV-048 22 4 O 3

CBX32MV-060 12 4 O 3

CBX32MV-068 12 4 O 7

CH33-62D 12 4 O 8

CX34-49C 13 4 O 2

CX34-6OD 14 4 O O

CX34-62D 12 4 O 5

Table 11. XP15-060

Target *Add

Subcooling charge

INDOOR MATCHUPS Heat Cool

(+5OF) (+IOF) Ib oz

CH23-68 28 6 0 0

CBX27UH-060-230 17 6 O O

CB3OU-51*R -65"P 19 6 O 2

CBX32M-O48*R -O6O*P 19 6 O 2

CBX32MV-O48*R -O6O*P 19 6 O 2

CH33-62D 18 6 O 1

*Amount of charge required in addition to charge shown on unit

nameplate. (Remember to consider lineset length difference.)

505328M 04_8

Page 18

Table 12. 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

INSTALLING SERVICE VALVE CAPS

Disconnect gauge set and re-install all service valve caps.

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 the

unit 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), The system

should be left in the emergency heat mode at least six

hours to allow the crankcase heater sufficient time to

prevent compressor slugging.

HIGH-PRESSURE SWITCH

XP15 units are equipped with a high-pressure switch that

is located in the liquid line to the compressor. The normally

closed SPST auto-reset switch opens at 590 psi,

LOW-PRESSURE SWITCH

XP15 units are equipped with a low-pressure switch that is

located in the vapor line to the compressor. The normally

closed SPST auto-reset switch opens at 25 psi and closes

at 55 psi,

SINGLE-SPEED CONDENSER FAN MOTOR

The XP15 is equipped with a single-speed condenser fan

motor. The compressor contactor and defrost control

board (DCB) controls the operation of the motor,

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,

Replacement filter driers must be suitable for use with

HFC-410A refrigerant,

OUTDOOR UNIT INSTALL CAPS

SERVICE VALVE _ _/

Figure 29. Installing Service Valve Port Caps

The LSOM detects the most common fault conditions in

the system. When an abnormal condition is detected, the

LSOM communicates the specific condition through its

ALERT and TRIP lights, The LSOM is capable of detecting

both mechanical and electrical system problems. See

figure 30 for LSOM LED locations.

The outdoor unit and indoor blower cycle on demand from

the room thermostat, When the thermostat blower switch

is in the ON position, the indoor blower operates

continuously.

THERMOSTAT OPERATION

Some indoor thermostats incorporate isolating contacts

and an emergency heat function (which includes an amber

indicating light). The thermostat is not included with the

unit and must be purchased separately,

Page 19

POWER LED .....

TRIP LED

ALERT LED

Figure 30. LSOM

XP15 SERIES

Table 13. LSOM LED Troubleshooting Codes

Status LED Status LED Status LED Troubleshooting Information

Condition Description

Green Power LED ON LSOM has power

Green Power LED OFF LSOM not powering up

System and compressor

check out OK

Thermostat demand signal

Y1 is present, but

compressor not running

NO TE -During 5-minute

delay in LSOM the red trip

LED will be on.

Red Trip LED ON

Red Trip and Yellow

Alert LEDs Flashing Simultaneous flashing,

Yellow Alert Flash

Code 1"

Yellow Alert Flash

Code 2*

Yellow Alert Flash

Code 3*

Yellow Alert Flash

Code 4*

Long Run Time - Compres-

sor is running extremely

long run cycles

System Pressure Trip -

Discharge or vapor pressure

out of limits or compressor

overloaded

Short Cycling -Compres-

sor is running only briefly

Locked Rotor

Open Circuit

Yellow Alert Flash

Code 5*

Yellow Alert Flash Open Start Circuit -Cur-

Code 6* rent only in run circuit

Yellow Alert Flash Open Run Circuit - Current

Code 7* only in start circuit

Yellow Alert Flash Welded Contactor -

Code 8* Compressor always runs

Yellow Alert Flash Low Voltage - Control cir-

Code 9* cuit <17VAC

24VAC control power is present at the LSOM terminal.

Determine/verify that both R and C LSOM terminals are connected and voltage is present

at both terminals.

1 Verify Y terminal is connected to 24VAC at contactor coil.

2 Verify voltage at contactor coil falls below 0.5VAC when off.

3 Verify 24VAC is present across Y and C when thermostat demand signal is present; if not

present, R and C wires are reversed.

1 Compressor protector is open.

2 Outdoor unit power disconnect is open.

3 Compressor circuit breaker or fuse(s) is open.

4 Broken wire or connector is not making contact.

5 Low pressure switch open if present in the system.

6 Compressor contactor has failed to close.

Indicates that the control circuit voltage is too low for operation.

1 LOW refrigerant charge.

2 Evaporator blower is not running.

3 Evaporator coil is frozen.

4 Faulty metering device.

5 Condenser coil is dirty.

6 Liquid line restriction (filter drier blocked if present).

7 Thermostat is malfunctioning.

1 Check high head pressure or discharge line sensor.

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

3 Condenser fan is not running.

4 Return air duct has substantial leakage.

5 If low pressure switch is present, see Flash Code 1 information.

1 Thermostat demand signal is intermittent.

2 Time delay relay or DCB is defective.

3 If high pressure switch is present, see Flash Code 2 information.

4 If low pressure switch is present, see Flash Code 2 information.

1 Run capacitor has failed.

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

3 Excessive liquid refrigerant in the compressor.

4 Compressor bearings are seized.

1 Outdoor unit power disconnect is open.

2 Unit circuit breaker or fuse(s) is open.

3 Unit contactor has failed to close.

4 High pressure switch is open and requires manual reset.

5 Open circuit in compressor supply wiring or connections.

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

7 Compressor windings are damaged.

1 Run capacitor has failed.

2 Open circuit in compressor start wiring or connections.

3 Compressor start winding is damaged.

1 Open circuit in compressor start wiring or connec_ons.

2 Compressor start winding is damaged.

1 Compressor contactor failed to open.

2 Thermostat demand signal not connected to LSOM.

1 Control circuit transformer is overloaded.

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

*Flash code number corresponds to a number of LED flashes, followed by a pause, and then repeated. Reset ALER Tflash code by removing 24VAC power

from LSOM; last code will display for 1 minute after LSOM is powered on.

Note: If the unit is equipped with a two-stagged compressor, upon Y2 signal detection and after five seconds, the LSOM will send 24 VAC to the solenoid.

Once the solenoid is fully energized, the L SOM reduces voltage to between 4 to 18 VDC .Every 15 minutes the solenoid voltage will be increase to 24 volts

for a few seconds to ensure solenoid valve is engaged until Y2 signal is no longer present.

505328M 04_8

Page 20

LSOM--LED Functions

AIMPORTANT

See table 13 on page 20 for the complete explanation of

troubleshooting codes.

LED Function Description

Color

Indicates voltage within the range of

Green Power 19-28VAC is present at LSOM con-

nection.

Yellow Alert

Communicates an abnormal system

condition through a unique flash code.

The alert LED flashes a number of

times consecutively; then pauses;

then repeats the process. This

consecutive flashing correlates to a

particular abnormal condition.

Indicates there is a demand signal

from the thermostat but no current to

Red Trip the compressor is detected by the

LSOM.

Resetting Alert Codes

Alert codes can be reset manually or automatically:

Cycle the 24VAC power to LSOM off and on. Af-

Manual ter power up, existing code will display for one

minute and then clear.

After an alert is detected, the LSOM continues

Automatic to monitor the compressor and system. Whentif

conditions return to normal, the alert code is

turned off automatically.

LSOM--L Terminal Connection

The L connection is used to communicate alert codes to

the room thermostat. On selected Lennox SignatureStat"

thermostats, a blinking check LED will display on the room

thermostat and on select White-Rodgers room

thermostats, an icon on the display will flash. Either will

flash at the same rate as the LSOM yellow alert LED,

NOTE -ROOM THERMOSTATS WITH SERVICE OR

CHECK LIGHT FEATURE--The room thermostat may

blink the Check or Service LED or it may come on sofid,

Confirm fault by observing and interpreting the code from

the LSOM yellow alert LED at the unit,

LSOM--Installation Verification

To verify correct LSOM installation, two functional tests

can be performed.

TEST 1:

1. Disconnect power from the compressor and force a

thermostat call for cooling.

2. The red trip LED should turn on indicating a

compressor trip as long as 24VAC is measured at the

Y terminal, If the red LED does not function as

described, refer to table 13 on page 20 to verify the

wiring,

TEST 2:

1. Disconnect power from the compressor and 24VAC

power from the LSOM

2. Remove the wire from the Y terminal of LSOM and

reapply power to the compressor, allowing the

compressor to run. The yellow alert LED will begin

flashing a code 8 indicating a welded contactor,

3. While the LSOM is off, reattach the wire to the Y

terminal,

4. Reapply power to the compressor and 24VAC power

to the LSOM; the yellow alert LED will flash the

previous code 8 for one minute and then turn off. If the

yellow LED does not function as described, refer to

table 13 on page 20 to verify the wiring,

DEFROST CONTROL BOARD (DCB) FUNCTION

The DCB measures differential temperatures to detect

when the system is performing poorly because of ice

build-up on the outdoor coil. The DCB self-calibrates when

the defrost system starts and after each system defrost

cycle. The DCB components are illustrated in figure 31.

Note -Component Locations Vary by Board Manufacturer.

TEST PINS

DEFROST

TERMINATION

PIN SETTINGS

SENSOR

PLUG IN (COIL

AND AMBIENT

SENSORS)

DELAY

PINS

REVERSING

VALVE

PRESSURE

SWITCH

CIRCUIT

CONNECTIONS

rEs_ PI [_ O rAN

°

o_7 o

Owl

0-Ps

¢0_MON _2

TStPS O_ C _ 0 v_ _2

LOW

AMBIENT

THERMOSTAT

PINS

_DIAGNOSTIC

LEDS

24V TERMINAL

STRIP

CONNECTIONS

Figure 31. Defrost Control Board (DCB)

The DCB 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 DCB 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 DCB initiates defrost cycles.

Page 21

XP15 SERIES

Pressure Switch Connections

The unit's automatic reset pressure switches (LO PS - $87

and HI PS - $4) are factory-wired into the DCB on the

LO-PS and HI-PS terminals, respectively.

Pressure Switch Event Settings

The following are the auto reset event values for low and

high pressures thresholds:

•High Pressure (auto reset) - trip at 590 psig, reset to

418 psig.

• Low Pressure (auto reset) - trip at 25 psig, reset to 55

psig.

Five-Strike Lockout Safety Function

The five-strike lockout safety function is designed to

protect the unit's compressor from damage. The DCB

monitors for an active state on the DCB's Y1 input as

referenced in figure 31 on page 21. When the Y1 input is

active the internal control logic of the DCB will do the

following:

• Count any HI-PS and LO-PS pressure switch trips

(open and close).

• If a pressure switch trips four times during the current

active state on the Y1 input, then the DCB's control

logic will reset the pressure switch trip counter to zero

at the end of currently active Y1 input state.

• If the pressure switch opens for a fifth time during the

current Y1 input state, the DCB will enter a lockout

condition.

The system will require servicing to determine the cause of

the pressure switch condition. Once the condition has

been rectified, use the following procedure to reset the

DCB.

DEFROST SYSTEM SENSORS

Sensors connect to the DCB through a field-replaceable

harness assembly that plugs into the DCB. Through the

sensors, the DCB detects outdoor ambient and coil

temperature fault conditions. As the detected temperature

changes, the resistance across the sensor changes.

Sensor resistance values can be checked by ohming

across pins shown in table 14.

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 14, 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.

Table 14. Sensor Temperature /Resistanc4 Range

Temperature Resistance values Pins/Wire

Sensor Range °F (°C) range (ohms) Color

Outdoor -35 (-37) to 120 280,000 to 3750 3 and 4

(48) (Black)

Coil -35 (-37) to 120 280,000 to 3750 5 and 6

(48) (Brown)

Note: Sensor resistance increases as sensed temperature

decreases.

Ambient Sensor--The ambient sensor as illustrated in

figure 32 on page 24 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 DCB will not

perform demand defrost operation. The DCB 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--The coil temperature sensor as illustrated

in figure 32 on page 24, 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 DCB 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.

NOTE -Within a single room thermostat demand, if

five-strikes occur, the DCB will lock out the unit. The DCB's

24 volt power R must be cycled OFF, or the TESTpins on

DCB must be shorted between 1 to 2 seconds to reset the

DCB.

DCB OPERATIONAL MODES

The DCB has four basic operational modes which are

TEST, NORMAL CALIBRATION and DEFROST.

TEST

1. When Y1 is energized and 24V power is being applied

to the DCB, a test cycle can be initiated by: placing the

termination temperature jumper across the Test pins

(P1) for 2 to 5 seconds.

2. If the jumper remains across the Test pins longer than

five seconds, the DCB will ignore the test pins and

revert to normal operation,

3. The jumper will initiate one cycle per test.

4, Enter the TEST MODE by placing a jumper across the

TEST pins on the DCB after power-up. The TEST pins

are ignored and the test function is locked out if the

shunt is applied on the TEST pins before power-up.

5, DCB timings are reduced, the low-pressure switch is

ignored and the DCB will clear any active lock out

condition,

6, Each test pin shorting will result in one test event, For

each TEST the jumper must be removed for at least

one second and reapplied, Refer to flow chart

illustrated in figure 33 on page 24 for TEST operation,

NOTE -The Y1 input must be active (ON) and the 0 room

thermostat terminal into DCB must be inactive

NORMAL

The DCB 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

The DCB is considered uncalibrated when power is

applied to the DCB, after cool mode operation, or if the coil

temperature exceeds the termination temperature when it

is in heat mode.

DEFROST

For detail information on DEFROST MODE, see Detail

Defrost Mode Operation on page 26.

Page 22

505328M 04/08

Table 15. Defrost Control Board (DCB) Inputs, Outputs and Configurable Settings

DCB DCB Label or

Location Description Purpose Function

P1 TEST Test Mode

Defrost Temperature Termina-

P1 50, 70, 90, 100 tion Shunt (Jumper) Pins

24VAC Thermostat Input /

Wl Output

C 24VAC Common

L Thermostat Service Light

P2 R 24VAC

Y2 Thermostat Input

O Thermostat Input

Y1 Thermostat Input

P3 55, 50, 45, 40 Low Ambient Thermostat Pins

DIS-YEL Coil Sensor

P4 AMB-BLACK Ambient Sensor

COIL-BROWN Discharge Sensor

P5

P6

DS1

DS2

FAN

O OUT

LO-PS

DELAY

TST, PS DF, C, R, O, Y1, Y2

RED LED

GREEN LED

TWO CONNECTORS

O OUT

LO-PS

Delay Mode

Factory Test Connectors

Diagnostic LED

Condenser Fan Operation

24 VAC output

Low-Pressure Switch

Y2 OUT Y2 OUT 24 VAC Output

Y1 OUT Y1 OUT 24 VAC Common Output

HS-PS HS-PS High-Pressure Switch

L Line output

24V 24V 24 Volt output

See Test Mode on page 22 for further details.

The DCB as illustrated in figure 31 on page 21 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.

24VAC common

Thermostat service light connection,

24VAC

Controls the second stage operation of the unit,

Reversing valve solenoid.

Controls the operation of the unit,

Provides selection of the Y2 compressor lock-in temperature. Val-

id 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 sen-

sor.

(P4-4) Connection for outdoor ambient temperature sensor.

No discharge sensor is used, replaced by !OK resistor.

The DCB 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

jumperingthe TES Tpins on P1.

No field use.

Valid states for DCB's two LEDs are OFF, ON and FLASHING

which indicate diagnostics conditions that are described in table

16 on page on page 25.

These two connections provide power for the condenser fan.

24 VAC output connection for reversing valve.

When the low pressure switch trips, the DCB will cycle off the

compressor, and the strike counter in the DCB will count one

strike. The low pressure switch is ignored under the following

conditions:

• during the defrost cycle and 90 seconds after the termination

of defrost

• when the average ambient sensor temperature is below 0°F

(-18°C)

• for 90 seconds following the start up of the compressor

• during TEST mode

24 VAC output for second stage compressor solenoid.

24 VAC common output, switched for enabling compressor

contactor.

When the high pressure switch trips, the DCB will cycle off the

compressor, and the strike counter in the DCB will count one

strike.

24VAC service light output,

24VAC typically used to supply power to the Lennox System

Operation Monitor (LSOM)

Page23

XP15 SERIES

WIRETIE

\

SLEEVE

AMBIENT SENSOR - Extend tip

of plastic sensor just outside of

plastic sleeve.

Place ambient sensor and wire

from DCB inside of plastic sleeve

and route through gap between

corner post and coil support as

shown. Secure with wire tie.

MODELS -024 AND -036

24 TUBES

UP

APRIL 2006)

/

12 TUBES /

UP

16 TUBES UP

/

MODELS -048 AND -060

NOTE- No discharge sensor used; replaced by fOK

resistor

COIL SENSOR - Clip coil temperature sensor from the DCB on the return

bend shown on models as follows:

Model -024 and -036:12 tubes up from bottom (11-1/2");

Model -048 and -060 (before April 2006): 16 tubes up from bottom (15-1/2")

Model -048 and -060 (after April 2006): 24 tubes up from bottom (23-1/2")

Figure 32. Heat Pump Unit Sensor Locations

Short test pins for

Iongerthan one second

but less than two

seconds

Clear 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.

1

Y1 Active ("0" line inactive) /

Short test pins for more than two seconds

L

No further test mode

operation will be

executed until the test

short is removed and

reapplied.

Clear any short cycle lockout and five-strike

fault lockout function, if applicable.

.finOO0.,N ModeII .fin.E T,N Mode II

The DCB will check for ambient and coil

faults (open or shorted). If a fault exists,

the unit will remain in HEAT MODE and

no further TEST MODE operation will be

executed until the test short is removed

and reapplied. If no fault exists the unit

will go into DEFROST MODE.

If in DEFROST Mode ]

The unit will terminate

defrost and enter HEAT

MODE un-calibrated with

defrost timer set for 34

minute test. No further test

mode operation will be

executed until the test

short is removed and

reapplied.

Test pin short REMAINS in place for more than five seconds

The unit will return to HEAT MODE un-calibrated with defrost

timer set for 34 minutes. No further test mode operation will be

executed until the test short is removed and reapplied.

Test pins short REMOVED before a

maximum of five seconds

The unit will remain in DEFROST MODE

until termination on time or temperature.

Figure 33. Test Mode

505328M 04/08

Page 24

Table 16. DCB Diagnostic LEDs

DS2 DS1 Condition Possible Cause(s) Solution

Green Red

1 Check control transformer power (24V).

No power (24V) to DCB terminals R and 2 If power is available to DCB and LED(s) do not light,

OFF OFF Power problem C or DCB failure.

replace DCB.

SIMULTANEOUS Unit operating normally or in standby None required.

SLOW FLASH Normal operation mode.

ALTERNATING Initial power up, safety trip, end of room None required (Jumper TEST pins to override)

SLOW FLASH 5-minute anti-short cycle delay thermostat demand.

SIMULTANEOUS Sensor being detected open or shorted or out of temperature range. DCB will revert to

FAST FLASH Ambient sensor problem time/temperaturedefrost operation. (System will still heat or cool).

ALTERNATING Sensor being detected open or shorted or out of temperature range. DCB will not perform demand

FAST FLASH Coil sensor problem or time/temperature defrost operation. (System will still heat or cool).

ON Indicates that DCB has internal component failure. Cycle 24 volt power to DCB. If code does not

ON DCB failure clear, replace DCB.

FAULT and LOCKOUT CODES (Each fault adds 1 strike to that code's counter; 5 strikes per code = LOCKOUT)

1 Remove any blockages or restrictions from coils

SLOW

OFF FLASH Low pressure fault

OFF ON Low pressure lockout

SLOW

FLASH OFF High pressure fault

ON OFF High pressure lockout

1 Restricted air flow over indoor or out-

door coil.

2 Improper refrigerant charge in sys-

tem.

3 Improper metering device installed or

incorrect operation of metering de-

vice.

4 Incorrect or improper sensor location

or connection to system.

2

3

4

and/or fans. Check indoor and outdoor fan motor for

proper current draws.

Check system charge using approach and

subcooling temperatures.

Check system operating pressures and compare to

unit charging charts.

Make sure all pressure switches and sensors have

secure connections to system to prevent refrigerant

leaks or errors in pressure and temperature

measurements.

SLOW Discharge line temperature

FLASH ON fault

FAST

FLASH ON

FAST

OFF FLASH

FAST

FLASH OFF

Discharge line temperature

Lockout

Discharge sensor fault

Discharge sensorlockout

This code detects shorted sensor or high discharge temperatures. If the discharge line temperature

exceeds a temperature of 300°F (148°C) during compressor operation, the board 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).

The board detects open sensor or out of temperature sensor range. This fault is detected by allow-

ing the unit to run for 90 seconds before checking sensor resistance. Ifthe sensor resistance is not

within range after 90 seconds, the board will count one fault. After five faults, the board will lockout.

SLOW Discharge line temperature

FLASH ON fault

FAST Discharge line temperature

FLASH ON lockout

FAST

FLASH

OFF

Some heat pump units do not use a defrost line sensor. Therefore this code is not applicable.

Some heat pump units do not use a defrost line sensor. However, on these units a resistor is

OFF Discharge sensor fault installed across pins P4-1 and P4-2. If the resistor is missing or damaged then this fault code will

be displayed.

FAST Discharge sensor lockout

FLASH Some heat pump units do not use a defrost line sensor. Therefore this code is not applicable.

Page 25

XP15 SERIES

DETAILED DEFROST MODE OPERATION

The defrost mode has three basic operational modes

which are defrost cycles, actuation and termination, These

modes are described as follows:

Defrost Cycles--The demand DCB initiates a defrost

cycle based on either frost detection or time,

Event

Frost

Detection

Time

Description

If the compressor runs longer than 34

minutes and the actual difference between

the clear coil and frosted coil temperatures

exceeds the maximum difference allowed

by the DCB, a defrost cycle will be initiated.

IMPORTANT -The DCB will allow a

greater accumulation of frost and will

initiate fewer defrost cycles than a

time/temperature defrost system.

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 DCB 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 DCB logs the compressor run time.

If the DCB is not calibrated, a defrost cycle will be initiated

after 34 minutes of heating mode compressor run time.

The DCB 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 DCB fails to calibrate, another defrost cycle will be

initiated after 90 minutes of heating mode compressor run

time, Once the DCB 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 DCB or after six hours of heating

mode compressor run time has been logged since the last

defrost cycle,

NOTE -If ambient or coil fault is detected, the DCB will not

execute the TEST mode.

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 34 minutes of run time,

DCB DIAGNOSTICS

See table 16 on page 25 to determine DCB operational

conditions and to diagnose cause and solution to

problems.

Before the start of each heating and cooling season, the

following service checks should be performed by a

qualified service technician. First, turn off electrical power

to the unit prior to performing unit maintenance.

_WARNING

• Inspect and clean the outdoor and indoor coils. The

outdoor coil may be flushed with a water hose.

NOTE -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, etc.)

• Visually inspect the refrigerant lines and coils for leaks.

• Check wiring for loose connections.

• Check voltage at the indoor and outdoor units (with

units operating).

• Check the amperage draw at the outdoor fan motor,

compressor, and indoor blower motor. Values should

be compared with those given on unit nameplate.

• Check, clean (or replace) indoor unit filters.

• Check the refrigerant charge and gauge the system

pressures.

• Check the condensate drain line for free and

unobstructed flow; clean, if necessary.

• Outdoor unit fan motor is prelubricated and sealed. No

further lubrication is needed.

NOTE -If owner reports insufficient cooling, the unit

should be gauged and refrigerant charge checked.

Refer to section on refrigerant charging in this

instruction.

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.

IMPORTANT

3, Reusable Filter--Many indoor units are equipped

with reusable foam filters. Clean foam filters with a

Page 26

505328M 04/08

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, Electronic Air Cleaner--Some systems are

equipped with an electronic air cleaner, designed to

remove airborne particles from the air passing through

the cleaner. If your system is so equipped, ask your

dealer for maintenance instructions.

5. Indoor Unit--The indoor unit's evaporator coil is

equipped with a drain pan to collect condensate

formed as your system removes humidity from the

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.)

IMPORTANT

6, Outdoor Unit--Make sure no obstructions restrict

airflow to the outdoor unit. Leaves, trash or shrubs

crowding the unit cause the outdoor unit to work harder

and use more energy. Keep shrubbery trimmed away

from the unit and periodically check for debris which

collects around the unit.

When removing debris from around the unit, be aware

of metal edges on parts and screws. Although special

care has been taken to keep exposed edges to a

minimum, physical contact with metal edges and

corners while applying excessive force or rapid motion

can result in personal injury.

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 heat

pump system.

HEAT PUMP OPERATION

Your new Lennox heat pump has several characteristics

that you should be aware of:

• 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.

• 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.

• 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 RESTART

PROCEDURE

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.

THERMOSTAT OPERATION

Though your thermostat may vary somewhat from the

description below, its operation will be similar.

Temperature Setting Levers

Most heat pump thermostats have two temperature

selector levers: one for heating and one for cooling. Set the

levers or dials to the desired temperature setpoints for both

heating and cooling. Avoid frequent temperature

adjustment; turning the unit off and back on before

pressures equalize puts stress on the unit compressor.

Fan Switch

In AUTO or INT (intermittent) mode, the blower operates

only when the thermostat calls for heating or cooling. This

mode is generally preferred when humidity control is a

priority. The ON or CONT mode provides continuous

indoor blower operation, regardless of whether the

compressor or auxiliary heat are operating. This mode is

required when constant air circulation or filtering is desired.

System Switch

Set the system switch for heating, cooling or auto

operation. The auto mode allows the heat pump to

automatically switch from heating mode to cooling mode to

maintain predetermined comfort settings. Many heat

pump thermostats are also equipped with an emergency

heat mode which locks out heat pump operation and

provides temporary heat supplied by the auxiliary heat.

Indicating Light

Most heat pump thermostats have an amber light which

indicates when the heat pump is operating in the

emergency heat mode.

Temperature Indicator

The temperature indicator displays the actual room

temperature.

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XP15 SERIES

PROGRAMMABLE THERMOSTATS

Your Lennox system may be controlled by a

programmable thermostat, These thermostats provide the

added feature of programmable time-of-day setpoints for

both heating and cooling, Refer to the user's information

manual provided with your particular thermostat for

operation details,

PRESERVlCE CHECK

If your system fails to operate, check the following before

calling for service:

• Check to see that all electrical disconnect switches are

ON,

• Make sure the room thermostat temperature selector

and system switch (HEAT, COOL and AUTO) are

properly set,

• Check for any blown fuses or tripped circuit breakers.

• Make sure unit access panels are in place.

• Make sure air filter is clean.

• If service is needed, locate and write down the unit

model number and have it handy before calling.

OPTIONAL ACCESSORIES

Optional accessories for the XP15 include the following

(also, see Engineering Handbook for more details):

• Compressor starter kit

• Low ambient kit

• Vapor line drier

• Wire tie kit

Customer Address

Indoor Unit Model Serial

Outdoor Unit Model Serial

Notes:

START-UP CHECKS

Refrigerant Type:

Rated Load Amps

Condenser Fan Full Load Amps

COOLING MODE

Vapor Pressure:

Supply Air Temperature:

HEATING MODE

Actual Amps

Actual Amps:

Liquid Pressure:

Ambient Temperature:

SUBCOOLING

APPROACH

COIL TEMP DROP

Rated Volts Actual Volts

Return Air Temperature:

Vapor Pressure: Liquid Pressure:

Supply Air Temperature: Ambient Temperature: Return Air Temperature:

System Refrigerant Charge (Refer to manufacturer's information on unit or installation instructions for required subcooling and approach

temperatures.)

Subcooling: A B

Saturated Condensing Temperature (A)

minus Liquid Line Temperature (B)

Approach: A B

Liquid Line Temperature (A)

minus Outdoor Air Temperature (B)

Indoor Coil Temp. Drop (18 to 22°F) A B

Return Air Temperature (A)

minus Supply Air Temperature (B)

505328M 04/08

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