¢>,2008 Lennox industries Inc. DatIas, Texas, USA RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE _, WARNING AI_ CAUTION A IMPORTANT INSTALLATION INSTRUCTIONS Elite ® Series XP16 Series Units HEAT PUMPS _ Technical 505,329M J_.LLPublications 04/08 Litho U.S.A. Supersedes 01/08 Shipping and Packing List ...................... 1 XP16 Heat Pumps ............................. 1 Unit Dimensions ............................... 2 General Information ........................... 3 Recovering Refrigerant from Existing System ..... 5 Removing Existing Outdoor Unit ................. 6 Positioning New Outdoor Unit ................... 6 Removing and Installing Panels ................. 7 New or Replacement Line Set ................... 9 Brazing Connections ........................... 11 Removing Indoor Unit Metering Device ........... 11 Flushing the System ........................... 12 Installing New Indoor Unit Metering Device ........ 13 Testing for Leaks .............................. 13 Evacuating the System ......................... 15 Servicing Unit Delivered Void of Charge ........... 16 Electrical Connections ......................... 16 Start-Up and Charging Procedures ............... 17 System Operation ............................. 17 Charge using the Subcooling Method ............ 21 System Operation ............................. 21 Defrost System ............................... 21 Maintenance .................................. 25 Homeowner Information ........................ 26 Checklists .................................... 28 Check unit for shipping damage. Consult last carrier immediately if damage is found. 1 -Assembled XP16 outdoor unit A IMPORTANT The XP16 Heat Pumps, which will also be referred to in this instruction as the outdoor unit, uses HFC-410A refrigerant. This outdoor unit must be installed with a matching indoor unit and line set as outlined in the Lennox XP f 6 Engineering Handbook. This outdoor unit is designed for use in systems that use check thermal expansion valve (CTXV) refrigerant metering devices. 04/08 IIIHIIIIII]]IIII]IIIIIIIII]IIIIIIIII] Page 1 505,329M IIII]III]]IIIIIIIII]IIHI]I]II
Shipping and Packing List ...................... 1XP16 Heat Pumps ............................. 1Unit Dimensions ............................... 2General Information ........................... 3Recovering Refrigerant from Existing System ..... 5Removing Existing Outdoor Unit ................. 6Positioning New Outdoor Unit ................... 6Removing and Installing Panels ................. 7New or Replacement Line Set ................... 9Brazing Connections ........................... 11Removing Indoor Unit Metering Device ........... 11Flushing the System ........................... 12Installing New Indoor Unit Metering Device ........ 13Testing for Leaks .............................. 13Evacuating the System ......................... 15Servicing Unit Delivered Void of Charge ........... 16Electrical Connections ......................... 16Start-Up and Charging Procedures ............... 17System Operation ............................. 17Charge using the Subcooling Method ............ 21System Operation ............................. 21Defrost System ............................... 21Maintenance .................................. 25Homeowner Information ........................ 26Checklists .................................... 28
Check unit for shipping damage. Consult last carrierimmediately if damage is found.
1 -Assembled XP16 outdoor unit
A IMPORTANT The XP16 Heat Pumps, which will also be referred to in thisinstruction as the outdoor unit, uses HFC-410Arefrigerant. This outdoor unit must be installed with amatching indoor unit and line set as outlined in the LennoxXP f 6 Engineering Handbook.
This outdoor unit is designed for use in systems that usecheck thermal expansion valve (CTXV) refrigerantmetering devices.
WARNING OPERATING SERVICE VALVESThe liquid and vapor line service valves are used forremoving refrigerant, flushing, leak testing evacuatingchecking charge and charging
Each valve is equipped with a service port which has afactory-installed valve stem
IMPORTANT
These instructions are intended as a general guide and donot supersede local codes in any way. Consult authoritieswho have jurisdiction before installation.
When servicing or repairing HVAC components, ensurethe fasteners are appropriately tightened. Table 1 showstorque values for fasteners.
Table 1 Torque Requirements
Parts Recommended Torque
Service valve cap 8 ft Ib 11 NM
Sheet metal screws 16 in Ib 2 NM
Machine screws #10 28 in Ib 3 NM
Compressor bolts 90 in Ib 10 NM
Gauge port seal cap 8 ft Ib 11 NM
USING MANIFOLD GAUGE SETS
When checking the system charge only use a manifoldgauge set that features low loss anti-blow back fittingsSee figure 2 for a typical manifold gauge connection setup
Manifold gauge sets used with HFC-410A refrigerantsystems must be capable of handling the higher systemoperating pressures The gauges should be rated for usewith pressures of 0 - 800 on the high side and a low side of30" vacuum to 250 psi with dampened speed to 500 psiGauge hoses must be rated for use at up to 800 psi ofpressure with a 4000 psi burst rating
I/6 TURN 1/12 TURN
9
8 4
Figure 1 Cap Tightening Distances
IMPORTANT
To Access Angle-Type Service Port:
A service port cap protects the service port core fromcontamination and serves as the primary leak seal1 Remove service port cap with an appropriately sized
wrench
2 Connect gauge to the service port
3 When testing is completed replace service port cap andtighten as follows:
• With Torque Wrench: Finger tighten and thentighten per table 1
• Without Torque Wrench: Finger tighten and use anappropriately sized wrench to turn an additional1/6 turn clockwise as illustrated in figure 1
A valve stem cap protects the valve stem fromcontamination and assures a leak-free seal,
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" forvapor-line valve sizes) to back the stem outcounterclockwise 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,• Without Torque Wrench: Finger tighten and use an
appropriately sized wrenched to turn an additional1/12 turn clockwise as illustrated in figure 1.
SERVICE PORTCAP _-
SERVICE PORTSERVICE PORT
CLOSED) INSERT HEXWRENCH HERE
VALVE STEMFRONT-SEATED
TOINDOORUNIT
TO OUTDOOR
STEM CAP
CLOSED TO BOTHINDOORAND OUTDOOR UNITS
Figure 3. Angle-Type Service Valve(Font-Seated Closed)
NOTE - A label with specific torque requirements may beaffixed to the stem cap. If the label is present, use thespecified torque.
NOTE- To prevent stripping of the cap, the wrench shouldbe appropriately sized and fit snugly over the cap beforetightening the cap.
SERVICE PORT CAP
SERVICE PORT SERVICE PORTCORE
OPEN TO BOTH(VALVE STEM SHOWN OPEN)
INDOOR AND INSERT HEX WRENCH HEREOUTDOOR UNITS
TO INDOORUNIT
STEM CAP
TO OUTDOOR UNIT
Figure 4. Angle-Type Service Valve(Back-Seated Opened)
To Access Bali-Type Service Port:
A service port cap protects the service port core fromcontamination and serves as the primary leak seal.
1. Remove service port cap with an appropriately sizedwrench.
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 thentighten per table 1,
• Without Torque Wrench: Finger tighten and use anappropriately sized wrench to turn an additional1/6 turn clockwise as illustrated in figure 1.
505329M 04/08
Page 4
OPEN TO LINE SET WHEN VALVE IS CLOSED,TO BOTH LINE SET AND UNIT WHEN VALVE ISOPEN.
TO INDOOR UNIT
TO OPEN ROTATE STEMCOUNTERCLOCKWISE 90° .
TO CLOSE ROTATE STEMCLOCKWISE 90 ° .
BALL (SHOWNCLOSED)
VALVESTEM
CORE
SERVICE PORT CAP
TO OUTDOOR UNITSTEM CAP
Figure 5. Bali-Type Service Valve
To Open and Close Bali-Type Service Valve:
A valve stem cap protects the valve stem fromcontamination and assures a leak-free seal,
1. Remove stem cap with an appropriately sized wrench,
2. Use an appropriately sized wrenched to open. To openvalve, roate stem counterclockwise 90°, To closerotate stem clockwise 90°.
3. Replace the stem cap and tighten as follows:
• With Torque Wrench: Finger tighten and thentighten per table 1.
• Without Torque Wrench: Finger tighten and use anappropriately sized wrench to turn an additional1/12 turn clockwise as illustrated in figure 1,
NOTE - A label with specific torque requirements may beaffixed to the stem cap. If the label is present, use thespecified torque.
Remove existing HCFC-22 refrigerant using one of thefollowing procedures:
METHOD 1:
If the existing outdoor unit is not equipped with shut-offvalves, or if the unit is not operational and you plan to usethe existing HCFC-22 to flush the system,
NOTE - Use recovery machine instructions for specificsetup requirements,
1. Disconnect all power to the existing outdoor unit,
2. Connect to the existing unit a gauge set, cleanrecovery cylinder and a recovery machine. Use theinstructions provided with the recovery machine onhow to setup the connections,
3. Remove all HCFC-22 refrigerant from the existingsystem, Check gauges after shutdown to confirm thatthe entire system is completely void of refrigerant,
RECOVERY MACHINEMANIFOLD GAUGES
/OUTDOOR UNIT
Figure 6. Typical Refrigerant Recovery(Method 1)
NOTE - Use recovery machine instructions for specificsetup requirements.METHOD 2:
Use this method if the existing outdoor unit is equippedwith manual shut-off valves, and plan on using newHCFC-22 refrigerant to flush the system,
IMPORTANT: Some system configurations may containhigher than normal refrigerant charge due to either largeinternal coil volumes, and/or long line sets, The followingconditions may cause the compressor to stop functioning:
The following devices could prevent full system chargerecovery into the outdoor unit:
• Outdoor unit's high or low-pressure switches (ifapplicable) when tripped can cycled the compressorOFF.
• Compressor can stop pumping due to tripped internalpressure relief valve.
• Compressor has internal vacuum protection that isdesigned to unload the scrolls (compressor stopspumping) when the pressure ratio meets a certainvalue or when the suction pressure is as high as 20psig. (Compressor suction pressures should never beallowed to go into a vacuum, Prolonged operation atlow suction pressures will result in overheating of thescrolls and permanent damage to the scroll tips, drivebearings and internal seals),
Once the compressor can not pump down to a lowerpressure due to one of the above system conditions, shutoff the suction valve. Turn OFF the main power to unit anduse a recovery machine to recover any refrigerant left inthe indoor coil and line set.
Perform the following task:1, Start the existing HCFC-22 system in the cooling
mode and close the liquid line valve.2, Pump as much of the existing HCFC-22 refrigerant
with the compressor back into the outdoor unit untilyou have reached the limitations of the outdoorsystem, Turn the outdoor unit main power OFF anduse a recovery machine to remove the remainingrefrigerant in the system,
Page 5XP16 SERIES
NOTE - It may be necessary to bypass the low pressureswitches if equipped to ensure complete refrigerantevacuation.
3. When the low side system pressures reach 0 psig,close the suction line valve,
4. Check gauges after shutdown to confirm that thevalves are not allowing refrigerant to flow back into thelow side of the system.
Perform the following task at the existing outdoor unit:• Disconnect line set at the service valves,
• Disconnect electrical service at the disconnect switch.
• Remove old outdoor unit,
A CAUTION
See Unit Dimensions on page 3 for sizing mounting slab,platforms or supports. Refer to figure 7 for mandatoryinstallation clearance requirements.
CONTROL PANELACCESS LOCATION
* SEE NOTES BELOW THIS FIGURE FOR FURTHER DETAILS.
Figure 7. Installation Clearances
NOTES:
• Service clearance of 30 in. (762 mm) must bemaintained on one of the sides adjacent to the controlbox.
• Clearance to one of the other three sides must be 36in, (914 mm).
• Clearance to one of the remaining two sides may be12 in, (305 mm) and the final side may be 6 in, (152mm).
• 48 in. (1219 mm) clearance required on top of unit.
• A clearance of 24 in. (610 mm) must be maintainedbetween two units,
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
• Some localities are adopting sound ordinances basedon the unit's sound level registered from the adjacentproperty, not from the installation property. Install theunit as far as possible from the property line,
• When possible, do not install the unit directly outsidea window, Glass has a very high level of soundtransmission, For proper placement of unit in relationto a window see the provided illustration in figure 8.
INSTALLUNITAWAYFROMWINDOWS--------' II--
IIIIIHIlls
Figure 8. Outside Unit Placement
PLACING UNIT ON SLABWhen installing unit at grade level, the top of the slabshould be high enough above grade so that water fromhigher ground will not collect around the unit. The slabshould have a slope tolerance as described in figure 9,
NOTE - If necessary for stability, anchor unit to slab asdescribed in Stabilizing Unit on Uneven Surfaces on page7,
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 BUILDINGSTRUCTURE.
iL
BUILDING
STRUCTURE_-r
MOUNTING
SLAB --T-
GROUNDLEVEL
Figure 9. Slab Mounting at Ground Level
ELEVATING THE UNIT (SMALL-BASE UNITS)If additional elevation is necessary, raise the unit byextending the length of the unit support feet. This may bedone by cutting four equal true-cut lengths of Schedule(SCH) 40, 4" (101.6mm) piping to the height required asillustrated in figure 10.
505329M 04/08
Page 6
BASE
LEG DETAIL
4" (101.6MM) SCH 40
Figure 10. Elevated Slab Mounting using FeetExtenders (Small Base Units)
NOTE - Keep the height of extenders short enough toensure a sturdy installation. If it is necessary to extendfurther, consider a different type of field-fabricatedframework that is sturdy enough for greater heights.
The inside diameter of the 4" (101.6mm) piping isapproximately 0.25" (6.35mm) greater than thepre-installed feet on the unit. Devise a shim that will take upthe space and hold the extenders onto the feet during thisprocedure. Small strips of 0.125" (3.175mm) thickadhesive foam may be used. One or two small 1"(25.4mm) square strips should be adequate to hold theextender in place.
ELEVATING THE UNIT (LARGER-BASE UNITS)
Unlike the small-base units which use round support feet,the larger-base units are outfitted with elongated supportfeet as illustrated in figure 11 which uses a similar methodfor elevating the unit.
If additional elevation is necessary, raise the unit byextending the length of the unit support feet. This may beachieved by using a 2" SCH 40 female threaded adapter.
The specified coupling will fit snuggly into the recessedportion of the feet. Use additional 2" SCH 40 male threadedadaptors which can be threaded into the female threadedadaptors to make additional adjustments to the level of theunit.
NOTE - Keep the height of extenders short enough toensure a sturdy installation. If it is necessary to extendfurther, consider a different type of field-fabricatedframework that is sturdy enough for greater heights.
BASE
LEG DETAIL
2" (50.8MM) SCH 40FEMALE THREADEDADAPTER
Figure 11. Elevated Slab Mounting using FeetExtenders (Larger Base Units)
ROOF MOUNTINGInstall unit at a minimum of four inches above the surfaceof the roof. Care must be taken to ensure weight of unit isproperly distributed over roof joists and rafters. Eitherredwood or steel supports are recommended.
CAUTION
Page 7XP16 SERIES
REMOVING PANELSRemove the Iouvered panels as follows:
1. Remove two screws, allowing the panel to swing openslightly as illustrated in figure 12.
NOTE - Hold the panel firmly throughout this procedure2, Rotate bottom corner of panel away from hinge corner
post until lower three tabs clear the slots as illustratedin figure 12, detail B.
3, Move panel down until lip of upper tab clears the topslot in corner post as illustrated in figure 12, detail A,
INSTALLING PANEL
Install the Iouvered panels as follows:1, Position the panel almost parallel with the unit as
illustrated in figure 13, detail D with the screw side asclose to the unit as possible.
2, With a continuous motion slightly rotate and guide thelip of top tab inward as illustrated in figure 12, detailsA and C, then upward into the top slot of the hingecorner post.
3, Rotate panel to vertical to fully engage all tabs,
4, Holding the panel's hinged side firmly in place, closethe right-hand side of the panel, aligning the screwholes.
5, When panel is correctly positioned and aligned, insertthe screws and tighten,
IMPORTANT! DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB. TAB ISFOR 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.
SCREWHOLES _
LIP
\
DETAIL
ROTATE IN THIS DIRECTION;THEN DOWN TO REMOVE
PANEL
Figure 12. Removing/Installing Louvered Panels(Details A, B and C)
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNITAS POSSIBLE) WHILE INSTALLING PANEL.
HOLD DOOR FIRMLY TO THE HINGEDANGLE MAY BE TOO SIDE TO MAINTAIN
To help stabilize an outdoor unit, some installations mayrequire strapping the unit to the pad using brackets andanchors commonly available in the marketplace,
With unit positioned at installation site, remove two sideIouvered panels to expose the unit base pan, Install thebrackets as illustrated in figure 14 and using conventionalpractices; replace the panels after installation is complete,
Slab Side Mountingk
#101/2" LONG SELF-DRILLINGMETAL SCREWS
STABILIZING
BRACKET (18 GAUGEMETAL - 2" WIDTH;HEIGHT AS REQ'D)
MountingSTABILIZING BRACKET MINIMUM 1 J(18 GAUGE METAL- 2" PER SIDE _WIDTH; HEIGHT ASREOD,;BENDTOFORM
liI "FOR EXTRA
STABILITY
ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY,2 BRACKETS PER SIDE, 2" FROM EACH CORNER.
Figure 14. Installing Stabilizer Brackets
505329M 04/08
Page 8
A IMPORTANT
This section provides information on installation orreplacement of existing line set. If line set are not beinginstalled then proceed to Brazing Connections on page 11.
If refrigerant lines are routed through a wall, seal andisolate the opening so vibration is not transmitted to thebuilding. Pay close attention to line set isolation duringinstallation of any HVAC system. When properly isolatedfrom building structures (walls, ceilings, floors), therefrigerant lines will not create unnecessary vibration andsubsequent sounds. Also, consider the following whenplacing and installing a high-efficiency air conditioner,
REFRIGERANT LINE SET
Field refrigerant piping consists of liquid and suction linesfrom the outdoor unit (braze connections) to the indoor unitcoil (flare or sweat connections). Use Lennox L15 (sweat,non-flare) series line set, or use field-fabricated refrigerantlines as listed in table 2,
Table 2. Refrigerant Line Set
Model
Field Connections Recommended Line Set
Liquid Suction Liquid SuctionLine Line Line Line L15 Line Set
L15-413/8". 3/4" 3/8" 3/4"-024 (10 ram) (19 ram) (10 ram) (19 ram) 15 ft. - 50 ft.
NOTE - When installing refrigerant lines longer than 50feet, see the Lennox Refrigerant Piping Design andFabrication Guidelines, or contact Lennox TechnicalSupport Product Applications for assistance. To obtain thecorrect information from Lennox, be sure to communicatethe following points:
• Model (XP16) and size of unit (e,g. -060).
• Line set diameters for the unit being installed as listedin table 2 and total length of installation,
• Number of elbows and if there is a rise or drop of thepiping,
MATCHING WITH NEW OR EXISTING INDOOR COILAND LINE SET
The RFCl-metering line consisted of a small bore copperline that ran from condenser to evaporator coil. Refrigerantwas metered into the evaporator by utilizingtemperature/pressure evaporation effects on refrigerant inthe small RFC line. The length and bore of the RFC linecorresponded to the size of cooling unit.
If the XP16 is being used with either a new or existingindoor coil which is equipped with a liquid line which servedas a metering device (RFCI), the liquid line must bereplaced prior to the installation of the XP16 unit. Typicallya liquid line used to meter flow is 1/4" in diameter andcopper.
INSTALLING LINE SET
Line Set Isolation--This reference illustratesprocedures, which ensure proper refrigerant line setisolation:
• Installation of line set on horizontal runs isillustrated in figure 15,
• Installation of a transition from horizontal tovertical is illustrated in figure 16,
• Installation of line set on vertical runs is illustrated infigure 17,
TO HANG LINE SET FROM JOIST ORRAFTER, USE EITHER METAL STRAPPINGMATERIAL OR ANCHORED HEAVY NYLONWIRE TIES.
STRAPPING MATERIAL
(AROUND SUCTIONLINE ONLY)
8 FEET
WIRE TIE
(AROUND/ SUCTION LINE
ONLY)
TAPE ORWIRE TIE
METALSLEEVE
TAPE ORWIRE TIE
STRAP THE SUCTION LINE TOTHE JOIST OR RAFTER AT 8 FEETINTERVALS THEN STRAP THELIQUID LINE TO THE SUCTION
LINE.
Figure 15. Refrigerant Line Set: InstallingHorizontal Runs
Page 9XP16 SERIES
ANCHOREDHEAVYNYLONWIRETIE
WALL
METALSLEEVE
AUTOMOTIVEMUFFLER-TYPEHANGER
WALLSTUD
METALSLEEVE
S; sA cY, o 't.X\ L,QU,DL,NE
k\SUCTION LINE - WRAPPED IN
ARMAFLEX
STRAP LIQUID LINE TOSUCTION LINE
_ LIQUID LINE
xSUCTION LINE - WRAPPED INARMAFLEX
IMPORTANT - REFRIGERANT LINES MUST NOT CONTACT WALL.
LIQUID LINEOUTSIDE WALL SUCTION LINE
NOTE - SIMILAR INSTALLATIONPRACTICES SHOULD BE USEDIF LINE SET IS TO BE INSTALLEDON EXTERIOR OF OUTSIDEWALL.
m
/ / I/ / / / /
WIRE TIE
INSIDE WALLSTRAP
SLEEVE
WIRE TIE
-- WOOD BLOCK
WIRE TIE
STRAP
IMPORTANT! REFRIGERANTLINES MUST NOT CONTACTSTRUCTURE,
Figure 16. Refrigerant Line Set: Transition fromVertical to Horizontal
Figure 17. Refrigerant Line Set: Installing VerticalRuns (New Construction Shown)
1CUT AND DEBUR
INSTALL CORE ONLY FOR
3OTH SERVICE PORTS after theyhave coolED.
INDOOR UNIT
REMOVE CAP AND CORE FROMBOTH LIQUID AND SUCTION
SERVICE PORTS
outdoorUNIT
SERVICE PORT MUST BEOPEN TO ALLOW EXITPOINT FOR NITROGEN SERVICE
_. SUCTION LINE _ /VALVE
LIQUID LINE SERVICE_
VALVE
Figure 18. Brazing Connections
505329M 04/08
Page 10
Usethefollowingproceduretobrazethelinesettothenewair conditionerunit.Figure18is providedas a generalguidefor preparingto brazethe line set to the airconditionerunit.
WARNING
WARNÁNG
_WARNING
1. Cut ends of the refrigerant lines square (free fromnicks or dents). Debur the ends. The pipe must remainround, do not pinch end of the line.
2. Remove service cap and core from both the suctionand liquid line service ports.
3. Connect gauge low pressure side to liquid line servicevalve.
4. To protect components during brazing, wrap a wetcloth around the liquid line service valve body andcopper tube stub and use another wet clothunderneath 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 therefrigeration gauge set into the valve stem portconnection on the liquid line service valve and out ofthe valve stem port connection on the suction servicevalve.
NOTE - The RFCIV or TXV metering device at the indoorunit will allow low pressure nitrogen to flow through thesystem.)
NO TE - Use silver alloy brazing rods with five or six percentminimum silver alloy for copper-to-copper brazing or 45percent silver alloy for copper-to-brass or copper-to-steelbrazing.
6, Braze the liquid line to the liquid line service valve.Turn off nitrogen flow. Repeat procedure starting atparagraph 4 for brazing the suction line to the suctionservice valve.
7, After all connections have been brazed, disconnectmanifold gauge set the from service ports and removewrapping. Reinstall the service port core for both of theoutdoor unit's service valves,
Remove the existing HCFC-22 refrigerant flow controlorifice or thermal expansion valve from the indoor coil. Theexisting indoor unit HCFC-22 metering device is notapproved for use with HFC-410A refrigerant and mayprevent proper flushing.REPLACEMENT PARTS
If replacement parts are necessary for the indoor unit,order kit 69J46. The kit includes:
• 10 -- Brass nuts for liquid line assemblies
• 20 -- Teflon rings
• 10 -- Liquid line orifice housings
• 10 -- Liquid line assemblies
PISTONLIQUID LINE ORIFICE HOUSINGS (10) / RETAINER
TEFLON RINGS (20)
..(_J jBRASS NUTS (10) _
--/"1 . STRANER,, O%ER
LIQUID LINE ASSEMBLIES
(INCLUDES STRAINER) (10) LIQUID LINEASSEMBLY
Figure 19.69J46 Kit Components
TYPICAL FIXED ORIFICE REMOVAL PROCEDURE1. On fully cased coils, remove the coil access and
plumbing panels.
2. Remove any shipping clamps holding the liquid lineand distributor assembly.
3. Using two wrenches, disconnect liquid line from liquidline orifice housing. Take care not to twist or damagedistributor tubes during this process.
4. Remove and discard fixed orifice, valve stemassembly if present and Teflon washer as illustrated infigure 20.
Page 11XP16 SERIES
5. Use a field-provided fitting to temporary reconnect theliquid line to the indoor unit's liquid line orifice housing,
1. On fully cased coils, remove the coil access andplumbing panels,
2. Remove any shipping clamps holding the liquid lineand distributor assembly,
3. Disconnect the equalizer line from the TXV equalizerline fitting on the suction line,
(Uncased Coil Shown)TWO PIECE
PATCH PLATEUNCASED COIL LIQUID LINE STUB END
ONLY) ORIFICE HOUSING
DISTRIBUTOR TXVTUBES
RING
SENSINGLINE
/MALE EQUALIZER LINE /
FITTING / SUCTIONSENSING BULB L_, LIQUID
LINE
Figure 21. Typical TXV Removal
4. Remove the suction line sensing bulb.
5. Disconnect the liquid line from the TXV at the liquid lineassembly,
6. Disconnect the TXV from the liquid line orifice housing.Take care not to twist or damage distributor tubesduring this process,
7. Remove and discard TXV and the two Teflon rings asillustrated.
8. Use a field-provided fitting to temporary reconnect theliquid line to the indoor unit's liquid line orifice housing,
A IMPORTANT
A IMPORTANT
IMPORTANT
CAUTION
505329M 04/08
Page 12
If theoriginalsystemused:• HCFC-22refrigerant,thenflushthesystemusingthe
procedureprovidedinthissection,• HFC-410Arefrigerant,thenproceedto Installing New
Refrigerant Metering Device.
INVERTED HCFC-22 CYLINDER/ CONTAINS CLEAN HCFC-22 TO
BE USED FOR FLUSHING. GAUGE
!O_ U'! MANIFOLD
LOW HIGHI PRESSURE PRESSURE
suc t'_SERVICE VALVE _ _ I : _'_ :I '_J
/\/\ _=n _ _ i-gh,/ \ _ i I u" w _ ,_ 'U
OPENEDIIII CLOSED
RECOVERYCYLINDER
RECOVERY MACHINE
NOTE - THE INVERTED HCFC-22 CYLINDER MUST CONTAIN AT LEAST THE SAMEAMOUNT OF REFRIGERANT AS WAS RECOVERED FROM THE EXISTING SYSTEM,
Figure 22. Typical Flushing Connection
REQUIRED EQUIPMENTEquipment required to flush the existing line set and indoorunit coil:
• Two clean HCFC-22 recovery bottles,
• Oilless recovery machine with pump-down feature,
• Two gauge sets (one for HCFC-22; one forHFC-410A).
FLUSHING PROCEDURE1. Connect the following:
• HCFC-22 cylinder with clean refrigerant to thesuction service valve,
• HCFC-22 gauge set to the liquid line valve,
• Recovery machine with an empty recovery tank tothe gauge set,
2. Set the recovery machine for liquid recovery and startthe recovery machine. Open the gauge set valves toallow the recovery machine to pull a vacuum on theexisting system line set and indoor unit coil.
3. Invert the cylinder of clean HCFC-22 and open itsvalve to allow liquid refrigerant to flow into the systemthrough the suction line valve, Allow the refrigerant topass from the cylinder and through the line set and theindoor unit coil before it enters the recovery machine.
4. After all of the liquid refrigerant has been recovered,switch the recovery machine to suction recovery sothat all of the HCFC-22 suction is recovered. Allow therecovery machine to pull a vacuum on the system,
5. Close the valve on the inverted HCFC-22 drum andthe gauge set valves. Pump the remaining refrigerantout of the recovery machine and turn the machine off.
XP16 units use CTXV for metering refrigerant only. Thissection provides instructions on installing CTXVrefrigerant metering device.
1/2 TURN
Figure 23. Tightening Distance
TYPICAL CTXV INSTALLATION PROCEDUREThe CTXV unit can be installed internal or external to theindoor coil. In applications where an uncased coil is beinginstalled in a field-provided plenum, install the CTXV in amanner that will provide access for field servicing of theCTXV, Refer to Figure 24 for reference during installationof CTXV unit.
TWOPIECE (Uncased Coil Shown)PATCH PLATE
UNCASED COILONLY) LIQUID LINE
. .'_ORIFICE STUB END
HOUSING
DISTRIBUTOR CTXVTUBES. -
RING
SENSINGLINE
MALE EQUALIZER LINE
FITTING (SEE FIGURE 26FOR FURTHER DETAILS) LINE
SENSING BULB INSULATION ISREQUIRED IF MOUNTED EXTERNALTO THE COIL CASING SEE FIGURE 25FOR BULB POSITIONING.
LIQUIDLINE
Figure 24. Typical CTXV Installation
1, Remove the field-provided fitting that temporaryreconnected the liquid line to the indoor unit'sdistributor assembly,
Page13XP16 SERIES
2. Install one of the provided Teflon rings around thestubbed end of the CTXV and lightly lubricate theconnector threads and expose surface of the Teflonring with refrigerant oil.
3. Attach the stubbed end of the CTXV to the liquid lineorifice housing, Finger tighten and use an appropriatelysized wrench to turn an additional 1/2 turn clockwiseas illustrated in figure 23, or 20 ft-lb,
4. Place the remaining Teflon washer around the otherend of the CTXV. Lightly lubricate connector threadsand expose surface of the Teflon ring with refrigerantoil,
5. Attach the liquid line assembly to the CTXV. Fingertighten and use an appropriately sized wrench to turnan additional 1/2 turn clockwise as illustrated in figure23, or 20 ft-lb,
6. Attach the suction line sensing bulb in the properorientation as illustrated in figure 25 using the clampand screws provided,
NOTE - Insulating the sensing bulb once installed may berequired when the bulb location is external to the coilcasing.
ON LINES SMALLER THANSUCTION LINE 7/8", MOUNT SENSING BULB
AT EITHER THE 3 OR 9
'Lr"* _,,,_ __,_,"_ __CK POSITION.
'X_L,,'*"L_"
BULB\_
SUCTION LINE
(BULB .
ON 7/8" AND LARGER LINES,MOUNT SENSING BULB ATEITHER THE 4 OR 8 O'CLOCK
'TO%M%EVL%MOUNT
NOTE - NEVER MOUNT ON BOTTOM OF LINE.
Figure 25. TXV Sensing Bulb Installation
7. Remove and discard either the flare seal cap or flarenut with copper flare seal bonnet from the equalizerline port on the suction line as illustrated in figure 26.
A IMPORTANT
FLARE SEAL_CAP ÷ J_ FLARE NUT
X COPPEROR --FLARE SEAL
BONNET
J
•_MALE BRASS EQUALIZERLINE FITTING
SUCTION LINE
Figure 26. Copper Flare Seal Bonnet Removal8. Connect the equalizer line from the CTXV to the
equalizer suction port on the suction line. Fingertighten the flare nut plus 1/8 turn (7 ft-lbs) as illustratedin figure 23,
NOTE - To prevent any possibility of water damage,properly insulate all parts of the CTXV assembly that maysweat due to temperature differences between the valveand its surrounding ambient temperatures,
See the Lennox XP16 Engineering Handbook forapproved CTXV kit match-ups and applicationinformation.
The reference CTXV kits include:
O_TEFLON
RINGS (2) _ I_
STRAP (1)
Figure 27. CTXV Kit Components
After the line set has been con nected to the indoor unit andair conditioner, check the line set connections and indoorunit for leaks. Use the following procedure to test for leaks:
IMPORTANT
505329M 04/08
Page 14
,A WARNING
,WARNING
7. After leak testing disconnect gauges from serviceports.
Evacuating the system of non-condensables is critical forproper operation of the unit. Non-oondensables aredefined as any gas that will not condense undertemperatures and pressures present during operation ofan air conditioning system. Non-condensables and watersuction combine with refrigerant to produce substancesthat corrode copper piping and compressor parts.
,A WARNING
,WARNING
1. Connect an HFC-410A manifold gauge set highpressure hose to the suction valve service port.(Normally, the high pressure hose is connected to theliquid line port; however, connecting it to the suctionport better protects the manifold gauge set from highpressure damage.)
2. With both manifold valves closed, connect the cylinderof HFC-410A refrigerant to the center port of themanifold gauge set. Open the valve on the HFC-410Acylinder (suction only).
3. Open the high pressure side of the manifold to allowHFC-410A into the line set and indoor unit, Weigh ina trace amount of HFC-410A, [A trace amount is amaximum of two ounces (57 g) refrigerant or threepounds (31 kPa) pressure]. Close the valve on theHFC-410A cylinder and the valve on the high pressureside of the manifold gauge set, Disconnect theHFC-410A cylinder.
4. Connect a cylinder of dry nitrogen with a pressureregulating valve to the center port of the manifoldgauge set,
5. Adjust dry nitrogen pressure to 150 psig (1034 kPa).Open the valve on the high side d the manifold gaugeset in order to pressurize the line set and the indoor unit,
6. After a few minutes, open one of the service valveports and verify that the refrigerant added to thesystem earlier is measurable with a leak detector.
IMPORTANT
1. Connect manifold gauge set to the service valve portsas follows:
• low pressure gauge to suction 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 ofmercury),
NOTE - During the early stages of evacuation, it isdesirable to close the manifold gauge valve at least once todetermine if there is a rapid rise in sure indicates arelatively large leak. If this occurs, repeat the leak testingprocedure.
NOTE - The term absolute pressure means the totalactual pressure within a given volume or system, abovethe absolute zero of pressure. Absolute pressure in avacuum is equal to atmospheric pressure minus vacuumpressure.
6. When the absolute pressure reaches 23,000 microns(29.01 inches of mercury), close the manifold gaugevalves, turn off the vacuum pump and disconnect themanifold gauge center port hose from vacuum pump.Attach the manifold center port hose to a dry nitrogencylinder with pressure regulator set to 150 psig (1034kPa) and purge the hose. Open the manifold gaugevalves to break the vacuum in the line set and indoorunit. Close the manifold gauge valves.
Page15XP16 SERIES
7, Shut off the dry nitrogen cylinder and remove themanifold gauge hose from the cylinder. Open themanifold gauge valves to release the dry nitrogen fromthe line set and indoor unit,
8, Reconnect the manifold gauge to the vacuum pump,turn the pump on, and continue to evacuate the line setand indoor unit until the absolute pressure does notrise above 500 microns (29.9 inches of mercury) withina 20-minute period after shutting off the vacuum pumpand closing the manifold gauge valves.
9, When the absolute pressure requirement above hasbeen met, disconnect the manifold hose from thevacuum pump and connect it to an upright cylinder dHFC-410A refrigerant, Open the manifold gauge valve1 to 2 psig in order to release the vacuum in the line setand indoor unit,
10. Close manifold gauge valves and shut off theHFC-410A cylinder and remove the manifold gaugeset,
If the system is void of refrigerant, clean the system usingthe procedure described below,
1, Use nitrogen to pressurize the system and check forleaks. Repair all leaks,
2, Evacuate the system to remove as much of themoisture as possible,
3. Use nitrogen to break the vacuum and install a newfilter drier in the system.
4, Evacuate the system again. Then, weigh theappropriate amount of HFC-410A refrigerant as listedon unit nameplate into the system.
5, Monitor the system to determine the amount ofmoisture remaining in the oil. It may be necessary toreplace the filter drier several times to achieve therequired dryness level. If system dryness is notverified, the compressor will fail in the future.
In the U,S.A., wiring must conform with current local codesand the current National Electric Code (NEC). In Canada,wiring must conform with current local codes and the currentCanadian Electrical Code (CEC),Refer to the furnace or blower coil installation instructionsfor additional wiring application diagrams and refer to unitnameplate for minimum circuit ampacity and maximumovercurrent protection size,230VAC SUPPLY VOLTAGE
The XP16 outdoor unit is rated for 230VAC applicationsonly, A hard-start kit is required for applications where thesupply voltage is less than 230VAC,
24VAC TRANSFORMERUse the transformer provided with the furnace or coilblower for low-voltage control power (24VAC - 40 VAminimum)
NOTE - The addition of accessories to the system couldexceed the 40 VA power requirement of thefactory-provided transformer, Measure the system'scurrent and voltage after installation is complete to
determine transformer loading. If loading exceeds thefactory-provided transformer capacity, a largerfield-provided transformer will need to be installed in thesystem.
_WARNING
WIRING CONNECTIONS1, Install line voltage power supply to unit from a properly
sized disconnect switch.2, Ground unit at unit disconnect switch or to an earth
ground.
NOTE - Connect conduit to the unit using a proper conduitfitting. Units are approved for use only with copperconductors. See figure 28 for high voltage field wiringdiagram. A complete unit wiring diagram is located on theback side of the unit's access panel.
Old'DOORFAN
ro--oq
K31
ohvo_l
i__..._._I_WlIN
LLII_LE-CAPAC ][TOR
CIZOUAL
CAPACITOR
AI_OEFROSTCONTROL
E
GROUND_LUG
CONTACTOR
m
GROUND
z_208 =
60/ImlmLZ
mLI
LINE VOLTAGEFIELD INSTALLED
z_ NOTE-FOR USE WITH COPPER CONDUCTORS ONLY, REFER TO UNIT RATING PLATE FOR
MINZMUM CZRCUIT AMPACITY AN0 MAXIMUM 0VER-CURRENT PROTECTION SIZE
Figure 28. Outdoor Unit Typical Field Wiring
NOTE - For proper voltages, select thermostat wiregauge per the following chart:
Table 3. Wire Run LengthWire run length AWG # Insulation type
less than 100' (30m) 18 color-coded, temperature
more than 100' (30m) 16 rating 35°C minimum
3, Install room thermostat (ordered separately) on aninside wall approximately in the center of theconditioned area and 5 feet (1.5 m) from the floor,
NOTE -Thermostat should not be installed on an outsidewall or where it can be effected by sunlight, drafts orvibrations,
4. Install low voltage wiring from outdoor to indoor unitand from thermostat to indoor unit (figures 29 and 30),
NOTE - 24VAC, Class II circuit connections are made inthe low voltage junction box,
Page 16505329M 04/08
( ANDINDOORUNIT.)OUTDOORUNITq ] NDOOR UN T TB11
I_11 i L_I"- i
I It t E_ tId_Pt- i- q_]- 4i vl t t E_l t
ILSLFt--i---_4- 41@4-t- t _ aI_1t t E_-,L_J
ou, _Lt --t 4t _ J I J
SOME CONNECTIONS MAY NOT APPLY. REFER TO SPECIFIC THERMOSTAT
A2 THERMOSTAT
@
Figure 29. Outdoor Unit and Blower UnitThermostat Designations
{SOME CONNECTIONS MAY NOT APPLY. REFER TO SPECIFIC THERMOSTATA_J_J _N R H T_N
rc_3-1_vT-_x_TM_,S,GNATURESTATOUTDOOR UNIT 1 I TB1 I A2 THERMOSTAT
[ L_
I-- __ I -- _y1) I OUTDOOR-_ i I _ _ i SENSOR; USE
I -- -- TWISTED PAIR, !I-- Qg)_---I-- _ 1
/[ I L J
Figure 30. Outdoor Unit and CB31MV/CBX32MVThermostat Designations
/i',ROTE-FOR USE WITH COPPER CO_DBCTORSONLY.REFER TO UNIT RATING PLATE FORMINIMUM CIRCUIT AMPACITY ANDMAXIMUM OVER-CURRENT PROTECTION SIZE
A REFER TO COMPRESSORIN UNITFOR ACTUAL TERMINAL ARRANGE_NT,
Z_ WARNING-ELECTRIC SHOCK HAZARD,CANCAUSE INJURYOR DEATH.UNIT MUST BE OROUNOEDINACCORDANCE WITH RATIONAL AND LOCAL CODES, /_ Gll- AND KSR ARE OPTIONAL LOW AMBIENT CONTROLS
Z_ REMOVE3UMPORFOR TWO STAGE COOL
Z_ RYI4 SENSOR,OUTDOORTENP (OPTIONAL}OPTIONAL HARO START KIT MAY DE REUUIREO ONAPPLICATIONGWHERE VOLTASES ARE LESS THANEGO VOLT. KIT INCLUDES K31 AND C7 WITHALL NECESSARYWIRING.
wJZ [[_@ BLUE cWRIIRMEpED
TERM,NAL•-- --J II DEFROSTBOARDDETAIL
SHIPPEDASSHOWNABOVEWITHTERMINALili
CRIMPED TO BLUE WIRE; USE TERMINAL ORCUT OFF TERMINAL AND SPLICE BLUE WIREWITH Y2 WIRE TO INDOOR UNIT,
DENOTESOPTIONAL CONPONENTSLINE VOLTAGE FIELD INSTALLED
J J J CLASS II VOLTAGEFIELD INSTALLED/_k L34 SECONDSTAGE, SOLENOID IS LOCATED IN
COI_RESSOR. COIL IS 25VOC, 00 NOT CONNECT24VAC TO COIL TERMINALS.
Z_ S4O _ NRI ARE USED ON 04G AND 060 UNITS ONLY
IMPORTANT
1. Rotate fan to check for binding.
Figure 31. XP16 Wiring
2. Inspect all factory- and field-installed wiring for looseconnections.
3. After evacuation is complete, open both the liquid andvapor line service valves to release the refrigerantcharge contained in outdoor unit into the system.
4. Replace the stem caps and tighten to the value listedin table 1.
5. Check voltage supply at the disconnect switch. Thevoltage must be within the range listed on the unit'snameplate. If not, do not start the equipment until you
Page 17XP16 SERIES
have consulted with the power company and thevoltage condition has been corrected.
6, Set the thermostat for a cooling demand. Turn onpower to the indoor indoor unit and close the outdoorunit disconnect switch to start the unit.
7. Recheck voltage while the unit is running. Power mustbe within range shown on the nameplate,
8, Check system for sufficient refrigerate by using theprocedures listed under Testing and ChargingSystem,
TESTING AND CHARGING SYSTEM
This system uses HFC-410A refrigerant which operates atmuch higher pressures than HCFC-22. The pre-installedliquid line filter drier is approved for use with HFC-410Aonly. Do not replace it with components designed for usewith HCFC-22, This unit is NOT approved for use with coilswhich use capillary tubes as a refrigerant metering device.
SETTING UP TO CHECK CHARGE
1. Close manifold gauge set valves. Connect the centermanifold hose to an upright cylinder of HFC-410A,
2, Connect the manifold gauge set to the unit's serviceports as illustrated in figure 2.
• 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 using theillustration in figure 32,
HEATING MODE INDOOR AIRFLOW CHECK
Blower airflow (CFM) may be calculated by energizingelectric heat and measuring:
• Temperature rise between the return air and supply airtemperatures at the indoor coil blower unit,
• Measuring voltage supplied to the unit,
• Measuring amperage being drawn by the heat unit(s).
Then, apply the measurements taken in following formulato determine CFM:
CFM =Amps x Volts x 3.41
1.98 x Temperature rise (F)
CALCULATING CHARGE
If the system is void of refrigerant, first, locate and repairany leaks and then weigh in the refrigerant charge into theunit, To calculate the total refrigerant charge:
Additional chargeAmount Adjust amount, for specified perspecified variation in line set indoor unit
on length listed on table match-up listed in Totalnameplate in figure 33. tables 4 through 7. charge
All temperatures are iNDOOR WETexpressed in °F COiL BULB
Step 1. Determine the desired DT--Measure entering air tempera-ture using dry bulb (A) and wet bulb (B). DT is the intersecting value ofA and B in the table (see triangle).
Step 2. Find temperature drop across coil--Measure the coil's drybulb entering and leaving air temperatures (A and C). TemperatureDrop Formula: (TDrop) = A minus C.
Step 3. Determine if fan needs adjustment--If the difference be-tween the measured TDrop and the desired DT (TDropiDT) is within±3 °, no adjustment is needed, See examples: Assume DT = 15 and Atemp. = 72 °, these C temperatures would necessitate stated actions:
4. Weigh in the unit nameplate charge plusany charge required for line set differencesover feet,
This nameplate is for illustration purposes
only. Go to actual nameplate on outdoorunit for charge information.
Figure 33. Using Weigh In Method
505329M 04/08
Page 18
8UBCOOLING2
USE COOLINGMODE
60°F (15 °) --
USE HEATINGMODE
Check the airflow as illustrated in figure 32 to be sure the indoor airflow is as required.(Make any air flow adjustments before continuing with the following procedure0
Measure outdoor ambient temperature; determine whether to use cooling mode orheating mode to check charge.
3 Connect gauge set.
4 Check liquid and vapor line pressures. Compare pressures with either heat or cooling modenormal operating pressures in tables 8 and 9 (second stage - high capacity),
NOTE - The reference table is a general guide. Expect m#nor pressure variations. Significantdifferences may mean improper charge or other system problem.
5 Set thermostat for heat/cool demand, depending on mode being used:
Using cooling mode--When the outdoor ambient temperature is 60°F (15°C) and above.Target subcooling values (second stage - high capacity) in table 8 are based on 70 to 80°F(21-27°C) indoor return air temperature; if necessary, operate heating to reach thattemperature range; then set thermostat to cooling mode setpoint to 68°F (20°C) which shouldcall for second stage (high capacity) cooling. When pressures have stabilized, continue withstep 6.%
SAT o
LIQ o -
SC o =
Using heating mode--When the outdoor ambient temperature is below 60°F (15°C). Targetsubcooling values (second stage - high capacity) in table 9 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) which should call for second stage(high capacity) heating. 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 10 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 setand/or match-up.
10 If subcooling value is greater than shown in tables 4 through 7 for the applicable unit, removerefrigerant; if less than shown, add refrigerant.
11 If refrigerant is added or removed, repeat steps 4 through 10 to verify charge.
Figure 34. Using Subcooling Method -- Second Stage (High Capacity)
NOTE - Use the tables 8 and 9 to perform maintenancechecks; it is not a procedure for charging the system. Minorvariations in these pressures may be due to differences ininstallations. Significant deviations could mean that thesystem is not properly charged or that a problem existswith some component in the system.
Table 8. Normal Operating Pressures - Cooling 1
XP 16 -024 -036 -048 -060
°F (°C) 2 Liq I Vap Liq I Vap Liq I Vap Liq I VapFirst Stage (Low Capacity) Pressure 3
65 (18.3} 232 146 225 144 235 144 225 138
75 (23.9} 264 148 261 147 268 145 264 141
85 (29.4) 307 149 302 149 310 147 305 142
95 (35.6) 353 151 349 151 356 148 352 146
165 (46.6) 403 153 397 153 407 150 405 148
115(46.1) 460 155 461 157 466 152 459 150
Second Stage (High Capacity) Pressure 3
65 (18.3) 240 143 239 139 244 140 241 134
75 (23.9) 279 145 278 141 283 141 280 136
85 (29.4) 322 147 322 143 326 144 324 137
95 (35.6) 371 149 367 146 374 147 373 138
165 (46.6) 423 151 426 148 427 148 425 142
115(46.1) 485 154 489 151 491 151 486 146
Table 9. Normal Operating Pressures - Heating 1
XP 16 -024 -036 -048 -060
°F (°C) 2 Liq I Vap Liq IVap Liq IVap Liq I VapFirst Stage (Low Capacity) Pressure 3
46 (4.4) 337 93 328 98 369 75 351 63
50 (16) 322 117 333 118 366 114 335 92
Second Stage (High Capacity) Pressure 3
26 (-7.0) 279 62 296 62 311 58 308 59
36 (-1.6) 288 76 309 75 334 72 323 70
46 (4.4) 302 93 322 92 354 89 318 69
56(16) 306 112 336 113 381 108 329 82
1 Most-popular-match-up pressures. Indoor match up, indoor air quality, and indoor loadcause pressures to vary.2 Temperature of the air entering the outdoor coil.3 Liquid -+10 & Vapor -+5psig.
INSTALLING SERVICE VALVE CAPSDisconnect gauge set and re-install both the liquid andsuction service valve caps,
INSTALL CAPS
OUTDOOR UNIT /SERVICE VALVES_
Figure 35. Installing Service Valve Caps
505329M 04/08
Page 20
Theoutdoorunitandindoorblowercycleondemandfromtheroomthermostat.Whenthethermostatblowerswitchis in the ON position,the indoorbloweroperatescontinuously.THERMOSTATOPERATIONSomeindoorthermostatsincorporateisolatingcontactsandanemergencyheatfunction(whichincludesanamberindicatinglight).Thethermostatis not includedwiththeunitandmustbepurchasedseparately.EMERGENCY HEAT (AMBER LIGHT)
An emergency heat function is designed into some roomthermostats. This feature is applicable when isolation of theoutdoor unit is required, or when auxiliary electric heat isstaged by outdoor thermostats. When the room thermostat isplaced in the emergency heat position, the outdoor unitcontrol circuit is isolated from power and field-provided relaysbypass the outdoor thermostats. An amber indicating lightsimultaneously comes on to remind the homeowner that heis operating in the emergency heat mode.
Emergency heat is usually used during an outdoor unitshutdown, but it should also be used following a poweroutage if power has been off for over an hour and theoutdoor temperature is below 50°F (10°C). System shouldbe left in the emergency heat mode at least six hours toallow the crankcase heater sufficient time to preventcompressor slugging.
FILTER DRIER
The unit is equipped with a large-capacity bifiow filter drierwhich keeps the system clean and dry. If replacement isnecessary, order another of like design and capacity. Thereplacement filter drier must be suitable for use withHFC-410A refrigerant.
DEFROST SYSTEM DESCRIPTIONThe demand defrost controller measures differentialtemperatures to detect when the system is performingpoorly because of ice build-up on the outdoor coil. Thecontroller self-calibrates when the defrost system startsand after each system defrost cycle. The defrost controlboard components are shown in figure 36.
The control monitors ambient temperature, outdoor coiltemperature, and total run time to determine when adefrost cycle is required. The coil temperature probe isdesigned with a spring clip to allow mounting to the outsidecoil tubing. The location of the coil sensor is important forproper defrost operation.
NOTE - The demand defrost board accurately measuresthe performance of the system as frost accumulates on theoutdoor coil. This typically will translate into longer runningtime between defrost cycles as more frost accumulates onthe outdoor coil before the board initiates defrost cycles.
TEST PINS --
DEFROSTTERMINATIONPIN SETTINGS
SENSORPLUG IN
(COIL &AMBIENT
SENSORS)
DELAYPINS
REVERSINGVALVE
PRESSURE/
SWITCHCIRCUIT X
CONNECTIONS
LOWAMBIENTTHERMOSTATPINS
-- DIAGNOSTICLEDS
24V TERMINALSTRIPCONNECTIONS
Note - Compo-nent locationsvary by boardmanufacturer,
Figure 36. Defrost Control BoardDEFROST BOARD DIAGNOSTIC LEDS
The state (Off, On, Flashing) of two LEDs on the defrostboard (DSl [Red] and DS2 [Green])indicate diagnosticsconditions that are described in table 12 on page 24,
DEFROST BOARD PRESSURE SWITCHCONNECTIONS
The unit's automatic reset pressure switches (LOPS - $87and HI PS - $4) are factory-wired into the defrost board onthe LO-PS and HI-PS terminals, respectively.
Low Pressure Switch (LO-PS)--When the low pressureswitch trips, the defrost board will cycle off the compressor,and the strike counter in the board will count one strike.The low pressure switch is ignored under the followingconditions:
• During the defrost cycle and 90 seconds after thetermination of defrost
• When the average ambient sensor temperature isbelow 15° F (-9°C)
• For 90 seconds following the start up of thecompressor
• During test mode
High Pressure Switch (HI-PS)--When the high pressureswitch trips, the defrost board will cycle off the compressor,and the strike counter in the board will count one strike.
DEFROST BOARD PRESSURE SWITCH SETTINGS
High Pressure (auto reset) - trip at 590 psig, reset at 418.
Low Pressure (auto reset) - trip at 25 psig; reset at 55.
PRESSURE SWITCH 5-STRIKE LOCKOUTThe internal control logic of the board counts the pressureswitch trips only while the Y1 (Input) line is active. If apressure switch opens and closes four times during a Y1(Input), the control logic will reset the pressure switch tripcounter to zero at the end of the Y1 (Input). If the pressureswitch opens for a fifth time during the current Y1 (Input),the control will enter a lockout condition.
Page 21XP16 SERIES
The 5-strike pressure switch lockout condition can be resetby cycling OFF the 24-volt power to the control board or byshorting the TEST pins between 1 to 2 seconds. All timerfunctions (run times) will also be reset.
If a pressure switch opens while the Y1 Out line isengaged, a 5-minute short cycle will occur after the switchcloses.
DEFROST SYSTEM SENSORS
Sensors connect to the defrost board through afield-replaceable harness assembly that plugs into theboard as illustrated in figure 39 on page 23. Through thesensors, the board detects outdoor ambient, coil, anddischarge temperature fault conditions. As the detectedtemperature changes, the resistance across the sensorchanges. Sensor resistance values can be checked byohming across pins shown in table 11.
Table 11. Sensor Temperature/Resistance Range
Pins/WTemperature Resistance values ire
Sensor Range °F (°C) range (ohms) Color
Outdoor -35 (-37) to 120 (48) 280,000 to 3750 3 & 4(Black)
Coil -35 (-37) to 120 (48) 280,000 to 3750 5 & 6(Brown)
Discharge (if 24 (-4) to 350 (176) 41,000 to 103 1 & 2applicable) (Yellow)
Note: Sensor resistance increases as sensed temperature decreases.
Figure 37 shows how the resistance varies as thetemperature changes for both type of sensors.
NOTE - When checking the ohms across a sensor, beaware that a sensor showing a resistance value that is notwithin the range shown in table 11, maybe performing asdesigned. However, if a shorted or open circuit is detected,then the sensor may be faulty and the sensor harness willneed to be replaced.
1 ml157_OI
mMm7450
19275
11775
B 15425
_ 19975
26200
[] 34375
mm46275
I 62700 85300i
10000 30000 50000 70000 90000
RESISTANCE (OHMS)
Figure 37. Temperature/Resistance Chart(Ambient and Coil Sensors)
Ambient Sensor--The ambient sensor considersoutdoor temperatures below -35°F (-37°C) or above 120°F(48°C) as a fault. If the ambient sensor is detected as beingopen, shorted or out of the temperature range of thesensor, the board will not perform demand defrostoperation. The board will revert to time/temperaturedefrost operation and will display the appropriate faultcode. Heating and cooling operation will be allowed in thisfault condition.
Coil Sensor--The coil temperature sensor considersoutdoor temperatures below -35°F (-37°C) or above 120°F(48°C) as a fault. If the coil temperature sensor is detectedas being open, shorted or out of the temperature range ofthe sensor, the board will not perform demand ortime/temperature defrost operation and will display theappropriate fault code. Heating and cooling operation willbe allowed in this fault condition.
Discharge Line Sensor--If the discharge linetemperature exceeds a temperature of 300°F (148°C)during compressor operation, the board will de-energizethe compressor contactor output (and the defrost output, ifactive). The compressor will remain off until the dischargetemperature has dropped below 225°F (107°C) and the5-minute anti-short cycle delay has been satisfied. Thissensor has two fault and lockout codes:
.
,
If the board recognizes five high discharge linetemperature faults during a single (Y1) compressordemand, it reverts to a lockout mode and displays theappropriate code. This code detects shorted sensor orhigh discharge temperatures. (Code on board is"Discharge Line Temperature Fault and Lockout").
If the board recognizes five temperature sensor rangefaults during a single (Y1) compressor demand, itreverts to a lockout mode and displays the appropriatecode. The board detects open sensor orout-of-temperature sensor range. This fault isdetected by allowing the unit to run for 90 secondsbefore checking sensor resistance. If the sensorresistance is not within range after 90 seconds, theboard will count one fault. After five faults, the boardwill lockout. (Code on board is "Discharge SensorFault and Lockout").
505329M 04/08
Page 22
EAR _LY- -ONI= ON LATER MODELS
MODELS
= DISCHARGE LINE SENSORI
LOCATIONSL ..... ,
DEFROST BOARD
DEFROST SENSORHARNESS
SENSOR
COIL SENSOR -APPLY GREASE BETWEENRETURN BEND AND SENSOR
COIL SENSOR - 12TUBES UP FROM
BOTTOM (11-1/2")
XP16-048COIL SENSOR -13 TUBES UP FROMBOTTOM (12-1/2")
Figure 39. Sensor Locations
The discharge line sensor, which covers a range of 150°F(65°C) to 350°F (176°C), is designed to mount on a V2"refrigerant discharge line.
NOTE - Within a single room thermostat demand, if5-strikes occur, the board will lockout the uniL Defrostboard 24 volt power R must be cycled OFF or the TESTpins on board must be shorted between I to 2 seconds toreset the board.
Second-Stage Operation--If the board receives a call forsecond-stage compressor operation Y2 in heating orcooling mode and the first-stage compressor output isactive, the second-stage compressor solenoid output willbe energized.
If first-stage compressor output is active in heating modeand the outdoor ambient temperature is below the selectedcompressor lock-in temperature, the second-stagecompressor solenoid output will be energized without theY2 input. If the jumper is not connected to one of thetemperature selection pins on P3 (40, 45, 50, 55°F), thedefault Iockqn temperature of 40°F (4.5°C) will be used.
The board de-energizes the second-stage compressorsolenoid output immediately when the Y2 signal isremoved or the outdoor ambient temperature is 5°F abovethe selected compressor lock-in temperature, or thefirst-stage compressor output is de-energized for anyreason.
Defrost Temperature Termination Shunt (Jumper)Pins--The defrost board selections are: 50, 70, 90, and100°F (10, 21, 32 and 38°C). The shunt termination pin isfactory set at 50°F (10°C). If temperature shunt is notinstalled, default termination temperature is 90°F (32°C).
DELAY MODEThe defrost board has a field-selectable function to reduceoccasional sounds that may occur while the unit is cyclingin and out of the defrost mode. When a jumper is installedon the DELAY pins, the compressor will be cycled off for 30seconds going in and out of the defrost mode. Units areshipped with jumper installed on DELAY pins.
NOTE - The 30 second off cycle is NOTfunctional whenjumpering the TEST pins.OPERATIONAL DESCRIPTION
The defrost control board has three basic operationalmodes: normal, defrost, and calibration.
• Normal Mode--The demand defrost board monitorsthe O line, to determine the system operating mode(heat/cool), outdoor ambient temperature, coiltemperature (outdoor coil) and compressor run time todetermine when a defrost cycle is required.
• Calibration Mode--The board is considereduncalibrated when power is applied to the board, aftercool mode operation, or if the coil temperatureexceeds the termination temperature when it is in heatmode.
Calibration of the board occurs after a defrost cycle toensure that there is no ice on the coil. Duringcalibration, the temperature of both the coil and theambient sensor are measured to establish thetemperature differential which is required to allow adefrost cycle.
• Defrost Mode--The following paragraphs provide adetailed description of the defrost system operation.
Page 23XP16 SERIES
Table 12. Defrost Control Board Diagnostic LEDs
DS2 DS1Green Red Condition/Code Possible Cause(s) Solution
OFF OFF Power problem No power (24V) to board terminals 1 Check control transformer power (24V).R & C or board failure. 2 If power is available to board and LED(s) do
not light, replace board.
Simultaneous Normal operation Unit operating normally or in stand- None required.SLOW Flash by mode.
Alternating SLOW 5-minute anti-short cycle Initial power up, safety trip, end of None required (Jumper TEST pins to override)Flash delay room thermostat demand.
Simultaneous Ambient Sensor Problem Sensor being detected open or shorted or out of temperature range. Board will revert toFAST Flash time/temperature defrost operation. (System will still heat or cool).
Alternating Coil Sensor Problem Sensor being detected open or shorted or out of temperature range. Board will not per-FAST Flash form demand or time/temperature defrost operation. (System will still heat or cool).
ON ON Circuit Board Failure doeslndicateSnotclear,thatboardreplacehaSboard.internalcomponent failure. Cycle 24 volt power to board. If code
Table 13. Defrost Control Board Diagnostic Fault and Lockout Codes
DS2 DS1Green Red Condition/Code Possible Cause(s) Solution
(Each fault adds 1 strike to that code's counter; 5 strikes per code = LOCKOUT)
OFF
OFF
SLOWFlash
ON
SLOW Low Pressure FaultFlash
ON Low Pressure LOCKOUT
OFF High Pressure Fault
OFF High Pressure LOCKOUT
1 Restricted air flow over indoor oroutdoor coil.
2 Improper refrigerant charge insystem.
3 Improper metering deviceinstalled or incorrect operationof metering device.
4 Incorrect or improper sensorlocation or connection to sys-tem.
1 Remove any blockages or restrictions fromcoils and/or fans. Check indoor and outdoorfan motor for proper current draws.
2 Check system charge using approach andsubcooling temperatures.
3 Check system operating pressures andcompare to unit charging charts.
4 Make sure all pressure switches and sensorshave secure connections to system to preventrefrigerant leaks or errors in pressure andtemperature measurements.
SLOW ON Discharge Line TemperatureFlash Fault
FASTFlash
ON Discharge Line Tempera-ture LOCKOUT
This code detects shorted sensor or high discharge temperatures. If the discharge linetemperature exceeds a temperature of 300°F (148°C) during compressor operation, theboard 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).
OFF Fast Discharge Sensor FaultFlash
Fast OFF Discharge SensorFlash LOCKOUT
The board detects open sensor or out of temperature sensor range. This fault is detectedby allowing the unit to run for 90 seconds before checking sensor resistance. If the sen-sor resistance is not within range after 90 seconds, the board will count one fault. After 5faults, the board will lockout.
DETAILED DEFROST SYSTEM OPERATION
The demand defrost control board initiates a defrost cyclebased on either frost detection or time.
Frost Detection--If the compressor runs longer than 34minutes and the actual difference between the clear coiland frosted coil temperatures exceeds the maximumdifference allowed by the control, a defrost cycle will beinitiated.
IMPORTANT- The demand defrost control board will allowa greater accumulation of frost and will initiate fewerdefrost cycles than a time/temperature defrost system.
Time--If six hours of heating mode compressor run timehas elapsed since the last defrost cycle while the coiltemperature remains below 35°F (2°C), the demanddefrost control will initiate a defrost cycle.
Actuation--When the reversing valve is de-energized,the Y1 circuit is energized, and the coil temperature isbelow 35°F (2°C), the board logs the compressor run time.If the board is not calibrated, a defrost cycle will be initiatedafter 34 minutes of heating mode compressor run time,The control will attempt to self-calibrate after this (and allother) defrost cycle(s),
505329M 0_08
Page 24
Short test pins for longer than1 second but less than 2.0
seconds
Clear any short cyclelockout and/or 5-strike
fault lockout function, ifapplicable. No other func-tions will be executed and
unit will continue in the
mode it was operating,
1
Y1 Active ("0" line inactive) //
I
Short test pins for more than 2.0 seconds
I If in COOLING Mode
Clear any short cycle lockout or 5-strike fault lock-out function, if applicable.
i
If in HEATING Mode I I If in DEFROST Mode
No further test
mode operation willbe executed until
the test short is re-moved and reap-
plied.
The controller will check for ambient and coil
faults (open or shorted) If a fault exists, theunit will remain in Heat Mode and no further
test mode operation will be executed until thetest short is removed and re applied. If no
fault exists, the unit will go into Defrost mode.
I
The unit will terminate defrost andenter Heat Mode uncalibrated with
defrost timer set for 34 minute
test. No further test mode opera-tion will be executed until the testshort is removed and reapplied.
Test pin short REMAINS in place for more than 5 seconds
tThe unit will return to Heat mode uncalibrated with defrost timer set for
34 minutes. No further test mode operation will be executed until thetest short is removed and re applied.
Test pins short REMOVEDof5 secondsbef°re a maximum
The unit will remain in Defrost mode until ter-mination on time or temperature
Figure 40. Test ModeCalibration success depends on stable systemtemperatures during the 20-minute calibration period. Ifthe board fails to calibrate, another defrost cycle will beinitiated after 90 minutes of heating mode compressor runtime. Once the defrost board is calibrated, it initiates ademand defrost cycle when the difference between theclear coil and frosted coil temperatures exceeds themaximum difference allowed by the control or after sixhours of heating mode compressor run time has beenlogged since the last defrost cycle.
Termination--The defrost cycle ends when the coiltemperature exceeds the termination temperature or after14 minutes of defrost operation, If the defrost is terminatedby the 14-minute timer, another defrost cycle will beinitiated after 34 minutes of run time,
Test Mode--When Y1 is energized and 24V power isbeing applied to the board, a test cycle can be initiated byplacing the termination temperature jumper across the"Test" pins for 2 to 5 seconds, If the jumper remains acrossthe "Test" pins longer than five seconds, the control willignore the test pins and revert to normal operation, Thejumper will initiate one cycle per test,
Enter the TEST mode by placing a shunt (jumper) acrossthe TEST pins on the board after power-up. (The TESTpins are ignored and the test function is locked out if theshunt is applied on the TEST pins before power-up). Boardtimings are reduced, the low-pressure switch is ignoredand the board will clear any active lockout condition,
Each test pin shorting will result in one test event. Foreach TEST the shunt (jumper) must be removed for atleast one second and reapplied, Refer to flow chart (figure40) for TEST operation,
Note: The Y1 input must be active (ON) and the 0 roomthermostat terminal into board must be inactive.
DEFROST BOARD DIAGNOSTICSSee table 12 on page 24 to determine defrost boardoperational conditions and to diagnose cause and solutionto problems,
kWARNING
Before the start of each heating and cooling season, thefollowing service checks should be performed by aqualified service technician. First, turn off electrical powerto the unit prior to performing unit maintenance.
• Inspect and clean the outdoor and indoor coils. Theoutdoor coil may be flushed with a water hose.
NOTE - It may be necessary to flush the outdoor coilmore frequently if it is exposed to substances whichare 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 shouldbe compared with those given on unit nameplate.
• Check, clean (or replace) indoor unit filters.
• Check the charge and gauge the system pressures.
Page25XP16 SERIES
• Check the condensate drain line for free andunobstructed flow; clean, if necessary
• Adjust blower speed for cooling Measure the pressuredrop over the coil to determine the correct blower CFMRefer to the unit information service manual for pressuredrop tables and procedure
• Check drive belt for wear and proper tension
NOTE - if owner reports insufficient cooling, the unitshould be gauged and refrigerant charge checkedRefer to section on refrigerant charging in thisinstruction
IMPORTANT
Use this check-out procedure (see checklist immediatelyfollowing) to verify part-load and full-load capacityoperation of two-stage modulation compressors
TOOLS REQUIREDRefrigeration gauge setDigital volt/amp meterElectronic temperature thermometer
On-off toggle switchPROCEDURENOTE - Block outdoor coil to maintain a minimum of 375
psig during testing)
1 Turn main power OFF to outdoor unit2 Adjust room thermostat set point 5°F above the room
temperature3 Remove control access panel Install refrigeration
gauges on unit Attach the amp meter to the common(black wire) wire of the compressor harness Attachthermometer to discharge line as close as possible tothe compressor
4 Turn toggle switch OFF and install switch in series withY2 wire from room thermostat
5 Cycle main power ON6 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 isgoing to compressor solenoid
9 Allow pressures and temperatures to stabilize beforetaking 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 directionnoted in chart, the compressor is properly modulatingfrom low to high capacity (If no amperage, pressuresor temperature readings change when this test isperformed, the compressor is not modulating betweenlow and high capacity and replacement is necessary)
12 After testing is complete, return unit to original set up
In order to ensure peak performance, your system must beproperly maintained Clogged filters and blocked airflowprevent your unit from operating at its most efficient level
1 Air Filter--Ask your Lennox dealer to show you whereyour indoor unit's filter is located It will be either at theindoor unit (installed internal or external to the cabinet)or behind a return air grille in the wall or ceiling Checkthe filter monthly and clean or replace it as needed
2 Disposable Filter--Disposable filters should bereplaced with a filter of the same type and size
NOTE - If you are unsure about the filter required foryour system, call your Lennox dealer for assistance
,& IMPORTANT
3 Reusable Filter--Many indoor units are equippedwith reusable foam filters Clean foam filters with amild soap and water solution; rinse thoroughly; allowfilter to dry completely before returning it to the unit orgrille
NOTE - The filter and all access panels must be inplace any time the unit is in operation
4, Electronic Air Cleaner--Some systems areequipped with an electronic air cleaner, designed toremove airborne particles from the air passing throughthe cleaner. If your system is so equipped, ask yourdealer for maintenance instructions,
5, Indoor Unit--The indoor unit's evaporator coil isequipped with a drain pan to collect condensateformed as your system removes humidity from theinside air. Have your dealer show you the location ofthe drain line and how to check for obstructions. (Thiswould also apply to an auxiliary drain, if installed,)
IMPORTANT
6 Outdoor Unit--Make sure no obstructions restrictairflow to the outdoor unit Leaves, trash or shrubscrowding the unit cause the outdoor unit to work harder
Page 26505329M 04/08
and use more energy. Keep shrubbery trimmed awayfrom the unit and periodically check for debris whichcollects around the unit.
When removing debris from around the unit, be awareof metal edges on parts and screws. Although specialcare has been taken to keep exposed edges to aminimum, physical contact with metal edges andcorners while applying excessive force or rapid motioncan result in personal injury.
Cleaning of the outdoor unit's coil should be performedby a trained service technician. Contact your dealerand set up a schedule (preferably twice a year, but atleast once a year) to inspect and service your airconditioning or heat pump system.
HEAT PUMP OPERATION
Your new Lennox heat pump has several characteristicsthat you should be aware of:
• Heat pumps satisfy heating demand by deliveringlarge amounts of warm air into the living space. Thisis quite different from gas- or oil-fired furnaces or anelectric furnace which deliver lower volumes of
considerably hotter air to heat the space.
• Do not be alarmed if you notice frost on the outdoor coilin the winter months. Frost develops on the outdoorcoil during the heating cycle when temperatures arebelow 45°F (7°C). An electronic control activates adefrost cycle lasting 5 to 15 minutes at preset intervalsto clear the outdoor coil of the frost.
• During the defrost cycle, you may notice steam risingfrom the outdoor unit. This is a normal occurrence. Thethermostat may engage auxiliary heat during thedefrost cycle to satisfy a heating demand: however,the unit will return to normal operation at theconclusion of the defrost cycle.
EXTENDED POWER OUTAGE
The heat pump is equipped with a compressor crankcaseheater which protects the compressor from refrigerantslugging during cold weather operation.
If power to your unit has been interrupted for several hoursor more, set the room thermostat selector to theEmergency Heat setting to obtain temporary heat withoutthe risk of serious damage to the heat pump.
In Emergency Heat mode, all heating demand is satisfiedby auxiliary heat; heat pump operation is locked out. After asix-hour compressor crankcase warm-up period, thethermostat can be switched to the HEAT setting andnormal heat pump operation may resume.
THERMOSTAT OPERATIONSThough your thermostat may vary somewhat from thedescription below, its operation will be similar.
Temperature Setting Levers
Most heat pump thermostats have two temperatureselector levers: one for heating and one for cooling. Set thelevers or dials to the desired temperature setpoints for bothheating and cooling. Avoid frequent temperatureadjustment; turning the unit off and back on beforepressures equalize puts stress on the unit compressor.
Fan Switch
In AUTO or INT (intermittent) mode, the blower operatesonly when the thermostat calls for heating or cooling. Thismode is generally preferred when humidity control is apriority. The ON or CONT mode provides continuousindoor blower operation, regardless of whether thecompressor or auxiliary heat are operating. This mode isrequired when constant air circulation or filtering is desired.
System Switch
Set the system switch for heating, cooling or autooperation. The auto mode allows the heat pump toautomatically switch from heating mode to cooling mode tomaintain predetermined comfort settings. Many heatpump thermostats are also equipped with an emergencyheat mode which locks out heat pump operation andprovides temporary heat supplied by the auxiliary heat.
Indicating Light
Most heat pump thermostats have an amber light whichindicates when the heat pump is operating in theemergency heat mode.
Temperature Indicator
The temperature indicator displays the actual roomtemperature.PROGRAMMABLE THERMOSTATSYour Lennox system may be controlled by aprogrammable thermostat. These thermostats provide theadded feature of programmable time-of-day setpoints forboth heating and cooling. Refer to the user's informationmanual provided with your particular thermostat foroperation details.PRESERVlCE CHECKIf your system fails to operate, check the following beforecalling for service:• Check to see that all electrical disconnect switches are
ON.
• Make sure the room thermostat temperature selectoris properly set.
• Make sure the room thermostat system switch isproperly set.
• If you discover any blown fuses or tripped circuitbreakers, call your Lennox dealer for assistance.
• Make sure unit access panels are in place.• Make sure air filter is clean.
• Locate unit model number and have it handy beforecalling.
OPTIONAL ACCESSORIESRefer to the Lennox XPf6 Engineering Handbook foroptional accessories that may apply to this unit. Thefollowing may or may not apply:
Compressor Discharge Line HigherIndoor Return Air Same
Indoor Coil Discharge Air LowerPRESSURES
Suction (Vapor) Lower
Liquid Higher
Customer Address
Indoor Unit Model Serial
Outdoor Unit Model Serial
Notes:
START UP CHECKS
Refrigerant Type:
1st Stage: Rated Load Amps
2nd Stage: Rated Load Amps
Outdoor Unit Fan Full Load AmpsCOOLING MODE
Suction Pressure: 1st Stage:
Liquid Pressure: 1st Stage:
Supply Air Temperature: 1st Stage:
Temperature: Ambient:
Actual Amps Rated Volts Actual Volts
Actual Amps Rated Volts Actual Volts
Actual Amps: 1st Stage 2nd Stage
2nd Stage:
2nd Stage:
2nd Stage:Return Air:
System Refrigerant Charge (Refer to manufacturer's information on unit or installation instructions for required sub-cooling and approach temperatures,)
Subcooling: A B SUBCOOLING
Saturated Condensing Temperature (A) -- =minus Liquid Line Temperature (B)
Approach: A B APPROACH
Liquid Line Temperature (A) minus -- =Outdoor Air Temperature (B)
Indoor Coil Temperature Drop (18 to 22°F) A B COIL TEMP DROP
Return Air Temperature (A) minus -- =Supply Air Temperature (B)
