XP16 Series - HvacPartsShop.com
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1. LULU A IIUIELLJ JU IY FRIRRPRRRPRRPRRPPRPAPPREREY DT PY PSISPCSTPIRRIPRIRIRIRPRIRIPRRIPRPIPPIREIP LU UA San A ih hal man Da A D D D ARRRRPRPPRPHPIPPIREREE JY LLL DU AYU LULU fae ROTATE IN THIS DIRECTION __ gt THEN DOWN TO REMOVE PANEL MAINTAIN MINIMUM PANEL ANGLE AS CLOSE TO PARALLEL WITH THE UNIT AS POSSIBLE WHILE INSTALLING PANEL HOLD DOOR FIRMLY TO THE HINGED ANGLE MAY BE TOO oe ee SIDE TO MAINTAIN EXTREME cee eG UY TA ee FULLY ENGAGED TABS I ea PREFERRED ANGLE L gt FOR INSTALLATION Detail D FIGURE 1 Il UNIT COMPONENTS Unit components are illustrated in figure 2 XP16 UNIT COMPONENTS OUTDOOR FAN COMPRESSOR FILTER DRIER eo hahahahahahaha S HH IPS 3 3 SWITCH LOW PRESSURE SWITCH VAPOR LINE M LINE SENE SERVICE VALVE FIGURE 2 A Control Box Figure 3 XP16 units are not equipped with a 24V transformer All 24 VAC controls are powered by the indoor unit Refer to wir ing diagram UNIT CONTROL BOX U DUAL CAPACITOR C12 COMPRESSOR CONTACTO K1 TIR DEFROST o CONTROL GROUNDING A108 FIGURE 3 Electrical openings are provided under the control box cov er Fiel2. LENNOX UNT INFORMATION XP16 Service Literature peso XP16 SERIES UNITS The XP16 is a high efficiency residential split system heat pump unit which features a scroll compressor and R 410A refrigerant XP16 units are available in 2 3 4 and 5 tons tons XP16 units are rated for 230 volts only Applications where supply voltage is less requires a hard start kit The series is designed for use with an indoor unit with an expan sion valve approved for R 410A This manual is divided into sections which discuss the major components refrigerant system charging procedure maintenance and operation sequence Information contained in this manual is intended for use by qualified service technicians only All specifications are subject to change A IMPORTANT Operating pressures of this R 410A unit are higher than pressures in R 22 units Always use service equipment rated for R 410A A WARNING Warranty will be voided if covered equipment is re moved from original installation site Warranty will not cover damage or defect resulting from Flood wind lightning or installation and opera tion in a corrosive atmosphere chlorine fluorine salt recycled waste water urine fertilizers or oth er damaging chemicals AWARNING TABLE OF CONTENTS Improper installation adjustment alteration service Specifications Electrical Page 2 or maintenance can cause property damage person al injury or loss o
3. A 1 2 3 4 B 1 Sequence of Operation XP16 024 060 Cooling First Stage Low Capacity Transformer from indoor unit supplies 24VAC power to the thermostat and outdoor unit controls Internal wiring energizes terminal O by cooling mode selection energizing the reversing valve Cooling de mand initiates at Y1 in the thermostat The defrost board checks for open low or high pres sure switches and proper coil ambient and discharge sensor readings If checks show no issues the defrost board sends 24 volts through Y1 OUT signal to the K1 compressor contactor coil HARD START KIT IF USED Compressor begins start up Relay K31 remains closed during start up and capacitor C7 remains in the circuit As compres sor speeds up K31 is energized de energizing ca pacitor C7 K1 1 N O closes energizing compressor B1 and out door fan motor B4 Solenoid L34 is NOT energized The slider ring re mains open limiting compressor to low capacity Second Stage High Capacity Second stage thermostat demand goes through Y2 on the defrost board and energizes rectifier plug D4 D4 converts the AC voltage to DC voltage and energizes L34 unloader solenoid L34 then closes the slider ring allowing the compressor to operate at high capacity Heating Low Capacity Internal wiring de energizes terminal O by heating mode selection de energizing the reversing valve Heating demand initiates at Y1 in the thermostat The defrost b
4. 6 shows sensor temperature to resistance range 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 1 may be performing as de signed 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 1 Sensor Temperature Resistance Range Resistance values Pins Wire range ohms Color 280 000 to 3750 3 amp 4 Black 280 000 to 3750 5 amp 6 Brown 41 000 to 103 1 amp 2 Yellow Temperature Range F C 35 37 to 120 48 Sensor Outdoor Coil 35 37 to 120 48 Discharge if 24 4 to 350 applicable 176 Note Sensor resistance increases as sensed temperature decreases Ambient and Coil Sensor Discharge Sensor 5750 TEMPERATURE F TEMPERATURE F 10000 30000 50000 70000 2000 3000 4000 RESISTANCE OHMS RESISTANCE OHMS DISCHARGE LINE SENSOR IN ONE OF TWO LOCATIONS DETAIL C DEFROST BOARD DEFROST SENSOR HARNESS DETAIL A AMBIENT SENSOR COIL SENSOR APPLY GREASE BETWEEN RETURN BEND AND SENSOR FIGURE 7 Page 6 DETAIL B XP16 024 COIL SENSOR 7 tubes up from bottom 7 1 2 XP16 036 COIL SENSOR 17 tubes
5. 230V 1ph 4 208 230V 1ph 4 208 230V 1ph 2 Maximum overcurrent protection amps 20 35 45 60 3 Minimum circuit ampacity 14 0 22 0 28 2 33 9 Compressor Rated load amps 10 25 16 67 21 15 25 87 Locked rotor amps 52 82 96 118 Power factor 0 98 0 99 0 99 0 99 Outdoor Coil Full load amps 1 1 1 1 1 7 1 8 Fan Motor Locked rotor amps 2 2 1 3 1 2 9 OPTIONAL ACCESSORIES must be ordered extra Compressor Hard Start Kit Required 10J42 in applications with less than 230V 81J69 n E Compressor Low Ambient Cut Off 45F08 Freezestat 3 8 in tubing 93G35 5 8 in tubing 50A93 e e Indoor Blower Relay 40K58 e Low Ambient Kit 68M04 e Monitor Kit Service Light 76F53 Outdoor Thermostat 56A87 Voies Mounting Box 31461 SignatureStat Home Comfort Control 81M28 Refrigerant L15 41 20 L15 41 40 Line Sets L15 41 30 L15 41 50 L15 65 30 L15 65 40 L15 65 50 Field Fabricate Time Delay Relay 58M81 NOTE Extremes of operating range are plus 1096 and minus 59 of line voltage 1 Refrigerant charge sufficient for 15 ft length of refrigerant lines HACR type breaker or fuse 2 3 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Hard start kit is required in applications where the supply voltage is less than 230V Page 2 I UNIT IN
6. STATIONARY SCROLL c ENTRIFUGAL FORCE SUCTION G DISCHARGE POCKET FIGURE 12 TWO STAGE MODULATION Bypass Ports Closed High Capacity FIGURE 13 Bypass Ports Open Low Capacity Page 12 INTERNAL SOLENOID L34 The internal unloader solenoid controls the two stage op eration of the compressor by shifting a slide ring mecha nism to open two by pass ports in the first compression pocket of the scrolls in the compressor The internal sole noid is activated by a 24 volt direct current solenoid coil The coil power requires 20VAC The internal wires from the solenoid in the compressor are routed to a 2 pin fusite con nection on the side of the compressor shell The external electrical connection is made to the compressor with a molded plug assembly This plug contains a full wave rectifi er that converts 24 volt AC into 24 volt DC power to power the unloader solenoid Refer to unit diagram for internal cir cuitry view of plug If itis suspect the unloader is not operating properly check the following A IMPORTANT This performance check is ONLY valid on systems that have clean indoor and outdoor coils proper air flow over coils and correct system refrigerant charge All components in the system must be func tioning proper to correctly perform compressor mod ulation operational check Accurate measurements are critical to this test as indoor system loading and outdoor ambient can affect variations between low a
7. adh oa coe Dae l 10N45 Acid Test Tubes Checkmate RT750A three pack a mI temperatures Checkmate RT751 Tubes three 6 12 months room temperature 2 Checkmate RT752C Tubes three pack 74N40 Easy Oil Test Tubes 2 3 years room temperature 3 years refrigerated 74N39 Acid Test Kit Sporian One Shot TA 1 E LUD Page 15 G High Low Pressure Switch A IMPORTANT Pressure switch settings for R 410A refrigerant will be significantly higher than units with R 22 An auto reset single pole single throw high pressure switch is located in the liquid line This switch shuts off the compres sor when liquid line pressure rises above the factory setting The switch is normally closed and is permanently adjusted to trip open at 590 10 psi An auto reset single pole single throw low pressure Switch is located in the suction line This switch shuts off the compressor when suction pressure drops below the factory setting The switch is closed during normal operating pres sure conditions and is permanently adjusted to trip open at 25 5 psi The switch automatically resets when suction line pressure rises above 40 5 psi Under certain condi tions the low pressure switch is ignored See Pressure Switch Circuit in the Defrost Control description lll REFRIGERANT SYSTEM Refer to figure 18 for refrigerant flow The reversing valve is energized during cooling demand and during defrost XP16 COOLING CYCL
8. allow system pressures to stabilize 3 Compare stabilized pressures with those provided in tables 5 and 6 Normal Operating Pressures Minor variations in these pressures may be expected due to differences in installations Significant differences could mean that the system is not properly charged or that a problem exists with some component in the sys tem Pressures higher than those listed indicate that the system is overcharged Pressures lower than those listed indicate that the system is undercharged Contin ue to check adjusted charge using approach values 4 Use the same digital thermometer used to check out door ambient temperature to check liquid line tempera ture and record in table 4 Verify the unit charge using the approach method The difference between the am bient and liquid temperatures should match values giv en in table 4 Add refrigerant to lower the approach tem perature and remove it to increase the approach tem perature Loss of charge results in low capacity and ef ficiency 5 If the values do not agree with those in table 4 add re frigerant to lower the approach temperature or recover refrigerant from the system to increase the approach temperature TABLE 4 Approach Values for Charging Second Stage High Capacity _ Liquid Line Temperature Outdoor Temperature Approach Temperature XP16 024 036 048 060 XP16 018 036 048 060 F C 8 4 4 768 9 9
9. compres sor back down to low stage and back up to high stage a few times in order to get the bypass seals to properly seat Compare Y1 readings with Y2 readings in table 3 Some readings should be higher lower or the same If the read ings follow what table 3 specifies the compressor is op erating and shifting to high capacity as designed If the readings do not follow what table 3 specifies continue to step 2 to determine if problem is with external solenoid plug power TABLE 3 Unit Readings Compressor Operation Y1 1st Stage Y2 Expected Results 2nd Stage Compressor Voltage Same Amperage Higher Condenser Fan motor Amperage Same or Higher Temperature Ambient Same Outdoor Coil Discharge Air Higher in Cooling Lower in Heating Compressor Discharge Line Higher Indoor Return Air Same Indoor Coil Discharge Air Lower in Cooling Higher in Heating Pressures Suction Vapor Lower Liquid STEP 2 Confirm DC voltage output on compressor solenoid plug A Compressor solenoid plug WITH built in full wave rectifier LSOM I that converts 24 volt AC into 24 volt DC power See Table 1 for units equipped with the LSOM I 1 Shut power off to outdoor unit 2 Supply 24 volts AC control voltage to the wire ends of the full wave rectifier plug Listen for a click as the so lenoid is energized See figure 14 apply 24v
10. compressor figure9 The discharge pressure forcing down on the top scroll helps seal off the upper and lower edges tips of the scrolls figure 11 During a single orbit several pockets of gas are compressed simultaneous ly providing smooth continuous compression P gg c in BEC SN N N N N N hhh SSM SS WEPFZFZPZPgP Z S y E 4 2 2 4 4 4 SSSSSSSSASAT RR VETE SSS SSASASASS Nee M The scroll compressor is tolerant to the effects of liquid re turn If liquid enters the scrolls the orbiting scroll is allowed to separate from the stationary scroll The liquid is worked toward the center of the scroll and is discharged Due to its efficiency the scroll compressor is capable of drawing a much deeper vacuum than reciprocating com pressors Deep vacuum operation can cause internal fusite arcing resulting in damaged internal parts and will result in compressor failure This type of damage can be detected and will result in denial of warranty claims The scroll com pressor can be used to pump down refrigerant as long as the pressure is not reduced below 7 psig NOTE During operation the head of a scroll compressor may be hot since it is in constant contact with discharge gas The scroll compressors in all XP16 model units are de signed for use with R410A refrigerant and operation at high pressures Compressors are shipped from the factory with 3MA 32MMMA P O E oil See
11. gauge ports are ac cessible from the outside of the unit Use the service ports for leak testing evacuating charging and checking charge Each valve is equipped with a service port which has a fac tory installed Schrader valve A service port cap protects the Schrader valve from contamination and serves as the primary leak seal To Access Schrader Port 1 Remove service port cap with an adjustable wrench 2 Connect gauge to the service port 3 When testing is complete replace service port cap Tight en finger tight then an additional 1 6 turn To Open Service Valve 1 Remove the stem cap with an adjustable wrench 2 Use a service wrench with a hex head extension to back the stem out counterclockwise as far as it will go NOTE Use a 3 16 hex head extension for 3 8 line sizes or a 5 16 extension for large line sizes 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn To Close Service Valve 1 Remove the stem cap with an adjustable wrench 2 Use a service wrench with a hex head extension to turn the stem clockwise to seat the valve Tighten the stem firmly NOTE Use a 3 16 hex head extension for 3 8 line sizes or a 5 16 extension for large line sizes 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn Service Valve stem cap VA Valve Closed service to outdoor coil service port cap Schrader valve open to lin
12. motor for proper current draws E System 2 Check system charge using approach amp sub Improper metering device cooling temperatures fe installed or incorrect operation 3 Check system operating pressures and SLOW OFF High Pressure Fault of metering device compare to unit charging charts ial a 4 Incorrect or improper sensor 4 Make sure all pressure switches and sensors location or connection to sys have secure connections to system to prevent ee ee eee tem refrigerant leaks or errors in pressure and temperature measurements SLOW ON Discharge Line Tempera This code detects shorted sensor or high discharge temperatures If the discharge Flash ture Fault line temperature exceeds a temperature of 285 F 140 C during compressor op eration the board will de energize the compressor contactor output and the defrost FAST ON Discharge Line Tempera output if active The compressor will remain off until the discharge temperature has Flash ture LOCKOUT dropped below 225 F 107 C OFF Fast Discharge Sensor Fault The board detects open sensor or out of temperature sensor range This fault is Flash detected by allowing the unit to run for 90 seconds before checking sensor resist ance If the sensor resistance is not within range after 90 seconds the board will count one fault After 5 faults the board will lockout Flash LOCKOUT Page 10 B Two Stage Scroll Compressor B1 TWO STAGE MODULATED SCROLL slider ring solenoid a
13. motor through the normally closed fan relay con tacts on the defrost board The compressor runs high capacity High Capacity Ambient temperature below defrost board Y2 lock in temperature Room thermostat in heating mode Room thermostat outputs Y1 signal to the defrost board in the heat pump and to the indoor unit The defrost board checks for open low or high pres sure switches and proper coil ambient and discharge sensor readings If checks show no issues the defrost board sends 24 volts through Y1 OUT signal to the K1 compressor contactor coil The defrost board Y2 locks in sends 24 volts through Y2 OUT to the L34 compressor solenoid plug The plug converts the 24volt AC outputs to a 24volt DC signal in put to the L34 internal high capacity solenoid valve in the compressor K1 1 closes energizing the compressor and outdoor fan motor through the normally closed fan relay con tacts on the defrost board The compressor runs on high capacity Defrost Mode When a defrost cycle is initiated the control ener gizes the reversing valve solenoid and turns off the condenser fan The control will also put 24VAC on the W1 auxiliary heat line The unit will stay in this mode until either the coil sensor temperature is above the selected termination temperature the de frost time of 14 minutes has been completed or the room thermostat demand cycle has been satisfied If the temperature select shunt is not installed the default
14. termination temperature will be 90 F If the room thermostat demand cycle terminates the cycle the defrost cycle will be held until the next room thermostat demand cycle If the coil sensor temperature is still below the selected termination temperature the control will continue the defrost cycle until the cycle is terminated in one of the meth ods mentioned above If a defrost is terminated by time and the coil temperature did not remain above 35 F 2 C for 4 minutes the control will go to the 34 minute Time Temperature mode
15. 129 15 3453 37 5195 ior aso 198 s255 os sso 39 5224 115 8 200 6 07 2 no seso ie 5456 m sro sss m2 376 1 ws 594 ma 392 a 5655 a 3054 ias 5725 ms 390 7 sos ne sso 47 5955 62 4 148 593 8 eso me 4122 160 608 1 120 a177 t 654 121 a232 52 6207 uz a288 153 60 1 us ses iss 697 5 124 4402 155 645 0 109 360 0 140 539 0 Subtract the liquid line temperature from the saturation temperature according to the chart to determine the subcooling value Compare the subcooling value with those in table 3 If subcooling value is greater than shown recover some refrigerant if less add some refrigerant TABLE 3 Subcooling Values for Charging Second Stage High Capacity Saturation Temperature Liquid Line Temperature Subcooling Value Charge Using the Approach Method Outdoor Temperature gt 65 F 18 C The following procedure is intended as a general guide and is for use on expansion valve systems only For best results indoor temperature should be 70 F 21 C to 80 F 26 C Monitor system pressures while charging 1 Check the outdoor ambient temperature using a digital thermometer and record in table 4 2 Attach high pressure gauge set and operate unit for several minutes to
16. 5 8 4 4 F CO 8 4 4 9 5 8 4 4 8 4 4 E 1 0 C 0 5 F 1 0 C 0 5 Page 20 A IMPORTANT Use tables 5 and 6 as a general guide when perform ing maintenance checks This is not a procedure for charging the unit Refer to Charging Checking Charge section Minor variations in these pressures may be expected due to differences in installations Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system TABLE 5 Normal Operating Pressures Cooling XP16 024 036 048 060 F C 2 Liq Vap Liq Vap Liq Vap Liq Vap First Stage Low Capacity Pressure 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 0 353 151 349 151 356 148 352 146 105 40 6 403 153 397 153 407 150 405 148 115 46 1 460 155 461 157 466 152 459 Second Stage High Capacity Pressure 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 0 371 149 367 146 374 147 373 138 105 40 6 423 151 426 148 427 148 425 142 115 46 1 485 154 489 151 491 151 486 146 1 These are most popular match up pressures Indoor match up indoor air quality and indoor load ca
17. E SHOWING MANIFOLD GAUGE CONNECTIONS OUTDOOR UNIT DISTRIBUTOR L ISl EXPANSION CHECK VALVE 4 COIL SENSOR REVERSING VALVE BIFLOW e FILTER DRIER OUTDOOR COIL INTERNAL LOW HIGH PRESSURE PRESSURE MUFFLER COMPRESSOR LIMIT INDOOR UNIT Hause maroro JH JJ TO R 410A DRUM LIQUID LINE SERVICE lt lt X SUCTION SERVICE PORT ti INDOOR VALVE L NOTE ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW REFRIGERANT WILL FLOW IN OPPOSITE DIRECTION IN HEATING CYCLE FIGURE 18 Page 16 A Plumbing Field refrigerant piping consists of liquid and vapor lines from the outdoor unit sweat connections Use Lennox L15 sweat series line sets as shown in table 1 TABLE 1 Liquid Suction L15 65 3 8 in 3 4 in 024 15 ft 50 ft 036 3 8 in 7 8 in i s 048 10 mm Q2mm m 18 m 3 8 in 1 1 8 in Field 10 mm 29 mm Fabricated B Service Valves A IMPORTANT Only use Allen wrenches of sufficient hardness 50Rc Rockwell Harness Scale min Fully in sert the wrench into the valve stem recess Service valve stems are factory torqued from 9 ft Ibs for small valves to 25 ft Ibs for large valves to prevent refrigerant loss during ship ping and handling Using an Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench or stripping the valve stem recess Service valves figures 19 and 20 and
18. FORMATION All major components indoor blower and coil must be matched according to Lennox recommendations for the compressor to be covered under warranty Refer to the En gineering Handbook for approved system matchups A misapplied system will cause erratic operation and can re sult in early compressor failure ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A CAUTION Electrostatic discharge can affect electronic components Take precautions during unit instal lation and service to protect the unit s electronic controls Precautions will help to avoid control exposure to electrostatic discharge by putting the unit the control and the technician at the same electrostatic potential Neutralize electro static charge by touching hand and all tools on an unpainted unit surface before performing any service procedure 4 CAUTION To prevent personal injury or damage to panels unit or structure be sure to observe the following While installing or servicing this unit carefully stow all removed panels out of the way so that the panels will not cause injury to personnel nor cause damage to objects or structures nearby nor will the panels be subjected to damage e g being bent or scratched While handling or stowing the panels consider any weather conditions especially windy conditions that may cause panels to be blown around and bat tered Remove the louvered panels as follows 1 Remove 2 screws
19. The coil temperature probe is de signed with a spring clip to allow mounting to the outside coil tubing The location of the coil sensor is important for proper defrost operation NOTE The demand defrost board 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 board initiates defrost cycles Diagnostic LEDs The state Off On Flashing of two LEDs on the defrost board DS1 Red and DS2 Green indicate diagnostics conditions that are described in table 2 Defrost Board Pressure Switch Connections The unit s automatic reset pressure switches LO PS S87 and HI PS S4 are factory wired into the defrost board on the LO PS and HI PS terminals respectively Low Pressure Switch LO PS When the low pressure switch 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 following condi tions Jlelelelelelele Page 5 during the defrost cycle and 90 seconds after the termina tion of defrost when the average ambient sensor temperature is below 15 F 9 C for 90 seconds following the start up of the compressor during test mode High Pressure Switch HI PS When the high pressure switch trips the defrost
20. Y ATOB con QugloEFRosT contro SRPUNDIS 40000000 328 5 3 ap S KI COMPRESSOR CONTACTOR S4 NOTE HIGH FOR USE WITH COPPER CONDUCTORS PRESSURE ONLY REFER TO UNIT RATING SWITCH PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVER CURRENT PROTECTION SIZE REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRANGEMENT WARNING RT28 ELECTRIC SHOCK HAZARD CAN CAUSE INJURY DISCHARGE QR DEATH UNIT MUST BE GROUNDED I ACCORDANCE WITH NATIONAL AND LOCAL CODES DENOTES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED CLASS VOLTAGE FIELD INSTALLED RT2I S87 LOW LI RTIS DEFROST PRESSURE REVERSING AMBIENT COIL SWITCH VALVE SENSOR SENSOR SENSOR Z KI 1 COMPRESSOR CONTACTOR K3I CRANKCASE CRANKCASE THERMOSTAT HEATER A EQUIPMENT GROUND Page 23 gt PpbPbP 2006 Lennox Industries Inc REMOVE JUMPER FOR TWO STAGE COOL RTI4 SENSOR OUTDOOR TEMP OPTIONAL K31 AND C7 ARE OPTIONAL HARD START KIT SII AND K58 ARE OPTIONAL LOW AMBIENT CONTROLS L34 SECOND STAGE SOLENOID IS LOCATED IN COMPRESSOR COIL IS 24VDC DO NOT CONNECT 24VAC TO COIL TERMINALS S40 AND HRI ARE USED ON 048 AND 060 UNITS ONLY SIGNATURE 31MV M28 CB CBX32MV A2 THERMOSTAT m HEAT PUMP OUTDOOR UNITS XP16 024 230 XP 116 036 2350 XP16 048 230 XP16 060 230 upersedes Form No New Form No 535 287W Litho U S A A 1 2 5 3 4 B 5
21. ac solenoid fusite terminals compressor fusite terminals compressor FIGURE 14 3 Unplug the full wave rectifier plug from the fusite con nection on the compressor Turn the low voltage power back onto the unit Supply 24VAC to the wires of the full wave rectifier plug Set volt meter to DC volts and measure the DC voltage at the female connector end of the full wave rectifier plug The DC voltage reading should be 1 5 to 3 volts lower than the input voltage to the plug wire leads EX Input voltage is 24VAC output voltage is 22VDC See figure 15 rectifier plug lead apply 24vac solenoid fusite terminals compressor fusite terminals compressor FIGURE 15 If the above checks verify that the solenoid plug is pro viding power to cycle into high capacity operation contin ue to step 3 to determine if problem is with solenoid coil in compressor STEP 3 Confirm internal unloader solenoid has prop er resistance 1 Shut all power off to unit main and low voltage 2 Unplug the molded plug from the compressor solenoid 2 pin fusite 3 Using a volt meter set on the 200 ohm scale Replace the Compressor under these conditions Bad Solenoid a Measure the resistance at the 2 pin fusite The resist ance should be 32 to 60 ohms depending on compressor temperature If no resist ancereplace compressor b Measure the resistance from each fusite pin to ground There should not be continuity to grou
22. allowing the panel to swing open slightly see figure 1 2 Hold the panel firmly throughout this procedure Rotate bottom corner of panel away from hinge corner post until lower 3 tabs clear the slots see figure 1 De tail B 3 Move panel down until lip of upper tab clears the top slot in corner post see figure 1 Detail A Position and Install Panel Position the panel almost parallel with the unit figure 1 Detail D with the screw side as close to the unit as possible Then in a continuous mo tion Page 3 Slightly rotate and guide the lip of top tab inward figure 1 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 Removing Installing Louvered Panels IMPORTANT Do not allow panels to hang on unit by top tab Tab is for alignment and not designed to support weight of panel Panel shown slightly rotated to allow top tab to exit or enter top slot for removing or installing panel S SCREW It HOLES UL TEDD LIP Detail maA UJI YUU UU UI c
23. ar coil and frosted coil temperatures exceeds the maxi mum difference allowed by the control a defrost cycle will be initiated Time If 6 hours of heating mode compressor run time has elapsed since the last defrost cycle while the coil tem perature remains below 35 F 2 C the demand de frost control will initiate a defrost cycle Actuation When the reversing valve is de energized the Y1 circuit is energized and the coil temperature is below 35 F 2 C the board logs the compressor run time If the board is not calibrated a defrost cycle will be initiated after 34 minutes of heating mode compressor run time The con trol will attempt to self calibrate after this and all other de frost cycle s Calibration success depends on stable system tempera tures during the 20 minute calibration period If the board fails to calibrate another defrost cycle will be initiated after 45 minutes 90 minutes on 1 to 4 boards of heating mode compressor run time Once the defrost board is calibrated it initiates a demand defrost cycle when the difference be tween the clear coil and frosted coil temperatures exceeds the maximum difference allowed by the control OR after 6 hours of heating mode compressor run time has been logged since the last defrost cycle NOTE If ambient or coil fault is detected the board will not execute the TEST mode Termination The defrost cycle ends when the coil tem perature exceeds the termination t
24. 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 psig Low Pressure auto reset trip at 25 psig reset at 40 psig 5 Strike Lockout Feature The internal control logic of the board counts the pressure switch trips only while the Y1 Input line is active If a pres sure switch opens and closes four times during a Y1 Input the control logic will reset the pressure switch trip counter to zero at the end of the Y1 Input If the pressure switch opens for a fifth time during the current Y1 Input the con trol will enter a lockout condition The 5 strike pressure switch lockout condition can be reset by cycling OFF the 24 volt power to the control board or by shorting the TEST pins between 1 and 2 seconds All timer functions run times will also be reset If a pressure switch opens while the Y1 Out line is engaged a 5 minute short cycle will occur after the switch closes Defrost System Sensors Sensors connect to the defrost board through a field re placeable harness assembly that plugs into the board Through the sensors the board detects outdoor ambient coil and discharge temperature fault conditions As the de tected temperature changes the resistance across the sensor changes Sensor resistance values can be checked by ohming across pins shown in table 1 The graph in figure
25. contactor output and the defrost output if active The compressor will remain off until the discharge temperature has dropped below 225 F 107 C and the 5 minute anti short cycle delay has been satisfied This sensor has two fault and lockout codes 4 If the board recognizes five high discharge line temper ature faults during a single Y1 compressor demand it reverts to a lockout mode and displays the appropri ate code This code detects shorted sensor or high dis charge temperatures Code on board is Discharge Line Temperature Fault and Lockout 5 If the board recognizes five temperature sensor range faults during a single Y1 compressor demand it re verts to a lockout mode and displays the appropriate code The board detects open sensor or out of temper ature sensor range This fault is detected by allowing the unit to run for 90 seconds before checking sensor resistance If the sensor resistance is not within range after 90 seconds the board will count one fault After 5 faults the board will lockout Code on board is Dis charge Sensor Fault and Lockout Page 7 The discharge line sensor which covers a range of 150 F 65 C to 350 F 176 C is designed to mount on a 2 re frigerant discharge line NOTE Within a single room thermostat demand if 5 strikes occur the board will lockout the unit Defrost board 24 volt power R must be cycled OFF or the TEST pins on board must be shor
26. ctuator coil FIGURE 9 The scroll compressor design is simple efficient and re quires few moving parts A cutaway diagram of the scroll compressor is shown in figure 1 The scrolls are located in the top of the compressor can and the motor is located just below The oil level is immediately below the motor The scroll is a simple compression concept centered around the unique spiral shape of the scroll and its inherent properties Figure 10 shows the basic scroll form Two iden tical scrolls are mated together forming concentric spiral shapes figure 11 One scroll remains stationary while the other is allowed to orbit figure 12 Note that the orbiting scroll does not rotate or turn but merely orbits the station ary scroll SCROLL FORM FIGURE 10 Page 11 CROSS SECTION OF SCROLLS DISCHARGE DISCHARGE PRESSURE STATIONARY SCROLL u SUCTION y M NI Spay DTI TIPS SEALED BY a DISCHARGE PRESSURE ORBITING SCROLL FIGURE 11 The counterclockwise orbiting scroll draws gas into the outer crescent shaped gas pocket created by the two scrolls fig ure 4 1 The centrifugal action of the orbiting scroll seals off the flanks of the scrolls figure 4 2 As the orbiting motion continues the gas is forced toward the center of the scroll and the gas pocket becomes compressed figure 4 3 When the compressed gas reaches the center it is dis charged vertically into a chamber and discharge port in the top of the
27. d indoor unit Reconnect the manifold gauge to the vacuum pump turn the pump on and continue to evacuate the line set and indoor unit until the absolute pressure does not rise above 500 microns 29 9 inches of mercury within a 20 minute period after shutting off the vacuum pump and closing the manifold gauge valves 9 When the absolute pressure requirement above has been met disconnect the manifold hose from the vacu um pump and connect it to an upright cylinder of R 410A refrigerant Open the manifold gauge valves to break the vacuum from 1 to 2 psig positive pressure in the line set and indoor unit Close manifold gauge valves and shut off the R 410A cylinder and remove the manifold gauge set co 1 Page 19 C Charging Charge Using the Weigh in Method Outdoor Temperature lt 65 F 18 C If the system is void of refrigerant or if the outdoor ambient temperature is cool first locate and repair any leaks and then weigh in the refrigerant charge into the unit 1 Recover the refrigerant from the unit 2 Conduct leak check evacuate as previously outlined 3 Weigh in the unit nameplate charge If weighing facili ties are not available or if charging the unit during warm weather use one of the following procedures Charge Using the Subcooling Method Outdoor Temperature lt 65 F 18 C When the outdoor ambient temperature is below 65 F 18 C use the subcooling method to charge the unit If nece
28. d thermostat wiring is made to a 24V terminal strip located on the defrost control board located in the control box See figure 4 24V THERMOSTAT TERMINAL STRIP 9 FIGURE 4 1 Compressor Contactor K1 The compressor is energized by a contactor located in the control box See figure 3 Single pole contactors are used in all XP16 series units K1 is energized through the con trol board by the indoor thermostat terminal Y1 24V when thermostat demand is present A DANGER Electric Shock Hazard May cause injury or death Line voltage is present at all compo nents when unit is not in operation on units with single pole contactors Disconnect all remote electrical power supplies before opening unit panel Unit may have multiple power supplies 2 Dual Capacitor C12 The compressor and fan in XP16 series units use permanent split capacitor motors The capacitor is located inside the unit control box see figure 3 A single dual capacitor C12 is used for both the fan motor and the compressor see unit wir ing diagram The fan side and the compressor side of the ca pacitor have different MFD ratings See side of capacitor for ratings 3 Start Kit option The start kit consists of a potential relay K31 and start ca pacitor C7 The potential relay controls the operation of the starting circuit The relay is normally closed when contactor K1 is de energ
29. door unit to an absolute pressure of 23 000 microns 29 01 inches of mercu ry During the early stages of evacuation it is desirable to close the manifold gauge valve at least once to deter mine if there is a rapid rise in absolute pressure A rapid rise in pressure indicates a relatively large leak If this occurs repeat the leak testing procedure NOTE The term absolute pressure means the total actual pressure within a given volume or system above the absolute zero of pressure Absolute pres sure in a vacuum is equal to atmospheric pressure mi nus vacuum pressure When the absolute pressure reaches 23 000 microns 29 01 inches of mercury close the manifold gauge valves turn off the vacuum pump and disconnect the manifold gauge center port hose from vacuum pump Attach the manifold center port hose to a nitrogen cylin der with pressure regulator set to 150 psig 1034 kPa and purge the hose Open the manifold gauge valves to break the vacuum in the line set and indoor unit Close the manifold gauge valves A CAUTION Danger of Equipment Damage Avoid deep vacuum operation Do not use compres O 1 sors to evacuate a system Extremely low vacuums can cause internal arcing and compressor failure Damage caused by deep vacuum operation will void warranty 7 Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder Open the manifold gauge valves to release the nitrogen from the line set an
30. e set which will pressurize line set and indoor unit 7 After a few minutes open a refrigerant port to ensure the refrigerant you added is adequate to be detected Amounts of refrigerant will vary with line lengths Check all joints for leaks Purge nitrogen and R 410A mixture Correct any leaks and recheck B Evacuating the System Evacuating the system of noncondensables is critical for proper operation of the unit Noncondensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system Noncondensables and water vapor combine with refrigerant to produce substances that corrode copper pip ing and compressor parts NOTE This evacuation process is adequate for a new installation with clean and dry lines If excessive mois ture is present the evacuation process may be re quired more than once A IMPORTANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns Use an instrument that reads from 50 microns to at least 10 000 microns 1 Connect manifold gauge set to the service valve ports e low pressure gauge to vapor line service valve e high pressure gauge to iquid 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 Page 18 5 Evacuate the line set and in
31. e heater HR1 prevents liquid from accu mulating in the compressor HR1 is controlled by a thermo stat located on the liquid line When liquid line temperature drops below 50 F the thermostat closes energizing HR1 The thermostat will open de energizing HR1 once liquid line temperature reaches 70 F F Drier A filter drier designed for all XP16 model units is factory installed in the liquid line The filter drier is designed to re move moisture and foreign matter which can lead to com pressor failure Moisture and or Acid Check Because POE oils absorb moisture the dryness of the system must be verified any time the refrigerant sys tem is exposed to open air A compressor oil sample must be taken to determine if excessive moisture has been introduced to the oil Table 4 lists kits available from Lennox to check POE oils If oil sample taken from a system that has been exposed to open air does not test in the dry color range the filter drier MUST be replace A IMPORTANT Replacement filter drier MUST be approved for R 410A refrigerant and POE application Foreign Matter Check It is recommended that a liquid line filter drier be replaced when the pressure drop across the filter drier is greater than 4 psig To safeguard against moisture entering the system follow the steps in section IV sub section B Evacuating the System when replacing the drier TABLE 4 10N46 Refrigerant Analysis Checkmate RT700 te fue mw
32. e set when valve is closed front seated valve front seated Service Valve Valve Open insert hex stem cap wrench here service port to outdoor coil service port cap to indoor coil Schrader valve FIGURE 19 Vapor Line Ball Valve 4 amp 5 Ton Only Vapor line service valves function the same way as the oth er valves the difference is in the construction If a valve has failed you must replace it A ball valve is illustrated in figure 20 The ball valve is equipped with a service port with a factory installed Schrader valve A service port cap protects the Schrader valve from contamination and assures a leak free Seal Page 17 Ball Valve Valve Open Use Adjustable Wrench To open rotate Stem Clockwise 90 To close rotate Stem Counter clockwise 90 44 stem cap to outdoor coil ball shown open service port cap Schrader valve FIGURE 20 IV CHARGING A Leak Testing After the line set has been connected to the indoor and out door units check the line set connections and indoor unit for leaks A WARNING Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may result in personal injury or death A WARNING Fire Explosion and Personal Safety Hazard Failure to follow this warning could result in damage personal injury or death Never use oxygen to pressurize or purge r
33. ean the coil 2 Condenser fan motor is prelubricated and sealed No further lubrication is needed 3 Visually inspect connecting lines and coils for evidence of oil leaks 4 Check wiring for loose connections 5 Check for correct voltage at unit unit operating 6 Check amp draw condenser fan motor Unit nameplate Actual NOTE If owner complains of insufficient cooling the unit should be gauged and refrigerant charge checked Refer to section on refrigerant charging in this instruction 1 Clean and inspect condenser coil Coil may be flushed with a water hose after disconnecting power 2 Visually inspect all connecting lines joints and coils for evidence of oil leaks B Indoor Coil 1 Clean coil if necessary 2 Check connecting lines and coils for evidence of oil leaks 3 Check the condensate line and clean it if necessary C Indoor Unit 1 Clean or change filters 2 Adjust blower speed for cooling Measure the pressure drop over the coil to determine the correct blower CFM Refer to the unit information service manual for pressure drop tables and procedure 3 Belt Drive Blowers Check belt for wear and proper ten sion 4 Check all wiring for loose connections 5 Check for correct voltage at unit blower operating 6 Check amp draw on blower motor Unit nameplate Actual Page 22 VII WIRING DIAGRAM AND SEQUENCE OF OPERATION START CAPACITOR O Ofer POTENTIAL RELA
34. efrigeration lines Oxygen when exposed to a spark or open flame can cause damage by fire and or an explosion that can result in personal injury or death A WARNING Danger of explosion When using a high pressure gas such as dry nitrogen to pressurize a refriger ant or air conditioning system use a regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa Using an Electronic Leak Detector or Halide 1 Connect a cylinder of R 410A to the center port of the manifold gauge set 2 With both manifold valves closed open the valve on the R 410A cylinder vapor only 3 Open the high pressure side of the manifold to allow the R 410A into the line set and indoor unit Weigh in a trace amount of R 410A A trace amount is a maximum of 2 ounces 57 g or 3 pounds 31 kPa pressure Close the valve on the R 410A cylinder and the valve on the high pressure side of the manifold gauge set Disconnect the R 410A cylinder 4 Connect a cylinder of nitrogen with a pressure regulat ing valve to the center port of the manifold gauge set 5 Connect the manifold gauge set high pressure hose to the vapor valve service port Normally the high pres sure hose is connected to the liquid line port however connecting it to the vapor port better protects the man ifold gauge set from high pressure damage 6 Adjust the nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gaug
35. electrical section in this manual for compressor specifications TWO STAGE OPERATION The two stage scroll compressor operates like any stan dard scroll compressor with the exception the two stage compressor modulates between first stage low capacity approximately 6796 and second stage high capacity Modulation occurs when gas is bypassed through bypass ports figure 13 bypass ports open in the first suction pock et This bypassing of gas allows the compressor to operate on first stage low capacity if thermostat demand allows Indoor thermostat setting will determine first or second stage operation The compressor will operate on first stage until demand is satisfied or the indoor temperature reaches the thermostat set point calling for second stage Second stage high capacity is achieved by blocking the bypass ports figure 13 bypass ports closed with a slider ring The slider ring begins in the open position and is con trolled by a 24VDC internal solenoid On a Y2 call the inter nal solenoid closes the slider ring blocking the bypass ports and bringing the compressor to high capacity Two stage modulation can occur during a single thermostat de mand as the motor runs continuously while the compressor modulates from first stage to second stage HOW A SCROLL WORKS eS MOVEMENT OF ORBIT p dr INTERMEDIATE GAS CRESCENT SHAPED GAS POCKET quate SUCTION POCKET x FLANKS 2t pode HISH PRESSURE GAS
36. emperature 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 Test Mode When Y1 is energized and 24V power is being applied to the board a test cycle can be initiated by placing the termination temperature jumper across the Test pins for 2 to 5 seconds If the jumper remains across the Test pins longer than 5 seconds the control will ignore the test pins and revert to normal operation The jumper will initiate one cycle per test Enter the TEST mode by placing a shunt jumper across the TEST pins on the board 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 Board timings are reduced the low pressure switch and loss of charge detection fault is ignored and the board will clear any active lockout condition Each test pin shorting will result in one test event For each TEST the shunt jumper must be removed for at least 1 second and reapplied Refer to flow chart figure 8 for TEST operation Note The Y1 input must be active ON and the O room thermostat terminal into board must be inactive Defrost Board Diagnostics See table 2 to determine defrost board operational condi tions and to diagnose cause and solution to problems Page 8 Test Mode Y1 Active O line inactive Y Y S
37. f life Installation and service must Unit Information esses Page 3 be performed by a qualified installer or service agency II Unit Components Page 4 ARN N G Ill Refrigerant System Page 16 A IV Charging sees Page 18 Electric shock hazard Can cause injury or death Before attempting to perform V Service and Recovery Page 21 any service or maintenance turn the electrical power to unit OFF at discon VI Maintenance 000 Page 22 nect switch es Unit may have multiple power supplies VII Wiring Diagram 0 00 Page 23 Technical A ADP ene Page 1 2006 Lennox Industries Inc SPECIFICATIONS General Model No XP16 024 XP16 036 XP16 048 XP16 060 Data Nominal Tonnage 2 3 4 5 Connections Liquid line o d in 3 8 3 8 3 8 3 8 sweat Vapor line o d in 3 4 7 8 7 8 1 1 8 Refrigerant 1 R 410A charge furnished 9 Ibs 9 oz 12 Ibs 8 oz 15 Ibs 7 oz 13 Ibs 8 oz Outdoor Net face area sq ft Outer coil 13 22 18 67 24 5 24 93 Coil Inner coil 12 65 18 0 23 64 24 14 Tube diameter in 5 16 5 16 5 16 5 16 No of rows 2 2 2 2 Fins per inch 22 22 22 22 Outdoor Diameter in 18 22 22 26 Fan No of blades 3 4 4 3 Motor hp 1 10 1 6 1 4 1 3 Cfm 2215 3150 3980 4380 Rpm 1040 844 836 850 Watts 145 215 305 280 Shipping Data Ibs 1 pkg 219 265 309 345 ELECTRICAL DATA Line voltage data 60hz 4 208 230V 1ph 4 208
38. hort test pins for longer Short test pins for more than 2 0 seconds than 1 second but less than 2 0 seconds Clear any short cycle lockout and 5 strike fault lockout function if applicable y y Y Clear any short cycle lockout If in COOLING Mode If in HEATING Mode If in DEFROST Mode and 5 strike fault lockout Y Y Y function if applicable No No further test mode The controller will check for The unit will terminate other functions will be operation will be ambient and coil faults open or defrost and enter Heat executed and unit will executed until the test shorted If a fault exists the Mode uncalibrated with continue in the mode it was short is removed and unit will remain in Heat Mode defrost timer set for 34 operating reapplied and no further test mode minute test No further operation will be executed until test mode operation will the test short is removed and re be executed until the test applied If no fault exists the short is removed and unit will go into Defrost mode reapplied Y Y Test pin short REMAINS in place for more than 5 seconds Test pins short REMOVED before a y maximum of 5 seconds The unit will return to Heat mode uncalibrated with defrost Y timer set for 34 minutes No further test mode operation will The unit will remain in Defrost mode be executed until the test short is removed and re applied until
39. ized When K1 is energized the compressor immediately begins start up K31 remains closed during compressor start up and and start capacitor C7 remains in the circuit When compressor reaches approximately 7596 of its speed K31 is energized When K31 energizes the contacts open and start capacitor C7 is taken out of the cir cuit Page 4 4 Defrost Control The demand defrost controller measures differential tem peratures to detect when the system is performing poorly because of ice build up on the outdoor coil The controller self calibrates when the defrost system starts and after each system defrost cycle The defrost control board com ponents are shown in figure 5 Defrost Control Board Note Component Locations Vary by Board Manufacturer TEST PINS FAN DEFROST zO LOW TERMINATION 1 7 1 AMBIENT PIN SETTINGS THERMOSTAT Oo PINS SENSOR PLUG IN COIL AMBIENT amp DISCHARGE SENSORS I DIAGNOSTIC LEDS DELAY PINS 7 REVERSING VALVE 7 4 24V TERMINAL STRIP CONNECTIONS LO PS PRESSURE SWITCH CIRCUIT COMMON CONNECTIONS ems o Y OUT HI PS Oo sIsTsTsIsIsIsIs I TSTPS DF C R O YI Y FIGURE 5 The control monitors ambient temperature outdoor coil temperature and total run time to determine when a de frost cycle is required
40. nd If solenoid coil is grounded replace compressor Good Solenoid a Seals not shifting replace compressor b Slider ring not shifting replace compressor Page 14 C Outdoor Fan Motor All units use single phase PSC fan motors which require a run capacitor In all units the condenser fan is controlled by the compressor contactor ELECTRICAL DATA tables in this manual show specifi cations for condenser fans used in XP16 s Access to the condenser fan motor on all units is gained by removing the four screws securing the fan assembly See figure 16 The grill fan assembly can be removed from the cabinet as one piece See figure 17 The con denser fan motor is removed from the fan guard by re moving the four nuts found on top of the grill See figure 17 if condenser fan motor replacement is necessary A DANGER Make sure all power is disconnected before beginning electrical service procedures Remove screws LENN S d Screws FIGURE 16 ALIGN FAN HUB FLUSH WITH END OF SHAFT FIGURE 17 D Reversing Valve L1 and Solenoid A refrigerant reversing valve with electromechanical so lenoid is used to reverse refrigerant flow during unit op eration The reversing valve requires no maintenance It is not repairable If the reversing valve has failed it must be replaced E Crankcase Heater HR1 amp Thermostat S40 The compressor in the unit is equipped with a 70 watt belly band type crankcas
41. nd high capacity readings STEP 1 Confirm low to high capacity compressor op eration Tools required Refrigeration gauge set Digital volt amp meter Electronic temperature thermometer On off toggle switch Page 13 Procedure 1 Turn main power OFF to outdoor unit 2 Adjust room thermostat set point above heating op eration on heat pump or below cooling operation the room temperature 5 F 3 Remove control access panel Install refrigeration gauges on unit Attach the amp meter to the common black wire wire of the compressor harness Attach thermometer to discharge line as close as possible to the compressor 4 Turn toggle switch OFF and install switch in series with Y2 wire from room thermostat 5 Cycle main power ON 6 Allow pressures and temperatures to stabilize before taking any measured reading may take up to 10 min utes NOTE Block outdoor coil to maintain a minimum of 375 psig during testing 7 Record all of the readings for the Y1 demand on table 3 8 Close switch to energize Y2 demand 9 Allow pressures and temperatures to stabilize before taking any measured reading this may take up to 10 minutes 10 Record all of the readings of Y2 demand on table 3 NOTE On new installations or installations that have shut down for an extended period of time if the compres sor does not cycle from low stage to high stage on the first attempt it may be necessary to recycle the
42. oard checks for open low or high pres sure switches and proper coil ambient and discharge sensor readings If checks show no issues the defrost board sends 24 volts through Y1 OUT signal to the K1 compressor contactor coil HARD START KIT IF USED Compressor begins start up Relay K31 remains closed during start up and capacitor C7 remains in the circuit As compres sor speeds up K31 is energized de energizing ca pacitor C7 K1 1 closes energizing the compressor and outdoor fan motor Solenoid L34 is NOT energized The slider ring re mains open limiting compressor to low capacity High Capacity Ambient temperature above defrost board Y2 lock in temperature Room thermostat in heating mode Room thermostat outputs Y1 and Y2 if applicable to that room thermo stat signal to the defrost board in the heat pump and to the indoor unit 2 3 4 B 1 2 3 4 Page 24 The defrost board checks for open low or high pres sure switches and proper coil ambient and discharge sensor readings If checks show no issues the defrost board sends 24 volts through Y1 OUT signal to the K1 compressor contactor coil The defrost board sends 24 volts through Y2 OUT to the L34 compressor solenoid plug The 2 wire com pressor solenoid plug converts the 24volt AC outputs to a 24volt DC signal input to the L34 internal high capac ity solenoid valve in the compressor K1 1 closes energizing the compressor and outdoor fan
43. 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 jumpering the TEST pins Operational Description The defrost control board has three basic operational modes normal calibration and defrost Normal Mode The demand defrost board 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 Mode The board is considered uncalibrated when power is applied to the board after cool mode opera tion or if the coil temperature exceeds the termination tem perature when it is in heat mode Calibration of the board occurs after a defrost cycle to en sure that there is no ice on the coil During calibration the temperature of both the coil and the ambient sensor are measured to establish the temperature differential which is required to allow a defrost cycle Defrost Mode The following paragraphs provide a de tailed description of the defrost system operation Detailed Defrost System Operation Defrost Cycles The demand defrost control board initi ates a defrost cycle based on either frost detection or time Frost Detection lf the compressor runs longer than 34 minutes and the actual difference between the cle
44. ssary restrict the air flow through the outdoor coil to achieve pressures in the 325 375 psig 2240 2585 kPa range These higher pressures are necessary for checking the charge Block equal sections of air intake panels and move obstructions sideways until the liquid pressure is in the 325 375 psig 2240 2585 kPa range See figure 21 Blocking Outdoor Coil BLOCK OUTDOOR COIL ONE SIDE AT A TIME WITH CARDBOARD OR PLASTIC SHEET UNTIL PROPER TESTING PRESSURES ARE REACHED CARDBOARD OR PLASTIC SHEET FIGURE 21 1 With the manifold gauge hose still on the liquid service port and the unit operating stably use a digital ther mometer to check the liquid line temperature and re cord in table 3 2 At the same time record the liquid line pressure reading 3 Use a temperature pressure chart for R 410A table 2 to determine the saturation temperature for the liquid line pressure reading record in table 3 TABLE 2 R 410A Temperature F Pressure Psig Psig F Psig F Psio 94 290 8 125 445 9 126 451 8 299 4 127 457 6 F 32 1008 63 178 5 33 1029 64 181 6 34 1050 184 3 35 36 37 38 113 6 197 3 39 40 118 0 203 9 41 107 1 187 7 109 2 190 9 303 8 128 463 5 308 2 129 469 5 3127 aso 4756 Foo sizz 9i aor 101 218 152 a878 tz 3284 125 4940 109 3910 194 5002 Foe 335 7 535 5065 105 340 5 126 5
45. ted between 1 to 2 seconds to reset the board Second Stage Operation If the board receives a call for second stage compressor operation Y2 in heating or cooling mode and the first stage compressor output is ac tive the second stage compressor solenoid output will be energized If first stage compressor output is active in heating mode and the outdoor ambient temperature is below the selected compressor lock in temperature the second stage com pressor solenoid output will be energized without the Y2 room thermostat input If the jumper is not connected to one of the temperature selection pins on P3 40 45 50 55 F the default lock in temperature of 40 F 4 5 C will be used The board de energizes the second stage compressor so lenoid output immediately when the Y2 signal is removed or the outdoor ambient temperature is 5 F above the se lected compressor lock in temperature or the first stage compressor output is de energized for any reason Defrost Temperature Termination Shunt Jumper Pins The defrost board selections are 50 70 90 and 100 F 10 21 32 and 38 C The shunt termination pin is factory set at 50 F 10 C If the temperature shunt is not installed the default termination temperature is 90 F 32 C Delay Mode The defrost board 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
46. termination on time or temperature FIGURE 8 Page 9 TABLE 2 Defrost Control Board Diagnostic LEDs DS1 Power problem No power 24V to board termi 1 Check control transformer power 24V nals R amp C or board failure 2 f power is available to board and LED s do not light replace board Simultaneous Normal operation Unit operating normally or in None required SLOW Flash standby mode Alternating 5 minute anti short cycle Initial power up safety trip end of None required Jumper TEST pins to override SLOW Flash delay room thermostat demand Simultaneous Ambient Sensor Problem Sensor being detected open or shorted or out of temperature range Board will re FAST Flash vert to 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 FAST Flash perform demand or time temperature defrost operation System will still heat or cool Circuit Board Failure Indicates that board has internal component failure Cycle 24 volt power to board If code does not clear replace board FAULT amp LOCKOUT CODES Each fault adds 1 strike to that code s counter 5 strikes per code LOCKOUT OFF SLOW Low Pressure Fault 1 Restricted air flow over indoor 1 Remove any blockages or restrictions from Flash or outdoor coil coils and or fans Check indoor and outdoor 2 Improper refrigerant charge in fan
47. tions to prevent moisture from entering the system The following steps will help to minimize the amount of moisture that enters the system during recovery of R 410A 1 Use a regulator equipped nitrogen cylinder to break the system vacuum Do not exceed 5 psi The dry nitro gen will fill the system and will help purge any mois ture 2 Remove the faulty component and quickly seal the sys tem using tape or some other means to prevent addi tional moisture from entering the system 3 Do not remove the tape until you are ready to install new component Quickly install the replacement com ponent 4 Evacuate the system to remove any moisture and other non condensables The XP16 system MUST be checked for moisture any time the sealed system is opened Any moisture not absorbed by the polyol ester oil can be re moved by triple evacuation Moisture that has been ab sorbed by the compressor oil can be removed by replacing the drier A IMPORTANT Evacuation of system only will not remove mois ture from oil Drier must be replaced to eliminate moisture from POE oil VI MAINTENANCE In order to maintain the warranty on this equipment the XP16 system must be serviced annually and a record of service maintained The following should be checked be tween annual maintenance A Outdoor Unit 1 Clean and inspect the outdoor coil The coil may be flushed with a water hose Ensure the power is turned off before you cl
48. up from bottom 17 1 2 XP16 060 COIL SENSOR 5 Dall 12 tubes up from bottom 11 1 2 XP16 048 COIL SENSOR 13 tubes up from bottom 12 1 2 CLIP COIL TEMPERATURE SENSOR FROM THE DEFROST BOARD ON THE RETURN BEND SHOWN Ambient Sensor The ambient sensor shown in detail A figure 7 considers outdoor temperatures below 35 F 37 C or above 120 F 48 C as a problem If the ambient sensor is detected as being open shorted or out of the tem perature range of the sensor the board will not perform de mand defrost operation The board will revert to time tem perature 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 shown in detail B figure 7 considers outdoor temperatures below 35 F 37 C or above 120 F 48 C as a problem If the coil tem perature sensor is detected as being open shorted or out of the temperature range of the sensor the board will not per form demand or time temperature defrost operation and will display the appropriate fault code Heating and cooling operation will be allowed in this fault condition Discharge Line Sensor lf the discharge line tempera ture shown in figure 7 exceeds a temperature of 285 F 140 C during compressor operation the board will de en ergize the compressor
49. use pressures to vary 2 Temperature of the air entering the outdoor coil 3 Liquid 10 amp Vapor 5 psig TABLE 6 Normal Operating Pressures Heating XP16 024 036 048 060 F C Liq Vap Liq Vap Liq Vap Liq Vap First Stage Low Capacity Pressure 40 4 4 337 93 328 98 369 75 351 63 50 10 322 117 333 118 366 114 335 92 Second Stage High Capacity Pressure 20 7 0 279 62 296 62 311 58 308 59 30 1 0 288 76 309 75 334 72 323 70 40 4 4 302 93 322 92 354 89 318 69 50 10 306 112 336 113 381 108 329 82 1 These are most popular match up pressures Indoor match up indoor air quality and indoor load cause pressures to vary 2 Temperature of the air entering the outdoor coil 3 Liquid 10 amp Vapor 5 psig Page 21 V SERVICE AND RECOVERY AWARNING Polyol ester POE oils used with R 410A refriger ant absorb moisture very quickly It is very impor tant that the refrigerant system be kept closed as much as possible DO NOT remove line set caps or service valve stub caps until you are ready to make connections A IMPORTANT Use recovery machine rated for R410 refrigerant If the XP16 system must be opened for any kind of service such as compressor or drier replacement you must take extra precau
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