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XPG15 ATTENTION SERVICE TECHNICIAN

1. XPG15 024 XPG15 030 XPG15 036 Model Number Add Charge Target SC Add Charge Target SC Add Charge Target SC Ib oz Heat Cool Ib oz Heat Cool Ib oz Heat Cool CH33 31 0 0 21 4 0 0 23 4 0 0 22 4 CH33 42 1 4 18 4 0 2 20 3 0 5 15 4 CH33 43 1 4 13 4 1 8 16 4 0 11 13 4 CH33 44 48B 1 4 13 4 1 8 16 4 0 11 13 4 CH33 48C 0 11 13 4 CH33 49C 1 5 10 8 CR33 48 1 4 18 4 0 2 20 3 0 5 15 4 CX34 31 0 0 21 4 0 0 23 4 0 0 22 4 CX34 38 1 4 18 4 0 2 20 3 0 5 15 4 CX34 43 1 4 13 4 1 8 16 4 0 11 13 4 CX34 44 48B 0 2 14 3 0 5 15 4 CX34 49 2 5 11 7 1 5 10 8 CX34 50 60C 1 8 16 4 0 11 13 4 XPG15 042 XPG15 048 XPG15 060 Model Number Add Charge Target SC Add Charge Target SC Add Charge Target SC Ib oz Heat Cool Ib oz Heat Cool Ib oz Heat Cool CH33 43 0 5 17 5 CH33 44 48B 0 5 17 5 CH33 48C 0 5 17 5 CH33 49C 1 7 11 7 0 0 17 6 0 11 20 6 CH33 60D 0 6 21 4 0 0 25 4 CH33 62D 1 5 14 6 1 0 18 6 CR33 48 0 0 15 5 CR33 50 60 1 7 11 6 0 0 45 2 1 8 45 2 CR33 60D 1 7 11 6 0 0 45 2 1 8 45 2 CX34 38 0 0 15 5 CX34 43 0 5 17 5 CX34 44 48B 0 0 27 3 CX34 49 1 7 11 7 0 0 17 6 0 11 20 6 CX34 60D 0 9 9 4 0 6 21 4 0 0 25 4 CX34 62C 1 5 7 4 1 5 14 6 0 0 14 6 CX34 62D 1 5 7 4 1 5 14 6 1 0 18 6 Amount of charge required in addition to charge shown on unit nameplate Remember to consider line set length difference 07 09 Page 36
2. Figure 28 Calibration Sequence 07 09 Page 54 Dealer Maintenance29 A WARNING Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the switch es Unit may have multiple power supplies W electrical power to unit OFF at disconnect Before the start of each heating and cooling season the following service checks should be performed by a licensed professional service technician or equivalent First turn off electrical power to the unit prior to performing unit maintenance e Inspect and clean the outdoor and indoor coils The outdoor coil may be flushed with a water hose NOTE It may be necessary to flush the outdoor coil more frequently if it is exposed to substances which are corrosive or which block airflow across the coil e g pet urine cottonwood seeds etc e Visually inspect the refrigerant lines and coils for leaks e Check wiring for loose connections e Check voltage at the indoor and outdoor units with units operating e Check the amperage draw at the outdoor fan motor compressor and indoor blower motor Values should be compared with those given on unit nameplate e Check clean or replace indoor unit filters e Check the refrigerant charge and gauge the system pressures e Check the condensate drain line for free and unobstructed flow clean if necessary e Outdoor unit fan motor is prelubricated
3. Inactive Display Ambient Code Temperature is K3 OFF less than 32 F K1 K2 K4 ON No End Heating Operation See Cooling Mode Is 5 minute ASCD Timer Expired Y v Remain Inactive K1 2 Does O Become Energize K3 OFF Active Comp K4 ON Contactor 9 No Return from Inactive criteria satisfied and Y1 Active K1 K2 K3 ON and K4 OFF Power Defrost Ambient Temperature less than 32 F 2 Neat Demand Calibration Sequence De energize K3 Comp Contactor Fifth Trip in this Heating Demand De energize K3 Comp Contactor Yes 5 Demand Satisfied Hi Ps Lockout Display Code Fifth Trip in this Heating Demand Lo Ps Lockout Yes P Display Code No Figure 27 Heating Mode Operation Page 53 XPG15 SERIES CALIBRATION SEQUENCE G A L B Re A DEFROST CONTROL ON BOARD RELAYS K1 Outdoor Fan Normally Closed Sequence K2 Reversing valve amp RL output K3 Compressor Y1 out With coil temperature less than 35 F a power defrost occurs K4 W out j 30 minutes after power up or after cooling operation A power defrost also occurs at return from heat pump Inactive ASCD Anti short Cycle Delay condition K1 K2 K3
4. LENNOX UNIT INFORMATION 15 0908 14 Service Literature Revised 11 2010 w Dave Lennox Signature Collection XPG15 Units TABLE OF CONTENTS A WARNING Specifications Electrical Data and Optional Improper installation adjustment alteration service or Accessories AE se E RRE 2 maintenance can cause personal injury loss of life or Unit Dimensions 3 damage to property Model Number Identification 3 Installation and service must be performed by a licensed Unit Parts Arrangement 4 professional installer or equivalent or a service agency Control Box Parts Arrangement 4 Scroll Compressor Operations 6 IMPORTANT Unit Components 7 A Operating Gauge Set and Service Valves 8 The Clean Air Act of 1990 bans the intentional venting of Recovering Refrigerant from Existing System 10 refrigerant CFCs HCFCs AND HFCs as of July 1 Outdoor Unit Placement 11 1992 Approved methods of recovery recycling or Removing and Installing Panels 11 reclaiming must be followed Fines and or incarceration New or Replacement Line Set 15 may be levied for noncompliance Brazing Connections 17 0 20 XPG15 is high effic
5. DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS K1 relay contact remain closed K2 relay contact close and output 24VAC to RL output to energize K229 field installed relay K2 relay contact close and energize reversing valve K3 relay contact open and de energize compressor contactor due to outdoor temperature being below 32 F 0 C Heat pump goes into inactive mode K4 relay contact close and send 24VAC to W out terminal Gas furnace will satisfy 1 heat demands K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from the room thermostat to the furnace control This allows the furnace to control the indoor blower operation during gas heat operation gt N gt an Page 49 XPG15 SERIES POWER DEFROST MODE RT21 RT43 54 serow d A DEFROST AMBIENT HIGH PRESSURE REVERSING B1 COIL SENSOR PRESSURE swITCH VALVE COMPRESSOR NOTE SENSOR SWITCH 5 IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST REPLACED WITH WIRE LIKE SIZE L1 RATING INSULATION THICKNESS AND TERMINATION BLACK COMFORT GAS FURNACE SENSE 5000 OR K1 1 7000 ONLY COMPRESSOR CONTACTOR 540 CRANKCASE THERMOSTAT gt O HR1 CRANKCASE m HEATER A OR 60969909959 N o r4 n FOR USE WITH CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE EQUIPMENT G
6. IMPORTANT Refrigerant lines must not contact wall OUTSIDE WALL VAPOR LINE LIQUID LINE WIRE TIE INSIDE WALL STRAP NON CORROSIVE METAL SLEEVE WIRE TIE WOOD BLOCK BETWEEN STUDS WOOD BLOCK WIRE TIE STRAP VAPOR LINE WRAPPED WITH ARMAFLEX OUTSIDE WALT LIQUID LINE PVC line CAULK FIBERGLASS INSULATION NOTE Similar installation practices should be used if line set is to be installed on exterior of outside wall Figure 11 Line Set Installation Page 16 07 09 Brazing Connections 14 Use the procedures outline in figures 12 and 13 for brazing A IMPORTANT line set connections to service valves A WARNING Danger of fire Bleeding the refrigerant charge from only the high side may result 4 in pressurization of the low side shell and f suction tubing Application of a brazing d torch to a pressurized system may result in ignition of the refrigerant and oil mixture Check the high and low pressures before applying heat A WARNING When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system use a regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa CAUTION Brazing alloys and flux contain materials which are hazardous to your health Avoid breathing vapors or fumes from brazing operations Perform operations only in well ventilated areas Wear gloves and protective goggles or
7. After all connections have been brazed disconnect manifold gauge set from service ports Apply additional water saturated cloths to both services valves to cool piping Once piping is cool remove all water saturated cloths Refer to the unit installation instructions for the next step in preparing the unit Figure 13 Brazing Procedures Continued Page 19 XPG15 SERIES Flushing 15 The following procedure should not be performed on a system which contain contaminants i e compressor burn out TYPICAL EXISTING FIXED ORIFICE REMOVAL PROCEDURE UNCASED OR COIL SHOWN 1A 1 TWO PIECE PATCH PLATE UNCASED COIL ONLY DISTRIBUTOR TUBES LIQUID LINE ORIFICE HOUSING TEFLON RING FIXED ORIFICE BRASS NUT DISTRIBUTOR ASSEMBLY REMOVE AND DISCARD WHITE TEFLON SEAL IF PRESENT LIQUID LINE ASSEMBLY INCLUDES STRAINER On fully cased coils remove the coil access and plumbing panels Remove any shipping clamps holding the liquid line and distributor as sembly Using two wrenches disconnect liquid line from liquid line orifice hous ing Take care not to twist or damage distributor tubes during this pro cess Remove and discard fixed orifice valve stem assembly if present and Teflon washer as illustrated above Use a field provided fitting to temporary reconnect the liquid line to the indoor unit s liquid line orifice housing 2 CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDU
8. Operation Mode RT13 AMBIENT SENSOR Eo BLACK CAPACITOR 54 87 LOW HIGH PRESSURE PRESSURE SWITCH e 699 ComfortSense amp at A COMPRESSOR Gas Furnace NOTE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION COMFORT GAS FURNACE SENSE 5000 OR 7000 ONLY N GOO gt FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRANGEMENT A WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES A USE ONLY COMFORT SENSE 7000 TO CONTROL THE SECOND STAGE OF GAS HEAT Dedicated Heat Pump XPG15 INPUTS OUT w RU YA w PUTS gt W O G WI w2 IN K229 out OUT Defrost Mode Natural Defrost DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS K1 relay contact open to cycle OFF outdoor fan K2 relay contact close and output 24VAC to RL output to energize K229 field installed relay K2 relay contact close and energize reversing valve K3 relay contact open and de energize compressor contactor K4 relay contact remain open K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from t
9. The ComfortSense 5000 and 7000 are the ONLY room thermostats approved by Lennox for use with the XPG15 series heat pump COMFORTSENSE 5000 COMFORTSENSE 7000 CATALOG X4147 CATALOG Y0349 IMPORTANT Setup is critical to ensure proper system operation Thermostat is not included and must be purchased separately System setup information and field wiring connections for both thermostat models are available starting on page 23 Page 1 Specifications Electrical Data and Optional Accessories1 SPECIFICATIONS General Model No XPG15 024 XPG15 030 XPG15 036 XPG15 042 XPG15 048 XPG15 060 Data Nominal Tonnage 2 2 5 3 3 5 4 5 Connections Liquid line o d in 3 8 3 8 3 8 3 8 3 8 3 8 sweat Vapor Suction line o d in 3 4 3 4 3 4 7 8 7 8 1 1 8 Refrigerant 1 HFC 410A charge furnished 11 Ibs 10 11 Ibs 11 11 Ibs 0 oz 12 Ibs 5 oz 14 Ibs 14 15 Ibs 8 oz 2 2 2 Outdoor Net face area sq ft Outer coil 20 73 20 73 20 73 20 73 27 21 27 21 Coil Inner 20 08 20 08 20 08 20 08 26 36 26 36 Tube diameter in 5 16 5 16 5 16 5 16 5 16 5 16 No of rows 2 2 2 2 2 2 Fins per inch 22 22 22 22 22 22 Outdoor Diameter in 26 26 26 26 26 26 Fan No of blades 3 3 3 3 3 3 Motor hp 1 15 1 15 1 12 1 5 1 5 1 3 Cfm 2100 2100 2300 3700 3910 4200 Rpm 825 825 825 825 825 825 Watts 100 100 112 233 212 200 Shipping Data Ibs 1 pkg 290 292 297 323 368 372 ELECTRICAL DATA Line voltage
10. 8 HEAT PUMP INACTIVE MODE Demand defrost control will enter heat pump inactive mode when any of the following conditions occurs Outdoor temperature is less than 32 F 0 C First Heat Pump Heating Call after Demand Defrost Control Calibration Compressor run time in Heat Pump heating mode was less than 30 minutes before Demand Defrost Control requested a natural defrost Second Heat Pump Call Compressor run time in Heat Pump heating mode was less than 7096 of the first heating call before Demand Defrost Control control requested a natural defrost e Third Heat Pump Call Heat Pump will become inactive at next call for natural defrost 9 RETURN FROM HEAT PUMP INACTIVE MODE When Demand Defrost Control determines outdoor temperature has been above 35 F 1 6 C for calculated predetermined time upon the next heat pump heating demand from the room thermostat the Demand Defrost Control will immediately begin a sacrificial power defrost cycle as per figure 25 NOTE Placing a jumper on the Demand Defrost Control s TEST pins will not activate the heat pump out of inactive mode Power 24VAC must be cycled to the Demand Defrost Control to activate the heat pump out of inactive mode 10 CALIBRATION MODE The Demand Defrost uncalibrated when e 24 power is applied to Demand Defrost Control during initial start up or any other time that power is reapplied to the Demand Defrost Control Co
11. N gt 07 09 Page 48 HEATING OPERATING MODE ROOM THERMOSTAT DEMAND FOR Y1 WITH OUTDOOR TEMPERATURE BELOW 32 F O C RT21 RT13 84 S87 LOW L1 A DEFROST AMBIENT HIGH PRESSURE REVERSING 81 COIL SENSOR PRESSURE SWITCH VALVE COMPRESSOR NOTE SENSOR SWITCH IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION L1 BLACK COMFORT GAS FURNACE SENSE 5000 OR 7000 ONLY N K1 1 COMPRESSOR CONTACTOR C 540 CRANKCASE THERMOSTAT gt HR1 CRANKCASE m HEATER A OR gt 7 o ra A gt gt 2 m FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRANGEMENT A WARNING COMPRESSOR A ELECTRIC SHOCK HAZARD CAN CAUSE INJURY CONTACTOR OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE K1 1 WITH NATIONAL AND LOCAL CODES O ZA USE ONLY COMFORT SENSE 7000 TO CONTROL THE SECOND STAGE OF GAS HEAT EQUIPMENT GROUND CAPACITOR Operation Mode ComfortSense Gas Furnace Dedicated Heat Pump XPG15 INPUTS OUT w RU YA w PUTS p gt IN K229 out OUT Heating Mode Outside Temperature above 32 F First Stage Heat ing Heat Pump x
12. When the absolute pressure requirement above has been met disconnect the manifold hose from the vacuum pump and connect it to an upright cylinder of HFC 410A refrigerant Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit Perform the following 1 6 TURN Close manifold gauge valves Shut off HFC 410A cylinder Reinstall service valve cores by removing manifold hose from service valve Quickly install cores with core tool while maintaining a positive system pressure Replace stem caps and secure finger tight then tighten an additional one sixth 1 6 of a turn as illustrated Figure 16 Evacuating System Page 22 A IMPORTANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns Use an instrument capable of accurately measuring down to 50 microns 4 WARNING Danger of Equipment Damage Avoid deep vacuum operation Do not use compressors to evacuate a system Extremely low vacuums can cause internal arcing and compressor failure Damage caused by deep vacuum operation will void warranty Evacuating the system of non condensables is critical for proper operation of the unit Non condensables are defined as any gas that will not condense under SIZE CIRCUIT AND INSTALL DISCONNECT SWITCH Refer to the unit nameplate for minimum circuit ampacity and maximum fuse or circuit breaker HACR per NEC Install power wiring and properly siz
13. 1 Remove any blockages or restrictions from coils and or fans Check indoor and outdoor fan motor for proper current draws 2 Check system charge using approach and subcool ing temperatures 3 Check system operating pressures and compare to unit charging charts Make sure all pressure switches and sensors have Secure connections to system to prevent refrigerant leaks or errors in pressure and temperature mea surements For proper operation the Demand Defrost Control must have 24VAC between R system power input and C system common e Placing a jumper on the Demand Defrost Control s TEST pins will not activate the heat pump out of inactive mode 24VAC power must be cycled to the Demand Defrost Control to activate the heat pump out of inactive mode e fthe Demand Defrost Control enters a low pressure LOCKOUT during heating mode the outdoor unit will enter the heat pump inactive mode The Demand Defrost Control will flash the low pressure code If the room thermostat calls for Y1 heating in low pressure LOCKOUT the Demand Defrost Control will alternately display two codes four 4 seconds for the low pressure LOCKOUT and then four 4 seconds heat pump inactive gas mode active code 07 09 Page 40 5 DEFROST SYSTEM SENSORS Sensors connect to the Demand Defrost Control through a field replaceable harness assembly that plugs into the Demand Defrost Control Through the sensors the Demand Defrost Control de
14. 6 R INSIDE OUTDOOR UNIT TEMPERATURE SENSO aoe LIQUID LINE LINE SERVICE VALVE D TEMPERATURE SENSOR Close manifold gauge set valves and connect the center hose to a cylinder of HFC 410A Set for liquid phase charging Connect the manifold gauge set s low pressure side to the true suction port Connect the manifold gauge set s high pressure side to the liquid line service port Position temperature sensor on liquid line near liquid line service port Figure 20 Gauge Set Connection 07 09 Page 32 ADDING OR REMOVING REFRIGERANT This system uses HFC 410A refrigerant which operates at much higher pressures than HCFC 22 The pre installed liquid line filter drier is approved for use with HFC 410A only Do not replace it with components designed for use with HCFC 22 This unit is NOT approved for use with coils which use capillary tubes or fixed orifices as a refrigerant metering device Check airflow using static pressure reading as defined in figure 21 Al S F L OW Proper air volume must be provided over the evaporator coil Se lect a blower motor speed tap that will provide 400 50 CFM per INDOOR COIL 12 000 Btuh of cooling capacity wet coil A static pressure read ing must be taken to see if the pressure drop falls within the proper range To ensure accuracy air must be read from below the coil and above the
15. Fasten 36 middle cable tie To remove sound reduction cover reverse order the above procedure 15 Check running current The readings should not exceed manufacturer s full load rated amps during heavy load periods Low amps are normal during low load conditions Excessive high current may be due to shorted or grounded windings a bad capacitor a faulty start relay or an indication of excessive bearing fatigue Caution When performing electrical measurements on compressors with internal thermal motor protection devices that have been running extremely hot be sure to give the compressor time to cool down prior to the electrical test This will allow the device to reset to its normal position 15 SERIES
16. ON and K4 OFF Calibration Sequence i Number of natural defrosts Did Defrost Terminate on Time without Coil Temperature greater than 35 F for 4 minutes Control does not calibrate and returns to 30 minute mode for another power defrost and calibration attempt K1 K2 K3 ON and K4 OFF Calibration attempted between 10 and 20 minutes following power defrost termination Was coil Board enters power defrost after 45 temperature stable minutes of accumulated during calibration compressor run time with coil attempt temperature less than 35 F K1 K2 ON and K4 OFF Yes Y Demand Mode 0 NO gt Criteria to initiate Natural Defrost Met v Initiate First Natural Defrost ace Pump K1 K2 K4 OFF andi 1 Set T1 ing Duration 150 seconds lak ON Resume Heat Pump Heating K1 K2 K4 OFF Enter HP and Inactive Display Criteria to K3 ON Code initiate Natural K3 OFF and Met K1 K2 K4 ON Initiate Second Natural Defrost K1 K2 K4 OFF andi 1 Set T2 T3 less than 30 Does 3 T2 less Duration 150 seconds minutes or T3 than 30 minutes or lt 0 7 2 T2 0 7T1 joes i 3 Criteria to initiate Natural Defrost Met
17. WIN Y1 DIAGNOSTIC LIGHT EMITTING DIODES Diagnostic light emitting diode descriptions are listed in table 10 Page 39 Table 9 Demand Defrost Control A108 Inputs Outputs and Jumper Settings o o O OUT 24VAC output connection for reversing valve LO PS Connection for low pressure switch 24VAC output for second stage gas heat W OUT furnace connection Y1 24VAC common output switched to enable compressor contactor Connection for high pressure switch ran 240 VAC line voltage connection for condenser fan Defrost Termination Settings Seven position 50 square pin header The defrost termination 7 temperature is measured by the defrost coil sensor The jumper termination pin is factory 9 set at 50 F 10 C If the temperature jumper is 100 not installed the default termination temperature is 90 F 32 C 0 0 24VAC output for external K229 relay to control RL blower operation during defrost heat pump inactive mode and a call for second stage gas heat furnace operations 24VAC system common W Out 24VAC output to furnace control to begin furnace heating operation Ro 24VAC system power input 24VAC thermostat input for second stage gas heat furnace operation 24VAC thermostat input for reversing valve operation Y1 24VAC thermostat input for compressor operation mo reteset Six position square pin header P4 provides connections for the temperature sensors PIN 1
18. YY T TIT ANGLE MAY BE TOO EXTREME HOLD DOOR FIRMLY ALONG A THE HINGED SIDE TO MAINTAIN FULLY ENGAGED TABS ROTATE IN THIS DIRECTION THEN DOWN TO REMOVE PANEL P III IIIIIIIIIU I IWI NARNIA SSD 5 Figure 10 Removing and Installing Panels 07 09 Page 14 New or Replacement Line Set13 REFRIGERANT LINE SET This section provides information on installation or replacement of existing line set If new or replacement line set is not being installed then proceed to Brazing Connections on page 17 A IMPORTANT Lennox highly recommends changing line set when converting the existing system from HCFC 22 to HFC 410A If that is not possible and the line set is the proper size as reference in table 2 use the procedure outlined under Flushing on page 17 If refrigerant lines are routed through a wall then seal and isolate the opening so vibration is not transmitted to the building Pay close attention to line set isolation during installation of any HVAC system When properly isolated from building structures walls ceilings floors the refrigerant lines will not create unnecessary vibration and subsequent sounds See figure 11 for recommended installation practices Also consider the following when placing and installing a high efficiency outdoor unit A IMPORTANT Refrigerant lines m
19. each TEST the jumper must be removed for at least one second and then reapplied DEMAND DEFROST CONTROL UPPER LEFT HAND CORNER Y1 Active Place a jumper on TEST pins for longer than one second but less than two seconds Clears any short cycle lockout and five strike fault lockout function if applicable No other functions will be executed and unit will continue in the mode it was operating ACTIVE more than two seconds Place a jumper on TEST pins for Y applicable Clears any short cycle lockout and five strike fault lockout function if Y O Line Status INACTIVE Y Y Ifin COOLING Mode If in DEFROST Mode No further test mode operation will be executed until the jumper is removed from the TEST pins and reapplied The unit will terminate defrost and enter HEAT MODE uncalibrated with defrost timer set for 34 minute test Ifin HEATING Mode If no ambient or coil sensor fault ex ist unit will go into DEFROST MODE If ambient or coil faults exist open or shorted unit will remain in HEAT If jumper on TEST pins remains in NOTE Placing a jumper on the TEST pins will not bring the unit pump from an inactive mode is to cycle the 24VAC power to the place for more than five seconds
20. out of inactive mode The only way manually activate the heat Demand Defrost Control 07 09 Ifjumper on TEST pins is removed before a maximum of five seconds Y for 34 minutes The unit will return to HEAT MODE un calibrated with defrost timer set The unit will remain in DEFROST MODE until termination on time or temperature Figure 24 Test Mode Page 44 The Demand Defrost Control is considered uncalibrated when e 24VAC power is applied to Demand Defrost Control during initial start up or any other time that power is reapplied to the Demand Defrost Control 5 QU E N C E O F O P E RATI O N e After being in cooling mode The Demand Defrost Control will perform a sacrificial power defrost after thirty 30 minutes of IS CLOC KWISE accumulated compressor runtime in the first heat pump heating demand with the coil temperature below 35 F 1 6 C This will ensure a clear outdoor coil before an attempt to calibrate the Demand Defrost Control e When the heat pump comes out of inactive mode The Demand Defrost Control will perform a sacrificial power defrost This will ensure a clear out door coil before an attempt to calibrate the Demand Defrost Control NOTE If the heat pump is running in a gas furnace heating demand when the heat pump comes out of inactive mode the Demand Defrost Control will cycle the gas furnace OFF and cycle the heat pump ON On this first call for heat pu
21. revision 1 11 will accept both inputs See Service and Application Note H 06 6 When W951 link is cut cooling blower profiles will be disabled in the heat pump heating mode XPG15 SETUP SELECTIONS Item Task Checked 1 Verify proper coil sensor location and all Demand Defrost Control jumper pin positions NOTE Demand defrost control will not output a W out when outdoor temperatures are above 65 F 18 C Page 27 XPG15 SERIES STEP 1 FIELD WIRING COMFORTSENSE LENNOX GAS FURNACE XPG15 HEAT PUMP GREEN YELLOW BROWN MOTI3A K229 RELAY FIELD INSTALLED ON FURNACE CONTROL PANEL 5000 Series Only 7000 Series Catalog X4147 Catalog Y0349 JUMPERED JUMPERED Cut W951 link on variable speed furnace control Required for two stage furnaces with 7000 Series ROOM THERMOSTAT CONFIGURATION I 7000 Series See the ComfortSense 5000 or 7000 series thermostats installation 3 Heat 1 Cool 3H 1C instruction for complete thermostat terminal connections 2 Heat 1 Cool 2H 1C 5000 Series 2 Heat 1 Cool 2H 1C Use W2 stage time feature for two stage furnace Figure 19 ComfortSense 5000 7000 Series Room Thermostat Connections 07 09 Page 28 STEP 2 ROOM THERMOSTAT SETUP COMFORTSENSE 5000 Required settings for XPG15 dual
22. 16 35 MINIMUM DEMAND DEFROST CONTROL NOTE Wire tie provides low voltage wire strain relief HOLE and to maintain separation of field installed low and high voltage circuits ROUTE HIGH VOLTAGE AND GROUND WIRES Any excess high voltage field wiring should be trimmed and secured away from any low WIRING ENTRY POINTS voltage field wiring To facilitate a conduit a cutout is located in the bottom of the control panel Connect conduit to the control panel using a proper conduit fitting ELECTRICAL INLET HIGH VOLTAGE PIPING PANEL HIGH VOLTAGE GROUND CONDUIT HOLE LUG CONTACTOR WATERTIGHT m CONDUIT FITTING E CONTROL PANEL WATERTIGHT FLEXIBLE CONDUIT m LL nn 00N immi ACCESS VIEW TO SERVICE ELECTRICAL INLET CONTROL WIRING LOW VOLTAGE DISCONNECT BOX USE BUSHING PROVIDED IN BAG ASSEMBLY USED HERE 07 09 Page 24 RT21 NOTE A108 GROUND IS DEFROST RT13 IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT DEFROST LUG COIL AMBIENT MUST BE REPLACED WITH WIRE OF LIKE SIZE CONTROL SENSOR SENSOR RATING INSULATION THICKNESS AND TERMINATION NOTE FOR USE WITH COPPER CONDUCTORS S4 ONLY REFER TO UNIT RATING PLATE E B1 FOR MINIMUM CIRCUIT AMPACITY AND OVO PRESSURE COMPRESSOR MAXIMUM OVERCURRENT PROTECTION SIZE K1 SWITCH 5 REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRA
23. A IMPORTANT Mineral oils are not compatible with HFC 410A If oil must be added it must be a Polyol Ester oil XPG15 SERIES LINE SET INSTALLATION Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation REFRIGERANT LINE SET TRANSITION FROM VERTICAL TO HORIZONTAL ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE MUFFLER TYPE HANGER AUTOMOTIVE MUFFLER TYPE HANGER 5 STRAP LIQUID LINE TO VAPOR LINE NON CORROSIVE METAL SLEEVE VAPOR LINE WRAPPED IN ARMAFLEX REFRIGERANT LINE SET INSTALLING HORIZONTAL RUNS To hang line set from joist or rafter use either metal strapping material or anchored heavy nylon wire ties 8 FEET 2 43 METERS pr STRAPPING MATERIAL AROUND VAPOR LINE ONLY WIRE TIE AROUND VAPOR LINE ONLY FLOOR JOIST OR 227 ROOF RAFTER S TAPE OR WIRE TIE gt x 8 FEET 2 43 METERS METAL SLEEVE STRAP THE VAPOR LINE TO THE JOIST OR RAFTER AT 8 FEET INTERVALS THEN STRAP THE LIQUID LINE TO THE VAPOR LINE TAPE OR WIRE TIE FLOOR JOIST OR ROOF RAFTER ee IMPORTANT Refrigerant lines must not contact structure REFRIGERANT LINE SET INSTALLING VERTICAL RUNS NEW CONSTRUCTION SHOWN NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig
24. DEFROST DEFROST CONTROL REQUESTED A NATURAL DEFROST HEAT PUMP CONTROL REQUESTED A NATURAL DEFROST HEAT GOES INTO NATURAL DEFROST MODE PUMP GOES INTO NATURAL DEFROST MODE Figure 25 Dual Fuel Defrost Cycles Page 45 XPG15 SERIES Operating Modes28 COOLING OPERATING MODE RT21 RT13 54 87 LOW L1 A DEFROST AMBIENT HIGH PRESSURE REVERSING 81 COIL SENSOR PRESSURE SWITCH VALVE COMPRESSOR NOTE SENSOR Firen 5 IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION L1 BLACK COMFORT GAS FURNACE SENSE O 5000 OR K1 1 7000 ONLY COMPRESSOR CONTACTOR S40 CRANKCASE THERMOSTAT gt O HR1 CRANKCASE m HEATER A 69099909999 c o e 0 c n gt o FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRANGEMENT A WARNING COMPRESSOR ELECTRIC SHOCK HAZARD CAN CAUSE INJURY CONTACTOR OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE K1 1 WITH NATIONAL AND LOCAL CODES O O ZA USE ONLY COMFORT SENSE 7000 TO CONTROL THE SECOND STAGE OF GAS HEAT EQUIPMENT GROUND CAPACITOR Operation Mode ComfortSense Gas Furnace Dedicated Heat Pump XPG15 INPUTS OUT w RU YA w PUTS gt w2 0 WI w IN K229 0 out OUT Cooling Mode OFF Coo
25. DEW POINT CONTROL or HUMIDITROL OUTDOOR SENSOR REQUIRED message is displayed instead of scroll options for these menus 4 Confirm temperature differential setting for first and second stages Factory defaults are 1 F See ComfortSense 7000 Installation instructions for procedures on how to confirm temperature differential settings COMFORTSENSE 5000 SETUP SELECTIONS CATALOG X4147 Checked INSTALLER SETUP INSTALLER SETUP NAME SELECT 0170 SYSTEM TYPE 7 Two Heat One Cool Heat Pump Heat pump with auxiliary or back up heat 0 Electric Heat is used as auxiliary heat source in heat 0200 AUXILIARY HEAT SOURCE pump application Factory setting DO NOT USE FOSSIL FUEL SETTING REMOTE OUTDOOR TEMPERATURE 0 No remote outdoor temperature sensor or SENSOR 1 Outdoor temperature sensor used for display ONLY 0340 Use W2 staged time feature for two stage furnaces with ComfortSense 5000 Confirm cycle per hour rate settings per stage settings See ComfortSense 5000 Installation instructions for procedures on how to confirm cycle rate IMPORTANT Do not use Y2 for furnace gas heat FURNACE SETUP SELECTIONS Checked Item Task 1 Integrated control must allow gas furnace operation with W and O input 2 Integrated control with the W951 link link from R to 0 must be cut Integrated control with catalog 23W25 and 19W60 after date code 0710
26. If outdoor sensor is not present and user tries to select the options DISPLAY INFO gt OUTDOOR TEMP LOW BALANCE POINT HIGH BALANCE POINT DEW POINT CONTROL or HUMIDITROL OUTDOOR SENSOR REQUIRED message is displayed instead of scroll options for these menus Table 5 ComfortSense 7000 Setup Selections Tab Menu Item Parameter Selection Description SYSTEM SETUP HEAT PUMP ELECTRIC COMPRESSOR STAGES 1 OPTIONS INDOOR HEAT STAGES 10R2 INSTALLER SETTINGS OUTDOOR SENSOR NO OUTDOOR SENSOR LOW OFF OUTDOOR SENSOR HIGH Use down arrow to go one step below lowest set point Select 1 or 2 to match number of furnace heat stages A ComfortSense 7000 outdoor sensor is not needed for use with XPG15 If a sensor is used to display outdoor temperature at thermostat set OUTDOOR SENSOR to YES and set LOW and HIGH to OFF 07 09 Page 30 STEP 3 SYSTEM OPERATION CHECKS The following table illustrates which terminals should have 24VAC inputs or outputs during certain operation modes Example In the cooling mode there should be 24VAC between Y1 and C on the Demand Defrost Control terminal strip Operation Mode ComfortSense Gas Furnace Dedicated Heat Pump XPG15 24VAC INPUTS RL Y1 OUTPUTS p gt Y1 W1 W G E L Y1 Y2 W W G Y1 IN K229 OUT OUT Cooling Mode OFF x x Cooling x x x Heating Mode Outside Temperature above 32 F First Sta
27. Operating and Temperature Pressures24 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 7 Normal Operating Pressure Liquid 10 and Vapor 5 PSIG XP 024 Liquid Vapor F HEATING MODE 60 15 5 432 365 389 328 345 3 pow sss 397 422 425 COOLING 115 46 1 MODE 273 237 255 zc T us xs ws z xe pw ume 3 pw 365 EN 483 501 482 111 105 105 106 129 123 123 123 130 134 140 133 136 141 136 136 143 144 294 272 Lm zz ws Low 3 G sr ss m t 22522013871 336 360 383 439 469 7 479 These are most popular match up pressures Indoor match up indoor air quality and indoor load cause pressures to vary Temperature of the air entering the outdoor coil Table 8 HFC 410A Temp F Pressure Psig F Psig F Psig F Psig F Psig F Psig 32 100 8 56 158 2 79 231 6 103 331 0 127 457 6 33 102 9 57 161 0 80 235 3 104 335 7 128 463 5 34 105 0 58 163 9 81 239 0 105 340 5 129 469 5 35 107 1 59 166 7 82 242 7 106 345 3 130 475 6 36 109 2 60 169 6 83 246 5 107 350 1 131 481 6 37 111 4 61 172 6 84 250 3 108 355 0 132 48
28. UNIT Units are outfitted with elongated support feet as illustrated in figure 8 detail C If additional elevation is necessary raise the unit by extending the height of the unit support feet This may be achieved by using a 2 SCH 40 female threaded adapter The specified coupling will fit snuggly into the recessed portion of the feet Use additional 2 SCH 40 male threaded adaptors which can be threaded into the female threaded adaptors to make additional adjustments to the level of the unit NOTE Keep the height of extenders short enough to ensure a Sturdy installation If it is necessary to extend further consider a different type of field fabricated framework that is sturdy enough for greater heights XPG15 SERIES DETAIL 125 INSTALL UNIT AWAY FROM WINDOWS DETAIL B 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 AWAY FROM BUILDING STRUCTURE TWO 90 ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION Outside Unit Placement DETAIL C LEG DETAIL 2 50 8MM SCH 40 FEMALE THREADED ADAPTER 2 50 8MM SCH 40 MALE THREADED ADAPTER Use additional 2 SCH 40 male threaded adapters which can be threaded into the female threaded adapters to make additional adjustments to the level of the unit Elevated Slab Mounting using Feet Extenders BUILDING STRUCTURE MO
29. UNIT MUST BE GROUNDED IN ACCORDANCE C12 L1 CAPACITOR S87 LOW REVERSING WITH NATIONAL AND LOCAL CODES one VALVE USE ONLY COMFORT SENSE 7000 TO CONTROL THE SECOND STAGE OF GAS HEAT 59 COMFORT GAS FURNACE SENSE TB4 5000 OR K1 1 7000 ONLY COMPRESSOR CONTACTOR CRANKCASE THERMOSTAT O HR1 CRANKCASE HEATER LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING DENOTES OPTIONAL COMPONENTS HEAT PUMP OUTDOOR UNITS COMPRESSOR EQUIPMENT GROUND Supersedes COMPRESSOR 0209 CONTACTOR New Form No XPG15 060 CAPACITOR 537168 01 Litho U S A Figure 18 XPG15 060 Wiring using ComfortSense 5000 7000 Thermostats 07 09 Page 26 System Setup Information19 COMFORTSENSE 7000 SETUP SELECTIONS CATALOG Y0349 Checked TAB MENU ITEM PARAMETER SELECTION DESCRIPTION SYSTEM SETUP HEAT PUMP ELECTRIC COMPRESSOR STAGES 1 OPTIONS INDOOR HEAT STAGES 4 1OR21 INSTALLER SETTINGS OUTDOOR SENSOR OA 2 NO OA LOW BALANCE POINT 3 OFF OA HIGH BALANCE POINT 3 OFF Use down arrow to go one step below lowest set point 1 Select 1 or 2 to match number of furnace heat stages 2 Outdoor sensor can be used in the display ONLY mode by setting OUTDOOR SENSOR to YES and the LOW and HIGH balance point to OFF 3 If outdoor sensor is not present and user tries to select the options DISPLAY INFO gt OUTDOOR TEMP LOW BALANCE POINT HIGH BALANCE POINT
30. being detected open or shorted or out of temperature range Board will revert to time temperature defrost operation System will still heat or cool Alternating Fast Flash Coil Sensor Problem Sensor being detected open or shorted or out of temperature range Board will not perform demand or time temperature defrost operation System will still heat or cool ON Circuit Board Failure Indicates that Demand Defrost Control has internal component failure Cycle 24VAC power to Demand Defrost Control If code does not clear replace Demand Defrost Control Heat Pump Inactive Gas Mode Active 1 Heat pump inactive mode due to out door temperature less than 32 F 2 Room thermostat temperature has called for second stage heat gas furnace heat 1 Code will reset when outdoor temperature raises above 35 F for a calculated time period 2 Room thermostat demand is satisfied by furnace gas heat FAULT and LOCKOUT CODES Each fault adds one strike to that code s counter five strikes per code per room thermostat demand LOCKOUT Low Pressure Fault Low Pressure Lockout High Pressure Fault NOTES High Pressure Lockout 1 Restricted air flow over indoor or out door coil 2 mproper refrigerant charge in sys tem 3 Improper metering device installed or incorrect operation of metering de vice 4 Incorrect or improper sensor location or connection to system
31. face shield to protect against burns Wash hands with soap and water after handling brazing alloys and flux Page 17 Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve A IMPORTANT Allow braze joint to cool before removing the wet rag from the service valve Temperatures above 250 F can damage valve seals A IMPORTANT Use silver alloy brazing rods with 5 minimum silver alloy for copper to copper brazing Use 45 minimum alloy for copper to brass and copper to steel brazing 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 refrigeration lines Oxygen when exposed to a spark or open flame can cause fire and or an ex plosion that could result in property damage personal injury or death XPG15 SERIES 1 PIPING PANEL REMOVAL AND PREPARING LINE CAP AND CORE REMOVAL SET Remove service cap and core from both the suction vapor and liquid line service ports Remove piping panel for easier access to service valves Cut ends of the refrigerant lines square free from nicks or dents and debur SERVICE PORT CAP the ends The pipe must remain round Do not crimp end of the line SERVICE PORT CORE lt CUT AND DEBUR S gt E H LINE SET S
32. fuel applications Use the following steps and the Installer Setup menu to match the thermostat to the HVAC system 1 Press and release the SYSTEM key 2 Press and hold the two blank keys on either side of the center blank key for approximately five seconds v TUE vw vw ver v 1 SCHEDULE GJ sro 59 3 Release the two keys when the thermostat display matches the display below 4 H 0 9 eG v bof LLL 4 Refer to the following figure to see how the thermostat keys are used to make selections from the setup menu ADVANCE TO NEXT INSTALLER SETUP CURRENT SETTING INSTALLER SETUP NUMBER CHANGE THE CURRENT EXIT INSTALLER SELING SETUP 5 The installer setup number is displayed on the left hand side of the screen The current installer set up number is displayed on the right hand side of the screen Use the up and down arrows on the right hand side of the display to select the proper setting for that particular set up number After the proper selection has been made as exampled in table 4 use the up arrow in the center of the thermostat to advance to the next setup screen 7 When all setup selections have been made press the DONE key to save your settings Thermostat display will return to the main screen NOTE Press and release the SYSTEM key then press and hold the center blank key to access the user setup screens The user setup options are limited to t
33. length of installation e Number of elbows vertical rise or drop the piping The compressor is charged with sufficient Polyol Ester oil POE for line set lengths up to 50 feet Recommend adding oil to system based on the amount of refrigerant charge in the system Systems with 20 pounds or less of refrigerant required no oil to be added For systems over 20 pounds add one ounce for every five 5 pounds of HFC 410A refrigerant Recommended POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATE RL32CF A IMPORTANT If this unit is being matched with an approved line set or indoor unit coil which was previously charged with mineral oil or if it is being matched with a coil which was manufactured before January of 1999 the coil and line set must be flushed prior to installation Take care to empty all existing traps Polyol ester POE oils are used in Lennox units charged with HFC 410A refrigerant Residual mineral oil can act as an insulator preventing proper heat transfer It can also clog the expansion device and reduce the system performance and capacity Failure to properly flush the system per the instructions below will void the warranty 4 WARNING Polyol ester POE oils used with HFC 410A refrigerant absorb moisture very quickly It is very important that the refrigerant system be kept closed as much as possible DO NOT remove line set caps or service valve stub caps until you are ready to make connections
34. nameplate on outdoor unit for charge information OUTDOOR USE Figure 22 Using HFC 410A Weigh In Method 07 09 Page 34 SUBCOOLING TEST AND CHARGING METHOD 1 Measure outdoor ambient temperature determine whether to use cooling mode or heating mode to check charge Determine whether you will be using cooling or heating mode and connect gauge set for the required mode as illustrated in figure 20 Check liquid and vapor line pressures Compare pressures with either heat or cooling mode normal operating pressures in table 7 Normal Operating Pressures NOTE The reference table is a general guide Expect minor pressure variations Significant differences may mean improper charge or other system problem Set thermostat for heat cool demand depending on mode being used USING COOLING MODE When the outdoor ambient temperature is 60 F 15 C and above Target subcooling values in table 6 are based on 70 to 80 F 21 27 C indoor return air temperature if necessary operate heating to reach that temperature range then set thermostat cooling mode setpoint to 68 F 20 C When pressures have stabilized continue with Step 5 USING HEATING MODE When the outdoor ambient temperature is below 60 F 15 C Target subcooling values in table 6 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 heating mode setpoint to 7
35. outdoor unit is void of charge To verify charge and add or remove refrigerant use the SUBCOOLING method WEIGHIN CHARGING METHOD CALCULATING SYSTEM REFRIGERANT CHARGE WHEN OUTDOOR UNIT IS VOID OF REFRIGERANT T If the system is void of refrigerant first locate and repair any leaks and then weigh in the refrigerant charge into the unit To calculate the total refrigerant charge Adjust amount for variation Additional charge specified Amount specified on in line set length listed on per indoor unit match up nameplate line set length table below listed in table 6 Total charge DALLAS TEXAS Refrigerant Charge per Line Set Length Liquid Line Ounces per 5 feet g per 1 5 m FACTORY CHARGE adjust from 15 feet 4 6 line set 8 LBS 9 025 236 PSIG Diameter ELECTRICAL RATING NOMINAL VOLTS 460 sm wate max s06 3 8 9 5 mm 3 ounce per 5 85 g per 1 5 T If line length is greater than 15 ft 4 6 m add this amount If line length is less than 15 ft 4 6 Ps sso c m subtract this amount I erro 785 max Fuse on crt FUSIBLE COUPE CIRCUIT 15 NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig NOTE The above nameplate is for illustration purposes only Go to actual
36. sensor reaches the selected termination temperature or after a 14 minute defrost If the above defrost was concluded due to termination temperature or if terminated by time with a coil temperature of greater than 35 F for more than a defined time a clear coil non iced condition can be assumed Otherwise the Demand Defrost Control remains in an uncalibrated state If the coil temperature is not considered stable the Demand Defrost Control will operate time temperature mode for 45 minutes Upon the completion of the 45 minute operation the Demand Defrost Control will initiate a sacrificial defrost to calibrate At that point a clear coil temperature at the particular outdoor ambient temperature can be determined XPG15 SERIES JUMPER TEST Placing the jumper on the test pins allows the technician to Clear short cycle lockout Clear five strike fault lockout Cycle the unit in and out of defrost mode Place the unit in defrost mode to clear the coil When Y1 is energized and 24V power is being applied to the Demand Defrost Control a test cycle can be initiated by placing a jumper on the Demand Defrost Control s TEST pins for 2 to 5 seconds If the jumper remains on the TEST pins for longer than five seconds the Demand Defrost Control will ignore the jumpered TEST pins and revert to normal operation The control will initiate one test event each time a jumper is placed on the TEST pins For
37. to avoid exposure to refrigerant and oil during service and installation Failure to follow this notice could result in damage to roof surface Removing and Installing Panels12 A IMPORTANT Do not allow panels to hang on unit by top tab Tab is for alignment and not designed to support weight of panel A IMPORTANT To help stabilize an outdoor unit some installations may require strapping the unit to the pad using brackets and anchors commonly available in the marketplace 4 WARNING To prevent personal injury or damage to panels unit or structure be sure to observe the following While installing or servicing this unit carefully stow all removed panels out of the way so that the panels will not cause injury to personnel nor cause damage to objects or structures nearby nor will the panels be subjected to damage e g being bent or scratched While handling or stowing the panels consider any weather conditions especially windy conditions that may cause panels to be blown around and battered XPG15 SERIES REMOVING AND INSTALLING PANELS wm installing panel Panel shown slightly rotated to allow top tab to exit or enter top slot for removing or LOUVERED PANEL REMOVAL REMOVE 4 SCREWS TO Remove the louvered panels as follows REMOVE PANEL FOR ACCESSING COMPRESSOR i AND CONTROLS 1 Remove two screws allowing the panel to swing open slightly 2 Hold the panel fi
38. using a high pressure gas such as dry nitrogen to pressurize a system use A IMPORTANT The Environmental Protection Agency EPA prohibits the intentional venting of HFC refrigerants during maintenance service repair and disposal of appliance Approved methods of recovery recycling or reclaiming must be followed A IMPORTANT If this unit is being matched with an approved line set or indoor unit coil which was previously charged with mineral oil or if it is being matched with a coil which was manufactured before January of 1999 the coil and line set must be flushed prior to installation Take care to empty all existing traps Polyol ester POE oils are used in Lennox units charged with HFC 410A refrigerant Residual mineral oil can act as an insulator preventing proper heat transfer It can also clog the expansion device and reduce the system performance and capacity Failure to properly flush the system per the instructions below will void the warranty a regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa 4 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 CONNECT GAUGE SET Connect an HFC 410A manifold gauge set high pressure hose to LOW H
39. 0 93 3 6792 42 9 24120 10 4 61693 26 2 204829 92 0 7007 42 3 24525 9 9 62712 27 0 210805 90 6 7225 41 7 24934 9 3 63752 27 8 217080 89 4 7444 41 1 25349 8 8 64812 28 7 223677 88 1 7666 40 5 25769 8 3 65895 29 5 230621 86 9 7890 39 9 26195 7 7 67000 30 4 237941 85 7 8115 39 3 26626 7 2 68128 31 3 245667 84 5 8343 38 7 27063 6 7 69281 32 2 253834 83 4 8573 38 1 27505 6 1 70458 33 2 262482 82 3 8806 37 5 27954 5 6 71661 34 1 271655 81 2 9040 37 0 28408 5 0 72890 35 1 281400 80 1 9277 36 4 28868 4 5 74147 36 1 291774 79 0 9516 35 8 29335 3 9 75431 37 1 302840 78 0 9757 35 2 29808 3 4 76745 38 2 314669 77 0 10001 34 7 30288 2 8 78090 39 2 327343 76 0 10247 34 1 30774 2 3 79465 75 0 10496 33 5 31267 1 7 80873 74 1 10747 33 0 31766 1 2 82314 73 1 11000 32 4 32273 0 6 83790 72 2 11256 31 9 32787 0 0 85302 71 3 11515 31 3 33309 0 5 86852 70 4 11776 30 7 33837 1 1 88440 69 5 12040 30 2 34374 1 7 90068 68 6 12306 29 6 34918 2 2 91738 67 7 12575 29 1 35471 2 8 93452 66 9 12847 28 6 36031 3 4 95211 66 0 13122 28 0 36600 4 0 97016 65 2 13400 27 5 37177 4 6 98870 64 4 13681 26 9 37764 5 2 100775 63 6 13964 26 4 38359 5 7 102733 62 8 14251 25 8 38963 6 3 104746 62 0 14540 25 3 39577 6 9 106817 61 2 14833 24 8 40200 7 5 108948 60 5 15129 24 2 40833 8 2 111141 59 7 15428 23 7 41476 8 8 113400 59 0 15730 23 2 42130 9 4 115727 58 2 16036 22 6 42794 10 0 118126 57 5 16345 22 1 43468 10 6 120600 07 09 Page 42
40. 2 F the heat pump is not allowed to respond to a first stage room thermostat heat call 1 The Demand Defrost Control redirects this 1 heat call to the furnace XPG15 SERIES Table 12 Ambient RT13 and Coil RT21 Sensors Temperature Resistance Range ee esse reme umm Resistance 136 3 2680 56 8 16657 21 6 44154 11 3 123152 133 1 2859 56 0 16973 21 0 44851 11 9 125787 130 1 3040 55 3 17293 20 5 45560 12 6 128508 127 3 3223 54 6 17616 20 0 46281 13 2 131320 124 7 3407 53 9 17942 19 4 47014 13 9 134227 122 1 3592 53 2 18273 18 9 47759 14 5 137234 119 7 3779 52 5 18607 18 4 48517 15 2 140347 117 5 3968 51 9 18945 17 8 49289 15 9 143571 115 3 4159 51 2 19287 17 3 50074 16 5 146913 113 2 4351 50 5 19633 16 8 50873 17 2 150378 111 2 4544 49 9 19982 16 3 51686 17 9 153974 109 3 4740 49 2 20336 15 7 52514 18 6 157708 107 4 4937 48 5 20695 15 2 53356 19 3 161588 105 6 5136 47 9 21057 14 7 54215 20 1 165624 103 9 5336 47 3 21424 14 1 55089 20 8 169824 102 3 5539 46 6 21795 13 6 55979 21 5 174200 100 6 5743 46 0 22171 13 1 56887 22 3 178762 99 1 5949 45 4 22551 12 5 57811 23 0 183522 97 6 6157 44 7 22936 12 0 58754 23 8 188493 96 1 6367 44 1 23326 11 5 59715 24 6 193691 94 7 6578 43 5 23720 11 0 60694 25 4 19913
41. 230 208 230V 1ph 60hz Nominal Cooling Capacity 024 2 tons 030 2 5 tons 036 3 tons 042 3 5 tons 048 4 tons 060 5 tons Page 3 XPG15 SERIES Unit Parts Arrangement4 SOUND DOME COVER SEE SOUND REDUCTION COVER ON PAGE 55 FOR FURTHER DETAILS cn DISCHARGE LINE COMPRESSOR MUFFLER TRUE SUCTION LINE yee ee 0 0000000000060c000020020 REVERSING VALVE REVERSING VALVE SOLENOID CHECK EXPANSION VALVE HR1 CRANKCASE HEATER LIQUID VALVE AND GAUGE PORT TRUE SUCTION LINE PORT g CRANKCASE HEATER THERMOSTAT 540 LIQUID LINE BI FLOW HIGH PRESSURE SWITCH 54 FILTER DRIER LOW PRESSURE SWITCH S87 Control Panel Parts Arrangement5 CAPACITOR C12 CONTACTOR 1POLE K1 1 4 DEMAND DEFROST CONTROL A108 LOW VOLTAGE CONTROL WIRE TIE 4 07 09 SENSOR LOCATIONS DETAIL WIRE TIE AMBIENT SENSOR Extend tip of plastic sensor just outside of plastic sleeve Place ambient sensor and wire from Demand Defrost Control inside of plastic sleeve and route through gap between corner post and coil support as shown NA models as follows Secure with wire tie DETAIL B 12 TUBES UP MO
42. 7 F 25 C When pressures have stabilized continue with Step 5 5 Read the liquid line temperature record in the LIQ space 6 Read the liquid line pressure then find its corresponding temperature in the temperature pressure chart listed in table 8 and record it in the SAT space Subtract LIQ temperature from SAT temperature to determine subcooling record itin SC space Compare SC results with table 6 being sure to note any additional charge for line set and or match up If subcooling value is greater than shown in table 6 for the applicable unit remove refrigerant if less than shown add refrigerant 10 If refrigerant is added or removed repeat steps 4 through 5 to verify charge 11 Disconnect gauge set and re install both the liquid and vapor service valve caps NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig Figure 23 Using HFC 410A Subcooling Method Page 35 XPG15 SERIES Indoor Coil Matchups23 Target subcooling and charging values for approved indoor coil match ups IMPORTANT This unit must be matched with an indoor coil as specified in this section or with Lennox Engineering Handbook Coils previously charged with HCFC 22 must be flushed Table 6 Indoor Coil Matchups and Target Subcooling
43. 7 8 38 113 6 62 175 4 85 254 1 109 360 0 133 494 0 39 115 8 56 158 2 86 258 0 110 365 0 134 500 2 40 118 0 63 178 5 87 262 0 111 370 0 135 506 5 41 120 3 64 181 6 88 266 0 112 375 1 136 512 9 42 122 6 65 184 3 89 270 0 113 380 2 137 519 3 43 125 0 66 187 7 90 274 1 114 385 4 138 525 8 44 127 3 67 190 9 91 278 2 115 390 7 139 532 4 45 129 7 68 194 1 92 282 3 116 396 0 140 539 0 46 132 2 69 197 3 93 286 5 117 401 3 141 545 6 47 134 6 70 200 6 94 290 8 118 406 7 142 552 3 48 137 1 71 203 9 95 295 1 119 412 2 143 559 1 49 139 6 72 207 2 96 299 4 120 417 7 144 565 9 50 142 2 73 210 6 97 303 8 121 423 2 145 572 8 51 144 8 74 214 0 98 308 2 122 428 8 146 579 8 52 147 4 75 217 4 99 312 7 123 434 5 147 586 8 53 150 1 76 220 9 100 317 2 124 440 2 148 593 8 54 152 8 77 224 4 101 321 8 125 445 9 149 601 0 55 155 5 78 228 0 102 326 4 126 451 8 150 608 1 Page 37 XPG15 SERIES System Operations25 The outdoor unit and indoor blower cycle on demand from the room thermostat When the thermostat blower switch is in the ON position the indoor blower operates continuously 1 ROOM THERMOSTAT EMERGENCY HEAT FUNCTION ComfortSense 5000 and 7000 thermostats have an emergency heat function This feature is applicable when isolation of the outdoor unit is required Emergency heat is usually used during an outdoor unit shutdown but it should also be used following a power outage if power has been off for over an hour and the outdoor tem
44. ARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES A USE ONLY COMFORT SENSE 7000 TO CONTROL THE SECOND STAGE OF GAS HEAT ComfortSense Gas Furnace Dedicated Heat Pump XPG15 W RL Y1 IN K229 OUT W OUT INPUTS OUT PUTS p gt o W2 O W1 W2 Heating Mode Outside Temperature above First Stage Heat ing Heat Pump DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS K1 relay contact remain closed K2 relay contact two sets remain open K3 relay contact close to energize compressor contactor K4 relay contact remain open K229 relay normally closed contacts remain closed XPG15 SERIES Page 47 HEATING OPERATING MODE ROOM THERMOSTAT DEMAND FOR Y1 AND W1 WITH OUTDOOR TEMPERATURE ABOVE 32 RT21 RT13 54 87 LOW 11 A DEFROST AMBIENT HIGH PRESSURE REVERSING B1 COIL SENSOR PRESSURE SWITCH VALVE COMPRESSOR NOTE SENSOR mE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION L1 BLACK COMFORT GAS FURNACE SENSE 5000 OR K1 1 7000 ONLY COMPRESSOR CONTACTOR 540 CRANKCASE THERMOSTAT gt HR1 CRANKCASE m HEATER OR A 5 COMPRESS gt z m FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RA
45. Control e Up to four pressure switch trips are allowed in a single thermostat demand without locking out the Demand Defrost Control If the thermostat demand is satisfied before a fifth pressure switch trip the control will reset the five strike counter to zero e If either pressure switch opens for a fifth time during a single Y1 demand the Demand Defrost Control will enter a lockout condition The system will require servicing to determine the cause of the pressure switch condition Once the condition has been rectified power to the Demand Defrost Control s R terminal must be cycled OFF or jumper placed on the TEST pins between 1 to 2 seconds to reset the Demand Defrost Control DEMAND DEFROST CONTROL BOARD A108 PART 102151 01 CATALOG 47W47 NOTE Component locations may vary by board manufacturer 1 TEST PINS DEFROST TERMINATION PIN SETTINGS 4 P4 2 5 amp REVERSING o out VALVE tops e i aM CIRCUIT 9007 CONNECTIONS e 01 e e HI PS co o o o oIoIeloIle TSTPS DF C R O YI Y2 P6 RL W OUT R P2 24v TERMINAL STRIP CONNECTIONS
46. DELS 024 030 036 AND 042 DEFROST COIL SENSOR Clip coil temperature sensor from the Demand Defrost Control on the return bend shown on SLEEVE DISCHARGE SENSOR Not required for this application 24 TUBES UP MODELS 048 AND 060 Figure 1 Sensor Locations Model Number Identification6 X PGI 036 Refrigerant Type X R 410A Unit Type P Heat Pump G Green Technology Series Page 5 ERIS Minor Revision Number Voltage 230 208 230V 1ph 60hz Nominal Cooling Capacity 024 2 tons 030 2 5 tons 036 3 tons 043 3 5 tons 048 4 tons 060 5 tons XPG15 SERIES A WARNING This product and or the indoor unit it is matched with may contain fiberglass wool Disturbing the insulation during installation maintenance or repair will expose you to fiberglass wool dust Breathing this may cause lung cancer Fiberglass wool is known to the State of California to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 Scroll Compressor Opera
47. Ground connection for outdoor coil COIL temperature sensor BROWN PIN 2 Connection for outdoor coil temperature sensor PIN 3 Ground connection for outdoor ambient AMB temperature sensor BLACK PIN 4 Connection for outdoor ambient temperature sensor DIS PIN 5 and PIN 6 Harness resistor fault 10K resistor 10K resistor built into wiring harness YELLOW connected to the DIS connector Eight position header Provides connections for the factory test first stage XPG15 SERIES 5 DEMAND DEFROST CONTROL DIAGNOSTICS See table 10 to determine Demand Defrost Control operational conditions and to diagnose cause and solution to problems Table 10 Demand Defrost Control Diagnostic Light Emitting Diodes Condition Code Power problem Possible Cause s No power 24VAC to Demand Defrost Control terminals R and C or Demand Defrost Control failure Solution 1 Check Demand Defrost Control transformer power 24VAC 2 f power is available to Demand Defrost Control and light emitting diode s do not light replace Demand Defrost Control Simultaneous Slow Flash Normal operation Unit operating normally or in standby mode None required Alternating Slow Flash 5 minute anti short cycle delay Initial power up safety trip end of room thermostat demand None required place a jumper on TEST pins to override Simultaneous FAST Flash Ambient Sensor Problem Sensor
48. IGH the vapor valve service port NOTE Normally the high pressure hose is connected to the MANIFOLD GAUGE SET liquid line port However connecting it to the vapor port better protects the manifold gauge set from high pressure damage O B With both manifold valves closed connect the cylinder of 1 aoc HFC 410A refrigerant to the center port of the manifold gauge set li OUTDOOR UNIT NOTE Later in the procedure the HFC 410A container will be replaced _ by the nitrogen container 4 B m oo T t TO VAPOR S SERVICE VALVE or NITROGEN TEST FOR LEAKS HFC 410A After the line set has been connected to the indoor and outdoor units check the line set connections and indoor unit for leaks Use the following procedure to test for leaks A With both manifold valves closed connect the cylinder of HFC 410A refrigerant to the center port of the manifold gauge set Open the valve on the HFC 410A cylinder vapor only B Openthe high pressure side of the manifold to allow HFC 410A into the line set and indoor unit Weigh in a trace amount of HFC 4104A A trace amount is a maximum of two ounces 57 g refrigerant or three pounds 31 kPa pressure Close the valve on the HFC 410A cylinder and the valve on the high pressure side of the manifold gauge set Disconnect the HFC 410A cylinder C Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set D Adjust dry nitrogen pr
49. IZE MATCHES SERVICE VALVE CONNECTION SERVICE VALVE CONNECTION COPPER TUBE N STUB 7 LIQUID LINE SERVICE VALVE LINE SET SIZE IS SMALLER THAN CONNECTION REFRIGERANT LINE SERVICE PORT CORE Q SERVICE SUCTION LINE SERVICE VALVE DO NOT CRIMP SERVICE VALVE CONNECTOR WHEN PIPE IS SMALLER THAN CONNECTION ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION VAPOR LINE SERVICE VALVES Connect gauge set low pressure side to liquid line service valve service port Connect gauge set center port to bottle of nitrogen with regulator With valve core removed from the suction vapor line service port nitrogen flow will have an exit point ATTACH GAUGES SUCTION VAPOR SERVICE PORT MUST BE OPEN AND SERVICE PORT CORE REMOVED TO ALLOW EXIT POINT FOR NITROGEN FLOW SUCTION VAPOR LINE SERVICE SUCTION VAPOR VALVE LINE INDOOR OUTDOOR UNIT io UNIT a N lt lt E c3 NITROGEN LIGUIDTINE LIQUID LINE SERVICE VALVE Figure 12 Brazing Procedures 07 09 Page 18 WRAP SERVICE VALVES To help protect service valve seals during brazing wrap water saturated cloths around service valve bodies and copper tube stubs Use additionalwater saturated cloths underneath the valve body to protect the base paint FLOW NITROGEN WARNING Flow regul
50. MOVEMENT ORBIT SUCTION SUCTION INTERMEDIATE ORBITING SUCTION 4 TRIP POCKET PRESSURE GAS CRESCENT SHAPED GAS POCKET DETAIL 1 DETAIL 2 STATIONARY FLANKS SEALED Ne SCROLL BY CENTRIFUGAL FORCE DETAIL 4 bd HIGH PRESSURE GAS DETAIL 3 DISCHARGE POCKET Figure 5 How a Scroll Works The scroll compressors in all XPG15 model units are designed for use with HFC 410A refrigerant and operation at high pressures Compressors are shipped from the factory with 3MA 32MMMA oil See electrical section in this manual for compressor specifications Unit Components8 See Unit Parts and Unit Control Box Parts Arrangement on page 4 for component locations 1 CONTACTOR K1 The compressor is energized by a contactor located in the control box All XPG15 units are single phase and single pole contactors A contactor is an electro magnetic switching device a relay used for switching a power or control circuit A contactor is activated by a control input which is typically a lower voltage than that which the contactor is Switching For location of the contactor see Control Panel Parts Arrangement on page 4 HIGH PRESSURE SWITCH 54 An auto reset single pole single throw high pressure Switch is located in the liquid line See Unit Parts Arrangement on page 4 for switch location and Defrost System on page 38 for complete details concerning this Switch N Page 7 3 LOW P
51. NGEMENT COMPRESSOR CONTACTOR WARNING b ELECTRIC SHOCK HAZARD CAN CAUSE INJURY L1 OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE CAPACITOR BO REVERSING WITH NATIONAL AND LOCAL CODES SWITCH VALVE USE ONLY COMFORT SENSE 7000 TO CONTROL THE SECOND STAGE OF GAS HEAT GAS FURNACE COMFORT SENSE 5000 OR 7000 ONLY COMPRESSOR CONTACTOR 540 CRANKCASE THERMOSTAT HEATER COMPRESSOR LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING L DENOTES OPTIONAL COMPONENTS HEAT PUMP LENNOX OUTDOOR UNITS l XPG15 024 230 XPG15 042 230 EGUIBMENE XPG15 030 230 XPG15 048 230 GROUND XPG15 036 230 Supersedes COMPRESSOR 0209 CONTACTOR 1 New Form Litho U S A YELLOW PURPLE CAPACITOR Figure 17 XPG15 024 030 036 042 and 048 Wiring using ComfortSense 5000 7000 Thermostats Page 25 XPG15 SERIES RT21 RT13 NOTE A108 DEFROST AMBIENT IF ANY WIRE IN THIS APPLIANCE IS REPLACED T DEFROST s MUST REPLACED WITH WIRE LIKE SIZE COIL SENSOR CONTROL SENSOR RATING INSULATION THICKNESS AND TERMINATION NOTE FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE A FOR MINIMUM CIRCUIT AMPACITY AND B1 A MAXIMUM OVERCURRENT PROTECTION SIZE HIGH COMPRESSOR PRESSURE REFER TO COMPRESSOR IN UNIT FOR K1 SWITCH 5 ACTUAL TERMINAL ARRANGEMENT COMPRESSOR A CONTACTOR WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH
52. Placing a jumper on the Demand Defrost Controls TEST pins will not activate the heat pump out of inactive mode 24VAC power must be cycled to the Demand Defrost Control to activate the heat pump out of inactive mode 3 Demand defrost control will not output a W out signal when the outdoor temperature is above 65 F 18 C 4 Ifthe Demand Defrost Control enters a low pressure LOCKOUT during heating mode the outdoor unit will enter the heat pump inactive mode The Demand Defrost Control will flash the low pressure code If the room thermostat calls for Y1 heating in low pressure LOCKOUT the Demand Defrost Control will alternately display two codes four 4 seconds for the low pressure LOCKOUT and then four 4 seconds heat pump inactive gas mode active code Page 31 XPG15 SERIES Servicing Units Delivered Void of 2 Inspect all factory and field installed wiring for loose Charge20 connections 3 After evacuation of the line set and indoor coil is If the outdoor unit is void of refrigerant clean the system complete open both the liquid and vapor line service using the procedure described below valves to release the refrigerant charge contained in 1 Use nitrogen to pressurize the system and check for outdoor unit into the system leaks Repair all leaks 4 Replace the stem caps and tighten as specified in 2 Evacuate the system to remove as much of the Operating Gauge Set and Service Valves on page 8 5 Check volt
53. RE INVERTED HCFC 22 CYLINDER CONTAINS CLEAN HCFC 22 TO BE USED FOR FLUSHING GAUGE MANIFOLD A Low 7 VAPOR LINE i SERVICE VALVE NA OPENED CLOSED EXISTING INDOOR UNIT LIQUID LINE SERVICE VALVE TANK RETURN INLET DISCHARGE RECOVERY MACHINE RECO CYLINDE Inverted HCFC 22 cylinder with clean refrigerant to the vapor service valve HCFC 22 gauge set low side to the liquid line valve HCFC 22 gauge set center port to inlet on the recovery machine with an empty recovery tank to the gauge set Connect recovery tank to recovery machines per machine instructions PROCEDURE UNCASED COIL SHOWN STUB END LIQUID LINE ORIFICE Bs EXISTING EXPANSION VALVE REMOVAL CHECK EXPANSION DISTRIBUTOR VALVE TEFLON 1 SENSING _ LINE EQUALIZER E LIQUID LINE ASSEMBLY WITH BRASS NUT MALE EQUALIZER LINE FITTING SENSING BULB LIQUID LINE On fully cased coils remove the coil access and plumbing panels Remove any shipping clamps holding the liquid line and distributor assembly C Disconnect the equalizer line from the check expansion valve equalizer line fitting on the vapor line Remove the vapor line sensing bulb Disconnect the liquid line from the check expansion valve at the liquid line assembly Disconnect the check expansion valve from the liquid line orifice housing Take care not to twist or damage distributor tubes dur
54. RESSURE SWITCH S87 The XPG15 is equipped with an auto reset low pressure switch which is located on the true suction line between the reversing valve and the compressor See Unit Parts Arrangement on page 4 for switch location and Defrost System on page 38 for more information TEMPERATURE SENSORS Detail information concerning the ambient RT13 and defrost coil RT21 sensors is available in section Defrost System on page 38 DUAL CAPACITOR C12 The compressor and fan in XPG15 2 1 2 to 4 ton units use permanent split capacitor motor A single DUAL capacitor is used for both the fan motor and the compressor see unit wiring diagram The two sides fan and compressor of the capacitor have different ratings and may change with each compressor The 5 ton unit uses a ECM motor and with the C12 capacitor only used with the compressor For location of the C12 capacitor see Control Panel Parts Arrangement on page 4 CRANKCASE HEATER HR1 Compressors in this model are equipped with the following crankcase heaters XPG15 SERIES Table 1 Crankcase Heater Electrical Specifications 1 TORQUE REQUIREMENTS Unit Size Tonnage Watts Voltage When servicing or repairing HVAC components ensure 2to3 40 240VAC the fasteners are appropriately tightened Table 2 shows torque values for fasteners 3 1 2 to 5 70 240VAC IMPORTANT HR1 prevents liquid from accumulating in the compressor HR1 i
55. ROUND COMPRESSOR CONTACTOR K1 1 CAPACITOR REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRANGEMENT A WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES A USE ONLY COMFORT SENSE 7000 TO CONTROL THE SECOND STAGE OF GAS HEAT Operation Mode ComfortSense Gas Furnace Dedicated Heat Pump XPG15 INPUTS OUT w RU YA w PUTS gt W1 We IN K229 out OUT Defrost Mode Power Defrost DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS K1 relay contact open to cycle OFF outdoor fan K2 relay contact close and output 24VAC to RL output to energize K229 field installed relay K2 relay contact close and energize reversing valve K3 relay contact close and energize compressor contactor K4 relay contact remain open K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from the room thermostat to the furnace control Indoor blower will cycle OFF DEFROST TERMINATION Once a power defrost mode has been initiated the next event will occur as explained on page 41 07 09 Page 50 NATURAL DEFROST MODE RT21 DEFROST COIL SENSOR 1 1 COMPRESSOR CONTACTOR C 540 CRANKCASE THERMOSTAT O HR1 CRANKCASE m HEATER A OR N o c n EQUIPMENT GROUND COMPRESSOR CONTACTOR K1 1
56. TING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRANGEMENT A WARNING COMPRESSOR ELECTRIC SHOCK HAZARD CAN CAUSE INJURY CONTACTOR OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE K1 1 WITH NATIONAL AND LOCAL CODES 2 0 ZA USE ONLY COMFORT SENSE 7000 CONTROL THE SECOND STAGE GAS HEAT EQUIPMENT GROUND CAPACITOR Operation Mode ComfortSense Gas Furnace Dedicated Heat Pump XPG15 INPUTS OUT w RU YA w PUTS gt We O G WI w IN K229 out OUT 32 F First Stage Heat ing Heat Pump X Second Stage Heating First Stage Gas Heat Third Stage Heat ing Second Stage Gas Heat DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS K1 relay contact remain closed K2 relay contact two sets close and output 24VAC to RL output to energize K229 field installed relay K3 relay contact open and de energize compressor contactor K4 relay contact remain closed K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from the room thermostat to the furnace control This allows the furnace to control the indoor blower operation during gas heat operations NOTE When Demand Defrost Control receives Y1 and W in room thermostat demands the gas furnace will satisfy both room thermostat demands before cycling OFF gt
57. UNTING 2 SLAB GROUND LEVEL 2 r Slab Mounting at Ground Level DETAIL D Slab Side Mounting N N 10 1 2 LONG SELF DRILLING SS SHEET METAL SCREWS COIL STABILIZING BRACKET 18 GAUGE k METAL 2 WIDTH HEIGHT AS lt BASE PAN REQUIRED 10 1 1 4 LONG HEX HD SCREW AND FLATWASHER N CONCRETE SLAB USE TWO PLASTIC ANCHORS HOLE DRILL 1 4 WOOD OR PLASTIC SLAB NO PLASTIC ANCHOR HOLE DRILL 1 8 MINIMUM ONE Deck Top Mounting PER SIDE STABILIZING BRACKET 18 GAUGE METAL 2 50 8MM WIDTH HEIGHT AS REQUIRED BEND TO FORM RIGHT ANGLE SAME FASTENERS AS SLAB SIDE MOUNTING ONE BRACKET PER SIDE MIN FOR EXTRA STABILITY TWO BRACKETS PER SIDE 2 50 8MM FROM EACH CORNER Stabilizing Unit on Uneven Surfaces IMPORTANT To help stabilize an outdoor unit some installations may require strapping the unit to the pad using brackets and anchors commonly available in the marketplace Figure 8 Placement Slab Mounting and Stabilizing Unit 07 09 Page 12 4 STABILIZING UNIT ON UNEVEN SURFACES A IMPORTANT Unit Stabilizer Bracket Use field provided Always use stabilizers when unit is raised above the factory height Elevated units could become unstable in gusty wi
58. age supply at the disconnect switch The 3 Use nitrogen to break the vacuum and install a new voltage must be within the range listed on the unit s filter drier in the system nameplate If not do not start the equipment until you 4 Evacuate the system again have consulted with the power company and the 5 Use figure 22 to charge the system voltage condition has been corrected 6 Monitor the system to determine the amount of 6 Set the thermostat for a cooling demand Turn on moisture remaining in the oil It may be necessary to power to the indoor unit and close the outdoor unit replace the filter drier several times to achieve the disconnect switch to start the unit el ne level sys sm dryness s nor 7 Recheck voltage while the unit is running Power must verified the compressor will fail in the future be within range shown on the nameplate Unit Start Up21 8 Check system for sufficient refrigerant by using the procedures listed under System Charge A IMPORTANT If unit is equipped with a crankcase heater it should be energized 24 hours before unit start up to prevent This section outlines procedures for compressor damage as a result of slugging Connecting gauge set for testing and charging 1 Rotate fan to check for binding Adding or removing refrigerant B TRUE SUCTION PORT CONNECTION OUTDOOR UNIT REFRIGERANT TANK CHARGE IN LIQUID PHASE DIGITAL SCALE
59. al codes Line voltage is present at all components when unit is not in operation on units with single pole contactors Disconnect all remote electric power supplies before opening access panel Unit may have multiple power supplies Electrostatic discharge affect electronic components precautions ELECTROSTATIC DISCHARGE ESD Precautions and Procedures during unit installation and service to protect the unit s electronic controls Precautions will help to avoid control exposure to electrostatic discharge by putting the unit the control and the technician at the same electrostatic potential Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface before performing any service procedure Page 23 XPG15 SERIES 3 ROUTE THERMOSTAT WIRES Install low voltage wiring from outdoor to indoor unit and from thermostat OUTDOOR UNIT to indoor unit as illustrated Run 24VAC control wires through hole with grommet 24VAC thermostat wire connections CONTROL PANEL NOTE Do not bundle any excess 24VAC control wires inside control box SEE PAGE 28 FOR SPECIFIC LOW VOLTAGE WIRING CONNECTIONS FOR PROPER VOLTAGES SELECT THERMOSTAT WIRE CONTROL WIRES GAUGE PER TABLE BELOW WIRE RUN LENGTH AWG INSULATION LESS THAN 100 30 METERS 18 TEMPERATURE RATING MORE THAN 100 30 METERS
60. and sealed No further lubrication is needed Outdoor Coil The outdoor coil may be flushed with a water hose Outdoor Coil Sea Coast Moist air in ocean locations can carry salt which is corrosive to most metal Units that are located near the ocean will require frequent inspections and maintenance These inspections will determine the necessary need to wash the unit including the outdoor coil When removing debris from around the unit be aware of metal edges on parts and screws Although special care has been taken to keep exposed edges to a minimum physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury Page 55 Sound Reduction SR1 Cover30 TOP CABLE TIE uM YS C3 MIDDLE CABLE TIE DISCHARGE GROMMET RIGHT TOP CAP BOTTOM CABLE TIE Figure 29 Sound Reduction Cover Parts ASSEMBLY PROCEDURE Figure 29 identifies the sound reduction parts The assembly procedure is as follows 1 Put SR1 base on unit base pan 2 Install compressor on base 3 Cover SR1 base with wet rags to protect against any brazing material Braze vapor tube Braze discharge tube Cool connections to ambient temperature Perform leak check Install vapor grommet 9 Install SR1 left and right side covers 10 Fasten 60 bottom cable tie 11 Install discharge grommet 12 Install top caps 13 Fasten 36 top cable tie 14
61. ated nitrogen at 1 to 2 psig through the refrigeration gauge set into the valve stem port connection on the liquid service 1 FIRE PERSONAL INJURY OR PROPERTY valve and out of the suction vapor valve stem port See steps 3B DAMAGE will result if you do not wrap a water and 3C on previous page and below for manifold gauge setup saturated cloth around both liquid and suction line service valve bodies and copper tube stub while BRAZE LINE SET brazing in the line set The braze when complete must be quenched with water to absorb any residual Water saturated cloths must remain water saturated throughout heat the brazing and cool down process Do not open service valves until refrigerant lines and A Braze liquid line to liquid line service valve indoor coil have been leak tested and evacuated Refer to procedures provided in this supplement Braze suction vapor line to suction vapor service valve WHEN BRAZING LINE SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE SUCTION VAPOR LINE SUCTION VAPOR SERVICE PORT MUST BE OPEN AND SERVICE PORT CORE REMOVED TO ALLOW EXIT POINT FOR NITROGEN FLOW WATER SATURATED CLOTHS IMPORTANT Allow braze joint to cool Apply additional water saturated cloths to help cool brazed joints Do not remove water saturated cloths until piping has cooled Temperatures above 250 F will damage valve seals LIQUID LINE WATER SATURATED CLOTHS 7 PREPARATION FOR NEXT STEP
62. coil See illustration to the left for an example on how to obtain an accurate reading TEST HOLES 1 Drill one 5 16 8 mm air test hole into the delta plate between the coil slabs Drill one 5 16 8 mm air test hole into the duct above the top of the coil 3 Connect the instrument for static pressure measurement hoses to the air entering side of coil Insert the hoses so that 1 4 6 mm extends inside the duct or end seal Seal around holes with Permagum Turn on electrical power to the furnace and set the thermostat to initiate a cooling demand Refer to indoor coil installation instruction for range of air vol umes and equivalent static pressure readings for these units CAUTION Take care when drilling test holes in the furnace Observe the static pressure reading If the reading is below flange and the duct Drill holes away from refrigerant piping the required air volume increase the blower speed if the Test holes should be drilled where specified in order to avoid reading is above the required air volume decrease the blow unit damage er speed Refer to the furnace wiring diagram for blower speed settings When the required static pressure readings are obtained re move the test hose lines and insert snaphole plugs into test holes Figure 21 Checking Indoor Airflow over Evaporator Coil using Static Pressure Reading Page 33 XPG15 SERIES Use WEIGH IN to initially charge a system when the
63. connections MAIN FUSE BOX BREAKER PANEL MANIFOLD GAUGES SERVICE DISCONNECT SWITCH RECOVERY MACHINE CLEAN RECOVERY OUTDOOR UNIT CYLINDER 2 REFRIGERANT Remove existing HCFC 22 refrigerant using one of the following procedures IMPORTANT Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes and or long line sets METHOD 1 Us this method if the existing outdoor unit is not equipped with shut off valves or if the unit is not operational and you plan to use the existing HCFC 22 to flush the system Remove all HCFC 22 refrigerant from the existing system Check gauges after shutdown to confirm that the entire system is completely void of refrigerant METHOD 2 Use this method if the existing outdoor unit is equipped with manual shut off valves and you plan to use new HCFC 22 refrigerant to flush the system The following devices could prevent full system charge recovery into the outdoor unit Outdoor unit s high or low pressure switches if applicable when tripped can cycle the compressor OFF Compressor can stop pumping due to tripped internal pressure relief valve Compressor has internal vacuum protection that is designed to unload the scrolls compressor stops pumping when the pressure ratio meets a certain value or when the suction pressure is as high as 20 psig Compressor suction pressures should never be allowed to go into a vacuum Pro
64. data 60hz 208 230V 1ph 2 Maximum overcurrent protection amps 30 30 35 40 50 60 3 Minimum circuit ampacity 17 4 18 1 21 5 23 5 28 4 35 8 Compressor Rated load amps 13 5 14 1 16 7 17 9 21 8 26 4 Locked rotor amps 58 3 73 0 79 0 107 0 117 0 134 0 Power factor 0 99 0 97 0 98 0 94 0 99 0 98 Outdoor Fan Full load amps 0 5 0 5 0 65 1 1 1 1 2 8 Motor Locked rotor amps 0 8 0 8 1 1 2 1 2 1 N A OPTIONAL ACCESSORIES must be ordered extra Compressor Hard Start Kit 88M91 Compressor Low Ambient Cut Off 45F08 Freezestat 3 8 in tubing 93G35 5 8 tubing 50A93 Low Ambient Kit 54M89 Indoor Blower Delay Relay 58 81 Mild Weather Kit 33M07 Suction Line Drier 88K44 Replacement Liquid Line Bi Flow 95M51 Drier 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 Snow Shield Kit 5 44W14 Snow Guard Kit 5 X8782 Thermostats 4 ComfortSense 5000 X4147 5 4 5 Outdoor Sensor for Y0349 X2658 ComfortSense 7000 Y0349 NOTE Extremes of operating range are plus 10 and minus 5 of line voltage Refrigerant charge sufficient for 15 ft 4 6 m length of refrigerant lines HACR type breaker or fuse 2 3 Refer to National or Ca
65. e Heating and cooling operation will be allowed in this fault condition Ambient Sensor RT13 The ambient sensor shown in figure 1 detail B considers outdoor temperatures below 35 F 37 C or above 120 F 48 C to be a fault If the ambient sensor is shorted or out of the temperature range of the sensor the Demand Defrost Control will not perform demand defrost operation The Demand Defrost Control will revert to time temperature defrost operation and will display the appropriate fault code Heating and cooling operation will be allowed in this fault condition NOTE If 5 strikes occur within a single room thermostat demand the Demand Defrost Control will lock out the unit Demand Defrost Control 24VAC power R must be cycled OFF or place a jumper on TEST pins between 1 to 2 seconds to reset the Demand Defrost Control Page 41 6 DEFROST MODE TERMINATION 27 Power Defrosts Once a power defrost mode has been initiated the following will occur e Will terminate and reset the internal timer if the coil sensor temperature exceeds the selected Defrost Termination Temperature Setting If the Defrost Termination Temperature Setting P1 jumper is not installed the default termination temperature is 90 F e internal timer shall count the time that the defrost mode is engaged and compressor is energized After 14 minutes of operation in the defrost mode the defrost sequence will terminate immediately and reset in
66. e Valves9 These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities who have jurisdiction before installation 07 09 Page 8 Operating Angle Type Service Valve 1 Remove stem cap with an appropriately sized wrench 2 Use a service wrench with a hex head extension 3 16 for liquid line valve sizes and 5 16 for vapor line valve sizes to back the stem out counterclockwise as far as it will go SERVICE PORT CAP SERVICE PORT CORE TO INDOOR VALVE STEM SHOWN OPEN VALVE STEM SHOWN CLOSED INSERT HEX WRENCH HERE INSERT HEX WRENCH HERE SERVICE PORT TO OUTDOOR UNIT ANGLE TYPE SERVICE VALVE BACK SEATED OPENED When service valve is OPEN the service port is open to linE set indoor and outdoor unit Operating Ball Type Service Valve 1 Remove stem cap with an appropriately sized wrench 2 Use an appropriately sized wrenched to open To open valve rotate stem counterclockwise 90 To close rotate stem clockwise 90 TO INDOOR UNIT TO OPEN ROTATE STEM COUNTERCLOCKWISE 90 BALL SHOWN CLOSED TO CLOSE ROTATE STEM CLOCKWISE 90 SERVICE PORT SERVICE PORT CORE SERVICE PORT CAP TO OUTDOOR STEM UNIT lt D Z SEF STEM CAP CORE ANGLE TYPE SERVICE VALVE FRONT SEATED CLOSED WHEN SERVICE VALVE IS CLOSED THE SERVICE PORT IS OPEN TO THE LINE SET AND INDOOR UNIT To Access Service Port A se
67. e orbiting motion continues the gas is forced toward the center of the scroll and the gas pocket becomes compressed as illustrated in figure 5 detail 3 When the compressed gas reaches the center it is discharged vertically into a chamber and discharge port in the top of the compressor The discharge pressure forcing down on the top scroll helps seal off the upper and lower edges tips of the scrolls as illustrated in figure 4 During a single orbit several pockets of gas are compressed simultaneously providing smooth continuous compression The scroll compressor is tolerant to the effects of liquid return 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 If the compressor is replaced conventional Lennox cleanup practices must be used Due to its efficiency the scroll compressor is capable of drawing a much deeper vacuum than reciprocating compressors 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 compressor can be used to pump down refrigerant as long as the pressure is not reduced below 7 psig NOTE During operation the head of scroll compressor may be hot since it is in constant contact with discharge gas 07 09 Page 6 2
68. ed disconnect switch MAIN FUSE BOX BREAKER PANEL SERVICE DISCONNECT SWITCH NOTE Units are approved for use only with copper conductors Ground unit at disconnect switch or to an earth ground A WARNING temperatures and pressures present during operation of an air conditioning system Non condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts Electrical18 In the U S A wiring must conform with current local codes and the current National Electric Code NEC In Canada wiring must conform with current local codes and the current Canadian Electrical Code CEC Refer to the furnace installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size 1 24VAC TRANSFORMER Use the transformer provided with the furnace or air handler for low voltage control power 24VAC 40 VA minimum Install room thermostat ordered separately on an inside wall approximately in the center of the conditioned area and 5 feet 1 5m from the floor It should not be installed on an outside wall or where it can be affected by sunlight or drafts 2 INSTALL THERMOSTAT THERMOSTAT NOTE 24VAC Class II circuit connections are made in the control panel Electric Shock Hazard Can cause injury or death Unit must be grounded in accordance with national and loc
69. essure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor unit E Afterafew minutes open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector F Afterleak testing disconnect gauges from service ports Figure 15 Leak Test Page 21 XPG15 SERIES Evacuating17 NOTE Remove cores from service valves if not already done 2 07 09 A D NITR BENIM gauge to the center port of the 1 CONNECT GAUGE SET Connect low side of manifold gauge set with 1 4 SAE in line tee to vapor line service valve OUTDOOR MANIFOLD UNIT 4000 1 4 SAE TEE WITH GAUGE SET SWIVEL COUPLER Connect high side of manifold gauge set to liquid line service valve A Connect micron gauge available i J connector on the 1 4 SAE in line tee MICRON GAUGE 1 Connect the vacuum pump with TO VAPOR SERVICE VALVE manifold gauge set The center port ine will be used later for both the FC 410A and nitrogen containers HFC 410A J air VACUUM PUMP TO LIQUID LINE SERVICE VALVE 1 1 EVACUATE THE SYSTEM RECOMMEND A Open both manifold valves and start the vacuum pump MINIMUM 3 8 HOSE Evacuate the line set and indoor unit to an absolute pressure o
70. f 23 000 microns 29 01 inches of mercury NOTE During the early stages of evacuation it is desirable to close the manifold gauge valve at least once A rapid rise in pressure indicates a relatively large leak If this occurs repeat the leak testing procedure NOTE The term absolute pressure means the total actual pressure within a given volume or system above the absolute zero of pressure Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure When the absolute pressure reaches 23 000 microns 29 01 inches of mercury perform the following Close manifold gauge valves Close valve on vacuum pump Turn off vacuum pump Disconnect manifold gauge center port hose from vacuum pump e X Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig 1034 kPa and purge the hose Open manifold gauge valves to break the vacuum in the line set and indoor unit Close manifold gauge valves Shut off the dry nitrogen cylinder and remove the manifold gauge hose from the cylinder Open the manifold gauge valves to release the dry nitrogen from the line set and indoor unit 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
71. ge Heat ing Heat Pump x x x X X Second Stage Heating First X X X X X X X X X X Stage Gas Heat Third Stage Heat ing Second Stage X X X X Gas Heat Heating Mode Outside Temperature below 32 F First Stage Heat ing First Stage X X Gas Heat Second Stage Heating Second X X X X Stage Gas Heat Defrost Mode Power Defrost X X Natural Defrost X X Emergency Heat Mode Emergency Heat Mode X X X x X X X Low and High Pressure Lock Out Mode Cooling LPS HPS X X X X X X X X Heating HPS X X X X X Heating LPS X X X X X X X X X IMPORTANT Set up is critical to ensure proper system operation Refer to installation instructions packaged with the unit as well as XPG15 service manual Both documents are available from www LennoxDaveNet net Field Installed Relay K229 De energizes Y1 and G inputs to furnace factory provided and field installed at indoor unit NOTES 1 For proper operation the Demand Defrost Control must have 24VAC between R system power input and C system common The above chart shows which terminals should have 24VAC inputs or outputs during certain operation modes Example In the cooling mode there should be 24VAC between Y1 and C on the Demand Defrost Control terminal strip 2
72. he room thermostat to the furnace control Indoor blower will cycle OFF DARN DEFROST TERMINATION Natural defrosts should be terminated after a fixed duration of 150 seconds Page 51 XPG15 SERIES COOLING HEATING AND TEST MODE FLOWS COOLING Mode Operation Thermostat Call for Cooling DEFROST CONTROL ON BOARD RELAYS K1 Outdoor Fan Normally Closed K2 Reversing valve amp RL output K3 Compressor Y1 out K4 W out ASCD Anti short Cycle Delay Is the 5 minute ASCD Timer Expired Y K3 ON K1 K2 K4 Off K1 K2 K3 and K4 5 Trip in this OFF Cooling Demand Hi Ps Lockout Display Code K1 K2 and K4 5 Trip in this Lo Ps Trip OFF Cooling Demand Lo Ps Lockout Display Code K1 K2 K3 and K4 OFF Figure 26 Cooling Mode Operation 07 09 Page 52 DEFROST CONTROL ON BOARD RELAYS H E A G K1 Outdoor Fan Normally Closed K2 Reversing valve amp RL output Mode O Input not Present i ASCD Anti short Cycle Delay Power Up gt lt K1 K2 K4 OFF Y Exit HP Inactive Display Normal Operation Code Thermostat Call for heat 4 Ye First Stage Enter HP Inactive Ambient E Display Code Tempeture is Dus Hon K3 OFF less than died K1 K2 K4 ON 32 Satisfied
73. hose features that would be used by the homeowner Press the DONE key when finished Table 4 ComfortSense 5000 Setup Selections MH Installer Setup Name Select 0170 System Type mius Heat One Cool Heat Pump Heat pump with auxiliary or back up 2 0 Electric heat is used as auxiliary heat source in heat pump application 0200 Auxiliary Heat Source Factory setting DO NOT SELECT FOSSIL FUEL 0 No remote outdoor temperature sensor 0340 Remote Outdoor Temperature Sensor or 1 Outdoor temperature sensor used for display only Page 29 XPG15 SERIES COMFORTSENSE 7000 Required settings for 15 dual fuel applications SCHEDUI OPTIONS Brem jc INSTALLER SETTINGS OPTIONS TAB INSTALLER SETTINGS ENTER ENTER Press OPTIONS tab then use the arrows to select INSTALLER SETTINGS Press ENTER twice INSTALLER SETTINGS NOTE After ENTER is pressed the first time a note states MUST BE SET BY QUALIFIED PERSON Press ENTER again to access installer settings Use the following procedure to set up thermostat for use with the XPG15 SYSTEM SETUP Set the thermostat for heat pump operation and define the number of compressor stages and the number of backup heat stages The default settings for the system are Heat Pump Electric 1 or 2 compressor stages and 1 or 2 indoor heat stages 1 For HEAT PUMP use arrows to select ELECTRIC then p
74. iency residential split system Leak Testing 21 dual fuel heat pump unit which features a scroll Evacualtilig eure ican i p ERROR E 21 compressor and HFC 410A refrigerant XPG15 units are Electrical 23 available in 2 2 1 2 3 3 1 2 4 and 5 ton sizes The series System Setup Information 23 is designed for use with an check expansion valve only Servicing Unit Delivered Void of Charge 32 approved for use with HFC 410A in the indoor unit This Unit StarEUp 32 manual is divided into sections which discuss the major System Charge 32 components refrigerant system charging procedure Indoor Coil Mat h NIMM QE ME 36 maintenance and operation sequence ndoor Coil Matchups The Lennox dedicated dual fuel XPG15 outdoor unit perang ane Temperature TER RUTER of technology allows the system to alternate between heat System Operations 38 pump heating when outdoor temperature is ABOVE 32 F Defrost System cansa ko a ra wa ec ass V 38 0 C and automatically switching over to gas furnace Operating MOdSS Se gawd el Yagua dase 46 heating when outdoor temperature is BELOW 32 F 0 C Dealer Maintenance 55 making the most efficient use of fuel sources Sound Reduction SR1 Cover 55 ATTENTION SERVICE TECHNICIAN
75. ing this process G Remove and discard check expansion valve and the two Teflon rings Use a field provided fitting to temporary reconnect the liquid line to the indoor unit s liquid line orifice housing FLUSHING LINE SET 3 The line set and indoor unit coil must be flushed with at least the same amount of clean refrigerant that previously charged the system Check the charge in the flushing cylinder before proceeding A Set the recovery machine for liquid recovery and start the recovery machine Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line set and indoor unit coil Invert the cylinder of clean HCFC 22 and open its valve to allow liquid refrigerant to flow into the system through the vapor line valve Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine After all of the liquid refrigerant has been recovered switch the recovery machine to vapor recovery so that all of the HCFC 22 vapor is recovered Allow the recovery machine to pull down to 0 the system Close the valve on the inverted HCFC 22 drum and the gauge set valves Pump the remaining refrigerant out of the recovery machine and turn the machine off Figure 14 Flushing Line Set and Indoor Coil 07 09 Page 20 Leak Testing16 IMPORTANT Leak detector must be capable of sensing HFC refrigerant A WARNING When
76. led in the liquid line The filter Parts drier is designed to remove moisture and foreign matter IMPORTANT To prevent stripping of the various caps used the appropriately sized wrench should be used and fitted snugly over the cap before tightening Table 2 Torque Requirements Recommended Torque which can lead to compressor failure See Unit Parts Service valve cap 8 ft lb FENM Arrangement on page 4 for bi flow liquid line filter drier Sheet metal screws 16 in Ib 2 NM location Machine screws 10 28 in Ib 3 NM CAUTION Compressor bolts 90 in Ib 10 NM Gauge port seal 8 ft Ib 11 NM Physical contact with metal edges and corners 2 OPERATING MANIFOLD GAUGE SET When checking the system charge only use a manifold gauge set that features low loss anti blow back fittings while applying excessive force or rapid motion can result in personal injury Be aware of and use caution when working near these areas during installation or while servicing this equipment Manifold gauge set used with HFC 410A refrigerant systems must be capable of handling the higher system operating pressures The gauges should be rated for use with pressures of 0 800 psig on the high side and a low side of 30 vacuum to 250 psig with dampened speed to 500 psi Gauge hoses must be rated for use at up to 800 psig of pressure with a 4000 psig burst rating Operating Gauge Set and Servic
77. ling DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS 1 K1 relay contact remain closed 2 K2 relay contact two sets remain open 3 Reversing valve is energized through room thermostat 4 K3 relay contact close to energize compressor contactor 5 K4 relay contact remain open EXCEPTIONS Low or high pressure switch open or five 5 strike pressure switch lockout or anti short delay five minutes active 07 09 Page 46 HEATING OPERATING MODE ROOM THERMOSTAT DEMAND FOR Y1 WITH OUTDOOR TEMPERATURE ABOVE 32 F O C RT21 DEFROST COIL SENSOR a K1 1 COMPRESSOR CONTACTOR C 540 CRANKCASE THERMOSTAT RT13 AMBIENT SENSOR 9 BLACK 54 87 LOW L1 A HIGH PRESSURE REVERSING 81 PRESSURE SWITCH VALVE COMPRESSOR e 69 NOTE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION COMFORT SENSE 5000 OR 7000 ONLY GAS FURNACE TB1 N gt lt HRI Q CRANKCASE m HEATER A OR 9 COOCOO 7 o ra A gt FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE EQUIPMENT GROUND COMPRESSOR CONTACTOR K1 1 Operation Mode CAPACITOR REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRANGEMENT A WARNING ELECTRIC SHOCK HAZ
78. longed operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips drive bearings and internal seals Once the compressor can not pump down to a lower pressure due to one of the above system conditions shut off the vapor valve Turn OFF the main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set Perform the following task A Startthe existing HCFC 22 system in the cooling mode and close the liquid line valve B Use the compressor to pump as much of the existing 22 refrigerant into the outdoor unit until the outdoor system is full Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system NOTE It may be necessary to bypass the low pressure switches if equipped to ensure complete refrigerant evacuation C When the low side system pressures reach 0 psig close the vapor line valve D Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system 07 09 Page 10 CLEARANCE ON ALL SIDES INCHES MILLIMETERS MINIMUM CLEARANCE ACCESS PANEL 2 s gt NOTES TN ABOVE UNIT Clearance to one of the other three 48 1219 Inun sides must be 36 inches 914mm 12 305 Clearance to one of the remaining AANA AN II two sides may be 12 inches S
79. lt vem n 305mm and the final side may be 6 inches 152mm LINE SET 36 914 CONNECTIONS MINIMUM CLEARANCE BETWEEN TWO UNITS 24 610 ACCESS PANEL LINE SET CONNECTIONS REAR VIEW OF UNIT Figure 7 Installation Clearances Unit Placement11 CAUTION In order to avoid injury take proper precaution when lift ing heavy objects See Unit Dimensions on page 3 for sizing mounting slab platforms or supports Refer to figure 7 for mandatory installation clearance requirements 1 POSITIONING CONSIDERATIONS Consider the following when positioning the unit Some localities are adopting sound ordinances based on the unit s sound level registered from the adjacent property not from the installation property Install the unit as far as possible from the property line e When possible do not install the unit directly outside a window Glass has a very high level of sound transmission For proper placement of unit in relation to a window see the provided illustration in figure 8 detail A Page 11 2 PLACING UNIT ON SLAB When installing unit at grade level the top of the slab should be high enough above grade so that water from higher ground will not collect around the unit The slab should have a slope tolerance as described in figure 8 detail B NOTE If necessary for stability anchor unit to slab as described in figure 8 detail D 3 ELEVATING THE
80. mp heating the Demand Defrost Control will initiate a sacrificial defrost to ensure a clear outdoor coil before an attempt to calibrate the Demand Defrost Control START HERE A THIRTY 30 MINUTES OF ACCUMULATED COMPRESSOR RUNTIME WITH COIL SACRIFICIAL POWER TEMPERATURE DEFROST GAS HEAT ACTIVE HEAT PUMP BELOW 35 F 1 6 C INACTIVE DUE TO FROST BUILD UP ON OUTDOOR COIL NATURAL DEFROSTS UNABLE TO PROPERLY CLEAR COIL THIRD HEAT PUMP CALL BETWEEN 10 AND 20 MINUTES OF HEATING RUN TIME AFTER THE THIRD HEAT PUMP HEATING CYCLE SACRIFICIAL DEFROST THE AFTER DEMAND DEFROST DEMAND DEFROST CONTROL WILL CONTROL HAS CALIBRATED ATTEMPT TO CALIBRATE SECOND NATURAL DEFROST 150 SECONDS FIRST HEAT PUMP HEATING CYCLE AFTER DEMAND DEFROST CONTROL HAS CONTROL CALIBRATED SECOND HEAT PUMP HEATING CYCLE AFTER DEMAND DEFROST CALIBRALED MODEN IN DEMAND HAS CALIBRATED FIRST NATURAL DEFROST 150 SECONDS FIRST HEAT PUMP CALL COMPRESSOR RUN TIME IN HEAT PUMP HEATING MODE WAS SECOND HEAT PUMP CALL COMPRESSOR RUN TIME IN HEAT PUMP HEATING MODE WAS LESS THAN 70 OF THE FIRST HEATING CALL BEFORE DEMAND LESS THAN 30 MINUTES BEFORE DEMAND DEFROST DEFROST CONTROL REQUESTED A NATURAL DEFROST HEAT PUMP CONTROL REQUESTED A NATURAL DEFROST HEAT GOES INACTIVE GAS HEAT ACTIVE PUMP GOES INACTIVE GAS HEAT ACTIVE MORE THAN 70 OF THE FIRST HEATING CALL BEFORE DEMAND MORE THAN 30 MINUTES BEFORE DEMAND
81. nadian Electrical Code manual to determine wire fuse and disconnect size requirements 2 These the only thermostats approved for ruse with XPG15 Heat Pumps 5 The XPG15 unit will be inactive below 32 F 0 C To prevent heavy snow accumulation in the unit during these inactive periods Lennox recommends the installation of the Snow Guard Top Cover and the Snow Shield Kit 07 09 Page 2 Unit Dimensions Inches mm 2 DISCHARGE AIR 39 1 2 1003 VAPOR LINE T LIQUID LINE INLET SIDE VIEW UNIT SUPPORT FEET 16 7 8 429 8 3 4 222 37 940 024 AND 036 47 1194 048 AND 060 35 1 2 902 4 1 2 114 18 1 2 470 1 25 HIGH VOLTAGE Mia LOW VOLTAGE ELECTRICAL INLET ELECTRICAL INLET ACCESS VIEW 26 7 8 683 i 3 3 4 95 p p 3 1 8 79 30 3 4 781 4 5 8 117 BASE Model Number Identification3 XPG15 036 230 2 Refrigerant Type X R 410A Unit Heat Pump Outdoor Unit G Green Technology Series Minor Revision Number Voltage
82. nd conditions Stabilizers may be used on factory height units when mounted on unstable an uneven surface With unit positioned at installation site perform the following A Remove two side louvered panels to expose the unit base B Install the brackets as illustrated in figure 8 detail D using conventional practices C Replace the panels after installation is complete ROOF MOUNTING Install the unit a minimum of six 6 inches 152 mm above the roof surface to avoid ice build up around the unit Locate the unit above a load bearing wall or area of the roof that can adequately support the unit Consult local codes for rooftop applications If unit coil cannot be mounted away from prevailing winter winds a wind barrier should be constructed Size barrier at least the same height and width as outdoor unit Mount barrier 24 inches 610 mm from the sides of the unit in the direction of prevailing winds PREVAILING WINTER WINDS WIND BARRIER INLET AIR 24 610 NN LARES AUN I III IAI MTIIGIIIIII II t IIIIIIIIIIIUI III INLET AIR Figure 9 Rooftop Application and Wind Barrier Page 13 NOTICE Roof Damage This system contains both refrigerant and oil Some rubber roofing material may absorbed oil and cause the rubber to swell when it comes into contact with oil The rubber will then bubble and could cause leaks Protect the roof surface
83. ntrol is considered e After being in cooling mode The Demand Defrost Control will perform a sacrificial power defrost after thirty 30 minutes of accumulated Page 43 compressor runtime in the first heat pump heating demand with the coil temperature below 35 F 29 This will ensure a clear outdoor coil before an attempts to calibrate the Demand Defrost Control e When the heat pump comes out of inactive mode The Demand Defrost Control will perform a sacrificial power defrost This will ensure a clear outdoor coil before an attempts to calibrate the Demand Defrost Control NOTE If the heat pump is running in a gas furnace heating demand when the heat pump comes out of inactive mode the Demand Defrost Control will cycle the gas furnace OFF and cycle the heat pump ON On this first call for heat pump heating the Demand Defrost Control will initial a sacrificial defrost to ensure a clear outdoor coil before an attempts to calibrate the Demand Defrost Control Calibration of the Demand Defrost Control occurs after a power defrost cycle to ensure that there is no ice on the coil During calibration the temperature of both the coil and ambient sensors are measured to establish a clear coil condition When the controller is in an uncalibrated state the controller should initiate a sacrificial defrost after 30 minutes of accumulated compressor runtime with coil temperature below 35 F The defrost cycle will terminate if the coil
84. ory wired into the Demand Defrost Control on the LO PS and HI PS terminals respectively 07 09 Page 38 Low Pressure Switch LO PS When the low pressure switch trips the Demand Defrost Control will cycle off the compressor and the strike counter in the Demand Defrost Control will count one strike The low pressure switch is ignored under the following conditions e During the defrost cycle and 90 seconds after the termination of defrost For90 seconds following the compressor start up During TEST mode High Pressure Switch HI PS When the high pressure switch trips the Demand Defrost Control will cycle off the compressor and the strike counter in the Demand Defrost Control will count one strike DEMAND DEFROST CONTROL PRESSURE SWITCH EVENT SETTINGS The following pressures are the auto reset event value triggers for low and high pressure thresholds High Pressure auto reset trip at 590 psig reset at 418 Low Pressure auto reset trip at 25 psig reset at 40 FIVE STRIKE LOCKOUT SAFETY FUNCTION The five strike lockout safety function is designed to protect the units compressor from damage Demand Defrost Control looks for 24VAC on its Y1 terminal When the Y1 input detects 24VAC the Demand Defrost Control internal control logic will do the following e Count any HI PS and LO PS pressure switch trips open and close Individual HI PS and LO PS trips are totaled by the Demand Defrost
85. perature is below 50 F 10 C The system should be left in the emergency heat mode at least six hours to allow the crankcase heater sufficient time to prevent compressor slugging 2 FILTER DRIER The unit is equipped with a large capacity biflow filter drier which keeps the system clean and dry If replacement is necessary order another of like design and capacity Defrost System26 The Demand Defrost Control provides a demand defrost algorithm field selectable defrost termination temperatures compressor anti short cycle timing and internal switching of outputs Additionally the software provides a inactive mode that shuts the heat pump off when icing conditions are detected and when second stage heating gas heat is desired The Demand Defrost Control monitors ambient temperature outdoor coil temperature and total run time to determine when a power or natural defrost cycle is required The coil temperature probe has a spring clip to allow mounting to the outside coil tubing The location of the coil sensor is important for proper defrost operation See figure 1 for proper coil sensor location 1 DIAGNOSTIC LIGHT EMITTING DIODES The state Off On Flashing of two light emitting diodes on the Demand Defrost Control DS1 Red and DS2 Green indicate diagnostic conditions that are described in table 10 2 DEMAND DEFROST CONTROL PRESSURE SWITCH CONNECTIONS The unit s pressure switches LO PS S87 and HI PS 54 are fact
86. ress SAVE HEAT PUMP NO BACKUP HEAT DUAL FUEL GAS OIL ELECTRIC 2 For COMPRESSOR STAGES use arrows to select 1 compressor stage then press SAVE COMPRESSOR STAGES 1 3 For INDOOR HEAT STAGES use arrows to select 1 or 2 indoor heat stages then press SAVE INDOOR HEAT STAGES 1 ww 4 OUTDOOR SENSOR Default is NO Balance Points Humiditrol Dew Point Control require an outdoor sensor This control sets the thermostat to test for and report outdoor temperature Scroll to OUTDOOR SENSOR and press ENTER use arrows to select NO press SAVE OUTDOOR SENSOR DEFAULT NO NO If outdoor sensor is used select LOW HIGH balance points to the OFF option as follows LOW BALANCE POINT Default 25 F heat pump only and if outdoor sensor installed If outdoor temperature is below programmed low balance point compressor heating is not allowed The options are OFF or any point from 40 F to the High Balance Point setting in 1 0 F steps LOW BALANCE POINT DEFAULT 25 F OFF HIGH BALANCE POINT Default is 50 F heat pump only and if outdoor sensor installed If outdoor temperature is above the high balance point then auxiliary heat is not allowed The options are OFF or any point from the Low Balance Point up to 75 F in 1 0 F steps HIGH BALANCE POINT DEFAULT 50 F OFF NOTE
87. rmly throughout this procedure Rotate bottom corner of panel away from hinged corner post until lower three tabs clear the slots as illustrated in detail B Position panel with holes aligned install screws and tighten 3 Move panel down until lip of upper tab clears the top slot in corner post as illustrated in detail A Detail A LOUVERED PANEL INSTALLATION Position the panel almost parallel with the unit as illustrated in detail D with the screw side as close to the unit as possible Then in a continuous motion 1 zn LIP Slightly rotate and guide the lip of top tab inward as illustrated in detail A and C then upward into the top slot of the hinge corner post 2 Rotate panel to vertical to fully engage all tabs Holding the panel s hinged side firmly in place close the right hand side of the panel aligning the screw holes PPDY FA a Y When panel is correctly positioned and aligned insert the screws and tighten LDL Detail C CY Y Maintain minimum panel angle as close to parallel with the unit as possible while installing panel LY LVV ee DY Detail B UL A Detail D ma LLLA LLLA CIC
88. rvice port cap protects the service port core from contamination and serves as the primary leak seal 1 Remove service port cap with an appropriately sized wrench 2 Connect gauge set to service port 3 When testing is completed replace service port cap and tighten as follows e With torque wrench Finger tighten and 1 6 TURN torque cap per table 2 1 Without torque wrench Finger tighten and 10 use an appropriately sized wrench to turn 9 an additional 1 6 turn clockwise Reinstall Stem Cap Stem cap protects the valve stem from damage and serves as the primary seal Replace the stem cap and tighten as follows 1 12 TURN e With Torque Wrench Finger tighten and then torque cap per table 2 Without Torque Wrench Finger tight en and use an appropriately sized wrench to turn an additional 1 12 turn clockwise NOTE A label with specific torque requirements may be affixed to the stem cap If the label is present use the specified torque Figure 6 Angle and Ball Type Service Valves XPG15 SERIES Page 9 Recovering Refrigerant from Existing System10 RECOVERING REFRIGERANT FROM SYSTEM DISCONNECT POWER 2 MANIFOLD GAUGE SET 7 all power to the existing outdoor unit at the disconnect Connect a gauge set clean recovery cylinder and a recovery Switch or main fuse box breaker panel machine to the service ports of the existing unit Use the instructions provided with the recovery machine to make the
89. s controlled by the crank case heater thermostat See Unit Parts Arrangement on page 4 for crankcase heater location CRANKCASE HEATER THERMOSTAT S40 Thermostat S40 controls the crankcase heater in all units S40 is located on the liquid line When liquid line temperature drops below 50 F the thermostat S40 closes and energizing HR1 crankcase heater The thermostat will open de energizing HR1 crankcase heater once liquid line temperature reaches 70 F See Unit Parts Arrangement on page 4 for crankcase heater Only use Allen wrenches of sufficient hardness 50Rc Rockwell Harness Scale minimum Fully insert the wrench into the valve stem recess Service valve stems are factory torqued from 9 ft lbs for small valves to 25 ft lbs for large valves to prevent refrigerant loss during shipping and handling Using an Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench or stripping the valve stem recess See the Lennox Service and Application Notes C 08 1 for further details and information thermostat location 8 CONDENSER FAN MOTOR B4 XPG15 units employs two types of fan motors one type is a single phase PSC fan motors used on 2 through 4 ton units A ECM motor is employed on the 5 ton unit The outdoor fan motor is controlled by the Demand Defrost Control K 1 relay 9 BI FLOW LIQUID LINE FILTER DRIER A liquid line bi flow filter drier designed for all XPG15 model units is factory instal
90. tects outdoor ambient and coil temperature fault conditions As the detected temperature change the resistance across the sensors changes Table 11 Sensor Temperature Resistance Range Temperature Resistance values Pins Wire Sensor Range F C range ohms Color Outdoor 35 37 120 280 000 to 3750 3 and 4 Ambient 48 Black Coil 35 37 to 120 280 000 to 3750 5 and 6 48 Brown NOTE Sensor resistance decreases as sensed temperature increases see figure 12 When a sensor indicates a resistance value that is not within the range as listed in table 11 then the following condition may be present Sensor detects an out of range outdoor ambient air temperature condition and is displaying light emitting diode diagnostic code on the Demand Defrost Control e The sensor is operating normally The ambient air temperature at the sensor is below or above the Demand Defrost Control s expected ohm values The Demand Defrost Control will indicate the sensor as faulty However the sensor has not failed Defrost Coil Sensor RT21 This sensor shown in figure 1 detail A considers outdoor temperatures below 35 F 37 C or above 120 F 48 C to be a fault If the defrost coil sensor is open shorted or out of the temperature range of the sensor the Demand Defrost Control will not perform demand or time temperature defrost operation and will display the appropriate fault cod
91. ternal timer regardless of the state of the coil sensor temperature EXCEPTIONS High pressure switch open or locked out or anti short cycle delay is active Natural Defrosts Natural defrosts should terminate after a fixed duration of 150 seconds TERMINOLOGY The following is terminology that is used throughout the remainder of this instruction Power Defrost A defrost cycle during which the compressor operates to melt any accumulated frost from the outdoor coil A power defrost is needed in order to calibrate the Demand Defrost Control During power defrost the following occurs e Reversing valve is energized as in a cooling mode Compressor is energized Outdoor fan is de energized Indoor blower is de energized Natural Defrost A defrost cycle where the compressor does not operate Because the outdoor ambient is above freezing just allowing the unit to sit idle will melt any frost from the outdoor coil During natural defrost the following occurs e Reversing valve is energized as in a cooling mode Compressor is de energized Outdoor fan is de energized Indoor blower is de energized Gas Heat Inactive Mode When the outdoor temperature is above 65 F the gas heat is not allowed to respond to a first stage room thermostat heat call Y1 The furnace is allowed to respond to a second stage thermostat heat call W1 Heat Pump Inactive Mode When the outdoor temperature is below 3
92. tions7 The B1 scroll compressor design is simple efficient and requires few moving parts A cutaway diagram of the scroll compressor is illustrated in figure 3 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 SCROLL FORM Figure 2 Scroll Form DISCHARGE SUCTION Figure 3 Scroll Compressor The scroll is a simple compression concept centered around the unique spiral shape of the scroll and its inherent properties Figure 2 illustrates the basic scroll form Two identical scrolls are mated together forming concentric spiral shapes as illustrated in figure 4 One scroll remains stationary while the other is allowed to ORBIT as illustrated in figure 5 Note that the orbiting scroll does not rotate or turn but merely ORBITS the stationary scroll DISCHARGE DISCHARGE PRESSURE STATIONARY SCROLL 1 N TIPS SEALED BY DISCHARGE PRESSURE N N SN 22 5 KK hehehe NNSASSSSAYTA ILILILILIL SSS Z lt ORBITING sono Figure 4 Cross Section of Scrolls The counterclockwise orbiting scroll draws gas into the outer crescent shaped gas pocket created by the two scrolls as illustrated in figure 5 detail 1 The centrifugal action of the orbiting scroll seals off the flanks of the scrolls as illustrated in figure 5 detail 2 As th
93. ust not contact structure Liquid lines that meter the refrigerant such as RFC1 liquid lines must not be used in this application Existing line set of proper size as listed in table 3 may be reused If system was previously charged with HCFC 22 refrigerant then existing line set must be flushed see Flushing the System on page 20 Field refrigerant piping consists of liquid and vapor lines from the outdoor unit to the indoor unit coil braze connections Use Lennox L15 sweat non flare series line set or field fabricated refrigerant line sizes as listed in table 3 Table 3 Refrigerant Line Set Inches Millimeters Valve Sizes Recommended Line Set Liquid Vapor Liquid Vapor L15 Line Line Line Line Line Sets 115 41 15 50 feet 3 8 10 3 4 19 3 8 10 3 4 19 5 15 meters L15 65 15 50 feet 3 8 10 7 8 22 3 8 10 7 8 22 10 22 10 gt 5 15 meters Field Fabricated 3 8 10 3 8 10 Page 15 NOTE When installing refrigerant lines longer than 50 feet see the Lennox Refrigerant Piping Design and Fabrication Guidelines or contact Lennox Technical Support Product Applications for assistance To obtain the correct information from Lennox be sure to communicate the following information Model and size of unit e g 036 e Line set diameters for the unit being installed as listed in table 3 and total

XPG15 ATTENTION SERVICE TECHNICIAN

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