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Lenovo 835 Personal Computer User Manual

1. SIDE VIEW 1 25 SIDE VIEW UNIT SUPPORT FEET UNIT SUPPORT FEET 8 1 2 9 1 2 216 241 8 3 4 222 5 1 2 13 1 2 140 343 XP16 024 BASE SECTION XP16 BASE WITH LEGS Mode Number A B 16 024 230 35 889 27 686 28 711 16 036 230 39 991 30 1 2 775 35 889 13 7 8 352 7 3 4 197 3 1 4 83 27 1 8 689 3 5 8 92 4 1 2 114 20 5 8 524 39 1 2 16 048 230 35 889 35 1 2 902 1003 16 7 8 429 8 3 4 222 3 1 8 79 30 3 4 781 4 5 8 117 3 3 4 95 26 7 8 683 39 1 2 16 060 230 45 1143 35 1 2 902 1003 2 Typical Unit Parts Arrangement FOR COIL SENSOR RT21 LOCATION SEE DETAIL A DUAL RUN CAPACITOR C12 COMPRESSOR 024 036 AND 048 ONLY SINGLE RUN CAPACITOR C1 060 ONLY DEMAND DEFROST CONTROL A108 DISCHARGE LINE SENSOR RT28 REVERSING VALVE L1 ty SN 2 n zac TRUE SUCTION PORT EXPANSION VALVE SENSING BULB CHECK EXPANSION LIQUID VALVE AND GAUGE PORT LIQUID
2. 40 Checklists 2 2 22 2 2 4 42 Shipping and Packing List Check unit for shipping damage Consult last carrier immediately if damage is found 1 Assembled outdoor unit The XP16 outdoor unit uses HFC 410A refrigerant This unit must be installed with a matching indoor blower coil and line set as outlined in the 16 Lennox Engineering Handbook Elite Series outdoor units are designed for use in check expansion valve CTXV systems only and are not to be used with other refrigerant flow control devices An indoor coil check expansion valve approved for use with HFC 410A must be ordered separately and installed prior to operating the unit 506640 01 Model Number Identification X P16 036 230 05 Refrigerant Type Minor Revision Number R 410A Voltage Unit Type 230 208 230V 1ph 60hz P Heat Pump Nominal Cooling Capacity 024 2 tons Series 036 3 tons 048 4 tons 060 5 tons Unit Dimensions inches mm DISCHARGE AIR 4 ale 1 LIQUID LINE CONNECTION ELECTRICAL INLETS 74 VAPOR LINE Manaus 4 3 4 1 4 108 121
3. Defrosted for 14 minute without the coil temperature going above 35 F 2 C for four 4 minutes and coil did not reach termination temperature DEFROST TERMINATION e Compressor runtime counter RESET e Outdoor Fan ON e Reversing Valve OFF W1 line OFF DEFROST TERMINATION Compressor runtime counter RESET Outdoor Fan ON Reversing Valve OFF W1 line OFF Attempt to Calibration Temperature measurements not taken for the first few minutes of each heat demand This is to allow coil temperatures to stabilize demand defrost control has a maximum of 20 minutes of accumulated compressor runtime in heat mode to calibrate demand defrost control This may involve more than one heating demand Was stable temperature attained NO Demand defrost control YES Calibration occurred 4 1 within 20 minutes gt reverts to 45 minute time temperature Figure 26 Defrost Calibration Page 36 Table 12 Ambient RT13 and Coil 21 Sensors Temperature Resistance Range Resistance Resistance ores Resistance porters Resistance 136 3 2680 56 8 16657 21 6 44154 11 3 1
4. 16 Start Up and Performance Customer Address Indoor Unit Model Serial Outdoor Unit Model Serial Notes START UP CHECKS Refrigerant Type 1st Stage Rated Load Amps Actual Amps Rated Volts Actual Volts 2nd Stage Rated Load Amps Actual Amps Rated Volts Actual Volts Outdoor Unit Fan Full Load Amps Actual Amps 1st Stage 2nd Stage COOLING MODE Suction Pressure 1st Stage 2nd Stage Liquid Pressure 1st Stage 2nd Stage Supply Air Temperature 1st Stage 2nd Stage Temperature Ambient Return Air System Refrigerant Charge Refer to manufacturer s information on unit or installation instructions for required subcooling and approach tempera tures Subcooling SUBCOOLING Saturated Condensing Temperature A minus Liquid Line Temperature B Approach APPROACH Liquid Line Temperature A minus Outdoor Air Temperature B Indoor Coil Temperature Drop 18 to 22 F COIL TEMP DROP Return Air Temperature A minus Supply Air Temperature B Page 43 XP16 SERIES
5. 48 1219 Clearance to one of the remaining two sides may be 12 inches 305mm and the final side be 6 inches 152mm LINE SET 36 914 CONNECTIONS MINIMUM CLEARANCE BETWEEN TWO UNITS UU ERU Figure 4 Installation Clearances Page 6 DETAIL Outside Unit Placement DETAIL Slab Mounting at Ground Level Install unit away from windows Install unit level or if on a slope maintain slope tolerance of two 2 degrees or two inches per five feet 50 mm per 1 5 m away from building structure BUILDING STRUCTURE MOUNTING TWO 90 ELBOWS INSTALLED LINE SET WILL GROUND LEVEL REDUCE LINE SET VIBRATION DETAIL __ Elevated Slab Mounting using Feet Extenders 10 1 2 LONG SELF DRILLING SHEET METAL SCREWS A STABILIZING BRACKET 18 GAUGE METAL 2 WIDTH HEIGHT 5 X REQUIRED 10 1 1 4 LONG HEX HD SCREW AND FLAT WASHER NG Concrete slab use two plastic anchors hole drill 1 4 Wood or plastic slab no plastic anchor hole drill 1 8 5 Stabilizing bracket 18 gauge metal 2 50 8mm width height as required bend to form LEG DETAIL right angle as exampled below FEMALE THREADED DETAI L Roof Mounting ADAPTER If unit coil cannot be mounted away from prevailing winter winds a wind barrier should b
6. 6969 69 999 TST PS DF R 0 ve Note Component locations vary by board manufacturer Figure 25 Demand Defrost Control A108 Page 30 Table 9 Demand Defrost Control A108 Inputs Outputs and Configurable Settings Control Control Label or Locations Description TEST Test Mode See Test Mode on page 39 for further details The demand defrost control as illustrated in figure 25 has valid selections mper Which are 50 70 90 and 100 10 21 32 and 38 C The shunt Pins p termination pin is factory set at 50 F 10 C If the temperature shunt is not installed the default termination temperature is 90 F 32 C we Thermostat Input 24VAC input output from indoor thermostat to indoor unit ea onan pee memes gena cz eene 55 50 45 40 i Ambient Thermostat Provides selection of the 2 compressor lock in temperature Valid Pins options are 40 45 50 and 55 degrees Fahrenheit P4 5 Ground connection for outdoor coil temperature sensor DIS YEL P4 6 Connection for outdoor coil temperature sensor P4 Purpose P4 3 Ground connection for outdoor ambient temperature sensor AMB BLACK Ambient Sensor P4 4 Connection for outdoor ambient temperature sensor COIL BROWN Discharge Sensor No discharge sensor is
7. Page 5 XP16 SERIES CAUTION In order to avoid injury take proper precaution when lift ing heavy objects Remove existing outdoor unit prior to placement of new outdoor unit See Unit Dimensions on page 2 for sizing mounting slab platforms or supports Refer to figure 4 for mandatory installation clearance requirements POSITIONING CONSIDERATIONS Consider the following when positioning the unit e 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 5 detail A PLACING UNIT ON SLAB When installing unit at grade level the top of the slab should be high enough above grade so that water from higher ground will not collect around the unit The slab should have a slope tolerance as described in figure 5 detail B NOTE If necessary for stability anchor unit to slab as described in figure 5 detail D ELEVATING THE UNIT Units are outfitted with elongated support feet as illustrated in figure 5 detail C CLEARANCE ON ALL SIDES INCHES MILLIMETERS ACCESS PANEL rem NOTES If additional elevation is necessary raise the unit by exte
8. Run24VAC control wires through wire tie C Make 24VAC control wire connections D Tighten wire tie to security 24V control wiring NOTE Wire tie provides low voltage wire strain relief and to maintain separation of field installed low and high voltage circuits XS D TIGHTEN WIRE TIE NY Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated See figures 14 and 15 for typical field connections when connecting unit to either a CBX32MV or CBX40UHV in non communicating mode For connections to other Lennox air handlers or furnaces see the ComfortSense 7000 installation instruction for further match component wiring illustrations 4 HIGH VOLTAGE POWER SUPPLY CONNECTIONS GROUND NOTE Any excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring NOTE To facilitate a conduit a cutout is lo cated in the bottom of the control box Connect conduit to the control box using a proper con duit fitting OUTDOOR UNIT CONTROL BOX CONDUIT CUTOUT Page 19 XP16 SERIES CBX32MV z HEAT PUMP UNIT OR ud cua TWO STAGE CBX40UHV PEN R w3 w2 lt ODOOOG D OG lt QOO 1 OUTDOOR UNIT
9. cooling mode and a setpoint of 68 F 20 C This should place the outdoor unit into second stage high capacity cooling mode When operating and temperature pressures have stabilized continue to step 3 Use HEATING MODE when e Outdoor ambient temperature is 59 F 15 0 C and below e Indoor return air temperature range is between 65 75 F 18 24 This temperature range is what the target subcooling values are base upon in tables 3 through 6 If indoor return air temperature is not within reference range set thermostat to heating mode and a setpoint of 77 F 25 C This should place the outdoor unit into second stage high capacity heating mode When operating and temperature pressures have stabilized continue to step 3 Read the liquid line pressure then find its corresponding temperature pressure listed in table 8 and record it in the SAT space to the left Read the liquid line temperature record in the LIQ space to the left Subtract LIQ temperature from SAT temperature to determine subcooling record itin SC space to the left Compare SC results with tables 3 through 6 either Heating or Cooling mode column also consider any additional charge required for line set lengths longer than 15 feet and or unit matched component combinations Add Charge column If subcooling value is A GREATER than shown for the applicable unit match component REMOVE refrigerant B LESS than shown for the appl
10. 0 CX34 50 60C 29 2 11 CX34 62C 21 9 2 16 CX34 62D 13 7 1 4 Amount of charge required in additional to charge shown on unit nameplate Remember to consider line set length difference Page 28 NORMAL OPERATING PRESSURES Use the following tables to perform maintenance checks it is not a procedure for charging the system Minor variations in these pressures may be due to differences in TEMPERATURE PRESSURES subcooling installations Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system Compute by determining condensing temperature from temperature pressure chart Subtract from liquid temperature entering TXV saturated Table 8 HFC 410A Temperature F Pressure Psig F Psi F Psi F Psi F Psi Typical pressures only expressed in psig liquid 10 9 9 9 9 and vapor 5 psig matched indoor component air 32 4008 1785 2908 125 4459 handler or coil indoor air quality and indoor load will cause the pressures to vary 33 102 9 64 181 6 95 295 1 126 451 8 Table 7 Normal Operating Pressures 34 1050 65 1843 96 2994 127 457 6 Normal Operating Pressures Cool
11. 30 minutes of run time Page 35 XP16 SERIES DEFROST CONTROL A108 CALIBRATION MODE SEQUENCE Occurs after power up and cooling operation or if the coil temperature exceeds the termination temperature while in Heat Mode t Demand defrost control defaults to 30 minute Time Temperature Mode Reset Compressor Runtime Reset Three Five Strike Counter Y DEMAND Accumulate compressor runtime of more than 30 minutes while coil temperature is below 35 F 2 C When the accumulated compressor time exceeds six 6 hours or if the coil sensor indicates frost is present THIRTY 30 MINUTE TIME TEMPERATURE MODE Accumulate compressor runtime while coil temperature is below 35 F 2 C When the accumulated compressor time exceeds 30 minutes go to Defrost on coil go to Defrost 45 MINUTE MODE minutes to Defrost Accumulate compressor runtime while coil temperature is below 35 F 2 C When the accumulated compressor time exceeds 45 gt lt DEFROST Outdoor Fan OFF Reversing Valve ON e Wlline ON Monitor coil temperature and time in defrost mode Y HOW DID DEFROST TERMINATE Y Y Coil temperature was above 35 F 2 for four 4 minutes of the 14 minute defrost OR reached defrost termination temperature
12. BROW COIL TEMP SENSOR BLACK SENSOR YELLON DISCHARGE CRANKCASE 4 CRANKCASE 4 sensor HEATER THERMOSTAT Figure 18 Typical Factory Wiring Diagram No Field Modifications Unit Start Up have consulted with the power company and the voltage condition has been corrected 6 Open both the liquid and vapor line service valves to A IMPORTANT release the refrigerant charge contained in outdoor unit into the system If unit is equipped with a crankcase heater it should be 7 energized 24 hours before unit start up to prevent compressor damage as a result of slugging Use figure 19 to determine next step in system preparation OPEN BOTH VAPOR AND LIQUID SERVICE VALVE STEMS TO RELEASE UNIT START UP REFRIGERANT FROM OUTDOOR UNIT TO 1 Rotate fan to check for binding SYSTEM 2 Inspect all factory and field installed wiring for loose connections 3 Verify that the manifold gauge set is connected as illustrated in figure 21 Use a temperature sensor positioned near the liquid line service port as illustrated in figure 21 which will be required later when using the subcooling method for optimizing the system refrigerant charge GO TO SERVICE AND WEIGH 4 Replace the stem caps and tighten to the value listed AM CHARGE ORAN in table 1 DELIVERED VOID OF CHARGE PAGE 26 5 Check voltage supply at the disconnect switch The voltage must be within the range listed on the u
13. Device This outdoor unit is designed for use in HFC 410A systems that use a check expansion valve metering device purchased separately at the indoor coil See the Lennox XP16 Engineering Handbook for approved check expansion valve kit match ups The check expansion valve device can be installed either internal or external to the indoor coil In applications where an uncased coil is being installed in a field provided plenum install the check expansion valve in a manner that will provide access for field servicing of the check expansion valve see figure 11 INDOOR EXPANSION VALVE INSTALLATION Remove the field provided fitting that temporarily 1 2 Turn TWO PIECE reconnected the liquid line to the indoor unit s distributor PATCH PLATE Uncased Coil Shown assembly UNCASED Install one of the provided Teflon rings around the STUB COIL ONLY END CHECK stubbed end of the check expansion valve and lightly HOUSING EXPANSION lubricate the connector threads and expose surface of DISTRIBUTOR re VALVE the Teflon ring with refrigerant oil TUBES __ Attach the stubbed end of the expansion valve to the liquid line orifice housing Finger tighten and use an appropriately sized wrench to turn an additional 1 2 turn gt Ga clockwise as illustrated in the figure above or 20 ft lb TEFLON 7 D Place the remaining Teflon washer around the other RING MES end of the check expansion valve Lightly lubricate Es
14. EITHER THE 4 OR 8 O CLOCK SEAL BONNET POSITION NEVER MOUNT ON gt BOTTOM OF LINE MALE BRASS EQUALIZER LINE FITTING VAPOR LINE NOTE NEVER MOUNT ON BOTTOM OF LINE Figure 11 Installing Indoor Check Expansion Valve Page 15 XP16 SERIES 4 IMPORTANT Leak detector must be capable of sensing HFC refrigerant CONNECT GAUGE SET Connect an HFC 410A manifold gauge set high pressure hose to the vapor valve service port NOTE Normally the high pressure hose is connected to the liquid line port However connecting it to the vapor port better protects the manifold gauge set from high pressure damage B With both manifold valves closed connect the cylinder of HFC 410A refrigerantto the center port of the manifold gauge set NOTE Later in the procedure the HFC 410A container will be replaced by the nitrogen container NITROGEN HFC 410A LOW HIGH MANIFOLD GAUGE SET OUTDOOR UNIT t TO VAPOR SERVICE VALVE oj rl Figure 12 Manifold Gauge Set Connections for Leak Testing TEST FOR LEAKS After the line set has been connected to the indoor and outdoor units check the line set connections and indoor unit for leaks Use the following procedure to test for leaks 1 With both manifold valves closed connect the cylinder of HFC 410A refrigerant to the center port of the manifold gauge set
15. OR HARMONY NOILdO LND OUTDOOR SENSOR X2658 AIR HANDLER CONTROL Y1 Y2 2 STAGE COMPR R O HEAT PUMP R DS DEHUM OR HARMONY NOILdO 1015 Figure 15 Heat Pump Application Humiditrol and Second Stage Outdoor Fan Relay Wiring with CBX32MV or CBX40UHV Page 20 C7 START CAPACITOR OPTIONAL POTENTIAL RELAY OPTIONAL 108 DEFROST CONTROL OUTDOOR FAN C12 DUAL CAPACITOR I E a 12 DUAL 1 1 COMPRESSOR CAPACITOR CONTACTOR CRANKCASE THERMOSTAT O HR1 CRANKCASE HEATER COMPRESSOR COIL COMPRESSOR EQUIPMENT GROUND COMPRESSOR CONTACTOR GROUND IS LUG COMPRESSOR CONTACTOR RT21 DEFROST COIL SENSOR PRESSURE SWITCH 587 LOW PRESSURE RT13 AMBIENT DISCHARGE SENSOR SENSOR RT28 en A COMPRESSOR 1 REVERSING VALVE H Y RENE a a CBX32MV TB1 CBX40UHV A 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 WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES CUT ON BOARD LINK FROM Y1 TO Y2 FOR 2 STAGE COMPRESSOR RT14 SENSOR OUTDOOR T
16. SIZE IS SMALLER NOT CRIMP SERVICE VALVE CONNECTOR WHEN PIPE IS BMALLER THAN CONNECTION REFRIGERANT LINE 3 ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION VAPOR LINE SERVICE VALVES Flow regulated nitrogen at 1 to 2 psig through the low side refrigeration gauge set into the liquid line service port valve and out of the suction vapor line service port valve Connect gauge set low pressure side to liquid line service valve service port USE REGULATOR TO FLOW Connect gauge set center port to bottle of PONE N HIGH NITROGEN ANTTO 2PSIG nitrogen with regulator Remove core from valve in suction vapor line service port to allow nitrogen to escape ATTACH GAUGES SUCTION VAPOR SERVICE PORT MUST BE OPEN TO ALLOW EXIT POINT FOR NITROGEN SUCTION VAPOR LINE SERVICE VALVE VAPOR LINE V INDOOR OUTDOOR UNIT 5 UNIT c3 LIQUID LINE LIQUID LINE SERVICE WHEN BRAZING LINE SET VALVE SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE NITROGEN Figure 8 Brazing Procedures 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 Page 12 WRAP SERVICE VALVES To help protect service valve seals durin
17. air handler for low voltage control power 24VAC 40 VA minimum INSTALL THERMOSTAT Install room thermostat ordered separately on an inside wall approximately in the center of the conditioned area and 5 feet 1 5m from the floor It should not be installed on an outside wall or where it can be affected by sunlight or drafts THERMOSTAT NOTE 24VAC Class II circuit connections are made in the control panel A WARNING Electric Shock Hazard Can cause injury or death Unit must be grounded in accordance with national and local codes Line voltage is present at all components when unit is not in operation on units with single pole contactors Disconnect all remote electric power supplies before opening access panel Unit may have multiple power supplies Page 18 3 LOW VOLTAGE CONNECTIONS CUTOUT WITH 4 GROMMET 24V CONTROL WIRES B S S a HIGH VOLTAGE FIELD WIRING LOW VOLTAGE 24V FIELD WIRING WIRE RUN LENGTH AWG INSULATION LESS THAN 100 30 METERS 18 TEMPERATURE RATING MORE THAN 100 30 METERS 16 35 C MINIMUM NOTE For proper voltages select thermostat wire control wires gauge per table above NOTE Do not bundle any excess 24VAC control wires inside control box A Run 24VAC control wires through cutout with grommet
18. connector threads and expose surface of the Teflon FS 4 ring with refrigerant oil DISTRIBUTOR EQUALIZER Attach the liquid line assembly to the check expansion ASSEMBLY LINE valve Finger tighten and use an appropriately sized wrench to turn an additional 1 2 turn clockwise as illustrated in the figure above or 20 ft Ib LIQUID LINE ASSEMBLY WITH BRASS NUT SENSING BULB INSTALLATION A Attach the vapor line sensing bulb in the proper orientation as illustrated to the right using the clamp and Screws provided 1 8 Turn FITTING SEE EQUALIZER LINE INSTALLATION FOR FURTHER DETAILS LIQUID LINE MALE EQUALIZER LINE N NOTE Confirm proper thermal contact between vapor line and expansion bulb before insulating the sensing bulb once installed B Connect the equalizer line from the check expansion valve to the equalizer vapor port on the vapor line Finger tighten the flare nut plus 1 8 turn 7 ft Ibs as illustrated below Sensing bulb insulation is required if mounted external to the coil casing ON LINES SMALLER THAN EQUALIZER LINE INSTALLATION VAPORLINE 7 8 MOUNT SENSING BULB AT EITHER THE 3 OR Remove and discard either the flare seal cap or flare nut with 9 O CLOCK POSITION copper flare seal bonnet from the equalizer line port on the vapor is WA line as illustrated in the figure to the right FLARE SEAL CAP FLARE NUT ON 7 8 AND LARGER LINES MOUNT SENSING BULB AT OR COPPER FLARE
19. illustrated in detail D with the screw side as close to the unit as possible Then in a continuous motion Slightly rotate and guide the lip of top tab inward as illustrated in detail A and C then upward into the top slot of the hinge corner post Rotate panel to vertical to fully engage all tabs Holding the panel s hinged side firmly in place close the right hand side of the panel aligning the screw holes When panel is correctly positioned and aligned insert the screws and tighten Detail C MAINTAIN MINIMUM PANEL ANGLE AS CLOSE TO PARALLEL WITH THE UNIT AS POSSIBLE WHILE INSTALLING PANEL IMPORTANT DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB TAB IS FOR ALIGNMENT AND NOT DESIGNED TO SUPPORT WEIGHT OF PANEL PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT OR ENTER TOP SLOT FOR REMOVING OR INSTALLING PANEL SCREW HOLES Detail A Hd 1 Detail B M ROTATE IN THIS DIRECTION P THEN DOWN TO REMOVE PANEL HOLD DOOR FIRMLY TO THE HINGED ANGLE MAY BE TOO SIDE TO MAINTAIN EXTREME FULLY ENGAGED TABS I PREFERRED ANGLE FOR INSTALLATION Detail D Figure 6 Removing and Installing Panels 4 WARNING To prevent personal injury or damage to panels unit or structure be sure to obser
20. metal screws 16 in Ib 2NM Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench or stripping the valve stem tae 220 recess Compressor bolts 90 in Ib 10 NM See the Lennox Service and Application Notes Gauge port seal cap 8 ft Ib 11 NM Corp 0807 L5 details and information C 08 1 for further Page 3 XP16 SERIES Operating Gauge Set and Service Valves A IMPORTANT To prevent stripping of the various caps used the appropriately sized wrench should be used and fitted snugly over the cap before tightening OPERATING SERVICE VALVES The liquid and vapor line service valves are used for refrigerant recovery flushing leak testing evacuating weighing in refrigerant and optimizing system charge Each valve is equipped with a service port which has a factory installed valve core Figure 2 provides information on how to access and operate both angle and ball type service valves USING MANIFOLD GAUGE SET When checking the system charge only use a manifold gauge set that features low loss anti blow back fittings Manifold gauge set used for HFC 410A refrigerant systems must be capable of handling the higher system operating pressures The manifold gauges should be rated for High side Pressure range of 0 800 pound force per square inch gauge psig Low side Use with 30 vacuum to 250 psig with dampened speed to 500 psig Manifold g
21. unit shutdown but it should also be used following a power outage if power has been off for over an hour and the outdoor temperature is below 50 F 10 C System should be left in the emergency heat mode at least six hours to allow the crankcase heater sufficient time to prevent compressor slugging DEFROST SYSTEM OVERVIEW The control monitors ambient temperature outdoor coil temperature and total run time to determine when a defrost cycle is required The coil temperature probe is designed with a spring clip to allow mounting to the outside coil tubing The location of the coil sensor is important for proper defrost operation NOTE The demand defrost control accurately measures the performance of the system as frost accumulates on the outdoor coil This typically will translate into longer running time between defrost cycles as more frost accumulates on the outdoor coil before the demand defrost control initiates defrost cycles DEFROST CONTROL CONNECTIONS JUMPERS SETTINGS AND FEATURES Pressure Switch 5 Strike Lockout The internal control logic of the demand defrost control counts the pressure switch trips only while the Y1 Input line is active If a pressure switch opens and closes four times during a Y1 Input the control logic will reset the pressure switch trip counter to zero at the end of the Y1 Input If the pressure switch opens for a fifth time during the current Y1 Input the control will enter a lockout cond
22. until termination on time or temperature Figure 27 Test Pin P1 Functions Page 39 XP16 SERIES Two Stage Modulation Compressors Checks Use this checklist on page 42 to verify part load and full load capacity operation of two stage modulation compressors TOOLS REQUIRED e Refrigeration gauge set e Digital volt amp meter e Electronic temperature thermometer On off toggle switch A IMPORTANT This performance check is ONLY valid on systems that have clean indoor and outdoor coils proper airflow over coils and correct system refrigerant charge All components in the system must be functioning proper to correctly perform compressor modulation operational check Accurate measurements are critical to this test as indoor system loading and outdoor ambient can affect variations between low and high capacity readings PROCEDURE NOTE Block outdoor coil to maintain a minimum of 375 psig during testing 1 Turn main power OFF to outdoor unit 2 Adjust room thermostat set point 5 F above the room temperature 3 Remove control access panel Install refrigeration gauges on unit Attach the amp meter to the common black wire wire of the compressor harness Attach thermometer to discharge line as close as possible to the compressor 4 Turn toggle switch OFF and install switch in series with Y2 wire from room thermostat 5 Cycle main power ON 6 Allow pressures and temperatures to stabiliz
23. 04 6 767 148 7 2098 106 4 5054 55 3 17301 203 3 785 147 9 2131 105 6 5141 54 0 17891 201 9 803 147 1 2165 104 8 5231 52 7 18516 200 6 821 146 2 2200 104 0 5323 51 4 19180 199 3 839 145 4 2235 103 3 5416 50 0 19887 198 0 857 144 6 2270 102 5 5512 48 6 20641 196 8 876 143 8 2306 101 7 5610 47 2 21448 195 5 894 143 0 2343 100 9 5711 45 7 22311 194 3 913 142 3 2380 100 1 5814 193 1 932 141 5 2418 99 3 5920 191 9 952 140 7 2456 98 5 6028 190 7 971 139 9 2495 97 7 6139 189 5 991 139 1 2534 96 9 6253 188 4 1011 138 3 2574 96 1 6370 187 2 1031 137 6 2615 95 3 6489 Page 38 TEST Placing the jumper on the field test pins P1 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 is energized and 24V power is being applied to the Control a test cycle can be initiated by placing a jumper the Control s TEST pins for 2 to 5 seconds If the jumper remains on the TEST pins for longer than five seconds the Control will ignore the jumpered TEST pins and revert to normal operation The Control will initiate one test event each time a jumper is placed on the TEST pins For each TEST the jumper must be removed for at least one second and then reapplied Y1 Active Place a jumper on TEST pins for longer than one second but less than two seconds Clears a
24. 1 1 8 29 mm 3 8 10 mm 1 1 8 29 mm Field Fabricated NOTE Some applications may required a field provided 7 8 to 1 1 8 adapter Page 9 XP16 SERIES 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 AUTOMOTIVE MUFFLER TYPE HANGER MUFFLER TYPE HANGER 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 WIRE TIE AROUND VAPOR LINE ONLY 8 FEET 2 43 METERS Nov STRAPPING MATERIAL AROUND VAPOR LINE ONLY m ME ROOF RAFTER SS TAPE OR j WIRE TIE NON CORROSIVE METAL SLEEVE TAPE OR STRAP THE VAPOR LINE TO THE JOIST WIRE TIE OR RAFTER AT 8 FEET 2 43 METERS INTERVALS THEN STRAP THE LIQUID LINE TO THE VAPOR LINE FLOOR JOIST OR ROOF RAFTER REFRIGERANT LINE SET INSTALLING VERTICAL RUNS NEW CONSTRUCTION SHOWN NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig OUTSIDE WALL VAPOR LINE LIQUID LINE STRAP WOOD BLOCK NON CORROSIVE
25. 10 8 1 4 eee ee MUR nad Grate CBX27UH 048 230 19 9 1 4 and Coils 5 F 1 F CBX27UH 060 230 13 14 3 3 Subcooling Ib oz CBX32M 048 19 9 1 4 CBX26UH 024 45 6 15 CBX32M 060 14 9 1 11 CBX27UH 024 230 20 7 9 CBX32MV 048 19 9 1 4 CBX27UH 030 230 17 7 1 3 CBX32MV 060 14 9 1 11 CBX32MV 024 030 20 7 0 9 CBX32MV 068 9 8 1 11 CBX32MV 036 17 7 1 3 CBX40UHV 048 19 9 1 4 CBX40UHV 024 17 7 1 3 CBX40UHV 060 14 9 1 11 CBX40UHV 030 17 7 1 3 CH23 68 24 10 1 12 CBX40UHV 036 17 7 1 3 CH33 49C 19 9 2 CH33 31B 31 8 1 12 CH33 50 60C 19 9 2 CR33 30 36A B C 45 4 0 0 CH33 60D 13 8 0 CX34 31A B 24 7 1 11 CH33 62D 1 9 1 CX34 38A B 18 8 1 10 CR33 50 60C 15 7 0 10 Table 4 16 036 230 CR33 60D 15 7 0 10 indoor AIr Handers pe Mode Add Charge 3 and Coils 5 F 1 CX34 62D 9 9 1 Subcooling Ibs oz CX34 62C 8 9 1 CBX26UH 036 50 0 0 Table 6 16 060 230 CBX27UH 036 230 22 0 9 Heating Cooling CBX27UH 042 230 24 11 3 0 Indoor Air Handers ME E Add Charge CBX32M 036 22 0 9 and Solis Subcooling Ibs oz CBX32MV 036 22 8 CBX26UH 060 20 9 4 13 CBX32MV 048 as 1 9 CBX27UH 060 230 10 6 2 3 CBX40UHV 030 22 0 9 CBXA2MJ60 17 6 1 12 CBX40UHV 036 0 E CBX32MV 060 17 6 1 12 CBX40UHV 042 24 11 3 0 GBXS2MV OGB 15 7 2 1 CBX40UHV 048 24 11 3 0 CBXAOUEN OGO 17 6 1 12 CH33 43B 13 10 2 7 CH23 682 37 9 2 10 CH33 48C 37 2 11 CH33 50 60C 33 8 1 0 CH33 43C 37 11 2 11 CH33 62D 15 7 1 4 CR33 48B C 49 0 2 CR33 50 60C 24 7 0 0 CX34 43B C 29 2 11 CR33 60D 24 7 0
26. 23152 133 1 2859 56 0 16973 21 0 44851 11 9 125787 130 1 3040 55 3 17293 20 5 45560 12 6 128508 127 3 3223 54 6 17616 20 0 46281 13 2 131320 124 7 3407 53 9 17942 19 4 47014 13 9 134227 122 1 3592 53 2 18273 18 9 47759 14 5 137234 119 7 3779 52 5 18607 18 4 48517 15 2 140347 117 5 3968 51 9 18945 17 8 49289 15 9 143571 115 3 4159 51 2 19287 17 3 50074 16 5 146913 113 2 4351 50 5 19633 16 8 50873 17 2 150378 111 2 4544 49 9 19982 16 3 51686 17 9 153974 109 3 4740 49 2 20336 15 7 52514 18 6 157708 107 4 4937 48 5 20695 15 2 53356 19 3 161588 105 6 5136 47 9 21057 14 7 54215 20 1 165624 103 9 5336 47 3 21424 14 1 55089 20 8 169824 102 3 5539 46 6 21795 13 6 55979 21 5 174200 100 6 5743 46 0 22171 13 1 56887 22 3 178762 99 1 5949 45 4 22551 12 5 57811 23 0 183522 97 6 6157 44 7 22936 12 0 58754 23 8 188493 96 1 6367 44 1 23326 11 5 59715 24 6 193691 94 7 6578 43 5 23720 11 0 60694 25 4 199130 93 3 6792 42 9 24120 10 4 61693 26 2 204829 92 0 7007 42 3 24525 9 9 62712 27 0 210805 90 6 7225 41 7 24934 9 3 63752 27 8 217080 89 4 7444 41 1 25349 8 8 64812 28 7 223677 88 1 7666 40 5 25769 8 3 65895 29 5 230621 86 9 7890 39 9 26195 7 7 67000 30 4 237941 85 7 8115 39 3 26626 72 68128 31 3 245667 84 5 8343 38 7 27063 67 69281 322 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 2933
27. 5 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 17 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 Page 37 XP16 SERIES Table 13 High Discharge Sensor 28 Temperature Resistance Range EEE eee meme xem remm Emm remm 303 1 183 186 1 1052 136 8 2656 94 5 6613 298 1 195 185 0 1072 136 0 2698 93 6 6739 293 4 207 183 9 1093 135 2 2740 92 8 6869 289 0 220 182 8 1114 134 5 2783 92 0 7002 284 8 232 181 8 1135 133 7 2827 91 2 7139 280 9 245 180 7 1157 132
28. 9 2872 90 3 7281 277 1 258 179 6 1179 132 2 2917 89 5 7426 273 6 270 178 6 1201 131 4 2963 88 6 7575 270 2 283 177 6 1223 130 6 3010 87 8 7729 267 0 297 176 6 1245 129 9 3057 86 9 7888 263 9 310 175 5 1268 129 1 3105 86 0 8051 260 9 323 174 6 1291 128 4 3154 85 2 8220 258 1 336 173 6 1315 127 6 3204 84 3 8394 255 3 350 172 6 1338 126 8 3255 83 4 8574 252 7 364 171 6 1362 126 1 3307 82 5 8759 250 1 378 170 6 1386 125 3 3359 81 6 8951 247 7 391 169 7 1411 124 6 3413 80 7 9149 245 3 405 168 7 1435 123 8 3467 79 8 9354 243 0 420 167 8 1460 123 1 3523 78 8 9566 240 8 434 166 9 1486 122 3 3579 77 9 9786 238 6 448 165 9 1511 121 6 3637 76 9 10013 236 5 463 165 0 1537 120 8 3695 76 0 10250 234 4 478 164 1 1563 120 1 3755 75 0 10495 232 4 492 163 2 1590 119 3 3816 74 1 10749 230 5 507 162 3 1617 118 5 3877 73 1 11014 228 6 523 161 4 1644 117 8 3940 72 1 11289 226 7 538 160 5 1672 117 0 4005 71 1 11575 224 9 553 1597 1699 116 3 4070 70 0 11873 223 2 569 158 8 1728 115 5 4137 69 0 12184 221 5 584 157 9 1756 114 8 4205 68 0 12509 219 8 600 157 1 1785 114 0 4274 66 9 12848 218 1 616 156 2 1815 113 2 4345 65 8 13202 216 5 632 155 3 1845 112 5 4418 64 7 13573 214 9 649 154 5 1875 111 7 4491 63 6 13961 213 4 665 153 6 1905 111 0 4567 62 5 14368 211 9 682 152 8 1936 110 2 4644 61 3 14796 210 4 698 152 0 1968 109 4 4722 60 2 15246 208 9 715 151 1 1999 108 7 4802 59 0 15719 207 5 732 150 3 2032 107 9 4884 57 8 16218 206 0 750 149 5 2064 107 1 4968 56 6 16744 2
29. BETWEEN STUDS METAL SLEEVE WIRE TIE WOOD BLOCK WIRE TIE STRAP VAPOR LINE WRAPPED WITH ARMAFLEX OUTSIDE WALL LIQUID LINE PVC ia pipe CAULK FIBERGLASS INSULATION NOTE Similar installation practices should be used if line set is to be installed on exterior of outside wall Figure 7 Line Set Installation Page 10 Brazing Connections Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves 4 WARNING A IMPORTANT Polyol Ester POE oils used with HFC 410A Allow braze joint to cool before removing the wet rag refrigerant absorb moisture very quickly It is very from the service valve Temperatures above 250 F can important that the refrigerant system be kept closed damage valve seals as much as possible DO NOT remove line set caps or service valve stub caps until you are ready to make connections A IM PORTANT AWARNING Danger of fire Bleeding the refrigerant charge from only the high side may result bi in pressurization of the low side shell and d 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 suction tubing Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture Check the high and low pressures before appl
30. EMP OPTIONAL L34 SOLENOID IS LOCATED IN COMPRESSOR COIL IS 24VDC DO NOT CONNECT 24VAC TO COIL TERMINALS 511 AND 58 ARE OPTIONAL LOW AMBIENT CONTROLS CUT ON BOARD LINK FROM R TO O FOR HEAT PUMP APPLICATIONS CUT ON BOEARD LINK FROM R TO DS FOR DEHUMIDIFICATION A A A COMFORTSENSE 7000 2081 IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING E DENOTES OPTIONAL COMPONENTS Figure 16 Typical Unit Wiring Diagram 024 036 and 048 Only Page 21 XP16 SERIES ATUS RT21 RT13 RT28 NOTE GROUND O 005 DEFROST AMBIENT DISCHARGE A FOR USE WITH COPPER CONDUCTORS CONTROL S SENSOR SENSOR ONLY REFER TO UNIT RATING PLATE SENSOR FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL ARRANGEMENT 54 B A WARNING HIGH ELECTRIC SHOCK HAZARD CAN CAUSE INJURY PRESSURE COMPRESSOR OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE SWITCH WITH NATIONAL AND LOCAL CODES A CUT ON BOARD LINK FROM Y1 TO Y2 FOR 2 STAGE COMPRESSOR AND TWO SPEED O RT14 SENSOR OUTDOOR TEMP OPTIONAL L1 587 LOW REVERSING L34 SOLENOID IS LOCATED IN COMPRESSOR OUTDOOR K1 PRESSURE VALVE COIL 15 24VDC DO NOT CONNECT 24 COMPRESSOR TO COIL TERMINALS CONTACTOR O
31. INDICATE DIRECTION OF REFRIGERANT FLOW REVERSING VALVE CHECK EXPANSION VALVE OUTDOOR COIL BI FLOW FILTER DRIER 3 9 INDOOR UNIT MUFFLER TRUE SUCTION LIQUID LINE SERVICE PORT COMPRESSOR CHECK EXPANSION VALVE INDOOR COIL NOTE Use gauge ports on vapor line valve and liquid valve for evacuating refrigerant lines and indoor coil Use true suction port to measure vapor pressure during charging Figure 22 Heat Pump Cooling Cycle Page 25 XP16 SERIES Optimizing System Refrigerant Charge This section provides instructions on optimizing the system charge This section includes e Optimizing procedure e Adjusting indoor airflow e Using subcooling method Approved matched components targeted subcooling SC values and add charge values e Normal operating pressures e Temperature pressures OPTIMIZING PROCEDURE 1 Move the low side manifold gauge hose from the vapor line service valve to the true suction port see figure 21 2 Set the thermostat for either cooling or heating demand Turn on power to the indoor unit and close the outdoor unit disconnect switch to start the unit 3 Allow unit to run for five minutes to allow pressures to stabilize 4 Check the airflow as instructed under Adjusting Indoor Airflow to verify or adjust indoor airflow for maximum efficiency Make any air flow adjustments before continuing with the optimizing procedure 5 Us
32. ION INSTRUCTIONS Elite Series XP16 Units HEAT PUMPS Technical 506640 01 Publications 12 10 Litho U S A Supersedes 11 10 TABLE OF CONTENTS Shipping and Packing List 1 General 1 Model Number Identification 2 Unit 2 Typical Parts 3 Caps and Fasteners Torque Requirements 3 Operating Gauge Set and Service Valves 3 Recovering Refrigerant from Existing System 5 New Outdoor Unit Placement 6 Removing and Installing Panels 8 Line Set Requirements 9 Brazing Connections 11 Indoor Refrigerant Metering Device Removal and Flushing Line Set and Indoor 14 Installing New Indoor Metering Device 15 Leak Test Line Set and Indoor 16 Evacuating Line Set and Indoor Coil 17 Electrical Connections 18 Unit 23 Servicing and Weighing In Refrigerant for Units Delivered Void of Charge 24 Optimizing System Refrigerant Charge 26 System Operation 30 Defrost System 34 Two Stage Modulation Compressors Checks 40
33. IZER Using two wrenches disconnect liquid line from liquid line orifice hous CINE FITTING ing Take care not to twist or damage distributor tubes during this pro SENSING BULB cess Remove and discard fixed orifice valve stem assembly if presentand A fully cased coils remove the coil access and plumbing panels Teflon washer as illustrated above B Remove any shipping clamps holding the liquid line and distributor Use a field provided fitting to temporary reconnect the liquid line to the assembly indoor unit s liquid line orifice housing C Disconnect the equalizer line from the check expansion valve equalizer line fitting on the vapor line CONNECT GAUGES AND EQUIPMENT FOR Remove the vapor line sensing bulb FLUSHING PROCEDURE Disconnect the liquid line from the check expansion valve at the liquid line assembly INVERTED HCFC 22 GAUGE CYLINDER CONTAINS MANIFOLD Disconnect the check expansion valve from the liquid line orifice CLEAN HCFC 22 TO BE housing Take care not to twist or damage distributor tubes during this A USED FOR FLUSHING process Remove and discard check expansion valve and the two Teflon rings Use a field provided fitting to temporary reconnect the liquid line to the VAPOR LINE indoor unit s liquid line orifice housing SERVICE VALVE OUTDOOR ae FLUSHING LINE SET CLOSED EXISTING The line set and indoor unit coil must be flushed with at least the INDOOR same amoun
34. LAY pins NOTE The 30 second off cycle is NOT functional when jumpering the TEST pins OPERATIONAL MODE OVERVIEW The demand defrost control has three basic operational modes Those modes are 1 Calibration Mode The demand defrost control is considered uncalibrated when power is applied to the demand defrost control after cool mode operation or if the coil temperature exceeds the termination temperature when it is in heat mode see figure 26 for further details 2 Normal Mode The demand defrost control monitors the O line to determine the system operating mode heat cool outdoor ambient temperature coil temperature outdoor coil and compressor run time to determine when a defrost cycle is required Calibration of the demand defrost control occurs after a defrost cycle to ensure that there is no ice on the coil During calibration the temperature of both the coil and the ambient sensor are measured to establish the temperature differential which is required to allow a defrost cycle 3 Defrost Mode The following paragraphs provide a detailed description of the defrost system operation DEFROST CYCLE ACTUATION The demand defrost control initiates a defrost cycle based on either frost detection or time 1 Frost Detection If the compressor runs longer than 30 minutes and the actual difference between the clear coil and frosted coil temperatures exceeds the maximum difference allowed by the demand defrost c
35. LENNOX gt 20 Lennox Industries Inc Dallas Texas USA These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE NOTICE TO INSTALLER BRAZING LINE SET TO SERVICE VALVES It is imperative to follow the brazing technique illustrated starting on page 11 to avoid damaging the service valve s internal seals 4 WARNING Improper installation adjustment alteration service or maintenance can cause personal injury loss of life or damage to property Installation and service must be performed by a licensed professional installer or equivalent or a service agency A IMPORTANT The Clean Air Act of 1990 bans the intentional venting of refrigerant CFCs HFCs and HCFCs as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration may be levied for noncompliance A IMPORTANT This unit must be matched with an indoor coil as specified in Lennox XP16 Engineering Handbook Coils previously charged with HCFC 22 must be flushed A CAUTION Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury Be aware of and use caution when working near these areas during installation or while servicing this equipment 12 10 Page 1 INSTALLAT
36. LINE CONNECTIONS LIQUID LINE BI FLOW FILTER DRIER LOW PRESSURE SWITCH 587 GROUND LUG SINGLE POLE CONTACTOR K1 AMBIENT TEMPERATURE SENSOR RT13 VAPOR VALVE AND GAUGE PORT SUCTION LINE CONNECTIONS DETAIL A eA XP16 048 COIL SENSOR EIGHT HAIRPIN UP FROM THE BOTTOM ON INSIDE ROW XP16 036 COIL SENSOR NINTH HAIRPIN UP FROM THE BOTTOM ON INSIDE XP16 060 COIL SENSOR SIXTH HAIRPIN UP FROM THE BOTTOM ON INSIDE ROW XP16 024 COIL SENSOR THIRD HAIRPIN DOWN FROM THE TOP ON INSIDE ese RR ed gt _ Figure 1 Unit Parts Arrangement Caps and Fasteners Torque Requirements A IMPORTANT When servicing or repairing HVAC equipment and components ensure the fasteners are appropriately tightened Table 1 list torque values for various caps and Only use Allen wrenches of sufficient hardness 50Rc fasteners Rockwell Harness Scale minimum Fully insert the wrench into the valve stem recess Table 1 Torque Requirements Service valve stems are factory torqued from 9 ft Ibs for Parts Recommended Torque small valves to 25 ft lbs for large valves to prevent Service valve cap 8 ft Ib 11 NM refrigerant loss during shipping handling Using Sheet
37. Open the valve on the HFC 410A cylinder vapor only 2 Open the high pressure side of the manifold to allow HFC 410A into the line set and indoor unit Weigh in a trace amount of HFC 410A A trace amount is a maximum of two ounces 57 g refrigerant or three pounds 31 kPa pressure Close the valve on the HFC 410A cylinder and the valve on the high pressure Page 16 side of the manifold gauge set Disconnect the HFC 410A cylinder Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set Adjust dry nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor unit After a few minutes open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector After leak testing disconnect gauges from service ports Evacuating Line Set and Indoor Coil Evacuating the system of non condensables is critical for proper operation of the unit Non condensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system Non condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts NOTE Remove cores from service valves if not already done Connectlow side of manifold ga
38. PTIONAL LOW AMBIENT CONTROLS AX CUT ON BOARD LINK FROM R TO FOR HEAT PUMP APPLICATIONS CBX32MV CUT ON BOEARD LINK FROM R TO DS FOR 1 CBX40UHV DEHUMIDIFICATION TB COMPRESSOR 2 COMFORTSENSE CONTACTOR 7000 2081 CRANKCASE O THERMOSTAT HR1 CRANKCASE HEATER YELLOW ume H I COMPRESSOR gt IF ANY WIRE THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING 544 DENOTES OPTIONAL COMPONENTS ME UA EQUIPMENT GROUND CAPACITOR L LE COMPRESSOR CONTACTOR Figure 17 Typical Unit Wiring Diagram 060 Only Page 22 PURPLE BLACK BLACK BLACK FAN MOTOR ORANGE CAPACITOR BLACK PURPLE X BLACK auc lt I lt BLACK YELLOW YELLOW Me Vds 4 BLACK LOW PRESSURE SWITCH YELLOW BLACK REVERS ING VALVE Oy TERMINAL YELLOW HIGH PRESSURE INSULATED SWITCH CONTACTOR QE zo GRAY RED GRAY RED GRAY RED
39. SCONNECT SWITCH RECOVERY MACHINE CLEAN RECOVERY OUTDOOR UNIT 3 RECOVERING REFRIGERANT CYLINDER Remove existing HCFC 22 refrigerant using one of the following procedures METHOD 1 METHOD 2 LIMITATIONS Use Method 1 if the existing outdoor unit is not equipped with shut off valves or NOTE When using Method 2 the listed devices if the unit is not operational and you plan to use the existing HCFC 22 to flush below could prevent full system charge recovery into the system the outdoor unit Recover all HCFC 22 refrigerant from the existing system using a recovery machine and clean recovery cylinder Check gauges after shutdown to confirm that the entire system is completely void of refrigerant METHOD 2 Use Method 2 if the existing outdoor unit is equipped with manual shut off valves and you plan to use new HCFC 22 refrigerant to flush the system Perform the following task A Startthe existing HCFC 22 system in the cooling mode and close the liquid line valve B Usethe compressor to pump as much of the existing HCFC 22 refrigerant into the outdoor unit until the outdoor system is full Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system NOTE It may be necessary to bypass the low pressure switches if equipped to Outdoor unit s high or low pressure switches if applicable when tripped can cycle the compressor OFF Compressor can stop pumping due
40. TEMPERATURE DISPLAY DEW POINT CONTROL HEAT PUMP AND X2658 OUTDOOR SENSOR IS REQUIRED FOR OUTDOOR DUAL FUEL BALANCE POINTS CONNECTED ON UNIT WITH LSOM RESISTOR KIT CAT 47W97 IS REQUIRED WHEN CONNECTING THE COMFORTSENSE 7000 WITH THE LSOM 2 FIELD PROVIDED JUMPER BETWEEN Y2 OUT BL ON HEAT PUMP TO Y2 ON CBX40UHV IMPORTANT USE CARE WHEN CUTTING LINKS TO PREVENT DAMAGE TO CONTROL SEE CBX40UHV INSTALLATION INSTRUCTION FOR FURTHER DETAILS CUT ON BOARD LINK Y1 Y2 FOR TWO STAGE HP CUT ON BOARD LINK R O CUT ON BOARD LINK R DS WHEN DEHUMIDIFICATION TERMINAL IS USED CBX32MV OR COMFORTSENSE CBX40UHV 7000 THERMOSTAT RED FAN RELAY NOT REQUIRED WITH SINGLE SPEED OUTDOOR FAN PURPLE RED BLACK PURPLE BLACK YELLOW BLUE BROWN NOT USED FOR APPLICATIONS WITHOUT LSOM BLUE NOT REQUIRED FOR SINGLE STAGE RESISTOR KIT CAT 47W97 IS REQUIRED WHEN CONNECTING THE COMFORTSENSE 7000 WITH THE LSOM 2 IMPORTANT USE CARE WHEN CUTTING LINKS TO PREVENT DAMAGE TO CONTROL SEE CBX40UHV INSTALLATION INSTRUCTION FOR FURTHER DETAILS CUT ON BOARD LINK Y1 Y2 FOR TWO STAGE A C ONLY CUT ON BOARD LINK R O CUT ON BOARD LINK R DS WHEN DEHUMIDIFICATION TERMINAL IS USED AIR HANDLER CONTROL Y1 Y2 2 STAGE COMPR R O HEAT PUMP R DS DEHUM
41. are series line set or field fabricated refrigerant line sizes as specified in table 2 If refrigerant lines are routed through a wall then seal and isolate the opening so vibration is not transmitted to the building Pay close attention to line set isolation during installation of any HVAC system When properly isolated from building structures walls ceilings floors the refrigerant lines will not create unnecessary vibration and subsequent sounds See figure 7 for recommended installation practices NOTE When installing refrigerant lines longer than 50 feet see the Lennox Refrigerant Piping Design and Fabrication Guidelines CORP 9351 L9 or contact Lennox Technical Support Product Applications for assistance To obtain the correct information from Lennox be sure to communicate the following information e Model 16 and size of unit e g 036 e Line set diameters for the unit being installed as listed in table 2 and total length of installation e Number of elbows vertical rise or drop in the piping USING EXISTING LINE SET Things to consider e Liquid line that meter the refrigerant such as RFC1 liquid line must not be used in this application e Existing line set of proper size as listed in table 2 may be reused e If system was previously charged with HCFC 22 refrigerant then existing line set must be flushed see Flushing Line Set and Indoor Coil on page 14 If existing line set is being used th
42. ature exceeds a temperature of 285 F 140 C during compressor operation the demand defrost control will de energize the compressor contactor output and the defrost output if active The compressor will remain off until the discharge temperature has dropped below 225 F 107 C and the 5 minute anti short cycle delay has been satisfied This sensor has two fault and lockout codes 1 If the demand defrost control recognizes five high discharge line temperature faults during a single Y1 compressor demand it reverts to a lockout mode and displays the appropriate code This code detects shorted sensor or high discharge temperatures Code on demand defrost control is Discharge Line Temperature Fault and Lockout 2 If the demand defrost control recognizes five temperature sensor range faults during a single 1 compressor demand it reverts to a lockout mode and displays the appropriate code The demand defrost control detects open sensor or out of temperature sensor range This fault is detected by allowing the unit to run for 90 seconds before checking sensor resistance If the sensor resistance is not within range after 90 seconds the demand defrost control will count one fault After five faults the demand defrost control will lockout Code on demand defrost control is Discharge Sensor Fault and Lockout The discharge line sensor which covers a range of 150 F 65 C to 350 F 176 C is designed to mount on a refrigera
43. auge set hoses must be rated for use to 800 psig of pressure with a 4000 psig burst rating Operating Angle Type Service Valve 1 Remove stem cap with an appropriately sized wrench for vapor line valve sizes to back the stem out counterclockwise as the service valve 2 77 SERVICE PORT SERVICE PORT CORE TO INDOOR UNIT STEM CAP 2 Use a service wrench with a hex head extension 3 16 for liquid line valve sizes and 5 16 VALVE STEM SHOWN OPEN INSERT HEX WRENCH HERE INSERT HEX HEAD EXTENSION HERE far as it will go to open TO INDOOR UNIT TO OUTDOOR UNIT VALVE STEM SHOWN CLOSED REMOVE STEM CAP When service valve stem is in the CLOSED position the service port is open to the line set and indoor unit TO OUTDOOR UNIT 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 A To open rotate stem counterclockwise TO INDOOR UNIT 90 Toclose rotate stem clockwise 90 BALL SHOWN CLOSED 2 VALVE STEM SERVICE PORT SERVICE PORT CORE SERVICE PORT CAP REMOVE STEM CAP TO OUTDOOR UNIT NOTE label with specific torque requirements may be affixed to the stem cap If the label is present use the specified torque To Access Service Port A service port cap prot
44. auge valves valve on vacuum pump and turn off vacuum pump e 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 e 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 When the absolute pressure requirement above has been met disconnect the manifold hose from the vacuum pump and connect it to an upright cylinder of HFC 410A refrigerant Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit G Perform the following 1 6 TURN Close manifold gauge valves Shutoff HFC 410A cylinder Reinstallservice 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 ad
45. ctual 7 Inspect drain holes in coil compartment base and clean if necessary NOTE If insufficient heating or cooling occurs the unit should be gauged and refrigerant charge should be checked Outdoor Coil It may be necessary to flush the outdoor coil more frequently if it is exposed to substances which are corrosive or which block airflow across the coil e g pet urine cottonwood seeds fertilizers fluids that may contain high levels of corrosive chemicals such as salts e Outdoor Coil The outdoor coil may be flushed with a water hose e Outdoor Coil Sea Coast Moist air in ocean locations can carry salt which is corrosive to most metal Units that are located near the ocean require frequent inspections and maintenance These inspections will determine the necessary need to wash the unit including the outdoor coil Consult your installing contractor for proper intervals procedures for your geographic area or service contract Indoor Unit 1 Clean or change filters 2 Lennox blower motors prelubricated permanently sealed No more lubrication is needed 3 Adjust blower speed for cooling Measure the pressure drop over the coil to determine the correct blower CFM Refer to the unit information service manual for pressure drop tables and procedure 4 Belt Drive Blowers Check belt for wear and proper tension 5 Check all wiring for loose connections Check for correct voltage at unit b
46. der of HFC 410A and purge the hose Then place the cylinder upside down on a scale 5 Check that fan rotates freely 10 Inspect all factory field installed wiring for loose connections Open the high side manifold gauge valve and weigh in liquid refrigerant Use figure 20 in calculating the correct weigh in charge Close manifold gauge valves Monitor the system to determine the amount of moisture remaining in the oil It may be necessary to replace the bi flow filter drier several times to achieve the required dryness level If system dryness is not verified the compressor will fail in the future Continue to Optimizing System Refrigerant Charge on page 26 to optimize the system charge using subcooling method CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE If the system is void of refrigerant first locate and repair any leaks and then weigh in the refrigerant charge into the unit To calculate the total refrigerant charge Amount specified on nameplate LIQUID LINE SET DIAMETER 3 8 9 5 MM Adjust amount for variation in line set length listed on line set length table below Additional charge specified per indoor Total Charge unit match listed on page 28 Refrigerant Charge per Line Set Length OUNCES PER 5 FEET G PER 1 5 M ADJUST FROM 15 FEET 4 6 M LINE SET 3 OUNCE PER 5 85 G PER 1 5 M If line length is greate
47. ditional one sixth 1 6 of a turn as illustrated Figure 13 Evacuating Line Set and Indoor Coil Page 17 XP16 SERIES 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 SIZE CIRCUIT AND INSTALL DISCONNECT SWITCH Refer to the unit nameplate for minimum circuit ampacity and maximum fuse or circuit breaker HACR per NEC Install power wiring and properly sized disconnect switch MAIN FUSE BOX BREAKER PANEL DISCONNECT SWITCH NOTE Units are approved for use only with copper conductors Ground unit at disconnect switch or to an earth ground Electrical Connections In the U S A wiring must conform with current local codes and the current National Electric Code NEC In Canada wiring must conform with current local codes and the current Canadian Electrical Code CEC Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size 24VAC TRANSFORMER Use the transformer provided with the furnace or
48. e 2 50 8MM SCH 40 constructed Size barrier at least the same height and width as outdoor unit Mount barrier 24 MALE THREADED inches 610 mm from the sides of the unit in the direction of prevailing winds as illustrated ADAPTER PREVAILING WINTER WINDS Use additional 2 SCH 40 male threaded adapters which can be threaded into the female threaded adapters to 2 make additional adjustments to the level of the unit WIND BARRIER DETAIL E Deck Top Mounting v One bracket side MINIMUM 2 minimum For extra INLET AIR stability two brackets per side two inches 51mm D from each corner SAME FASTENERS AS SLAB SIDE MOUNTING FOREXTRA STABILITY C 7 _ 7 Za SSA 2 INLET AIR a 5 N EE s Ez SS 2 S Figure 5 Placement Slab Mounting and Stabilizing Unit Page 7 XP16 SERIES Removing and Installing Panels LOUVERED PANEL REMOVAL Remove the louvered panels as follows 1 Remove two screws allowing the panel to swing open slightly 2 Hold the panel firmly throughout this procedure Rotate bottom corner of panel away from hinged corner post until lower three tabs clear the slots as illustrated in detail B 3 Move panel down until lip of upper tab clears the top slot in corner post as illustrated in detail A LOUVERED PANEL INSTALLATION Position the panel almost parallel with the unit as
49. e 421 148 409 145 424 147 421 141 51 1448 82 2427 113 3802 144 565 9 115 52 1474 83 2465 114 3854 145 5728 46 1 480 151 465 148 481 149 479 144 53 150 1 84 2503 115 3907 146 579 8 Normal Operating Pressures Heating First Stage Low Capacity Pressure 54 1528 85 2541 116 3960 147 586 8 10 312 112 350 115 336 414 385 108 55 155 5 86 2580 117 4013 148 593 8 60 56 1582 87 2620 118 4067 149 601 0 15 5 330 130 372 136 363 135 414 126 57 161 0 88 2660 119 4122 150 608 1 Second Stage High Capacity Pressure ae 299 e 321 61 289 57 332 59 58 163 9 89 2700 120 4177 151 6154 30 59 166 7 274 1 121 4232 152 6227 10 312 79 347 74 294 69 349 67 60 1696 91 2782 122 4288 153 630 1 20 325 93 367 90 321 80 361 75 4 4 61 1726 92 2823 123 4345 154 637 5 50 10 344 110 387 110 341 110 383 85 62 1754 93 286 5 124 4402 155 645 0 60 15 5 358 128 395 131 361 128 425 122 Temperature of air entering outdoor coil Page 29 XP16 SERIES System Operation A IMPORTANT Some scroll compressor have internal vacuum protector that will unload scrolls when suction pressure goes below 20 psig A hissing sound will be heard when the compressor is running unloaded Protecto
50. e before taking measurements may take up to 10 minutes 7 Record all of the readings for the Y1 demand 8 Close switch to energize Y2 demand Verify power is going to compressor solenoid 9 Allow pressures and temperatures to stabilize before taking measurements may take up to 10 minutes 10 Record all of the readings with the Y1 and Y2 demand 11 If temperatures and pressures change in the direction noted in Two Stage Modulation Compressor Field Operational Checklist on page 42 the compressor is properly modulating from low to high capacity If no amperage pressures or temperature readings change when this test is performed the compressor is not modulating between low and high capacity and replacement is necessary 12 After testing is complete return unit to original set up Maintenance DEALER Maintenance and service must be performed by a qualified installer or service agency At the beginning of each cooling season the system should be checked as follows Outdoor Unit 1 Clean and inspect outdoor coil may be flushed with a water hose Ensure power is off before cleaning 2 Outdoor unit fan motor is pre lubricated and sealed No further lubrication is needed 3 Visually inspect all connecting lines joints and coils for evidence of oil leaks 4 Check all wiring for loose connections 5 Check for correct voltage at unit unit operating 6 Check amp draw on outdoor fan motor Motor Nameplate A
51. e subcooling method to optimize the system charge see figure 24 Adjust charge as necessary ADJUSTING INDOOR AIRFLOW Heating Mode Indoor Airflow Check Only use when indoor unit has electric heat Indoor blower airflow CFM may be calculated by energizing electric heat and measuring Temperature rise between the return air and supply air temperatures at the indoor coil blower unit e Measuring voltage supplied to the unit e Measuring amperage being drawn by the heat unit s Then apply the measurements taken in the following formula to determine CFM Amps x Volts x 3 41 1 08 x Temperature rise F Cooling Mode Indoor Airflow Check Check airflow using the Delta T DT process using figure 23 ADJUSTING INDOOR AIRFLOW Temp DT of air 24 23 22 22 20 entering o 23 22 21 20 19 indoor 3 22 21 19 19 18 coil F 21 20 18 17 16 19 18 16 A5 18 18 16 15 15 a INDOOR All temperatures are COIL expressed in F 1 Determine the desired DT Measure entering air temper ature using dry bulb A and wet bulb B DT is the intersect ing value of A and B in the table see triangle 2 Find temperature drop across coil Measure the coil s dry bulb entering and leaving air temperatures A and C Tem perature Drop Formula Tprop A minus C 3 Determine if fan needs adjust
52. ects the service port core from contamination and serves as the primary leak seal 1 1 6 TURN Remove service port cap with an appropriately sized 1 wrench 0 2 3 Connect gauge set to service port When testing is completed replace service port cap and tighten as follows With torque wrench Finger tighten and torque cap per table 1 e Without torque wrench Finger tighten and use an appropriately sized wrench to turn an additional 1 6 turn clockwise Reinstall Stem Cap Stem cap protects the valve stem from damage and Serves as the primary seal Replace the stem cap and tighten as follows 1 12 TURN With Torque Wrench Finger tighten and then torque cap per table 1 Without Torque Wrench Finger tighten and use an appropriately sized wrench to turn an additional 1 12 turn clockwise Figure 2 Angle and Ball Type Service Valves Page 4 Recovering Refrigerant from Existing System DISCONNECT POWER 2 CONNECT MANIFOLD GAUGE SET Connect a manifold gauge set clean recovery cylinder and a Disconnect all power to the existing outdoor unit at the disconnect switch and or main fuse box breaker panel recovery machine to the service ports of the existing unit NOTE Use the recovery machine instructions to make the correct manifold gauge set connections for recovery MAIN FUSE refrigerant The illustration below is a typical connection BOX BREAKER PANEL MANIFOLD GAUGES DI
53. en or shorted or out of temperature range Demand defrost FAST Flash Fault Ambient Sensor Problem control will revert to time temperature defrost operation System will still heat or cool Alternatin Sensor being detected open or shorted or out of temperature range Demand defrost 9 Fault Coil Sensor Problem control will not perform demand or time temperature defrost operation System will FAST Flash still heat or cool Indicates that demand defrost control has internal component failure Cycle 24VAC ON ON Fault Defrost Lontigi power to demand defrost control If code does not clear replace demand defrost control SLOW 1 Remove any blockages or restrictions from OFF Flash Fault Low Pressure Fault 1 Restricted air flow over indoor or coils and or fans Check indoor and outdoor outdoor coil fan motor for proper current draws 2 Improper refrigerant charge in 2 Check system charge using subcooling OFF ON Lockout Low Pressure Lockout system method 3 mproper metering device 3 Check system operating pressures and installed or incorrect operation compare to unit subcooling tables in this at OFF Fault High Pressure Fault of metering device instruction or located on unit access panel 4 Incorrect or improper sensor 4 Make sure all pressure switches and sensors location or connection to have secure connections to system to prevent system refrigerant leaks or errors in pressure and ON OFF Lockout High Pressure Lockout temperature measure
54. en proceed to Brazing Connections on page 11 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 Line Set and Indoor Coil on page 13 A IMPORTANT If this unit is being matched with 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 Table 2 Refrigerant Line Set Inches mm Field Connections Recommended Line Set Suction Line 3 4 19 mm Liquid Line XP16 024 230 3 8 10 mm Liquid Line 3 8 10 mm L15 Line Set L15 41 15 ft 50 ft 4 6m 15 m Suction Line 3 4 19 mm XP16 036 230 3 8 10 mm 7 8 22 mm XP16 048 230 3 8 10 mm 7 8 22 mm L15 65 15 ft 50 ft 4 6 m 15 m XP16 060 230 3 8 10 mm
55. g brazing wrap water saturated cloths around service valve bodies and copper tube stubs Use additional water saturated cloths underneath the valve body to protect the base paint Flow regulated nitrogen at 1 to 2 psig through the refrigeration gauge set into the valve stem port connection on the liquid service valve and out of the suction vapor valve stem port See steps 3A 3B and 3C on manifold gauge set connections 5 FLOW NITROGEN 6 BRAZE LINE SET Wrap both service valves with water saturated cloths as illustrated here and as mentioned in step 4 before brazing to line set Water saturated cloths must remain water saturated throughout the brazing and cool down process LIQUID LINE SERVICE VALVE WHEN BRAZING LINE SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE IMPORTANT Allow braze joint to cool Apply additional water saturated cloths to help cool brazed WATER SATURATED joint Do not remove water saturated cloths until piping CLOTH has cooled Temperatures above 250 F will damage valve seals LIQUID LINE WARNING 1 FIRE PERSONAL INJURY OR PROPERTY SPICE VANE DAMAGE may result if you do not wrap a water saturated cloth around both liquid and suction line service valve bodies and copper tube stub while brazing in the line set The braze when complete must be quenched with water to absorb any residual heat 4 WHEN BRAZING LINE SET Do not open service valves until refrigerant lines a
56. icable unit match component ADD refrigerant If refrigerant is added or removed repeat steps 3 through 6 to verify charge 9 Close all manifold gauge set valves and disconnect gauge set from outdoor unit Replace the stem and service port caps and tighten as specified in Operating Service Valves on page 2 Recheck voltage while the unit is running Power must be within range shown on the nameplate Figure 24 Using HFC 410A Subcooling Method Second Stage High Capacity Page 27 XP16 SERIES APPROVED MATCHED SYSTEM COMPONENTS TARGETED SUBCOOLING SC VALUES AND ADD CHARGE VALUES Listed below are the approved matched system components air handlers and indoor coils targeted subcooling and add charge values for the XP16 This information is also listed on the unit charging sticker located on the outdoor unit access panel Subcooling values listed in the following tables are based Table 5 16 048 230 on outdoor ambient air temperature of Heating Cooling e 60 F 15 5 C and above for cooling mode Indoor Air Handers pip Add Charge 59 F 15 0 C and below for heating mode Subeooling ibe Table 3 16 024 230 CBX26UH 048 230
57. in the demand defrost control will count one strike Low pressure switch auto reset trip at 25 psig reset at 40 psig The low pressure switch is ignored under the following conditions e During the defrost cycle and 90 seconds after the termination of defrost e When the average ambient sensor temperature is below 15 F 9 C For 90 seconds following the start up of the compressor During test mode Ambient Sensor RT13 The ambient sensor considers outdoor temperatures below 35 F 37 C or above 120 F 48 C as a fault If the ambient sensor is detected as being open shorted or out of the temperature range of the sensor the demand defrost control will not perform demand defrost operation The demand defrost control will revert to time temperature defrost operation and will display the appropriate fault code Heating and cooling operation will be allowed in this fault condition Coil Sensor RT21 Coil Sensor The coil temperature sensor considers outdoor temperatures below 35 F 37 C or above 120 F 48 C as a fault If the coil temperature sensor is detected as being open shorted or out of the temperature range of the sensor the demand defrost control will not perform demand or time temperature defrost operation and will display the appropriate fault code Heating and cooling operation will be allowed in this fault condition High Discharge Temperature Sensor RT28 If the discharge line temper
58. ing 35 107 1 66 187 7 97 303 8 128 463 5 XP16 024 036 048 060 SE 36 109 2 67 1909 98 3082 129 469 5 Liq Vap Liq Vap Liq Vap Liq Vap C 37 114 f 1941 99 3127 130 4756 First Stage Low Capacity Pressure 65 38 113 6 69 197 3 100 3172 131 481 6 18 3 226 144 220 141 224 143 230 137 39 115 8 70 2006 101 3218 132 487 8 9 260 145 254 144 259 143 267 139 23 9 40 118 0 71 2039 102 3264 133 494 0 85 29 4 301 148 295 148 302 147 311 141 41 1203 72 2072 103 331 0 134 500 2 o 346 151 340 150 346 149 357 144 42 122 6 73 2106 104 3357 135 506 5 di ape 432 quo 1388 Maz 43 125 0 74 2140 105 3405 136 512 9 115 44 127 3 75 2174 4106 345 3 137 519 3 46 1 451 156 444 156 450 155 453 149 45 129 7 76 220 9 107 350 1 138 525 8 Second Stage High Capacity Pressure 65 46 132 2 77 2244 108 3550 139 5324 18 3 241 140 232 129 238 138 232 131 75 47 134 6 78 2280 109 3600 140 539 0 23 9 279 142 269 136 278 140 276 133 48 137 1 79 2316 110 3650 141 545 6 85 Baaj 1 3207 136 49 139 6 80 235 3 111 3700 142 5523 95 350 369 146 346 142 372 144 367 138 50 1422 81 2390 112 3751 143 5591 a
59. ition The 5 strike pressure switch lockout condition can be reset by cycling OFF the 24 volt power to the demand defrost control or by shorting the TEST pins between 1 to 2 seconds All timer functions run times will also be reset If a pressure switch opens while the Y1 Out line is engaged a 5 minute short cycle will occur after the switch closes Demand Defrost Control Pressure Switch Connections The unit s automatic reset pressure switches LO PS S87 and HI PS S4 are factory wired into the demand defrost control on the LO PS and HI PS terminals respectively Demand Defrost Control Sensors Sensors connect to the demand defrost control through a field replaceable harness assembly that plugs into the demand defrost control as illustrated in figure 1 Through the sensors the demand defrost control detects outdoor ambient coil and discharge temperature fault conditions As the detected temperature changes the resistance across the sensor changes Testing Demand Defrost Control Sensors Sensor resistance values can be checked by ohming across pins shown in table 11 Table 11 Sensor Temperature Resistance Range Resistance values range ohms Temperature Range F C 35 37 to 120 48 280 000 to 3750 3 amp 4 Black Sensor Outdoor Coil 35 37 to 120 48 280 000 to 3750 5 amp 6 Brown Discharge if 24 4 to 350 176 41 000 to 103 1 amp 2 applicable Yellow N
60. lower operating 7 Check amp draw on blower motor Motor Nameplate Actual 40 Indoor Coil 1 Clean coil if necessary 2 Check connecting lines joints and coil for evidence of oil leaks 3 Check condensate line and clean if necessary HOMEOWNER Cleaning of the outdoor unit s coil should be performed by a trained service technician Contact your dealer and set up a schedule preferably twice a year but at least once a year to inspect and service your outdoor unit The following maintenance be performed by the homeowner A IMPORTANT Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to the outdoor unit by treated water Prolonged exposure of the unit to treated water i e sprinkler systems soakers waste water etc will corrode the surface of steel and aluminum parts and diminish performance and longevity of the unit Outdoor Coil The outdoor unit must be properly maintained to ensure its proper operation e Please contact your dealer to schedule proper inspection and maintenance for your equipment e Make sure no obstructions restrict airflow to the outdoor unit Grass clippings leaves or shrubs crowding the unit can cause the unit to work harder and use more energy Keep shrubbery trimmed away from the unit and periodically check for debris which collects around the unit Cleaning of the outdoor unit s coil should be perf
61. ment lf the difference between the measured Tprop and the desired DT Tprop DT is within 39 no adjustment is needed See examples Assume DT 15 and A temp 72 these C temperatures would necessi tate stated actions C Tprp DT F ACTION 539 19 15 4 the airflow 58 14 15 1 within 3 range no change 62 10 15 5 Decrease the airflow 4 Adjust the fan speed See indoor unit instructions to in crease decrease fan speed Changing air flow affects all temperatures recheck tempera tures to confirm that the temperature drop and DT are within 3 Figure 23 Checking Airflow over Indoor Coil Using Delta T Formula Page 26 OPTIMIZE CHARGE USING SUBCOOLING METHOD 1 Check liquid and vapor line pressures Compare pressures with either second stage heat or cooling mode normal operating pressures listed in table 7 Table 7 is a general guide and expect minor pressures variations Significant pressure differences may indicate improper charge or other system problem Decide whether to use cooling or heating mode based on current outdoor ambient temperature Use COOLING MODE when e Outdoor ambient temperature is 60 F 15 5 C and above e Indoor return air temperature range is between 70 to 80 F 21 27 This temperature range is what the target subcooling values are base upon in tables 3 through 6 If indoor return air temperature is not within reference range set thermostat to
62. ments SLOW on Fault Discharge Line Temperature This code detects shorted sensor or high discharge temperatures If the discharge Flash Fault line temperature exceeds a temperature of 285 F 140 C during compressor operation the demand defrost control will de energize the compressor contactor FAST ON Discharge Line Temperature output the defrost output if active The compressor will remain off until the Flash 90509 Lockout discharge temperature has dropped below 225 F 107 C OFF ads Fault Discharge Sensor Fault The demand defrost control detects open sensor or out of temperature sensor range as This fault is detected by allowing the unit to run for 90 seconds before checking sensor resistance If the sensor resistance is not within range after 90 seconds the Fast OFF Lockout Discharge Sensor Lockout demand defrost control will count one fault After 5 faults the demand defrost control Flash will lockout Each fault adds 1 strike to that code s counter 5 strikes per code LOCKOUT Page 32 High Pressure Switch 54 When the high pressure switch trips the demand defrost control will cycle off the compressor and the strike counter in the demand defrost control will count one strike High Pressure auto reset trip at 590 psig reset at 418 Low Pressure Switch S87 When the low pressure switch trips the demand defrost control will cycle off the compressor and the strike counter
63. nd SERVICE VALVES POINT FLAME indoor have been leak tested and evacuated AWAY FROM SERVICE VALVE Refer to procedures provided in this supplement SUCTION VAPOR LINE WATER SATURATED CLOTH PREPARATION FOR NEXT STEP After all connections have been brazed disconnect manifold gauge set from service ports Apply additional water saturated cloths to both service valves to cool piping Once piping is cool remove all water saturated cloths Figure 9 Brazing Procedures continued Page 13 XP16 SERIES Flushing is only required when the existing system used 22 refrigerant If the existing system used HFC 410a then remove the original indoor coil metering device and proceed to Installing New Indoor Metering Device on page 15 TYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL REMOVAL PROCEDURE UNCASED OR PROCEDURE UNCASED COIL SHOWN COIL SHOWN STUB END TWO PIECE PATCH PLATE LIQUID LINE CHECK DISTRIBUTOR TUBES UNCASED COIL ONLY ORIFICE EXPANSION LIQUID LINE ORIFICE HOUSING DISTRIBUTOR a VALVE TEFLON RING FIXED ORIFICE BRASS NUT SENSING LINE DISTRIBUTOR 7 ASSEMBLY REMOVE AND DISCARD WHITE TEFLON SEAL IF PRESENT LIQUID LINE ASSEMBLY INCLUDES STRAINER LIQUID LINE ASSEMBLY WITH BRASS NUT On fully cased coils remove the coil access and plumbing panels Remove any shipping clamps holding the liquid line and distributor as sembly MALE EQUAL
64. nding the height of the unit support feet This may be achieved by using a 2 inch 50 8mm schedule 40 female threaded adapter The specified coupling will fit snuggly into the recessed portion of the feet Use additional 2 inch 50 8mm Schedule 40 male threaded adaptors which can be threaded into the female threaded adaptors to make additional adjustments to the level of the unit NOTE Keep the height of extenders short enough to ensure a sturdy installation If it is necessary to extend further consider a different type of field fabricated framework that is sturdy enough for greater heights ROOF MOUNTING Install the unit a minimum of 6 inches 152 mm above the roof surface to avoid ice build up around the unit Locate the unit above a load bearing wall or area of the roof that can adequately support the unit Consult local codes for rooftop applications See figure 5 detail F for other roof top mounting considerations NOTICE Roof Damage This system contains both refrigerant and oil Some rubber roofing material may absorb oil and cause the rubber to swell when it comes into contact with oil The rubber will then bubble and could cause leaks Protect the roof surface to avoid exposure to refrigerant and oil during service and installation Failure to follow this notice could result in damage to roof surface MINIMUM CLEARANCE ABOVE UNIT Clearance to one of the other three 30 762 sides must be 36 inches 914mm
65. nit s nameplate If not do not start the equipment until you Figure 19 Outdoor Unit Factory Charge Page 23 XP16 SERIES Service and Weigh In Refrigerant for Outdoor Units Delivered Void of Charge The following procedures are only required if it has been determine that the new outdoor unit is void of charge Skip to the next section if refrigerant charge is present LEAK CHECK REPAIR AND EVACUATE If the outdoor unit is void of refrigerant clean the system using the procedure described below 1 Leak check system using procedures provided on page 16 Repair any leaks discovered during leak test Evacuate the system using procedure provided in figure 13 Use nitrogen to break the vacuum and install a new filter drier in the system Evacuate the system again using procedure in figure 12 CONNECT MANIFOLD GAUGE SET AND WEIGH IN CHARGE After the evacuation procedure reconnect the manifold gauge set as illustrated in figure 21 NOTE Temperature sensor illustrated in figure 21 is not required for initial system weigh in charging 1 WEIGH IN CHARGING Close manifold gauge set valves and connect the center hose to a cylinder of HFC 410A Set for liquid phase charging 2 Connect the manifold gauge set s low pressure side to the true suction port Connect the manifold gauge set s high pressure side to the liquid line service port Connect the center hose of the gauge set to acylin
66. nt discharge line NOTE Within a single room thermostat demand if 5 strikes occur the demand defrost control will lockout the unit demand defrost control 24 volt power R must be cycled OFF or the TEST pins on demand defrost control must be shorted between 1 to 2 seconds to reset the demand defrost control Crankcase Heater HR1 and Crankcase Thermostat Switch S40 The reference models are equipped with a 70 watt belly band type crankcase heater HR1 prevents liquid from accumulating in the compressor HR1 is controlled by a thermostat located on the liquid line When liquid line temperature drops below 50 F the thermostat closes energizing HR1 The thermostat will open de energizing HR1 once liquid line temperature reaches 70 F Liquid Line Bi Flow Filter Drier The unit is equipped with a large capacity biflow filter drier which keeps the system clean and dry If replacement is necessary order another of like design and capacity The replacement filter drier must be suitable for use with HFC 410A refrigerant The replacement filter drier must be suitable for use with HFC 410A refrigerant SECOND STAGE OPERATION If the demand defrost control A108 receives a call for second stage compressor operation Y2 in heating or cooling mode and the first stage compressor output is active the second stage compressor solenoid output will be energized If first stage compressor output is active in heating mode and the outdoor ambie
67. nt temperature is below the selected compressor lock in temperature the second stage compressor solenoid output will be energized without the Y2 input If the jumper is not connected to one of the temperature selection pins on P3 40 45 50 55 F the default lock in temperature of 40 F 4 5 C will be used The demand defrost control de energizes the second stage compressor solenoid output immediately when the Y2 signal is removed or the outdoor ambient temperature is 5 F above the selected compressor lock in temperature or the first stage compressor output is de energized for any reason Page 33 XP16 SERIES Defrost System This section addresses e Emergency Heat e Defrost System Overview e Defrost Control Connections Jumper Settings and Features Operational Mode Overview Calibration Normal and Defrost e Defrost Cycle Actuation EMERGENCY HEAT AMBER LIGHT An emergency heat function is designed into some room thermostats This feature is applicable when isolation of the outdoor unit is required or when auxiliary electric heat is staged by outdoor thermostats When the room thermostat is placed in the emergency heat position the outdoor unit control circuit is isolated from power and field provided relays bypass the outdoor thermostats An amber indicating light simultaneously comes on to remind the homeowner that he is operating in the emergency heat mode Emergency heat is usually used during an outdoor
68. ny 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 Place a jumper on TEST pins for more than two seconds applicable Clears any short cycle lockout and five strike fault lockout function if O Line Status INACTIVE y If in COOLING Mode If in DEFROST Mode If in HEATING 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 45 minute test If no ambient or coil sensor fault exist unit will go into DEFROST MODE If ambient or coil faults exist open or shorted unit will remain in HEAT NOTE Placing a jumper on the TEST pins will not bring the unit out of inactive mode The only way manually activate the heat pump from an inactive mode is to cycle the 24VAC power to the Control MODE If jumper on TEST pins remains place for more than five seconds If jumper TEST pins is removed before a maximum of five seconds Y The unit will return to HEAT MODE un calibrated with defrost timer set for 34 minutes The unit will remain in DEFROST MODE
69. ontrol a defrost cycle will be initiated 2 Time If six hours of heating mode compressor run time has elapsed since the last defrost cycle while the coil temperature remains below 35 F 2 C the demand defrost control will initiate a defrost cycle Actuation When the reversing valve is de energized the Y1 circuit is energized and the coil temperature is below 35 F 2 C the demand defrost control logs the compressor run time If the demand defrost control is not calibrated a defrost cycle will be initiated after 30 minutes of heating mode compressor run time The control will attempt to self calibrate after this and all other defrost cycle s Calibration success depends stable system temperatures during the 20 minute calibration period If the demand defrost control fails to calibrate another defrost cycle will be initiated after 45 minutes of heating mode compressor run time Once the demand defrost control is calibrated it initiates a demand defrost cycle when the difference between the clear coil and frosted coil temperatures exceeds the maximum difference allowed by the control or after six hours of heating mode compressor run time has been logged since the last defrost cycle Termination The defrost cycle ends when the coil temperature exceeds the termination temperature or after 14 minutes of defrost operation If the defrost is terminated by the 14 minute timer another defrost cycle will be initiated after
70. ormed by a trained service technician Contact your dealer and set up a schedule preferably twice a year but at least once a year to inspect and service your outdoor unit Routine Maintenance In order to ensure peak performance your system must be properly maintained Clogged filters and blocked airflow prevent your unit from operating at its most efficient level 1 Air Filter Ask your Lennox dealer to show you where your indoor unit s filter is located It will be either at the indoor unit installed internal or external to the cabinet or behind a return air grille in the wall or ceiling Check the filter monthly and clean or replace it as needed 2 Disposable Filter Disposable filters should be replaced with a filter of the same type and size NOTE If you are unsure about the filter required for your system call your Lennox dealer for assistance 3 Reusable Filter Many indoor units are equipped with reusable foam filters Clean foam filters with a mild soap and water solution rinse thoroughly allow filter to dry completely before returning it to the unit or grille NOTE The filter and all access panels must be in place any time the unit is in operation 4 Indoor Unit The indoor unit s evaporator coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the inside air Have your dealer show you the location of the drain line and how to check for obstruction
71. ote Sensor resistance increases as sensed temperature decreases Tables 12 and 13 shows how the resistance varies as the temperature changes for various types of sensors NOTE When checking the ohms across a sensor be aware that a sensor showing a resistance value that is not within the range shown in table 11 may be performing as designed However if a shorted or open circuit is detected then the sensor may be faulty and the sensor harness will need to be replaced Defrost Temperature Termination Jumper Settings P1 The demand defrost control selections are 50 70 90 and 100 F 10 21 32 and 38 C The shunt termination pin is factory set at 50 F 10 C If temperature shunt is not installed default termination temperature is 90 F 32 Test Pins P1 Function Placing the jumper on the field test pins P1 allows the technician to e Clear short cycle lockout e Clear five strike fault lockout e Cycle the unit in and out of defrost mode e Place the unit in defrost mode to clear the coil See figure 27 for flowchart of test pin P1 operations Page 34 Compressor Delay Mode 5 The demand defrost control has a field selectable function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode When a jumper is installed on the DELAY pins the compressor will be cycled off for 30 seconds going in and out of the defrost mode Units are shipped with jumper installed on DE
72. r than 15 ft 4 6 add this amount If line length is less than 15 ft 4 6 m subtract this amount 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 nameplate on outdoor unit for charge information Figure 20 Using HFC 410A Weigh In Method Page 24 CONNECTIONS FOR OPTIMIZING SYSTEM CHARGE B TRUE SUCTION PORT CONNECTION OUTDOOR UNIT NOTE Refrigerant tank should be turned right side up to deliver vapor during charge optimizing procedure REFRIGERANT TANK CHARGE IN A LIQUID PHASE 1 DIGITAL SCALE TO LIQUID LINE SERVICE TEMPERATURE SENSOR VALVE LIQUID LINE D o TEMPERATURE SENSOR USE FOR SUBCOOLING METHOD INSIDE OUTDOOR UNIT 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 use only for subcooling method OUTDOOR UNIT NOTE ARROWS
73. r will reset when low pressure in system is raised above 40 psig DO NOT REPLACE COMPRESSOR This section addresses e Unit components sensors temperature switch pressure switches and demand defrost control e Second stage operation UNIT COMPONENTS Demand Defrost Control A108 The demand defrost control measures differential temperatures to detect when the system is performing poorly because of ice build up on the outdoor coil The controller se f calibrates when the defrost system starts and after each system defrost cycle The demand defrost control s components are shown in figure 25 e Demand defrost control connections jumpers and LED locations are shown in figure 25 e Demand defrost control connections jumpers and LED descriptions are listed on table 9 e Demand defrost control status fault and lockout LEDs are listed in table 10 TEST PINS P1 LOW AMBIENT DEFROST TERMINATION PIN SETTINGS P1 SENSOR PLUG IN COIL AND AMBIENT SENSORS P4 THERMOSTAT PINS P3 DELAY PINS P5 REVERSING VALVE O OUT Y2 OUT PRESSURE SWITCH CIRCUIT COMMON CONNECTIONS OUT DIAGNOSTIC LEDS DS1 AND DS2 O 24V TERMINAL STRIP CONNECTIONS P2
74. ry heat without the risk of serious damage to the heat pump In EMERGENCY HEAT mode all heating demand is satisfied by auxiliary heat heat pump operation is locked out After a six hour compressor crankcase warm up period the thermostat can be switched to the HEAT setting and normal heat pump operation may resume Preservice Check If your system fails to operate check the following before calling for service e Verify room thermostat settings are correct e Verify that all electrical disconnect switches are ON Check for any blown fuses or tripped circuit breakers e Verify unit access panels are in place e Verify air filter is clean e f service is needed locate and write down the unit model number and have it handy before calling Page 41 XP16 SERIES Accessories Lennox 16 Engineering Handbook For update to date information see any of the following e Lennox Product Catalog publications e Lennox Price Book Checklists Two Stage Modulation Compressors Field Operational Checklist Expected results during Y2 demand Y1 First Stage Toggle switch On Y2 Second Stage Unit Readings COMPRESSOR Voltage Amperage OUTDOOR UNIT FAN MOTOR Amperage Same or Higher TEMPERATURE Ambient Outdoor Coil Discharge Air Compressor Discharge Line Indoor Return Air Indoor Coil Discharge Air PRESSURES Suction Vapor Liquid Page 42
75. s This would also apply to an auxiliary drain if installed Thermostat Operation See the thermostat homeowner manual for instructions on how to operate your thermostat Heat Pump Operation Your new Lennox heat pump has several characteristics that you should be aware of e Heat pumps satisfy heating demand by delivering large amounts of warm air into the living space This is quite different from gas or oil fired furnaces or an electric furnace which deliver lower volumes of considerably hotter air to heat the space Do not be alarmed if you notice frost on the outdoor coil in the winter months Frost develops on the outdoor coil during the heating cycle when temperatures are below 45 F 7 C An electronic control activates a defrost cycle lasting 5 to 15 minutes at preset intervals to clear the outdoor coil of the frost e During the defrost cycle you may notice steam rising from the outdoor unit This is a normal occurrence The thermostat may engage auxiliary heat during the defrost cycle to satisfy a heating demand however the unit will return to normal operation at the conclusion of the defrost cycle Extended Power Outage The heat pump is equipped with a compressor crankcase heater which protects the compressor from refrigerant slugging during cold weather operation If power to your unit has been interrupted for several hours or more set the room thermostat selector to the EMERGENCY HEAT setting to obtain tempora
76. t 24 VAC common output switched for enabling compressor contactor When the high pressure switch trips the demand defrost control will cycle HS PS HS PS High Pressure Switch off the compressor and the strike counter in the demand defrost control will count one strike LT Service Light Output Output 24VAC service 24 service light output 2 output T MT used to supply power to the Lennox System Operation Page 31 XP16 SERIES DEMAND DEFROST CONTROL A108 DIAGNOSTIC LEDS The state Off On Flashing of two LEDs on the demand defrost control DS1 Red and DS2 Green indicate diagnostics conditions that are described in table 10 051 052 System Status Fault and Lockout Codes Table 10 Demand Defrost Control A108 Diagnostic LEDs DS2 DS1 x F Green Red Type Condition Code Possible Cause s Solution 1 No power V to demand 2 i con OFF OFF Status Power problem defrost control terminals R and C or demand defrost control failure trol and LED s do not light replace demand defrost control Simultaneous Stat N ti Unit operating normally or in N ired SLOW Flash atus ormal operation standby mode one required Alternating SLOW Initial power up safety trip of Flash Status 5 minute anti short cycle delay room thermostat demand None required jumper TEST pins to override Simultaneous Sensor being detected op
77. t of clean refrigerant that previously charged the system Check the charge in the flushing cylinder before proceeding Set the recovery machine for liquid recovery and start the RECOVERY recovery machine Open the gauge set valves to allow the CYLINDER recovery machine to pull a vacuum on the existing system line set and indoor unit coil D Invert cylinder of clean HCFC 22 and open its valve to allow lo DISCHARGE 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 HCFC 22 gauge set low side to the liquid line valve vapor is recovered Allow the recovery machine to pull down to 0 HCFC 22 gauge set center port to inlet on the recovery machine with an the system empty recovery tank to the gauge set Close the valve on the inverted HCFC 22 drum and the gauge Connect recovery tank to recovery machines per machine instructions set valves Pump the remaining refrigerant out of the recovery machine and turn the machine off RECOVERY MACHINE Inverted HCFC 22 cylinder with clean refrigerant to the vapor service valve Figure 10 Removing Indoor Refrigerate Metering Device and Flushing Procedures Page 14 Installing New Indoor Metering
78. 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 Prolonged operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips drive bearings and internal seals ensure complete refrigerant evacuation Once the compressor can not pump down to a lower pressure due to any of the above mentioned system C Whenthe low side system pressures reach 0 psig close the vapor line valve conditions shut off the vapor valve Turn OFF the main D Check gauges after shutdown to confirm that the valves are not allowing power to unit and use a recovery machine to recover refrigerantto flow back into the low side of the system any refrigerant left in the indoor coil and line set Figure 3 Refrigerant Recovery IMPORTANT The Environmental Protection Agency EPA prohibits the intentional venting of HFC refrigerants during maintenance service repair and disposal of appliance Approved methods of recovery recycling or reclaiming must be followed 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
79. uge set with 1 4 SAE in line tee to vapor line service valve Connect high side of manifold gauge set to liquid line service valve EE A34000 1 4 SAE TEE WITH M Connect micron gauge available SWIVEL COUPLER connector on the 1 4 SAE in line tee A Connect the vacuum pump with vacuum gauge to the center port of the 7 manifold gauge set The center port MICRON line will be used later for both the GAUGE 1 HFC 410A and nitrogen containers NITROGEN 1 CONNECT GAUGE SET TO VAPOR SERVICE VALVE HFC 410A J VACUUM PUMP TO LIQUID LINE SERVICE VALVE 1 2 EVACUATE THE SYSTEM ee nm 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 of 23 000 microns 29 01 inches of mercury NOTE During the early stages of evacuation it is desirable to close the manifold gauge valve at least once A rapid rise in pressure indicates a relatively large leak If this occurs repeat the leak testing procedure NOTE The term absolute pressure means the total actual pressure within a given volume or system above the absolute zero of pressure Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure When the absolute pressure reaches 23 000 microns 29 01 inches of mercury perform the following Close manifold g
80. used replaced by 10K resistor The demand defrost control has a field selectable function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode When a jumper is installed on the DELAY pins the compressor will be cycled off for 30 seconds going in and out of the PS DELAY Delay Mode defrost mode Units are shipped with jumper installed on DELAY pins NOTE The 30 second off cycle is NOT functional when TEST pins on P1 are jumpered TST PS DF C R 1 Y2 Factory Test Connectors No field use RED LED Valid states for demand defrost control two LEDs are OFF ON and Diagnostic LED FLASHING which indicate diagnostics conditions that are described in GREEN LED table 10 Condenser Fan Operation These two connections provide power for the condenser fan 24 VAC output 24 VAC output connection for reversing valve 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 during the defrost cycle and 90 seconds after the termination of Low Pressure Switch defrost when the average ambient sensor temperature is below 0 F 18 C for 90 seconds following the start up of the compressor during TEST mode Y2 OUT Y2 OUT 24 VAC Output 24 VAC output for second stage compressor solenoid Y1 OUT Y1 OUT 24 VAC Common Outpu
81. ve 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 M Wo being bent or scratched While handling or stowing the panels consider any weather conditions especially windy conditions that may cause panels to be blown around and battered Page 8 Line Set Requirements This section provides information on installation of new or replacement line set e Adding Polyol ester oil requirements e New or replacement line set installation e Using existing line set ADDING POLYOL ESTER OIL REQUIREMENTS A IMPORTANT Mineral oils are not compatible with HFC 410A If oil must be added it must be a Polyol Ester oil The compressor is charged with sufficient Polyol Ester oil POE for line set lengths up to 50 feet Recommend adding oil to system based on the amount of refrigerant charge in the system Systems with 20 pounds or less of refrigerant required no oil to be added For systems over 20 pounds add one ounce for every five 5 pounds of HFC 410A refrigerant Recommended topping off POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATE RL32CF NEW OR REPLACEMENT LINE SET INSTALLATION Field refrigerant piping consists of both liquid and vapor lines from the outdoor unit to the indoor coil Use Lennox L15 sweat non fl
82. ying heat Failure to follow this warning could result in damage personal injury or death AWARNING Never use oxygen to pressurize or purge refrigeration lines Oxygen 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 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 Avoid breathing vapors or fumes from brazing operations Perform operations only in well ventilated areas Wear gloves and protective goggles or face shield to protect against burns Wash hands with soap and water after handling brazing alloys and flux Page 11 XP16 SERIES Cut ends of the refrigerant lines square free from nicks or dents Remove service cap and core from and debur the ends The pipe must remain round Do not crimp end both the suction vapor and liquid line of the line service ports 1 CUT AND DEBUR CAP AND CORE REMOVAL CUT AND DEBUR VN SERVICE PORT SERVICE SERVICE SERVICE VALVE PORT E CONNECTION eS iS SERVICE COPPER TUBE 7 LINE SET SIZE MATCHES SERVICE VALVE CONNECTION E SUCTION VAPOR LINE REDUCER VALVE SERVICE VALVE CY LINE SET

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