Lenox P506640-01 manual

12/10 506640−01 *2P1210* *P506640-01* Page 1 E 20 Lennox Industries Inc. Dallas, T exas, USA These instruc tions are intended as a general guide and do not supersede local codes in any way. Cons ult authorities hav ing jurisdic tion before installation. RET AIN THESE INSTRUCTIONS FOR FUTURE REFERENCE NOTICE T O INST ALLER BRAZING LINE SET T O SER[...]

Page 2 Model Number Identification P 16 036 − − Unit T ype P = Heat Pump Series Nominal Cooling Capacity 024 = 2 tons 036 = 3 tons 048 = 4 tons 060 = 5 tons Minor Revision Number 230 V olt age 230 = 208/230V−1ph−60hz Refrigerant T ype X = R−410A X − 05 Unit Dimensions − inches (mm) ELECTRICAL INLETS SIDE VIEW DISCHARGE AIR V APOR LINE[...]

Page 3 XP16 SERIES T ypical Unit Parts Arrangement CHECK / EXPANSION VA LV E V APOR V AL VE AND GAUGE PORT / SUCTION LINE CONNECTIONS EXPANSION V AL VE SENSING BULB LOW PRESSURE SWITCH (S87) LIQUID LINE BI−FLOW FIL TER DRIER HIGH PRESSURE SWITCH (S4) COMPRESSOR LIQUID V ALVE AND GAUGE PORT / LIQUID LINE CONNECTIONS REVERSING V AL VE (L1) DEMAND D[...]

Page 4 Operating Gauge Set and Service V alves IMPORT ANT T o prevent stripping of the various cap s used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening. OPERA TING SERVICE V AL VES The liquid and vapor line service valves are used for refrigerant recovery , flushing, leak testing, evacuating, weighi[...]

Page 5 XP16 SERIES Recovering Refrigerant from Existing System Disconnect all power to the existing outdoor unit at the disconnect switch and/or main fuse box/breaker panel. DISCONNECT POWER CONNECT MANIFOLD GAUGE SET MANIFOLD GAUGES RECOVER Y MACHINE CLEAN RECOVERY CYLINDER OUTDOOR UNIT HIGH LOW Connect a manifold gauge set, clean recovery cylinde[...]

Page 6 New Out door Unit Placement CAUTION In order to avoid injury , take proper precaution when lif t- ing heavy object s. Remove existing out door unit prior to placement of new outdoor unit. See Unit Dimensions on p age 2 for sizing mounting slab, plat forms or supports. Refer to figure 4 for mandatory installation clearance requirement s. POSI[...]

Page 7 XP16 SERIES LEG DET AIL BASE 2" (50.8MM) SCH 40 FEMALE THREADED ADAPTER Concrete slab  use two plastic anchors (hole drill 1/4") W ood or plastic slab  no plastic anchor (hole drill 1/8") COIL BASE P AN CORNER POST ST ABILIZING BRACKET (18 GAUGE MET AL  2" WIDTH; HEIGHT AS REQUIRED)  Slab Side Mounting #10 1/2[...]

Page 8 Removing and Inst alling Panels LOUVERED P ANEL REMOV AL 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 det ail B. 3.[...]

Page 9 XP16 SERIES Line Set Requirement s This se ction provides information on: inst allation of new or replacement line set. S Adding Polyol ester oil requirements S New or replacement line set installation S Using existing line set. ADDING POL YOL ESTER OIL REQUIREMENTS IMPORT ANT Mineral oils are not compatible with HFC−410A . If oil must be [...]

Page 10 ANCHORED H EA VY NYLON WIRE TIE OR AUT OMOTIVE MUFFLER-TYPE HANGER STRAP LIQUID LINE TO V APOR LINE W ALL STUD LIQUID LINE NON−CORROSIVE MET AL SLEEVE V APOR LINE − WRAPPED IN ARMAFLEX AUT OMOTIVE MUFFLER-TYPE HANGER REFRIGERANT LINE SET  TRANSITION FROM VERTICAL TO HORIZONT AL Line Set Isolation  The following illustrations are e[...]

Page 1 1 XP16 SERIES Brazing Connections Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves. W ARNING Polyol Ester (POE) oils used with HFC− 410A refr igerant absorb moisture very quickl y . It is very important that the refrigerant sys tem be kept closed as much as possible. DO NOT remove line set ca[...]

Page 12 A TT ACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / V APOR LINE SER VICE V AL VES OUTDOOR UNIT LIQUID LINE V APOR LINE LIQUID LINE SERVICE VA LV E SUCTION / V APOR LINE SER VICE VA LV E A TT ACH GAUGES INDOOR UNIT SUCTION / V APOR SERVICE PORT MUST BE OPEN TO ALLOW EXIT POINT FOR NITROGEN A Connect gauge set low pressure side t[...]

Page 13 XP16 SERIES WHEN BRAZING LINE SET TO SER VICE V A L VES, POINT FLAME A W A Y FROM SERVICE V AL VE. LIQUID LINE SERVICE V AL VE LIQUID LINE BRAZE LINE SET W rap both service valves with water saturated cloths as illustrated here and as mentioned in step 4, before brazing to line set . W ater saturated cloths must remain water saturated throu[...]

Page 14 Indoor Refrigerant Metering Device Removal and Flushing Line Set and Indoor Coil Flushing is only required when the existing system used HCFC−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 . SENSING LINE TEFLON ® [...]

Page 15 XP16 SERIES Installing New Indoor Metering Device This out door unit is designed for use in HFC−410A systems that use a check / exp ansion valve metering device (purchased sep arately) at the indoor coil. See t he Lennox XP16 Engineering Handbook f o r ap pr o v e d che c k / ex pa n s i o n va lv e ki t ma t c h − u ps . The check / ex[...]

Page 16 Leak T est Line Set and Indoor Coil IMPORT ANT Leak detector must be cap able of sensing HFC refrigerant. TO V APOR SER VICE V AL VE HFC−410A MANIFOLD GAUGE SET OUTDOOR UNIT HIGH LOW NITROGEN A Connect an HFC−410A manifold gauge set high pressure hose to the vapor valve service port. NOTE  Normally , the high pressure hose is connect[...]

Page 17 XP16 SERIES 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 [...]

Page 18 IMPORT ANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns. W ARNING Danger of Equipment Dam age. Avoid deep vacuum operation. Do not use compressors to evacuat e a system. Extremely low vacuu ms can cause interna l arcing and compre[...]

Page 19 XP16 SERIES A Run 24V AC control wires through cutout with grommet. B Run 24V AC control wires through wire tie. C Make 24V AC control wire connections. D T ighten wire tie to security 24V control wiring. HIGH VOL T AGE F I EL D WI R IN G LOW VOL T AGE (24V) FI E LD W I RI N G CUTOUT WITH GROMMET NOTE − For proper voltages, select thermos[...]

Page 20 CBX32MV OR CBX40UHV HEA T PUMP UNIT (TWO−ST AGE) X2658 OUTDOOR SENSOR IS REQUIRED FOR OUTDOOR TEMPERATURE DISPLA Y , DEW POINT CONTROL, HEA T PUMP AND DUAL FUEL BALANCE POINTS. COMFORTSENSE T 7000 R RR W3 H W2 W2 W1 W1 W1 O O O L L Y1 Y1 Y1 Y2 Y2 G G CC C T T D B Y2 DS O. D. SENSOR (X2658) Y2 OUT BL 1 1 CUT ON−BOARD LINK R −O. CUT ON?[...]

Page 21 XP16 SERIES Figure 16. T ypical Unit Wiring Diagram (−024, −036 and −048 Only)[...]

Page 22 Figure 17. T ypical Unit Wiring Diagram (−060 Only)[...]

Page 23 XP16 SERIES Figure 18. T ypical Factory Wiring Diagram (No Field Modifications) Unit Start−Up IMPORT ANT If unit is equipped with a crankcase heater , it should be energized 24 hours before unit start−up to prevent compressor damage as a result of slugging. UNIT ST ART−UP 1. Rot ate fan to check for binding. 2. Inspect all factory− [...]

Page 24 Service and W eigh In Refrigerant for Outdoor Unit s Delivered V oid of Charge The following procedures are only required if it has been determine that the new out door unit is void of charge. Skip to the next section if refrigerant charge is present. LEAK CHECK, REP AIR AND EV ACUA TE If the outdoor unit is void of refrigerant, clean the s[...]

Page 25 XP16 SERIES TO LIQUID LINE SER VICE VA LV E TEMPERATURE SENSOR (USE FOR SUBCOOLING METHOD) DIGIT AL SCALE REFRIGERANT T ANK TEMPERA TURE SENSOR (LIQUID LINE) MANIFOLD GAUGE SET A Clos e m anifold g auge set valves and connect the center hose to a cy linder o f HFC−410A. S e t f or l iq u id p h a se c ha rg i n g. B Connect the manifold g[...]

Page 26 Optimizing System Refrigerant Charge This section provides instructions on optimizing the system charge. This section includes: S Optimizing procedure S Adjusting indoor airflow S Using subcooling method S Approved matched component s, targeted subcooling (SC) values and add charge values S Normal operating pressures S T emperature pressure[...]

Page 27 XP16 SERIES 1. Check liquid and vapor line pressures. Compare pressures with either second−st age heat or cooling mode normal operating pressures listed in t able 7. T able 7 is a general guide and expect minor pressures variations. Significant pressure dif ferences may indicate improper charge or other system problem. 2. Decide whether t[...]

Page 28 APPROVED MA TCHED SYSTEM COMPONENTS, T ARGETED SUBCOOLING (SC) V ALUES AND ADD CHARGE V ALUES Listed below are the approved matched system component s (air handlers and indoor coils), t argeted 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[...]

Page 29 XP16 SERIES NORMAL OPERA TING PRESSURES Use the following t ables to perform maintenance checks; it is not a procedur e for charging the system . Minor variations in these pressur es may be due to differences in installations. Signif icant dev iations could mean that the system is not properly charged or that a problem exists with some comp[...]

Page 30 System Operation IMPORT ANT Som e 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. Protector will reset when low pressure in system is raised above 40 psig. DO NOT REPLACE COMPRESSOR. This section address[...]

Page 31 XP16 SERIES T able 9. Demand Defrost Control (A108) Input s, Outputs and Configurable Settings Control Locations Control Label or Description Purpose Function P1 TEST Test Mode See Test Mode on page 39 for further details. P1 50, 70, 90, 100 Defrost Temperature Termination Shunt (Jumper) Pins Th e demand defrost control as illustrated in fi[...]

Page 32 DEMAND DEFROST CONTROL (A108) DIAGNOSTIC LEDS T h e s ta t e (O f f , On , Fl a s h i n g ) of tw o LE D s on th e demand defrost control ( D S 1 [R e d ] an d DS 2 [G r een]) i ndicate d iagnostics conditions that are described in table 10 . T able 10. Demand Defrost Control (A108) Diagnostic LEDs DS1 and DS2 System St atus, Fault and Lock[...]

Page 33 XP16 SERIES High Pressure Switch (S4) When the high pressure switch trips, the demand defrost control will cycle of f 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 de[...]

Page 34 Defrost System This section addresses: S Emergency Heat S Defrost System Overview S Defrost Control Connections, Jumper Settings and Features S Operational Mode Overview (Calibration, Normal and Defrost) S Defrost Cycle Actuation EMERGENCY HEA T (AMBER LIGHT) An emergenc y heat function is designed int o some room therm ostats. This feat ur[...]

Page 35 XP16 SERIES Compressor Delay Mode (P5) The demand defrost control has a field−select able function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode. When a jumper is inst alled on the DELA Y pins, the compressor will be cycled off for 30 seconds going in and out of the defrost mode. Unit [...]

Page 36 DEFROST CONTROL (A108) CALIBRA TION MODE SEQUENCE Occurs after power up and cooling operation, or if the coil temperature exceeds the termination temperature while in Heat Mode. Demand defrost control defaults to 30 mi nute  Time / T emperature Mode Reset Compressor Runtime / Reset Three / Five S trike Counter DEMAND MODE Accumulate comp[...]

Page 37 XP16 SERIES T able 12. Ambient (RT13) and Coil (RT21) Sensors T emperature / Resist ance Range Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance 136.3 2680 56.8 16657 21.6 44154 −1 1.3 123152 133.1 2859 56.0 16973 21.0 44851 −1 1.9 125787 130.1 3040 55.3 17293 20.5 45[...]

Page 38 T able 13. High Discharge Sensor (RT28) T emperature / Resist ance Range Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance 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 289.0 220 182.8 111 4 1[...]

Page 39 XP16 SERIES TEST Placing the jumper on the field test pins (P1) allows the technician to: S Clear short cycle lockout S Clear five−strike fault lockout S Cycle the unit in and out of defrost mode S Place the unit in defrost mode to clear the coil When Y1 is energized and 24V power is being applied to the Control, a test cycle can be initi[...]

Page 40 T wo−Stage Modulation Compressors Checks Use this checklist on page 42 to verify p art-load and full-load capacity operation of two-stage modulation compressors. TOOLS REQUIRED S Refrigeration gauge set S Digit al volt/amp meter S Electronic temperature thermometer S On-off toggle switch IMPORT ANT This performance check is ONL Y valid on[...]

Page 41 XP16 SERIES Indoor Coil 1. Clean coil if necessary . 2. Check connecting lines, joint s and coil for evidence of oil leaks. 3. Check condensate line and clean if necessary . HOMEOWNER Cleaning of t he o ut door unit’s coil should be performed b y a trained service technician. Cont act your dealer and set up a schedule (preferably twice a [...]

Page 42 Accessories For update−to−date information, see any of the following publications: S Lennox XP16 Engineering Handbook S Lennox Product Catalog S Lennox Price Book Checklists T wo−Stage Modulation Compressors Field Operational Checklist Unit Readings Y1 − First-St age Expected results during Y2 demand (T oggle switch On) Y2 − Secon[...]

Page 43 XP16 SERIES XP16 S tart−Up and Performance Customer Address Indoor Unit Model Serial Outdoor Unit Model Serial Notes: ST ART UP CHECKS Refrigerant T ype: 1st S tage: Rated Load Amps Actual Amps Rated V olts Actual V olts 2nd S tage: Rated Load Amps Actual Amps Rated V olts Actual V olts Outdoor Unit Fan Full Load Amps Actual Amps: 1st S t[...]