Page 1: Table Of Contents
Start−Up and Performance Checklist ... . . ATTENTION INSTALLERS The ComfortSense 5000 and 7000 are the ONLY room thermostats approved by Lennox for use with the XPG15 series heat pump. ® COMFORTSENSE 7000 ®...
Page 2: Unit Dimensions
Fiberglass wool may also cause respiratory, skin, and eye irritation. To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor. Lennox Industries Inc. P.O. Box 799900 Dallas, TX 75379−9900 Page 2 506212−01 11/10...
Page 3: Model Number Identification
REVERSING VALVE VAPOR VALVE AND GAUGE PORT CHECK EXPANSION VALVE LIQUID VALVE AND GAUGE PORT TRUE SUCTION LINE PORT CRANKCASE HEATER THERMOSTAT BI−FLOW FILTER DRIER LOW PRESSURE SWITCH HIGH PRESSURE SWITCH Figure 1. Typical Parts Arrangement Page 3 XPG15 SERIES...
Page 4: Unit Parts Arrangement
SENSORS LOCATIONS DETAIL A WIRE TIE DEFROST COIL SENSOR Clip coil temperature sensor from the demand defrost control on the return bend shown on models as follows: SLEEVE AMBIENT SENSOR Extend tip of plastic sensor just outside of plastic sleeve. Place ambient sensor and wire from demand defrost MODELS −048 AND −060...
Page 5: Shipping And Packing List
Fines and/or incarceration may be breaking off the wrench, or stripping the valve stem levied for noncompliance. recess. See the Lennox Service and Application Notes #C−08−1 for further details and information. WARNING IMPORTANT Improper installation, adjustment, alteration, service or...
Page 6 Operating Angle Type Service Valve: 1. Remove stem cap with an appropriately sized wrench. 2. Use a service wrench with a hex−head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve sizes) to back the stem out counterclockwise as far as it will go. SERVICE PORT CAP SERVICE PORT CORE (VALVE STEM SHOWN...
Page 7: Recovering Refrigerant From Existing System
When the low side system pressures reach 0 psig, close the vapor line valve. Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system. Page 7 XPG15 SERIES...
Page 8: Unit Placement
MINIMUM CLEARANCE CLEARANCE ON ALL SIDES INCHES (MILLIMETERS) ABOVE UNIT 6 (152) ACCESS PANEL NOTES: CONTROL PANEL 48 (1219) Clearance to one of the other three ACCESS LOCATION sides must be 36 inches (914mm). 30 (762) 12 (305) Clearance to one of the remaining two sides may be 12 inches (305mm) and the final side may be 6 inches (152mm).
Page 9 (51mm) from each corner. IMPORTANT To help stabilize an outdoor unit, some installations may require strapping the unit to the pad using brackets and anchors commonly available in the marketplace. Figure 6. Placement, Slab Mounting and Stabilizing Unit Page 9 XPG15 SERIES...
Page 10: Removing And Installing Panels
STABILIZING UNIT ON UNEVEN SURFACES NOTICE IMPORTANT Roof Damage! Unit Stabilizer Bracket Use (field−provided): This system contains both refrigerant and oil. Some Always use stabilizers when unit is raised above the rubber roofing material may absorbed oil and cause the factory height.
Page 11 Detail D ANGLE MAY BE TOO EXTREME HOLD DOOR FIRMLY ALONG THE HINGED SIDE TO MAINTAIN FULLY−ENGAGED TABS ROTATE IN THIS DIRECTION; THEN DOWN TO REMOVE PANEL PREFERRED ANGLE FOR INSTALLATION Figure 8. Removing and Installing Panels Page 11 XPG15 SERIES...
Page 12: New Or Replacement Line Set
Support Product Applications for assistance. set is not being installed then proceed to Brazing Connections on page . To obtain the correct information from Lennox, be sure to communicate the following information: IMPORTANT Model (XPG15) and size of unit (e.g. −036).
Page 13 INTERVALS THEN STRAP THE LIQUID NOTE Similar installation practices should be used if line set is LINE TO THE VAPOR LINE. to be installed on exterior of outside wall. FLOOR JOIST OR ROOF RAFTER Figure 9. Line Set Installation Page 13 XPG15 SERIES...
Page 14: Brazing Connections
Brazing Connections IMPORTANT Use the procedures outline in figures 10 and 11 for brazing Connect gauge set low pressure side to vapor line line set connections to service valves. service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port WARNING valve.
Page 15 OPEN AND SERVICE PORT CORE REMOVED SUCTION / TO ALLOW EXIT POINT FOR NITROGEN FLOW VAPOR LINE SERVICE VALVE SUCTION / VAPOR LINE OUTDOOR INDOOR UNIT UNIT NITROGEN LIQUID LINE SERVICE LIQUID LINE VALVE Figure 10. Brazing Procedures Page 15 XPG15 SERIES...
Page 16 WRAP SERVICE VALVES To help protect service valve seals during 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 NITROGEN WARNING Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration 1.
Page 17: Flushing Line Set And Indoor Coil
Close the valve on the inverted HCFC−22 drum and the gauge set valves. Pump the remaining refrigerant out of the recovery Connect recovery tank to recovery machines per machine instructions. machine and turn the machine off. Figure 12. Flushing Line Set and Indoor Coil Page 17 XPG15 SERIES...
Page 18: Installing Indoor Expansion Valve
Installing Indoor Expansion Valve This outdoor unit is designed for use in systems that use check expansion valve metering device. See the Lennox XPG15 Engineering Handbook for approved check expansion valve kit match−ups and application information. The check expansion valve unit can be installed 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...
Page 19: Leak Test Line Set And Indoor Coil
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 WARNING refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer.
Page 20: Evacuating Line Set And Indoor Coil
Evacuating Line Set and Indoor Coil CONNECT GAUGE SET HIGH NOTE Remove cores from service valves (if not already done). Connect low side of manifold gauge set with 1/4 SAE in−line tee to vapor line service valve OUTDOOR MANIFOLD A34000 1/4 SAE TEE WITH UNIT GAUGE SET Connect high side of manifold gauge...
Page 21: Electrical
LESS THAN 100’ (30 METERS) TEMPERATURE RATING MORE THAN 100’ (30 METERS) 16 35ºC MINIMUM. DEMAND DEFROST CONTROL NOTE Wire tie provides low voltage wire strain relief and to maintain separation of field installed low and HOLE high voltage circuits. Page 21 XPG15 SERIES...
Page 22 ROUTE HIGH VOLTAGE AND GROUND WIRES Any excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring. To facilitate a conduit, a cutout is located in the bottom of the control panel. Connect conduit to the control panel using a proper conduit fitting. ELECTRICAL INLET (HIGH VOLTAGE) PIPING PANEL...
Page 23 ® Figure 16. XPG15 (−024, −030, −036, −042 and −048) Wiring using ComfortSense 5000/7000 Thermostats Page 23 XPG15 SERIES...
Page 24 ® Figure 17. XPG15 (−060) Wiring using ComfortSense 5000/7000 Thermostats Page 24 506212−01 11/10...
Page 25: System Setup Information
XPG15 SETUP SELECTIONS Checked Item # Task Verify proper coil sensor location and all demand defrost control jumper pin positions NOTE Demand defrost control will not output a W out when outdoor temperatures are above 655F (185C). Page 25 XPG15 SERIES...
Page 26 STEP 1 FIELD WIRING LENNOX GAS FURNACE XPG15 HEAT PUMP COMFORTSENSE WIRE NUT GREEN YELLOW BROWN K229 RELAY FIELD INSTALLED ON FURNACE CONTROL PANEL 7000 Series 5000 Series Only (Catalog# Y0349) (Catalog# X4147) W OUT JUMPERED JUMPERED W IN GREEN Cut W951 link on variable speed furnace control.
Page 27 Electric heat is used as auxiliary heat source in heat pump application. 0200 Auxiliary Heat Source Factory setting. DO NOT SELECT FOSSIL FUEL. No remote outdoor temperature sensor. 0340 Remote Outdoor Temperature Sensor Outdoor temperature sensor used for display only. Page 27 XPG15 SERIES...
Page 28 ® COMFORTSENSE 7000 COMPRESSOR STAGES Required settings for XPG15 dual−fuel applications. 3. For INDOOR HEAT STAGES, use arrows to select 1 or 2 indoor heat stages; then press SAVE. INDOOR HEAT STAGES 4. OUTDOOR SENSOR Default is NO. Balance Points, Humiditrol, Dew Point Control require an outdoor sensor.
Page 29 The demand defrost control will flash the low pressure code. If the room thermostat calls for Y1 heating in low pressure LOCKOUT, the demand defrost control will alternately display two codes four (4) seconds for the low pressure LOCKOUT, and then four (4) seconds heat pump inactive − gas mode active code. Page 29 XPG15 SERIES...
Page 30: Servicing Unit Delivered Void Of Charge
2. Inspect all factory− and field−installed wiring for loose Servicing Units Delivered Void of Charge connections. If the outdoor unit is void of refrigerant, clean the system 3. After evacuation of the line set and indoor coil is using the procedure described below. complete, open both the liquid and vapor line service 1.
Page 31 6. When the required static pressure readings are obtained, re- move the test hose lines and insert snaphole plugs into test holes. Figure 20. Checking Indoor Airflow over Evaporator Coil using Static Pressure Reading Page 31 XPG15 SERIES...
Page 32 WEIGH IN to initially charge a system when the outdoor unit is void of charge. To verify charge and add or SUBCOOLING remove refrigerant use the method. WEIGH IN CHARGING 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.
Page 33 Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig. Figure 22. Using HFC−410A Subcooling Method Page 33 XPG15 SERIES...
Page 34: Indoor Coil Matchups
Target subcooling and charging values for approved indoor coil match−ups. IMPORTANT This unit must be matched with an indoor coil as specified in this section, or with Lennox Engineering Handbook. Coils previously charged with HCFC−22 must be flushed. Table 5. Indoor Coil Matchups and Target Subcooling XPG15−024...
Page 35: Operating And Temperature Pressures
559.1 139.6 207.2 299.4 417.7 565.9 142.2 210.6 303.8 423.2 572.8 144.8 214.0 308.2 428.8 579.8 147.4 217.4 312.7 434.5 586.8 150.1 220.9 317.2 440.2 593.8 152.8 224.4 321.8 445.9 601.0 155.5 228.0 326.4 451.8 608.1 Page 35 XPG15 SERIES...
Page 36: System Operations
INSTALLING ISOLATION GROMMETS DIAGNOSTIC LIGHT−EMITTING DIODES Locate the isolation grommets (provided). Slide grommets The state (Off, On, Flashing) of two light−emitting diodes onto vapor and liquid lines. Insert grommets into piping on the demand defrost control [DS1 (Red) and DS2 panel to isolate refrigerant lines from sheet metal edges.
Page 37 10K resistor built into wiring harness (YELLOW) connected to the DIS connector. DIAGNOSTIC LIGHT−EMITTING DIODES For factory test. Diagnostic light−emitting diode descriptions are listed Eight−position header. Provides connections in table 9. for the factory test. Page 37 XPG15 SERIES...
Page 38 TEST JUMPER Placing the jumper on the test pins allows the technician to: Clear short cycle lockout Clear five−strike fault lockout Cycle the unit in and out of defrost mode Place the unit in defrost mode to clear the coil When Y1 is energized and 24V power is being applied to the demand defrost control, a test cycle can be initiated by placing a jumper on the demand defrost control’s TEST pins for 2 to 5 seconds.
Page 39 The demand defrost control will flash the low pressure code. If the room thermostat calls for Y1 heating in low pressure LOCKOUT, the demand defrost control will alternately display two codes four (4) seconds for the low pressure LOCKOUT, and then four (4) seconds heat pump inactive − gas mode active code. Page 39 XPG15 SERIES...
Page 40 DEFROST SYSTEM SENSORS temperature range of the sensor, the demand defrost control will not perform demand or time/temperature Sensors connect to the demand defrost control through a defrost operation and will display the appropriate fault field-replaceable harness assembly that plugs into the code.
Page 41 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 41 XPG15 SERIES...
Page 42 TERMINOLOGY NOTE Placing a jumper on the demand defrost control’s TEST pins will not activate the heat pump out of inactive The following terminology is used throughout the mode. Power (24VAC) must be cycled to the demand remainder of this section. defrost control to activate the heat pump out of inactive 1.
Page 43 MORE THAN 70% OF THE FIRST HEATING CALL BEFORE DEMAND CONTROL REQUESTED A NATURAL DEFROST HEAT DEFROST CONTROL REQUESTED A NATURAL DEFROST HEAT PUMP PUMP GOES INTO NATURAL DEFROST MODE. GOES INTO NATURAL DEFROST MODE Figure 25. Dual−Fuel Defrost Cycles Page 43 XPG15 SERIES...
Page 44: Operating Modes
Operating Modes COOLING OPERATING MODE Operation Mode ComfortSense® Gas Furnace Dedicated Heat Pump (XPG15) INPUTS/OUT- PUTS " K229 Cooling Mode Cooling DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS 1. K1 relay contact remain closed. 2. K2 relay contact (two sets) remain open. 3.
Page 45 1. K1 relay contact remain closed. 2. K2 relay contact (two sets) remain open. 3. K3 relay contact close to energize compressor contactor. 4. K4 relay contact remain open. 5. K229 relay normally closed contacts remain closed. Page 45 XPG15 SERIES...
Page 46 HEATING OPERATING MODE ROOM THERMOSTAT DEMAND FOR Y1 AND W1 WITH OUTDOOR TEMPERATURE ABOVE 32ºF (OºC) Operation Mode ComfortSense® Gas Furnace Dedicated Heat Pump (XPG15) INPUTS/OUT- PUTS " K229 Heating Mode (Outside Temperature above 32ºF) First Stage Heat- ing (Heat Pump) Second Stage Heating (First Stage Gas Heat)
Page 47 6. K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from the room thermostat to the furnace control. This allows the furnace to control the indoor blower operation during gas heat operation. Page 47 XPG15 SERIES...
Page 48 POWER DEFROST MODE Operation Mode ComfortSense® Gas Furnace Dedicated Heat Pump (XPG15) INPUTS/OUT- PUTS " K229 Defrost Mode Power Defrost DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS 1. K1 relay contact open to cycle OFF outdoor fan. 2. K2 relay contact close and output 24VAC to RL output to energize K229 field installed relay. 3.
Page 49 6. K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from the room thermostat to the furnace control. Indoor blower will cycle OFF. DEFROST TERMINATION Natural defrosts should be terminated after a fixed duration of 150 seconds. Page 49 XPG15 SERIES...
Page 50 COOLING, HEATING, AND TEST MODE FLOWS COOLING Power−Up Mode Operation Thermostat Call for Cooling DEFROST CONTROL (ON−BOARD RELAYS) K1 – Outdoor Fan (Normally Closed) K2 – Reversing valve & RL output K3 – Compressor Y1 out K4 – W out ASCD –...
Page 51 (Comp Contactor) Lo−Ps Trip? Fifth Trip in this Heating Demand? De−energize K3 (Comp Contactor) Demand Hi−Ps Lockout / Display Code Satisfied? Fifth Trip in this Heating Demand? Lo−Ps Lockout / Display Code Figure 27. Heating Mode Operation Page 51 XPG15 SERIES...
Page 52 CALIBRATION SEQUENCE CALIBRATION DEFROST CONTROL (ON−BOARD RELAYS) K1 – Outdoor Fan (Normally Closed) Sequence K2 – Reversing valve & RL output K3 – Compressor Y1 out With coil temperature less than 35F, a power defrost occurs K4 – W out 30 minutes after power−up or after cooling operation.
Page 53: Dealer Maintenance
NOTE − If you are unsure about the filter required for Before the start of each heating and cooling season, the your system, call your Lennox dealer for assistance. following service checks should be performed by a IMPORTANT licensed professional service technician or equivalent.
Page 54 HEAT PUMP OPERATION OPTIONAL ACCESSORIES Your new Lennox heat pump has several characteristics Optional accessories for the XPG15 include the following: that you should be aware of: Accessory Lennox Catalog Number Heat pumps satisfy heating demand by delivering large amounts of warm air into the living space.
Page 55: Sound Reduction (Sr1) Cover
Liquid Line Temperature (B) Approach: APPROACH Liquid Line Temperature (A) minus Outdoor Air Temperature (B) Indoor Coil Temp. Drop (18 to 22°F) COIL TEMP DROP Return Air Temperature (A) COIL TEMP DROP minus Supply Air Temperature (B) Page 55 XPG15 SERIES...

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