Lennox Elite XP16−024−230 Installation Instructions Manual
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Lennox Elite XP16−024−230 Installation Instructions Manual

Elite xp16 series
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E20 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.
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.
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.
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.
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
*2P1210*
INSTALLATION
INSTRUCTIONS
®
Elite
Series XP16 Units
HEAT PUMPS
506640−01
12/10
Supersedes 11/10

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Servicing and Weighing In Refrigerant for Units
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Shipping and Packing List

Check unit for shipping damage. Consult last carrier
immediately if damage is found.
1 − Assembled outdoor unit

General

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 XP16 Lennox Engineering
®
Handbook. Elite
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.
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Series outdoor units are designed for
506640−01
*P506640-01*
Litho U.S.A.
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Summary of Contents for Lennox Elite XP16−024−230

  • Page 1: Table Of Contents

    General The XP16 outdoor unit uses HFC−410A refrigerant. This unit must be installed with a matching indoor blower coil CAUTION and line set as outlined in the XP16 Lennox Engineering ® Handbook. Elite Series outdoor units are designed for Physical contact with metal edges and corners while...

  • Page 2: Model Number Identification

    Model Number Identification P 16 036 − − −05 Refrigerant Type Minor Revision Number X = R−410A Voltage 230 = 208/230V−1ph−60hz Unit Type P = Heat Pump Nominal Cooling Capacity 024 = 2 tons Series 036 = 3 tons 048 = 4 tons 060 = 5 tons Unit Dimensions −...

  • Page 3: Typical Parts Arrangement

    Compressor bolts 90 in.− lb. 10 NM Gauge port seal cap 8 ft.− lb. 11 NM See the Lennox Service and Application Notes Corp.0807−L5 (C−08−1) further details information. Page 3 XP16 SERIES...
  • Page 4 Operating Gauge Set and Service Valves USING MANIFOLD GAUGE SET IMPORTANT When checking the system charge, only use a manifold gauge set that features low−loss anti−blow back fittings. To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted Manifold gauge set used for HFC−410A refrigerant snugly over the cap before tightening.

  • Page 5: Recovering Refrigerant From Existing System

    Recovering Refrigerant from Existing System CONNECT MANIFOLD GAUGE SET DISCONNECT POWER Connect a manifold gauge set, clean recovery cylinder and a Disconnect all power to the existing outdoor unit at the disconnect recovery machine to the service ports of the existing unit.. switch and/or main fuse box/breaker panel.

  • Page 6: New Outdoor Unit Placement

    New Outdoor Unit Placement If additional elevation is necessary, raise the unit by CAUTION extending the height of the unit support feet. This may be achieved by using a 2 inch (50.8mm) schedule 40 female In order to avoid injury, take proper precaution when lift- threaded adapter.
  • Page 7 DETAIL A Outside Unit Placement DETAIL B 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.

  • Page 8: Removing And Installing Panels

    Removing and Installing Panels LOUVERED PANEL REMOVAL IMPORTANT! DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB. TAB IS FOR Remove the louvered panels as follows: ALIGNMENT AND NOT DESIGNED TO SUPPORT WEIGHT OF PANEL. 1. Remove two screws, allowing the panel to swing open PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR slightly.

  • Page 9: Line Set Requirements

    Field refrigerant piping consists of both liquid and vapor outlined under Flushing Line Set and Indoor Coil on page lines from the outdoor unit to the indoor coil. Use Lennox L15 (sweat, non−flare) series line set, or field−fabricated refrigerant line sizes as specified in table 2.
  • Page 10 Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation: REFRIGERANT LINE SET INSTALLING REFRIGERANT LINE SET TRANSITION VERTICAL RUNS (NEW CONSTRUCTION SHOWN) FROM VERTICAL TO HORIZONTAL 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 ANCHORED HEAVY NYLON...

  • Page 11: Brazing Connections

    Brazing Connections Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves. WARNING 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.
  • Page 12 CAP AND CORE REMOVAL CUT AND DEBUR 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.
  • Page 13 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 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.

  • Page 14: Indoor Refrigerant Metering Device Removal And Flushing Line Set And Indoor Coil

    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. TYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL REMOVAL PROCEDURE (UNCASED...

  • Page 15: Installing New Indoor Metering Device

    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...

  • Page 16: Leak Test Line Set And Indoor Coil

    Leak Test Line Set and Indoor Coil 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 HIGH vapor valve service port. NOTE Normally, the high pressure hose is connected to the liquid MANIFOLD GAUGE SET line port.

  • Page 17: Evacuating Line Set And Indoor Coil

    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.

  • Page 18: Electrical Connections

    Electrical Connections IMPORTANT In the U.S.A., wiring must conform with current local codes Use a thermocouple or thermistor electronic vacuum and the current National Electric Code (NEC). In Canada, gauge that is calibrated in microns. Use an instrument wiring must conform with current local codes and the current capable of accurately measuring down to 50 microns.

  • Page 19: Low Voltage Connections

    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®...
  • Page 20 CBX32MV COMFORTSENSET HEAT PUMP UNIT 7000 X2658 OUTDOOR SENSOR IS REQUIRED FOR OUTDOOR (TWO−STAGE) CBX40UHV TEMPERATURE DISPLAY, DEW POINT CONTROL, HEAT PUMP AND DUAL FUEL BALANCE POINTS. CONNECTED ON UNIT WITH LSOM. RESISTOR KIT (CAT # 47W97) IS REQUIRED WHEN CONNECTING THE COMFORTSENSE 7000 WITH THE LSOM 2.
  • Page 21 Figure 16. Typical Unit Wiring Diagram (−024, −036 and −048 Only) Page 21 XP16 SERIES...
  • Page 22 Figure 17. Typical Unit Wiring Diagram (−060 Only) Page 22...

  • Page 23: Unit Start−Up

    Figure 18. Typical Factory Wiring Diagram (No Field Modifications) have consulted with the power company and the Unit Start−Up voltage condition has been corrected. 6. Open both the liquid and vapor line service valves to IMPORTANT release the refrigerant charge contained in outdoor unit into the system.

  • Page 24: Delivered Void Of Charge

    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 2.
  • Page 25 GAUGE SET MANIFOLD GAUGE SET HIGH CONNECTIONS FOR OPTIMIZING SYSTEM CHARGE 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 LIQUID PHASE DIGITAL SCALE TO LIQUID TEMPERATURE SENSOR LINE SERVICE (LIQUID LINE)

  • Page 26: Optimizing System Refrigerant Charge

    Optimizing System Refrigerant Charge This section provides instructions on optimizing the efficiency. Make any air flow adjustments before system charge. This section includes: continuing with the optimizing procedure. Optimizing procedure 5. Use subcooling method to optimize the system Adjusting indoor airflow charge (see figure 24).
  • Page 27 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.
  • Page 28 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.
  • Page 29 NORMAL OPERATING PRESSURES TEMPERATURE PRESSURES Use the following tables to perform maintenance checks; it Compute subcooling determining saturated is not a procedure for charging the system. Minor condensing temperature from temperature pressure variations in these pressures may be due to differences in chart.

  • Page 30: System Operation

    UNIT COMPONENTS System Operation Demand Defrost Control (A108) IMPORTANT The demand defrost control measures differential temperatures to detect when the system is performing Some scroll compressor have internal vacuum protector poorly because of ice build−up on the outdoor coil. The that will unload scrolls when suction pressure goes controller self−calibrates when the defrost system starts below 20 psig.
  • Page 31 Service Light Output 24VAC service light output. 24VAC typically used to supply power to the Lennox System Operation 24 Volt output Monitor (LSOM). Not used in this system. Page 31...
  • Page 32 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. Table 10. Demand Defrost Control (A108) Diagnostic LEDs DS1 and DS2 System Status, Fault and Lockout Codes Condition/Code Possible Cause(s)
  • Page 33 High Pressure Switch (S4) 2. If the demand defrost control recognizes five temperature sensor range faults during a single (Y1) When the high pressure switch trips, the demand defrost compressor demand, it reverts to a lockout mode and control will cycle off the compressor, and the strike counter displays the appropriate code.

  • Page 34: Defrost System

    If a pressure switch opens while the Y1 Out line is Defrost System engaged, a 5−minute short cycle will occur after the switch This section addresses: closes. Emergency Heat Demand Defrost Control Pressure Switch Connections Defrost System Overview The unit’s automatic reset pressure switches (LO PS − S87 Defrost Control Connections, Jumper Settings and and HI PS −...
  • Page 35 Compressor Delay Mode (P5) 1. Frost Detection If the compressor runs longer than 30 minutes and the actual difference between the clear The demand defrost control has a field−selectable function coil and frosted coil temperatures exceeds the to reduce occasional sounds that may occur while the unit maximum difference allowed by the demand defrost is cycling in and out of the defrost mode.
  • Page 36 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. Demand defrost control defaults to 30 minute Time / Temperature Mode Reset Compressor Runtime / Reset Three / Five Strike Counter DEMAND MODE THIRTY (30) MINUTE TIME / 45 MINUTE...
  • Page 37 Table 12. Ambient (RT13) and Coil (RT21) Sensors Temperature / Resistance Range Degrees Degrees Degrees Degrees Resistance Resistance Resistance Resistance Fahrenheit Fahrenheit Fahrenheit Fahrenheit 136.3 2680 56.8 16657 21.6 44154 −11.3 123152 133.1 2859 56.0 16973 21.0 44851 −11.9 125787 130.1 3040 55.3...
  • Page 38 Table 13. High Discharge Sensor (RT28) Temperature / Resistance Range Degrees Degrees Degrees Degrees Resistance Resistance Resistance Resistance Fahrenheit Fahrenheit Fahrenheit Fahrenheit 303.1 186.1 1052 136.8 2656 94.5 6613 298.1 185.0 1072 136.0 2698 93.6 6739 293.4 183.9 1093 135.2 2740 92.8 6869...
  • Page 39 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 Y1 is energized and 24V power is being applied to the Control, a test cycle can be initiated by placing a jumper on the Control’s TEST pins for 2 to 5 seconds.

  • Page 40: Two−Stage Modulation Compressors Checks

    7. Record all of the readings for the Y1 demand. Indoor Unit 1. Clean or change filters. 8. Close switch to energize Y2 demand. Verify power is going to compressor solenoid. 2. Lennox blower motors prelubricated permanently sealed. No more lubrication is needed.
  • Page 41 IMPORTANT Heat Pump Operation Your new Lennox heat pump has several characteristics Sprinklers and soaker hoses should not be installed that you should be aware of: where they could cause prolonged exposure to the Heat pumps satisfy heating demand by delivering outdoor unit by treated water.

  • Page 42: Checklists

    Accessories Lennox XP16 Engineering Handbook Lennox Product Catalog For update−to−date information, see any of the following Lennox Price Book publications: Checklists Two−Stage Modulation Compressors Field Operational Checklist Expected results during Y2 demand (Toggle switch On) Unit Readings Y1 − First-Stage Y2 −...
  • Page 43 XP16 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:...

This manual is also suitable for:

Elite xp16−048−230Elite xp16−036−230Elite xp16−060−230

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