Lennox XP21 Series Installation Instructions Manual
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Lennox XP21 Series Installation Instructions Manual

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E20 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
NOTICE TO INSTALLER
UNIT PLACEMENT
It is critical for proper unit operation to place outdoor unit on an
elevated surface as described in Unit Placement section on page 7.
DEFROST OPERATION
It is critical for proper defrost operation to set the defrost termination
pins (E47) on the heat pump control prior to starting system. See
Defrost System section on page 33 for further details.
BRAZING LINE SET TO SERVICE VALVES
It is imperative to follow the brazing technique illustrated starting on
page 13 to avoid damaging the service valve's internal seals.
NOTICE
A thermostat is not included and must be ordered
separately.
D The Lennox icomfort Touch
in communicating application
D In
non−icomfortt
®
ComfortSense
7000 thermostat may be used, as well
as other non−communicating thermostats.
In all cases, setup is critical to ensure proper system
operation.
Field wiring examples for non−icomforttapplications
begin on page 25.
See the icomfort Touch
®
for communicating and partial communicating field
wiring connections.
06/11
*2P0611*
®
thermostat must be used
applications,
the
Lennox
thermostat Quick Start Guide
INSTALLATION
INSTRUCTIONS
Dave Lennox Signature
Collection XP21 System
HEAT PUMPS
506601−01
06/11

TABLE OF CONTENTS

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Air Handler / Coil Match up and Targeted
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General

This outdoor unit is designed for use with HFC−410A
refrigerant only. This unit must be installed with an
approved indoor air handler or coil. See the Lennox XP21
Engineering Handbook for approved indoor component
match ups.
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Summary of Contents for Lennox XP21 Series

  • Page 1: Table Of Contents

    This unit must be installed with an See the icomfort Touch thermostat Quick Start Guide ® approved indoor air handler or coil. See the Lennox XP21 for communicating and partial communicating field Engineering Handbook for approved indoor component wiring connections.

  • Page 2: Unit Dimensions

    Unit Dimensions −− Inches (mm) 35−1/2 DISCHARGE AIR (902) 39−1/2 (1003) ELECTRICAL INLET (HIGH VOLTAGE) 37 (940) (−024 AND −036) 47 (1194) (−048 AND −060) 4−1/2 (114) SUCTION LINE INLET ELECTRICAL INLET (CONTROL WIRING − LOW VOLTAGE) LIQUID LINE SOLAR MODULE 18−1/2 INLET WIRING...

  • Page 3: Typical Unit Parts Arrangement

    LIQUID VALVE AND GAUGE PORT CRANKCASE HEATER (HR1) TRUE SUCTION LINE (BELLY BAND) PORT CRANKCASE HEATER THERMOSTAT (S40) LIQUID LINE BI−FLOW HIGH PRESSURE FILTER DRIER SWITCH (S4) LOW PRESSURE SWITCH (S87) Figure 1. Plumbing, Switches and Sensor Components Page 3 XP21 SERIES...

  • Page 4: Shipping And Packing List

    Assembled outdoor unit. See the Lennox Service and Application Notes #C−08−1 for further details and information. Bag assembly which includes the following: Page 4 506601−01...

  • Page 5: Supersedes

    1/12 turn clockwise. STEM CAP TO OUTDOOR UNIT NOTE A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque. Figure 2. Angle and Ball Service Valves Page 5 XP21 SERIES...

  • Page 6: Recovering Refrigerant From Existing System

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

  • Page 7: Unit Placement

    If it is necessary to extend to a window see the provided illustration in figure 5, further, consider a different type of field−fabricated detail A. framework that is sturdy enough for greater heights. Page 7 XP21 SERIES...
  • Page 8 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 9: Removing And Installing Panels

    (e.g., being bent or scratched). While handling or stowing the panels, consider any weather conditions, especially windy conditions, that INLET AIR may cause panels to be blown around and battered. INLET AIR Figure 6. Rooftop Application and Wind Barrier Page 9 XP21 SERIES...
  • Page 10 REMOVING AND INSTALLING PANELS Panel shown slightly rotated to allow top tab to exit (or enter) top slot for removing (or installing) panel. REMOVE 4 SCREWS TO WARNING REMOVE PANEL FOR LOUVERED PANEL REMOVAL ACCESSING COMPRESSOR Remove the louvered panels as follows: AND CONTROLS.

  • Page 11: New Or Replacement Line Set

    This section provides information on installation or replacement of existing line set. If new or replacement line To obtain the correct information from Lennox, be sure to set is not being installed then proceed to Brazing communicate the following information: Connections on page 13.
  • Page 12 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 13: Brazing Connections

    Wash hands with soap and water after handling brazing plosion, that could result in property alloys and flux. damage, personal injury or death. Page 13 XP21 SERIES...
  • Page 14 CAP AND CORE REMOVAL PIPING PANEL REMOVAL AND PREPARING LINE Remove service cap and core from both the suction / vapor and liquid line service ports. Remove piping panel for easier access to service valves. Cut ends SERVICE PORT CAP of the refrigerant lines square (free from nicks or dents) and debur the ends.
  • Page 15 After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water saturated cloths to both services valves to cool piping. Once piping is cool, remove all water saturated cloths. Refer to the unit installation instructions for the next step in preparing the unit. Figure 10. Brazing Procedures (Continued) Page 15 XP21 SERIES...

  • Page 16: Flushing Line Set And Indoor Coil

    Flushing Line Set and Indoor Coil The following procedure should not be performed on a system which contain contaminants (i.e., compressor burn out). TYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL REMOVAL PROCEDURE (UNCASED PROCEDURE (UNCASED COIL SHOWN) COIL SHOWN) STUB END TWO PIECE PATCH PLATE LIQUID LINE...

  • Page 17: 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 XP21 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 18: Leak Test Line Set And Indoor Coil

    1 or 2 psig (6.9 to 13.8 kPa). 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 19 Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core tool while maintaining a positive system pressure. Replace stem caps and secure finger tight, then tighten an additional one−sixth (1/6) of a turn as illustrated. Figure 14. Evacuating System Page 19 XP21 SERIES...

  • Page 20: Electrical

    temperatures and pressures present during operation of IMPORTANT an air conditioning system. Non−condensables and water suction combine with refrigerant to produce substances Use a thermocouple or thermistor electronic vacuum that corrode copper piping and compressor parts. gauge that is calibrated in microns. Use an instrument Electrical capable of accurately measuring down to 50 microns.
  • Page 21 HIGH VOLTAGE ELECTRICAL INLET CONDUIT HOLE CONTACTOR (HIGH VOLTAGE) WATERTIGHT CONDUIT FITTING WIRING ENTRY POINTS WATERTIGHT FLEXIBLE CONDUIT TO SERVICE DISCONNECT BOX ELECTRICAL INLET (CONTROL WIRING LOW VOLTAGE). USE BUSHING PROVIDED IN BAG ASSEMBLY HERE. ACCESS VIEW Page 21 XP21 SERIES...
  • Page 22 Figure 15. Typical XP21 Wiring Page 22 506601−01...

  • Page 23: Heat Pump Control (A175) Jumpers And Terminals

    Earlier produce units will have a default factory setting (jumper *NO JUMPER present) for 40ºF. Later produce units will have no jumper by default present on E48. Figure 16. Heat Pump Control Connections, Jumper Settings and LED Locations Page 23 XP21 SERIES...
  • Page 24 Table 3. Heat Pump Control (A175) Jumper and Terminal Descriptions Control ID Label Description PSC Fan 240VAC output connection for outdoor fan. PSC Fan 240VAC input connection for outdoor fan. 24VAC output for defrost auxiliary heat output. Thermostat service light connection. 24VAC thermostat input/output for second stage operation of the unit.

  • Page 25: Field Control Wiring

    Harmony IIIt zoning system applications. This will slow the indoor blower motor to the lowest speed setting. See furnace installation instruction or engineering handbook for lowest fan speed information. Figure 17. ComfortSense® 7000 Series Thermostat Air Hander/Two−Stage Heat Pump Page 25 XP21 SERIES...
  • Page 26 INTEGRATED FURNACE CONTROL INDOOR (A95) THERMOSTAT (S1) HEAT PUMP On−board link CONTROL (A175) Low voltage thermostat wiring 1. Thermostat T terminals are used for outdoor sensor input. Use for thermostat’s outdoor temperature display (optional). ® 2. R to L connection is required for this model when using the ComfortSense 7000 −...

  • Page 27: Servicing Unit Delivered Void Of Charge

    BConnect the manifold gauge set’s low pressure side to the true suction port. CConnect the manifold gauge set’s high pressure side to the liquid line service port. DPosition temperature sensor on liquid line near liquid line service port. Figure 19. Gauge Set Connections Page 27 XP21 SERIES...
  • Page 28 ADDING OR REMOVING REFRIGERANT Temperature rise between the return air and supply air This system uses HFC−410A refrigerant which operates at temperatures at the indoor coil blower unit, much higher pressures than HCFC−22. The pre−installed liquid line filter drier is approved for use with HFC−410A Measuring voltage supplied to the unit, only.
  • Page 29 11. If refrigerant is added or removed, repeat steps 5 through 6 to verify charge. 12. Disconnect gauge set and re−install both the liquid and suction service valve caps. Figure 22. Using HFC−410A Subcooling Method High Stage (High Capacity) Page 29 XP21 SERIES...

  • Page 30: Subcooling Values

    Air Handler / Coil Match ups and Targeted Subcooling Values Listed below are the targeted subcooling and charging values for approved indoor unit air handler / coil match ups. This information is also listed on the unit charging sticker located on the access panel. * Indicates amount of charge required in additional to charge shown on unit nameplate.

  • Page 31: Operating And Temperature Pressures

    20 (−7) 30 (−1) 40 (4) 50 (10) 60 (16) High Stage Cooling Operation 65 (18) 70 (21) 75 (24) 80 (27) 85 (29) 90 (32) 95 (35) 100 (38) 105 (41) 110 (43) 115 (46) Page 31 XP21 SERIES...

  • Page 32: System Operations

    Table 9 HFC−410A Temperature (°F) − Pressure (Psig) °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig 100.8 137.1 178.5 231.6 290.8 365.0 545.6 445.9 102.9 139.6 181.6 235.3 295.1 370.0 451.8 552.3 105.0 142.2 184.3...

  • Page 33: Defrost System

    Defrost calibration and operation (see figure 27) appropriate fault code. Heating and cooling operation will Defrost test (see figure 28) be allowed in this fault condition. Page 33 XP21 SERIES...
  • Page 34 If the jumper is not connected to one of the temperature High Discharge Line Temperature Sensor (RT28) selection pins on E48 (40, 45, 50, 55°F), the second stage See table 10 for sensor range. The high discharge line lock−in feature is inactive. Factory default is no jumper temperature sensor (location shown in figure 1 monitors present.
  • Page 35 E47 E47 pins*. pins*. Calibration Attempted (Unit Running in Heat Mode) Calibration Figure 27. Defrost Calibration Sequence of Operations Page 35 XP21 SERIES...
  • Page 36 MULTI−FUNCTION TEST PINS (E33) Placing the jumper on the field test pins (E33) using a specific sequence allows the technician to: Clear short cycle lockout Clear five−strike fault lockout Cycle the unit in and out of defrost mode Manually place the unit in defrost mode to clear the coil When Y1 is energized and 24V power is being applied to the heat pump control (A175), a test cycle can be initiated by placing a jumper on the heat pump control’s TEST pins for 2 to 5 seconds.
  • Page 37 CONTACTOR ENERGIZED LED ALERT CODE / OR NORMAL PRESSURE MODERATE CLOSED OPERATION SWITCH (S87) ALERT 410 DISPLAYED SERVICE REQUIRED WAITING FOR PRESSURE OPEN CLOSED SWITCH TO CLOSE Figure 29. Low Pressure Switch (S87) Sequence of Operation Page 37 XP21 SERIES...
  • Page 38 HIGH COMPRESSOR PRESSURE CLOSED Y1 DEMAND CONTACTOR SWITCH (S4) ENERGIZED HIGH PRESSURE CLOSED OPEN SWITCH (S4) COMPRESSOR CONTACTOR If 5−strike counter has four or less strikes when Y1 demand is terminated DE−ENERGIZED ® or satisfied, the strike counter will reset to zero. In a icomfort Touch thermostat enabled setup, the thermostat will terminate demand when the compressor contactor is de−energized.
  • Page 39 IS AT OR BELOW 225ºF LED ALERT CODE / OR COMPRESSOR NORMAL MODERATE CONTACTOR OPERATION ALERT 414 ENERGIZED CLEARED WAITING FOR TEMPERATURE DROP TO OR BELOW 225ºF Figure 31. High Discharge Temperature Sensor (RT28) Sequence of Operation Page 39 XP21 SERIES...
  • Page 40 INITIAL TRIP Y1 DEMAND SWITCH IS IGNORED FOR 90 SECONDS COMPRESSOR CONTACTOR ENERGIZED NORMAL W OUTPUT OPERATION ACTIVE) COMPRESSOR CONTACTOR DE−ENERGIZED LED ALERT COMPRESSOR CODE / OR W OUTPUT ANTI−SHORT MODERATE ACTIVE) CYCLE TIMER ALERT 418 BEGINS DISPLAYED ANTI−SHORT CYCLE TIMER COMPRESSOR ENDS ANTI−SHORT...
  • 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 XP21 SERIES...
  • Page 42 Table 12. 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 43: System Status, Fault And Lockout Led Codes

    Code 417 Heat pump Indicates that heat pump control has an internal component failure. Cycle 24 volt power applicable control failure to heat pump control. If code does not clear, replace the heat pump control. Page 43 XP21 SERIES...
  • Page 44 System fault and lockout LED (DS11 / DS14) alarm codes takes precedence over system status LED codes (cooling, heating stages or defrost/dehumidification). Only the latest active LED fault or lockout alarm code if present will be displayed. If no fault or lockout codes are active, then system status LEDs are routinely displayed.
  • Page 45 Fast simultaneous flashing of DS11, OEM mode Factory test mode. DS13, DS14 and DS15 1. Pause duration is two (2) seconds. 2. Fast flash duration is 1/2 second. Slow flash duration is one (1) second. Page 45 XP21 SERIES...
  • Page 46 Table 14. Compressor Fault and Alarm LED Codes and Related icomfort Touch ® Thermostat Alert Codes NOTE See notes 1 and 2 in table below for duration of fast / slow flashes and pause. Heat Pump Control icomfort LEDs ® Possible Touch Condition...
  • Page 47 1. Pause duration is two (2) seconds. 2. Fast flash duration is 1/2 second. Slow flash duration is one (1) second. 3. Initially a moderate status is displayed and is escalated to critical if alarm exists for more than 10 minutes. Page 47 XP21 SERIES...

  • Page 48: Field Component Configuration And Testing

    FAN MOTOR CONTROL (A177) OPERATION, AND Field Component Configuration and TROUBLESHOOTING Testing This section provides information concerning operation This section provides procedures for configuring, and testing of the fan control. adjusting and testing various components of this unit. Fan Motor Control Sequence of Operation Fan motor (B4) test procedure During start up, the following sequence is followed: Fan motor control (A177) configuration and testing...
  • Page 49 Between 24VDC and 32 VDC at each input ECM/Y1 − ECM/Y2 and ECM C (High Stage) NONE at each input Between 24VDC and 32 VDC ECM/Y2 and ECM C (EDA Operation) NONE 24VAC EXT ECM/R and ECM C NONE Page 49 XP21 SERIES...
  • Page 50 DEMAND BEGINS DEFAULT MISMATCHED REPLACE FAN MOTOR FAN MOTOR CONTROL BOARD LED CONTINUOUS FAST SPEED USED FLASH DEFAULT FAN REPLACE FAN MOTOR MOTOR FAILURE LED CONSTANT ON CONTROL BOARD SPEED USED FAN MOTOR LED STAGE INDICATOR: ONE STAGE ECM1/Y1 RPM SET PER ONE SLOW FLASH AND (LOW) ONLY...

  • Page 51: Control Box

    HIGH PRESSURE SWITCH (S4) YELLOW BLUE BLACK YELLOW YELLOW FAN MOTOR YELLOW YELLOW CONTROL SEE TABLE 15 FOR CFM PROFILE SELECTION OPTIONS. HEAT PUMP CONTROL Figure 35. Fan Motor Control, Wiring, Jumper Settings, Testing and LED Location Page 51 XP21 SERIES...
  • Page 52 CONTROL BOX FAN MOTOR CONTROL (A177) PULSE−WIDTH MODULATION (PWM) INPUT VOLTAGES DURING DEMAND ECM/Y1 ONLY − 24VDC BOTH ECM/Y1 AND ECM/Y2 − 24VDC AT EACH INPUT ECM/Y2 ONLY − 24VDC YELLOW WIRE HEAT PUMP BLUE WIRE CONTROL (A175) BLACK WIRE ONE YELLOW WIRE FROM PS (E24) TERMINAL ON HEAT PUMP CONTROL.
  • Page 53 Fan Motor Position Adjustment. FAN MOTOR POSITION ADJUSTMENT Loosen the four fan motor grille mounting fasteners and push the fan motor forward. tighten mounting hardware. ORIFICE RING GRILLE MOUNTING POINTS Figure 37. Fan Blade Clearance Adjustment Page 53 XP21 SERIES...
  • Page 54 HEAT PUMP CONTROL (A175) UNIT NOMINAL CAPACITY CODE CONFIGURATION In a communicating system, if the room thermostat is indicating either a error code 313, indoor and outdoor unit capacity mismatch error code, or error code 34, must program unit capacity for outdoor unit (see figure 38). START FINISH DS14 (Red)

  • Page 55: Maintenance (Dealer And Homeowner)

    Heavy snow and/or freezing rain can interfere with the 5. Check for correct voltage at unit (unit operating). performance of the outdoor fan assembly. Lennox 6. Check amp draw on outdoor fan motor. recommends use of the optional snow guard (X8782) in Motor Nameplate:_________ Actual:__________.
  • Page 56 Heat Pump Operation IMPORTANT Your new Lennox heat pump has several characteristics that you should be aware of: Sprinklers and soaker hoses should not be installed Heat pumps satisfy heating demand by delivering where they could cause prolonged exposure to the large amounts of warm air into the living space.

  • Page 57: Sunsource ® Home Energy System

    The SolarSynct package consists of the following (black wire) wire of the compressor harness. Attach components: thermometer to discharge line as close as possible to ® Lennox Solar Subpanel installed in a Dave Lennox the compressor. ® Signature Collection air conditioner or heat pump unit.
  • Page 58 XP21 Field Operational Checklist Cooling*** Heating*** Unit Readings Expected results Expected results Y2 Second First during Y2 demand Second during Y2 demand First Stage Stage Stage (Toggle switch On) Stage (Toggle switch On) Compressor Voltage Same Same Amperage Higher Higher Condenser Fan motor Amperage Same or Higher...
  • Page 59 Saturated Condensing Temperature (A) minus 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) minus Supply Air Temperature (B) Page 59 XP21 SERIES...

This manual is also suitable for:

Xp21−024Xp21−036Xp21−048Xp21−060

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