Lennox XPG20 Installation Instructions Manual
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Lennox XPG20 Installation Instructions Manual

Lennox XPG20 Installation Instructions Manual

Solar assist heat pumps
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E2009 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
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.
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.
IMPORTANT
The Clean Air Act of 1990 bans the intentional
venting of refrigerant (CFCs, HCFCs AND HFCs) as
of July 1, 1992. Approved methods of recovery,
recycling or reclaiming must be followed. Fines
and/or
incarceration
noncompliance.
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox' Engineering Handbook.
Coils previously charged with HCFC−22 must be
flushed.
06/09
*2P0609*
may
be
levied
for
INSTALLATION
INSTRUCTIONS
Dave Lennox Signature
Collection XPG20
SunSource
System
SOLAR ASSIST HEAT PUMPS
506238−01
06/09
Supersedes 05/09

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Summary of Contents for Lennox XPG20

  • Page 1: Table Of Contents

    Lennox System Operation Monitor (LSOM) ..LSOM Module and System Troubleshooting LEDs Defrost System .......

  • Page 2: Unit Dimensions

    (117) BASE Field Supplied Components The followings items are field supplied (not included). Parts Lennox Catalog Numbers Solar Module (see Figure 17 for specifications) 48W00 Solar Module Mounting Kit − Roof applications 48W01 Solar Module Mounting Kit − Pole applications...

  • Page 3: Unit Parts Arrangement

    FAN MOTOR FAN MOTOR MOUNT OUTDOOR FAN CONTACTOR SOLAR ASSIST DC MOTOR COUPLER DEFROST CONTROL SOLAR ASSIST DC MOTOR LENNOX SYSTEM OPERATION MONITOR (LSOM) RUN CAPACITOR SOLAR PANEL TERMINAL BLOCK VAPOR VALVE AND GAUGE PORT TWO−STAGE COMPRESSOR DISCHARGE LINE REVERSING VALVE COMPRESSOR TERMINAL BI−FLOW FILTER DRIER...

  • Page 4: Shipping And Packing List

    50Rc risks rounding or breaking off the wrench, or immediately if damage is found. stripping the valve stem recess. Assembled outdoor unit. See the Lennox Service and Application Notes Bag assembly that consist of the following: #C−08−1 for further details and information. Bushing (for low voltage wiring) Isolation grommets for liquid and suction lines Table 1.
  • Page 5 A label with VALVE specific torque requirements may be affixed to the stem Figure 1. Various Types of Service Valves cap. If the label is present, use the specified torque. Page 5 XPG20 SERIES...

  • Page 6: Recovering Refrigerant From Existing System

    pumping) when the pressure ratio meets a certain Recovering Refrigerant from Existing value or when the suction pressure is as high as 20 System psig. (Compressor suction pressures should never be Connect gauge set as illustrated in Figure 2 for removing allowed to go into a vacuum.

  • Page 7: Positioning New Outdoor Unit

    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. Figure 6. Slab Mounting at Ground Level Page 7 XPG20 SERIES...

  • Page 8: Removing And Installing Panels

    ELEVATING THE UNIT WARNING These units are outfitted with elongated support feet as illustrated in Figure 7. Unit must be grounded in accordance with national local codes. BASE Electric Shock Hazard. Can cause injury or death. Line voltage present components when unit is not in operation on units with single-pole contactors.

  • Page 9: New Or Replacement Line Set

    Figure 10 using conventional refrigerant lines will not create unnecessary vibration and practices. Replace the panels after installation is subsequent sounds. Also, consider the following when complete. placing and installing a high−efficiency air conditioner. Page 9 XPG20 SERIES...
  • Page 10 WIRE TIE OR AUTOMOTIVE MUFFLER-TYPE HANGER is existing, it must be replaced. If the XPG20 must be matched with a proper coil. The only existing installed coils that could be re−used would be current coils listed in the XPG20 matchup charts.

  • Page 11: Brazing Connections

    Cut ends of the refrigerant lines square (free from nicks or Remove service cap and core from both the suction and liquid dents). Debur the ends. The pipe must remain round, do not line service ports. pinch end of the line. Page 11 XPG20 SERIES...
  • Page 12 ATTACHED GAUGES USE REGULATOR TO FLOW NITROGEN AT 1 TO 2 PSIG. HIGH Connect gauge set low pressure side to liquid line service valve. Connect gauge set center port to bottle of nitrogen with regulator. ATTACH GAUGES SERVICE PORT MUST BE OPEN TO ALLOW EXIT POINT FOR NITROGEN SUCTION LINE SERVICE...

  • Page 13: Flushing The System

    4. Connect recovery tank to recovery machines per machine 4. Close the valve on the inverted HCFC−22 drum and the gauge set valves. instructions. Pump the remaining refrigerant out of the recovery machine and turn the machine off. Page 13 XPG20 SERIES...
  • Page 14 TYPICAL CHECK THERMAL EXPANSION VALVE (CTXV) INSTALLATION PROCEDURE This outdoor unit is designed for use in systems that use CTXV metering device. See the Lennox XPG20 Engineering Handbook for approved CTXV kit match−ups and application information. The CTXV 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 CTXV in a manner that will provide access for field servicing of the CTXV.

  • Page 15: Leak Testing The System

    Take care to empty all personal injury or death. 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...
  • Page 16 LEAK TESTING THE SYSTEM After the line set has been connected to the indoor unit and air conditioner, check the line set connections and indoor unit for leaks. Use the following procedure to test for leaks: MANIFOLD GAUGE SET HIGH OUTDOOR UNIT USE REGULATOR TO FLOW NITROGEN AT 1...

  • Page 17: Evacuating The System

    Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core tool while maintaining a positive system pressure. Replace the stem caps and secure finger tight, then tighten an additional one−sixth (1/6) of a turn as illustrated. Page 17 XPG20 SERIES...

  • Page 18: Servicing Unit Delivered Void Of Charge

    230VAC SUPPLY VOLTAGE IMPORTANT The XPG20 outdoor unit is rated for 230VAC applications only. Use a thermocouple or thermistor electronic 24VAC TRANSFORMER vacuum gauge that is calibrated in microns. Use an 24VAC for the heat pump is provided by the indoor unit instrument capable of accurately measuring down transformer.
  • Page 19 To ACCESS VIEW facilitate a conduit, a cutout is located in the bottom of the control box. Connect conduit to the control box using a proper conduit fitting. Page 19 XPG20 SERIES...

  • Page 20: Solar Module Setup And Connections

    (ECM) that is coupled directly to the AC powered ECM The solar module should be mounted in a location where it motor used in the XPG20 heat pump. This DC motor is will receive maximum sunlight throughout the year. When wired directly to the output of the single solar module.
  • Page 21 Solar module should be mounted with proper gap for The solar module should be grounded according to ventilation air to flow under the solar module for cooling. (See solar module manufacturer’s recommendations.) NEC 690 Section V or local code requirements. Page 21 XPG20 SERIES...
  • Page 22 TO EARTH GROUND PER NEC (FIELD PROVIDED) 690 SECTION V FIELD WIRING (FIELD PRO- VIDED) WEATHERPROOF ELECTRICAL PIPING MODULE ENCLOSURE (FIELD PROVIDED) XPG20 CONTROL BOX COMPLETE BOX AVAILABLE AS CAT # 48W03 GROUND CONTACTOR WATERTIGHT FLEXIBLE CONDUIT (FIELD PROVIDED) TO EARTH GROUND...
  • Page 23 MOTOR ALIGNMENT ADJUSTMENT OPERATIONS Before start up of the XPG20 unit, perform the procedure The DC motor is an electronically commutated brushless outlined in Figure 18. DC external rotor motor. The motor is rated at 1/5 HP and 8.5A FLA. The motor requires a 24 VDC nominal input (16 min to 28 max).

  • Page 24: Unit Start−Up

    5. Check voltage supply at the disconnect switch. The Unit Start−Up voltage must be within the range listed on the unit’s nameplate. If not, do not start the equipment until you IMPORTANT have consulted with the power company and the voltage condition has been corrected.
  • Page 25 Changing air flow affects all temperatures; recheck temperatures to confirm that the temperature drop and DT are within +3º. 4. Adjust the fan speed See indoor unit instructions to increase/decrease fan speed. Figure 20. Checking Indoor Airflow over Evaporator Coil using Delta−T Chart Page 25 XPG20 SERIES...

  • Page 26: Adding Or Removing Refrigerant

    Temperature rise between the return air and supply air Adding or Removing Refrigerant temperatures at the indoor coil blower unit, This system uses HFC−410A refrigerant which operates at Measuring voltage supplied to the unit, much higher pressures than HCFC−22. The pre−installed liquid line filter drier is approved for use with HFC−410A Measuring amperage being drawn by the heat unit(s).
  • Page 27 11. If refrigerant is added or removed, repeat steps 4 through 5 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 Second Stage (High Capacity) Page 27 XPG20 SERIES...
  • Page 28 Table 3. HFC−410A Normal Operating Pressures Table 4 XPG20−036 Matchups * Target Subcooling This table is used to perform maintenance checks and is INDOOR HEAT **Add Heating Cooling MATCH−UP PUMP charge (+5ºF) (+1ºF) not a procedure for charging the system. Minor varia- tions in these pressures may be due to differences in installations.

  • Page 29: System Operations

    If replacement is 115.8 200.6 321.8 487.8 necessary, order another of like design and capacity. 118.0 203.9 326.4 494.0 120.3 207.2 331.0 500.2 Lennox System Operation Monitor 122.6 210.6 335.7 506.5 (LSOM) 125.0 214.0 340.5 512.9 OVERVIEW 127.3 217.4 345.3 519.3...

  • Page 30: Lsom Module And System Troubleshooting Leds

    conditions return to normal, the alert code is turned off Disconnecting R wire from the LSOM’s R automatically. terminal. LSOM Module and System Turning the indoor unit off an on again Troubleshooting LEDs 2. Automatic Reset After an alert is detected, the LSOM continues to Use Tables 7 and 8 to identify either module or system monitor the compressor and system.
  • Page 31 LSOM module reduces voltage to between 4 to 18 VDC . Every 15 minutes the solenoid voltage will be increase to 24 volts for a few seconds to ensure solenoid valve is engaged until Y2 signal is no longer present. Page 31 XPG20 SERIES...
  • Page 32 Table 9. DCB Jumper and Terminal Descriptions DEFROST CONTROL BOARD Description 100135−05 (LENNOX CAT# 42W04) O OUT 24 VAC output connection for reversing valve. LO−PS Connection for low−pressure switch 24 VAC output for second stage compressor sole- NOTE Component locations may vary by board manufacturer.

  • Page 33: Defrost System

    (open and close). while the coil temperature remains below 35°F NOTE Individual HI−PS and LO−PS trips are totaled by (2°C), the demand defrost control will initiate a the DCB. defrost cycle. Page 33 XPG20 SERIES...
  • Page 34 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 35 8. Close switch to energize Y2 demand. Verify power is NOTE The LSOM has a five second delay between Y2 going to compressor solenoid (see note ** in the Field being powered and the solenoid energizing. Operational Checklist on page 42). Page 35 XPG20 SERIES...
  • Page 36 9. Allow pressures and temperatures to stabilize before As the detected temperature changes, the resistance taking any measured reading (this may take up to 10 across the sensor changes. Figure 25 shows how the minutes). resistance varies as the temperature changes for both type of sensors.
  • Page 37 Secure with wire tie. DETAIL A DEFROST COIL SENSOR: 12 TUBES UP FROM BOTTOM (11−1/2") OUTSIDE ROW DETAIL C DISCHARGE LINE SENSOR Figure 24. Defrost Coil, Ambient, and Discharge Line Sensor Locations Page 37 XPG20 SERIES...
  • Page 38 2. Ambient Sensor (RT13) This sensor (see mounting location in Figure 24, Detail A) considers Ambient and Coil Sensor outdoor temperatures below −35°F (−37°C), or 5750 above 120°F (48°C) as a fault condition. 7450 If the ambient sensor is detected as being open, 9275 shorted or out of the temperature range of the sensor, 11775...

  • Page 39: Defrost Control Board Diagnostic Leds

    90 seconds before checking sensor resistance. If the sensor resist- ance is not within range after 90 seconds, the board will count one fault. After 5 faults, the board Fast Discharge Sensor Lockout will lockout. Flash Page 39 XPG20 SERIES...

  • Page 40: Maintenance

    SERVICE CHECKS 1. Air Filter Ask your Lennox dealer to show you where your indoor unit’s filter is located. It will be either at the Before the start of each heating and cooling season, the...
  • Page 41 OPTIONAL ACCESSORIES 1. Temperature Setting Levers Optional accessories for the XPG20 include the following: Most heat pump thermostats have two temperature selector levers: one for heating and one for cooling. Low ambient kit Set the levers or dials to the desired temperature Snow Guard −...

  • Page 42: Field Operational Checklist

    On the XPG20 units, the Lennox System Operational Module controls the second−stage solenoid coil in compressor. Cooling Mode Operation − Block outdoor coil to maintain a minimum of 375 psig during testing. Heating Mode Operation − Block indoor coil to maintain a minimum of 375 psig during testing.

  • Page 43: Start−Up And Performance Checklist

    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 43 XPG20 SERIES...

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