Lennox XP16 Series Unit Information
Hfc-410a
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Also See for XP16 Series:
- Brochure & specs (4 pages) ,
- Installation instructions manual (29 pages) ,
- Installation instructions manual (21 pages)
Table of Contents
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Service Literature
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 may be
levied for noncompliance.
Corp. 0626−L5
Revised October 21, 2010
XP16 (HFC−410A) SERIES UNITS
Page 1
TABLE OF CONTENTS
Typical Serial Number Identification
Specifications
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Unit Wiring Diagram and Sequence of
Operations
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Checklists
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The XP16 is a high efficiency residential split−system
two−stage heat
pump unit, which features a scroll
compressor and HFC−410A refrigerant. XP16 units are
available in 2, 3, 4 and 5 tons. tons. XP16 units are rated for
230 volts only. Applications where supply voltage is less
requires a hard start kit. The series is designed for use with
an indoor unit with an expansion valve approved for
HFC−410A.
death.
Unit
accordance with national and local codes.
Line voltage is present at all components
when unit is not in operation on units with
single-pole contactors. Disconnect all
remote electric power supplies before
opening access panel. Unit may have
multiple power supplies.
XP16
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be
grounded
2006 Lennox Industries Inc.
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Table of Contents
Related Manuals for Lennox XP16 Series
Summary of Contents for Lennox XP16 Series
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Page 1: Table Of Contents
Disconnect all Approved methods of recovery, recycling or reclaiming remote electric power supplies before must be followed. Fines and/or incarceration may be opening access panel. Unit may have levied for noncompliance. multiple power supplies. 2006 Lennox Industries Inc. Page 1... -
Page 2: Model Number Identification
Model Number Identification − − − P 16 036 Refrigerant Type Minor Revision Number X = HFC−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 Typical Serial Number Identification 19 09... -
Page 3: Electrical Data
Electrical Data 208/230V−60 Hz−1 Ph Unit Compressor Condenser Fan Maximum Locked Over− Minimum Model Number Rated Load Motor Motor Nominal Full Load Locked Rotor Rotor current Circuity Amps (RLA) Type Amps (FLA) Amps (LRA) Amps Protection Ampacity (LRA) (amps) XP16−024−230−01 14.0 10.25 52.0... -
Page 4: Unit Dimensions
Unit Dimensions − Inches (mm) LIQUID LINE CONNECTION ELECTRICAL INLETS SUCTION LINE CONNECTION 4−3/4" 4−1/2" (121) (108) TOP VIEW SIDE VIEW UNIT SUPPORT UNIT SUPPORT FEET FEET 9−1/2 8−1/2 (241) (216) 8−3/4 8−1/4 (222) (210) 5−1/2 13−1/2 (140) (343) XP16−036 to −060 BASE WITH LEGS XP16−024 BASE SECTION Model Number XP16−024−01,... -
Page 5: Unit Parts Arrangement
Typical Unit Parts Arrangement CAPACITOR (LOCATION OF CAPACITOR VARIES.) DEFROST CONTROL (A108) FOR COIL SENSOR (RT21) LOCATION SEE FIGURE 2. CHECK EXPANSION VALVE COMPRESSOR GROUND AMBIENT TEMPERATURE CONTACTOR SENSOR (RT13) (K−1) DISCHARGE LINE SENSOR (RT28) REVERSING VALVE REVERSING VALVE SOLENOID TRUE SUCTION PORT HIGH PRESSURE SWITCH (S4) LOW PRESSURE SWITCH (S87) - Page 6 XP16−024 COIL SENSOR 7 tubes up from XP16−048 bottom (7−1/2") COIL SENSOR − EIGHT HAIRPIN UP FROM THE BOTTOM ON INSIDE ROW. XP16−036 COIL SENSOR 17 tubes up XP16−024 from bottom COIL SENSOR −THIRD (17−1/2") HAIRPIN DOWN FROM THE TOP ON INSIDE ROW.
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Page 7: Operating Gauge Set And Service Valves
Using an Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench, or stripping the valve stem recess. See the Lennox Service and Application Notes #C−08−1 for further details and information. Page 7 XP16... - Page 8 SERVICE VALVES ANGLE AND BALL 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.
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Page 9: Recovering Refrigerant From System
Recovering Refrigerant from 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 instructions provided with the recovery machine to make the connections. -
Page 10: Unit Placement
CLEARANCE ON ALL SIDES INCHES (MILLIMETERS) 6 (152) ACCESS PANEL MINIMUM CLEARANCE NOTES: ABOVE UNIT CONTROL PANEL Clearance to one of the other three ACCESS sides must be 36 inches (914mm). LOCATION 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 11 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.
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Page 12: Removing And Installing Panels
STABILIZING UNIT ON UNEVEN SURFACES Removing and Installing Panels IMPORTANT IMPORTANT Unit Stabilizer Bracket Use (field−provided): Do not allow panels to hang on unit by top tab. Tab is for Always use stabilizers when unit is raised above the alignment and not designed to support weight of panel. factory height. - Page 13 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.
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Page 14: New Or Replacement Line Set
This section provides information on installation or Technical Support Product Applications for assistance. 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 16. - Page 15 Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation: REFRIGERANT LINE SET TRANSITION REFRIGERANT LINE SET INSTALLING 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 ANCHORED HEAVY NYLON...
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Page 16: Brazing Connections
Brazing Connections IMPORTANT Use the procedures outline in figures 9 and 10 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 valve. WARNING Danger of fire. - Page 17 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 18 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.
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Page 19: Flushing Line Set And Indoor Coil
Flushing Line Set and Indoor Coil 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 CHECK DISTRIBUTOR TUBES (UNCASED COIL ONLY) ORIFICE EXPANSION LIQUID LINE ORIFICE HOUSING HOUSING VALVE... -
Page 20: Installing Indoor Metering Device
See the Lennox XP16 Engineering Handbook for approved expansion valve. Refer to below illustration for reference expansion valve kit match−ups. The expansion valve unit can be installed internal or external to the indoor coil. -
Page 21: Leak Test Line Set And Indoor Coil
Take care to empty all existing traps. Polyol ester (POE) oils are used in Lennox units charged with HFC−410A refrigerant. WARNING Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the expansion Refrigerant can be harmful if it is inhaled. -
Page 22: 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 23: Electrical
pressures present during operation of an air conditioning IMPORTANT system. Non−condensables and water suction combine with refrigerant to produce substances that corrode copper Use a thermocouple or thermistor electronic vacuum piping and compressor parts. gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns. -
Page 24: Servicing Units Void Of Charge
2. Inspect all factory− and field−installed wiring for loose Servicing Units Void of Charge connections. If the outdoor unit is void of refrigerant, clean the system 3. After evacuation is complete, open both the liquid and using the procedure described below. vapor line service valves to release the refrigerant 1. - Page 25 CHARGING INFORMATION FOR MODEL XP16−XXX−230−01 AND XP16−XXX−230−02 Unit Charging Sticker − 401193S, dated 02/06 If the system is low on charge, follow the appropriate 3. Subtract the liquid line temperature from the saturation procedure outlined below. Charging should be done with unit temperature (according to the chart) to determine operating in the cooling mode, if possible.
- Page 26 Table 3 − Indoor Units Matchups and Subcooling Charge Levels (XP16−XXX−230−05) Charging Temperatures and Pressures XP16 Model −024 −036 −048 −060 Table 1 − Subcooling Values Saturation Temperature minus Liquid Line Temperature °F (ºC) + 1ºF (0.5ºC) Temp. °F 8 (4.4) 7 (3.9 9 (5) 8 (4.4)
- Page 27 CHARGING INFORMATION FOR MODEL XP16−XXX−230−03, XP16−XXX−230−04 and XP16−XXX−230−05 ADDING OR REMOVING REFRIGERANT Temperature rise between the return air and supply air temperatures at the indoor coil blower unit, This system uses HFC−410A refrigerant which operates at much higher pressures than HCFC−22. The pre−installed Measuring voltage supplied to the unit, liquid line filter drier is approved for use with HFC−410A only.
- Page 28 WEIGH IN SUBCOOLING method for adding initial refrigerant charge, and then use method for verifying refrigerant charge. 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 29 SUBCOOLING CHARGING METHOD 1. Check the airflow as illustrated in figure 17 to be sure the indoor airflow is as required. (Make any air flow adjustments before continuing with the following procedure.) 2. Measure outdoor ambient temperature; determine whether to use cooling mode or COOLING heating mode to check charge.
- Page 30 CHARGING INFORMATION FOR MODEL XP16−XXX−230−03 Unit Charging Sticker − 401233S, dated 01/08 Table 4 − Indoor Units Matchups and Subcooling Charge Levels (XP16−XXX−230−05) Target Target Target INDOOR HEAT INDOOR HEAT INDOOR HEAT **Add **Add **Add Subcooling Subcooling Subcooling charge charge charge MATCH UPS PUMP...
- Page 31 Table 1 − Normal Operating Pressures (Liquid 10 & Suction 5 psig) (XP16−XXX−230−03) *Temperature Model −024 −036 −048 −048 −060 −060 of the air entering the °F (°C)* Liquid Line Pressure/Vapor Line Pressure outdoor coil. 65 (18) 232 / 146 225 / 144 235 / 144 225 / 138...
- Page 32 CHARGING INFORMATION FOR MODEL XP16−XXX−230−04 Unit Charging Sticker − 580094−01, dated 05/09 Table 2 − Indoor Units Matchups and Subcooling Charge Levels (XP16−XXX−230−05) Target Target Target Subcooling Subcooling Subcooling INDOOR HEAT INDOOR HEAT INDOOR HEAT *Add *Add *Add MATCHUP PUMP charge MATCHUP PUMP...
- Page 33 Table 1 − HFC−410A Normal Operating Pressures (Liquid 10 & Suction 5 psig) (XP16−XXX−230−04) *Temperature Model −024 −036 −036 −048 −060 of the air entering the °F (°C)* Liquid Line Pressure/Vapor Line Pressure outdoor coil. 65 (18) 232 / 146 225 / 144 235 / 144 225 / 138...
- Page 34 CHARGING INFORMATION FOR MODEL XP16−XXX−230−05 Unit Charging Sticker − 580275−01, dated 12/09 Table 2 − Indoor Units Matchups and Subcooling Charge Levels (XP16−XXX−230−05) Target Target Target Subcooling Subcooling Subcooling INDOOR HEAT INDOOR HEAT INDOOR HEAT *Add charge *Add charge *Add charge MATCHUP PUMP MATCHUP...
- Page 35 Table 1 − HFC−410A Normal Operating Pressures (Liquid 10 & Suction 5 psig) (XP16−XXX−230−05) Size −024 −036 −048 −060 Model XP16 Only XP16 and SPB*H4 F (C) Normal Operating Pressures − Cooling 65 (18.3) 75 (23.9) 85 (29.4) First Stage (Low Capac- ity) Pressure 95 (35.0) 105 (40.6)
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Page 36: System Operation
Table 2. HFC−410A Temperature (°F) − System Operation Pressure (Psig) The outdoor unit and indoor blower cycle on demand from °F Psig °F Psig °F Psig °F Psig the room thermostat. When the thermostat blower switch is in the ON position, the indoor blower operates continuously. 100.8 178.5 290.8... -
Page 37: Defrost System
High Pressure Switch (HI−PS) When the high pressure Defrost System switch trips, the defrost board will cycle off the compressor, and the strike counter in the board will count one strike. DEFROST SYSTEM DESCRIPTION DEFROST BOARD PRESSURE SWITCH SETTINGS TEST PINS High Pressure (auto reset) −... - Page 38 checking sensor resistance. If the sensor resistance is 5750 not within range after 90 seconds, the board will count 7450 one fault. After five faults, the board will lockout. Code 9275 on board is Discharge Sensor Fault and Lockout. 11775 The discharge line sensor, which covers a range of 150°F 15425 (65°C) to 350°F (176°C), is designed to mount on a ½"...
- Page 39 IMPORTANT − The demand defrost control board will allow a Calibration success depends stable system greater accumulation of frost and will initiate fewer defrost temperatures during the 20−minute calibration period. If the cycles than a time/temperature defrost system. board fails to calibrate, another defrost cycle will be initiated after 45 minutes of heating mode compressor run time.
- Page 40 TEST Placing the jumper on the field test pins (E33) 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 41 DEFROST BOARD DIAGNOSTIC LEDS The state (Off, On, Flashing) of two LEDs on the defrost board (DS1 [Red] and DS2 [Green]) indicate diagnostics conditions that are described in table 4. Table 4. Defrost Control Board Diagnostic LEDs Green Condition/Code Possible Cause(s) Solution Power problem No power (24V) to board terminals R and...
- Page 42 OUTDOOR FAN MOTOR The controller uses sensing devices to know what position the rotor is in at any given time. By sensing the position of the XP16−XXX−230−01 through 05, except rotor and then switching the motor windings on and off in XP16−060−230−05) sequence, the rotor shaft turns the blower.
- Page 43 3. Initiate a second stage call for cool. Check for 24 volts The DC filter capacitors inside the controller are connected electrically to the speed tap wires. The capacitors take between the fan motor YELLOW wire and fan motor approximately 5 minutes to discharge when the disconnect BLACK wire, then check for 24 volts between the fan is opened.
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Page 44: Maintenance
TWO−STAGE MODULATION COMPRESSOR 7. Record all of the readings for the Y1 demand. CHECKS 8. Close switch to energize Y2 demand. Verify power is going to compressor solenoid. IMPORTANT 9. Allow pressures and temperatures to stabilize before taking measurements (may take up to 10 minutes). This performance check is ONLY valid on systems that 10. - Page 45 Indoor Unit 1. Clean or change filters. 6. Check amp draw on outdoor fan motor. 2. Lennox blower motors are prelubricated and permanently Motor Nameplate:_________ Actual:__________. sealed. No more lubrication is needed. 7. Inspect drain holes in coil compartment base and clean 3.
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Page 46: Unit Wiring Diagram And Sequence Of Operations
Unit Wiring Diagrams and Sequence of Operations XP16−XXX−230−01 through 04) Figure 30. Unit Wiring Diagram (All Sizes) Page 46 XP16... - Page 47 Figure 31. Unit Wiring Diagram (−024, −036 and −048 Sizes) XP16−XXX−230−05 Page 47 XP16...
- Page 48 Figure 32. Unit Wiring Diagram (−060 Size Only) XP16−XXX−230−05 Page 48 XP16...
- Page 49 Sequence of Operation XP16−024/060 Cooling A – First Stage Low Capacity If checks show no issues, the defrost board sends 24 volts through Y1 OUT signal to the K1 Transformer from indoor unit supplies 24VAC power to compressor contactor coil. the thermostat and outdoor unit controls.
- Page 50 B – High Capacity (Ambient temperature below 4 − K1−1 closes, energizing the compressor and outdoor fan motor through the normally closed fan relay contacts on defrost board Y2 lock−in temperature) the defrost board. 1 − Room thermostat in heating mode. Room thermostat The compressor runs on high capacity.
- Page 51 Checklists Two−Stage Modulation Compressors Field Operational Checklist Expected results during Y2 demand (Toggle switch On) Unit Readings Y1 − First-Stage Y2 − Second-Stage COMPRESSOR Voltage Same Amperage Higher OUTDOOR UNIT FAN MOTOR Amperage Same or Higher TEMPERATURE Ambient Same Outdoor Coil Discharge Air Higher Compressor Discharge Line Higher...