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Lennox XC25-024-230-01, Installation And Service Procedure, Page: 5 / 72

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Lennox XC25-024-230-01 Installation And Service Procedure Download Page 5

5

XC25

Typical Unit Parts Arrangement

GROUND LUGS

OUTDOOR

CONTROL

INVERTER REACTOR,

230V, 4KW

DC INVERTER

CONTROL

CONTACTOR-SPST

(25FLA/35RES)

GROUND LUGS

CONTACTOR-SPST

(35FLA/40RES)

OUTDOOR CONTROL

INVERTER NOISE FILTER FOR

6KW INVERTER (208/240V,

60HZ, CURRENT RANGE 30A

MAXIMUM, INDUCTANCE

4.3MH)

INVERTER REACTOR,

230V, 6KW

CONTROL PANEL FOR

XC25-024 AND -036

CONTROL PANEL FOR

XC25-048 AND -060

DC INVERTER
CONTROL

Figure 1. Control Panel Components

Summary of Contents for XC25-024-230-01

Page 1: ...ctrical components may hold charge Do not remove this panel or service this area for 5 minutes after the power has been removed TABLE OF CONTENTS I OVERVIEW Model Number Identification 2 Typical Seria...

Page 2: ...Number of Blades Diameter inches Maximum Minimum XC25 024 230 01 70 59 13 lbs 10 oz 5 26 Model Number Unit Outdoor Fan Sound Rating Number dB 1 Factory Refrigerant Charge2 Number of Blades Diameter in...

Page 3: ...18 0 1 3 4100 1950 650 350 157 32 2 0 208 230V 60 Hz 1 Ph Model Number Unit Compressor Outdoor Fan RPM varies with compressor RPM Maximum Over current Protection amps 1 Minimum Circuity Ampacity2 Rate...

Page 4: ...ges and corners while applying excessive force or rapid motion can result in personal injury Be aware of and use caution when working nearby these areas during installation or while servicing this equ...

Page 5: ...R SPST 25FLA 35RES GROUND LUGS CONTACTOR SPST 35FLA 40RES OUTDOOR CONTROL INVERTER NOISE FILTER FOR 6KW INVERTER 208 240V 60HZ CURRENT RANGE 30A MAXIMUM INDUCTANCE 4 3MH INVERTER REACTOR 230V 6KW CONT...

Page 6: ...18 15 PSIG CRANKCASE HEATER THERMOSTAT S40 OPENS AT 70 F CLOSES AT 50 F COMPRESSOR TOP CAP SWITCH THERMAL VARIABLE CAPACITY COMPRESSOR HFC 410A 3 PHASE Figure 2 Plumbing Component Locations and Specif...

Page 7: ...ommended Torque Service valve cap 8 ft lb 11 NM Sheet metal screws 16 in lb 2 NM Machine screws 10 28 in lb 3 NM Compressor bolts 90 in lb 10 NM Gauge port seal cap 8 ft lb 11 NM TORQUE REQUIREMENTS W...

Page 8: ...TURN To Access Service Port A service port cap protects the service port core from contamination and serves as the primary leak seal 1 Remove service port cap with an appropriately sized wrench 2 Conn...

Page 9: ...THE UNIT Units are outfitted with elongated support feet as illustrated in figure 5 detail C If additional elevation is necessary raise the unit by ex tending the height of the unit support feet Use...

Page 10: ...ail D us ing conventional practices 3 Replace the panels after installation is complete ROOF MOUNTING Locate the unit above a load bearing wall or area of the roof that can adequately support the unit...

Page 11: ...C SLAB NO PLASTIC ANCHOR HOLE DRILL 1 8 INSTALL UNIT LEVEL OR IF ON A SLOPE MAINTAIN SLOPE TOLERANCE OF 2 DEGREES OR 2 INCHES PER 5 FEET 50 MM PER 1 5 M AWAY FROM BUILDING STRUCTURE MOUNTING SLAB BUIL...

Page 12: ...L INSTALLATION Position the panel almost parallel with the unit as illustrated in detail D with the screw side as close to the unit as possible Then in a continuous motion 1 SLIGHTLY ROTATE AND GUIDE...

Page 13: ...ANT If this unit is being matched with an approved line set or indoor unit coil that was previously charged with mineral oil or if it is being matched with a coil which was manufactured before January...

Page 14: ...ections Recommended Line Sets Model Number xx Liquid Line Suction Line L15 Line Set Model Line Set Length Catalog Number XC25 024 230 XX XC25 036 230 XX XC25 048 230 XX 3 8 10 mm 7 8 22 mm L15 65 30 3...

Page 15: ...BE USED IF LINE SET IS TO BE INSTALLED ON EXTERIOR OF OUTSIDE WALL PVC PIPE FIBERGLASS INSULATION CAULK OUTSIDE WALL VAPOR LINE WRAPPED WITH ARMAFLEX LIQUID LINE OUTSIDE WALL LIQUID LINE VAPOR LINE WO...

Page 16: ...lth Avoid breathing vapors or fumes from brazing operations Perform operations only in well ventilated areas Wear gloves and protective goggles or face shield to protect against burns Wash hands with...

Page 17: ...EN HIGH LOW B A C PIPING PANEL REMOVAL AND LINE SET PREPARATION CAP AND CORE REMOVAL Remove piping panel for easier access to service valves Cut ends of the refrigerant lines square free from nicks or...

Page 18: ...SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE WARNING 1 FIRE PERSONAL INJURY OR PROPERTY DAMAGE will result if you do not wrap a water saturated cloth around both liquid and suction line s...

Page 19: ...PROVIDED FITTING TO TEMPORARILY RECONNECT THE LIQUID LINE TO THE INDOOR UNIT S LIQUID LINE ORIFICE HOUSING LOW HIGH EXISTING INDOOR UNIT GAUGE MANIFOLD INVERTED HCFC 22 CYLINDER CONTAINS CLEAN HCFC 2...

Page 20: ...PLICATION INFORMATION A REMOVE THE FIELD PROVIDED FITTING THAT TEMPORARILY RECON NECTED THE LIQUID LINE TO THE INDOOR UNIT S DISTRIBUTOR AS SEMBLY B INSTALL ONE OF THE PROVIDED TEFLON RINGS AROUND THE...

Page 21: ...ith an approved line set or indoor unit coil which was previously charged with mineral oil or if it is being matched with a coil which was manufactured before January of 1999 the coil and line set mus...

Page 22: ...GEN WITH A PRESSURE REGULATING VALVE TO THE CENTER PORT OF THE MANIFOLD GAUGE SET D ADJUST DRY NITROGEN PRESSURE TO 150 PSIG 1034 KPA OPEN THE VALVE ON THE HIGH SIDE OF THE MANIFOLD GAUGE SET IN ORDER...

Page 23: ...DOES NOT RISE ABOVE 500 MICRONS 29 9 INCHES OF MERCURY WITHIN A 20 MINUTE PERIOD AFTER SHUTTING OFF THE VACUUM PUMP AND CLOSING THE MANIFOLD GAUGE VALVES F WHEN THE ABSOLUTE PRESSURE REQUIREMENT ABOVE...

Page 24: ...2 completing the circuit between terminals R and L on the outdoor control The 24VAC input to terminal L activates the load shedding mode in the outdoor control cycling the outdoor unit OFF The 7 Segm...

Page 25: ...the four unused wires at each end of the cable Each bundle should also include an additional wire that should be connected on each end to the C termi nal as shown in the figure below Any excess high v...

Page 26: ...trostatic potential Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface before performing any service procedure STEP 3 ELECTRICAL Continued Outdoor Control Unit...

Page 27: ...th the HI PS and TC N A Switched 24VAC Nominal N A Cntctr Contactor common N A 24VAC common Fan PWM PWM fan output N A 10 97 duty cycle 19 23 VDC peak N A COM PWM fan common connection N A N A Fan PWM...

Page 28: ...ter Connects to Tx of inverter Outdoor control communication receive pin P6 Pin 4 Inv 5V Inverter 5VDC volts Inverter 5VDC volts LIQ Liquid line temperature sensor sup ply N A N A N A LIQ Liquid line...

Page 29: ...ized 24 hours before unit start up to prevent compressor damage as a result of slugging 1 Rotate fan to check for binding 2 Inspect all factory and field installed wiring for loose connections 3 After...

Page 30: ...cases errors are related to electrical noise Make sure high voltage power is separated from RS Bus Check for mis wired and or loose connections between the stat indoor unit and outdoor unit Check for...

Page 31: ...r CFM may be set too low For zoning system zone CFM may be set too low E 413 N A N A N A Critical The high pressure switch has opened 5 times within one hour As a result the out door unit is locked ou...

Page 32: ...s 10 times within an hour sys tem is locked out Indicates power interruption brownout poor electrical connec tion or loose inverter input wire To clear disconnect power to outdoor unit and restart E 4...

Page 33: ...continues sending the in verter speed demanded by the thermostat The control sets indoor CFM and outdoor RPM to values according to demand percentage rather than the actual Hz Alarm is automatically c...

Page 34: ...unit type cannot be determined three bars ap pear OR 7 SEGMENT POWER UP DISPLAY STRING EXAMPLE FIRMWARE VERSION UNIT TYPE UNIT CAPACITY UNIT CODE IDLE MODE Figure 16 Outdoor Control 7 Segment Unit St...

Page 35: ...s repeated if cooling is active with outdoor fan speed set at 650 RPM and LIQ is 105 F pause pause pause Pump Down Mode While the unit is in pump down mode is displayed repeatedly Errors are shown if...

Page 36: ...cond time period the control exits the test mode If this occurs test mode must be repeated Error Code Recall Mode NOTE control must be in idle mode To enter error code recall mode push and hold button...

Page 37: ...uration and test mode Idle mode decimal flashes at 1 Hertz 0 5 second ON 0 5 second OFF Cooling operation Shows and the cooling demand percentage Example pause pause Fan RPM Shows and the current fan...

Page 38: ...l and liquid line temperature information All temperatures are dis played in Fahrenheit Outdoor control is either in IDLE mode or heating cooling demand To enable temperature display push and hold but...

Page 39: ...ELECTED Configuring Unit Selection Code Power up Unit selection code two digit number displayed represents unit size code outdoor unit capacity During initial power up firmware version unit type unit...

Page 40: ...ble through the thermostat s user interface Refer to the iComfort Wi Fi Installer s System Setup Guide D Compressor anti short cycle delay timer status D Cooling rate D Compressor shift delay timer st...

Page 41: ...r proper intervals procedures for your geographic area or service contract Indoor Unit 1 Clean or change filters 2 Lennox blower motors are pre lubricated and perman ently sealed No more lubrication i...

Page 42: ...ction Service technician will need to visually inspect the unit being serviced to determine which wiring diagram is applicable Quick verification can usually be made by comparing the wiring diagram lo...

Page 43: ...43 XC25 Figure 24 Typical Unit Wiring XC25 048 and 060...

Page 44: ...44 XC25 NOTE For more information on Load Shedding see Electrical on page 24 Figure 25 Load Shedding Feature Wiring Diagram...

Page 45: ...45 XC25 Factory Wiring Diagrams OUTDOOR CONTROL INVERTER REACTOR INVERTER Figure 26 Typical Factory Wiring XC25 024 and 036...

Page 46: ...46 XC25 OUTDOOR CONTROL INVERTER REACTOR INVERTER INVERTER NOISE FILTER Figure 27 Typical Factory Wiring XC25 048 and 060...

Page 47: ...of the outdoor fan motor 3 View the AIR HANDLER screen for actual CFM of the indoor blower motor From idle mode Outdoor Control 1 Sends a demand to the compressor inverter to start and run the compres...

Page 48: ...REACHES 5 WITHIN A SINGLE Y1 DEMAND LOW PRESSURE SWITCH S87 LOCKOUT LED ALERT CODE OR CRITICAL ALERT 411 DISPLAYED SERVICE REQUIRED2 LED ALERT CODE OR MODERATE ALERT 410 DISPLAYED SERVICE REQUIRED2 NO...

Page 49: ...MAND HIGH PRESSURE SWITCH S4 LOCKOUT LED ALERT CODE OR CRITICAL ALERT 413 CLEARED SERVICE REQUIRED2 LED ALERT CODE OR MODERATE ALERT 412 DISPLAYED NORMAL OPERATION CLOSED CLOSED OPEN OPEN OPEN CLOSED...

Page 50: ...Operation 69 Verifying High and Low Pressure Switch Operation OPERATION The unit s pressure switches LO PS S87 and HI PS S4 are factory wired into the control on the LO PS and HI PS termin als respect...

Page 51: ...D ALERT CODE OR CRITICAL ALERT 411 DISPLAYED SERVICE REQUIRED2 LED ALERT CODE OR MODERATE ALERT 410 DISPLAYED SERVICE REQUIRED2 NORMAL OPERATION CLOSED CLOSED OPEN OPEN 1 The thermostat will terminate...

Page 52: ...HIGH PRESSURE SWITCH S4 LOCKOUT LED ALERT CODE OR CRITICAL ALERT 413 CLEARED SERVICE REQUIRED2 LED ALERT CODE OR MODERATE ALERT 412 DISPLAYED NORMAL OPERATION CLOSED CLOSED OPEN OPEN OPEN CLOSED CLOSE...

Page 53: ...limit System is shut down The high pressure switch opens at 590PSIG and closes at 418PSIG Confirm that the system is prop erly charged with refrigerant Check for clogged TXV blockage to indoor unit bl...

Page 54: ...ected outdoor unit compressor and fan stop Anti short cycle is initiated If condition occurs 10 times within an hour system is locked out Indicates poor connection at compressor harness improper windi...

Page 55: ...utility company to limit the maximum power level usage of the outdoor unit The feature is activated by applying 24 volts AC power to the L and C terminals on the outdoor control Crankcase Heater Chec...

Page 56: ...detected the sensor is faulty the sensor needs to be replaced Figure 38 Checking Crankcase Heater Thermostat STATUS CODE None ERROR CODES None Compressor Sound Cover All units come with a soft sided...

Page 57: ...off compressor operation The auto reset switch closes when the compressor casing temperature falls to 151 187 F and the compressor is re energized This single pole single throw SPST bi metallic switch...

Page 58: ...E 442 Critical The top cap switch has opened 5 times within one hour As a result the outdoor unit is locked out When compressor thermal protection sensor opens 5 times within 1 hour outdoor stops wor...

Page 59: ...ts have an external device see illustration below NOTE A line filter is an electronic filter which is placed between electronic equipment and an external power source in order to attenuate conducted r...

Page 60: ...ostat CHECKOUT VAC Voltage Check Check for 208 240 VAC power at inverter contactor red wires see figure 46 With unit operating check for main VAC to motor and outdoor control VDC output to motor 1 No...

Page 61: ...e outdoor control therefore no status or error codes are displayed on either the outdoor control or iComfort Wi Fi room thermostat NOTE If the outdoor fan does not operate at the correct RPM or does n...

Page 62: ...s NOTE System fault and lockout codes take precedence over system status codes cooling heating operating percentages or defrost dehumidification Only the latest active fault or lockout codes are displ...

Page 63: ...on is re established E 125 Critical There is a hardware problem with the outdoor control There is a control hardware problem Replace the outdoor control if the problem pre vents operation and is persi...

Page 64: ...s into the outdoor control Through the sensors the control detects outdoor ambient coil and liquid temperature fault conditions As the detected tem perature changes the resistance across the sensor ch...

Page 65: ...61693 26 2 204829 92 0 7007 42 3 24525 9 9 62712 27 0 210805 90 6 7225 41 7 24934 9 3 63752 27 8 217080 89 4 7444 41 1 25349 8 8 64812 28 7 223677 88 1 7666 40 5 25769 8 3 65895 29 5 230621 86 9 7890...

Page 66: ...sensor range Outdoor unit control will not perform demand or time temperature defrost operation System will still heat or cool Check the resistance of the coil sensor and compare to temperature resis...

Page 67: ...ert Codes and Inverter LED Flash Codes NOTE System fault and lockout codes take precedence over system status codes cooling heating operating percentages or defrost dehumidification Only the latest ac...

Page 68: ...ated If condi tion occurs 5 times within an hour system will lock out To clear disconnect power to outdoor unit and restart E 434 53 5 flashes 3 flashes Moderate Critical Outdoor control has lost comm...

Page 69: ...24VAC System Operation System Refrigerant IMPORTANT The system must be operating at full capacity during charging Increase heat or decrease cooling the thermostat setting by 5 F to create system dema...

Page 70: ...4 13 12 72 20 20 19 18 17 17 16 15 15 14 13 12 11 10 70 19 19 18 18 17 17 16 15 15 14 13 12 11 10 57 58 59 60 61 62 63 64 65 66 67 68 69 70 TEMPERATURE OF AIR ENTERING INDOOR COIL F INDOOR COIL DRY BU...

Page 71: ...RN AIR TEMPERATURE IF NECESSARY OPERATE COOLING TO REACH THAT TEMPERATURE RANGE THEN SET THERMOSTAT TO HEATING MODE SETPOINT TO 77 F 25 C WHICH SHOULD CALL FOR SECOND STAGE HIGH STAGE HEATING WHEN PRE...

Page 72: ...72 XC25 Figure 59 XC25 Charging Sticker...

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