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2006 Lennox Industries Inc.

Corp. 0626−L5

Revised October 21, 2010

XP16

Service Literature

XP16 (HFC−410A) SERIES UNITS

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.

TABLE OF CONTENTS

Model Number Identification

2

. . . . . . . . . . . . . . . . . . . . 

Typical Serial Number Identification

2

. . . . . . . . . . . . . . 

Specifications

2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Electrical Data

3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Unit Dimensions

4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Unit Parts Arrangement

5

. . . . . . . . . . . . . . . . . . . . . . . . 

Operating Gauge Set and Service Valves

7

. . . . . . . . . 

Recovering Refrigerant from System

9

. . . . . . . . . . . . . 

Unit Placement

10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Removing and Installing Panels

12

. . . . . . . . . . . . . . . . . 

New or Replacement Line Set

14

. . . . . . . . . . . . . . . . . . 

Brazing Connections

16

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

Flushing Line Set and Indoor Coil

19

. . . . . . . . . . . . . . . 

Installing Indoor Metering Device

20

. . . . . . . . . . . . . . . . 

Leak Test Line Set and Indoor Coil

21

. . . . . . . . . . . . . . 

Evacuating Line Set and Indoor Coil

22

. . . . . . . . . . . . . 

Electrical

23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Servicing Units Void of Charge

24

. . . . . . . . . . . . . . . . . . 

Unit Start−Up

24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

System Refrigerant

24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

System Operation

36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Defrost System

37

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Maintenance

44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Unit Wiring Diagram and Sequence of 
Operations

46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Checklists

51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

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.

WARNING

Electric Shock Hazard. Can cause injury or
death. Unit must be grounded in
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.

Summary of Contents for XP16

Page 1: ...ervice Valves 7 Recovering Refrigerant from System 9 Unit Placement 10 Removing and Installing Panels 12 New or Replacement Line Set 14 Brazing Connections 16 Flushing Line Set and Indoor Coil 19 Inst...

Page 2: ...Factory Refrigerant Charge2 Number of Blades Diameter inches XP16 036 230 01 76 12 lbs 8 oz 4 22 XP16 036 230 02 76 12 lbs 8 oz 4 22 XP16 036 230 03 76 10 lbs 4 oz 4 22 XP16 036 230 04 76 10 lbs 4 oz...

Page 3: ...r Unit Compressor Condenser Fan Maximum Over current Protection amps 1 Minimum Circuity Ampacity2 Rated Load Amps RLA Locked Rotor Amps LRA Motor HP Motor Type Nominal RPM Full Load Amps FLA Locked Ro...

Page 4: ...75 35 889 13 7 8 352 7 3 4 197 3 1 4 83 27 1 8 689 3 5 8 92 4 1 2 114 20 5 8 524 XP16 036 05 39 991 30 1 2 775 35 889 13 7 8 352 7 3 4 197 3 1 4 83 27 1 8 689 3 5 8 92 4 1 2 114 20 5 8 524 XP16 048 01...

Page 5: ...HIGH PRESSURE SWITCH S4 COMPRESSOR LIQUID VALVE AND GAUGE PORT LIQUID LINE CONNECTIONS REVERSING VALVE DEFROST CONTROL A108 CONTACTOR K 1 GROUND LUG AMBIENT TEMPERATURE SENSOR RT13 TRUE SUCTION PORT...

Page 6: ...p from bottom 12 1 2 XP16 060 COIL SENSOR 12 tubes up from bottom 11 1 2 XP16 024 COIL SENSOR THIRD HAIRPIN DOWN FROM THE TOP ON INSIDE ROW XP16 036 COIL SENSOR NINTH HAIRPIN UP FROM THE BOTTOM ON INS...

Page 7: ...loss during shipping and handling 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 Note...

Page 8: ...10 11 12 1 12 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 size...

Page 9: ...re ratio meets a certain value or when the suction pressure is as high as 20 psig Compressor suction pressures should never be allowed to go into a vacuum Prolonged operation at low suction pressures...

Page 10: ...ass has a very high level of sound transmission For proper placement of unit in relation to a window see the provided illustration in figure 6 detail A PLACING UNIT ON SLAB When installing unit at gra...

Page 11: ...o 2 degrees or two inches per five feet 50 mm per 1 5 m away from building structure MOUNTING SLAB BUILDING STRUCTURE GROUND LEVEL Outside Unit Placement Slab Mounting at Ground Level SAME FASTENERS A...

Page 12: ...nit in the direction of prevailing winds NOTICE Roof Damage This system contains both refrigerant and oil Some rubber roofing material may absorb oil and cause the rubber to swell when it comes into c...

Page 13: ...C then upward into the top slot of the hinge corner post 2 Rotate panel to vertical to fully engage all tabs 3 Holding the panel s hinged side firmly in place close the right hand side of the panel a...

Page 14: ...s as listed in table 2 Table 2 Refrigerant Line Set Inches mm Model Valve Field Connections Recommended Line Set Liquid Line Vapor Line Liqui d Line Vapor Line L15 Line Sets 018 024 030 3 8 in 10 mm 3...

Page 15: ...FTER AT 8 FEET 2 43 METERS INTERVALS THEN STRAP THE LIQUID LINE TO THE VAPOR LINE FLOOR JOIST OR ROOF RAFTER REFRIGERANT LINE SET INSTALLING HORIZONTAL RUNS NOTE Similar installation practices should...

Page 16: ...rm operations only in well ventilated areas Wear gloves and protective goggles or face shield to protect against burns Wash hands with soap and water after handling brazing alloys and flux IMPORTANT C...

Page 17: ...M SERVICE VALVE Flow regulated nitrogen at 1 to 2 psig through the low side refrigeration gauge set into the liquid line service port valve and out of the suction vapor line service port valve CUT AND...

Page 18: ...ctions for the next step in preparing the unit WHEN BRAZING LINE SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE PREPARATION FOR NEXT STEP 7 WARNING 1 FIRE PERSONAL INJURY OR PROPERTY DAMAGE...

Page 19: ...ck expansion valve and the two Teflon rings H Use a field provided fitting to temporary reconnect the liquid line to the indoor unit s liquid line orifice housing LOW HIGH EXISTING INDOOR UNIT GAUGE M...

Page 20: ...line to the indoor unit s distributor assembly B Install one of the provided Teflon rings around the stubbed end of the expansion valve and lightly lubricate the connector threads and expose surface o...

Page 21: ...of HFC 410A refrigerant to the center port of the manifold gauge set Open the valve on the HFC 410A cylinder vapor only B Open the high pressure side of the manifold to allow HFC 410A into the line s...

Page 22: ...nd indoor unit until the absolute pressure 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 W...

Page 23: ...ol power 24VAC 40 VA minimum Refer to the unit nameplate for minimum circuit ampacity and maximum fuse or circuit breaker HACR per NEC Install power wiring and properly sized disconnect switch NOTE Un...

Page 24: ...t switch The voltage must be within the range listed on the unit s nameplate If not do not start the equipment until you have consulted with the power company and the voltage condition has been correc...

Page 25: ...on temperature according to the chart to determine subcooling Saturation temperature Liquid line temperature Subcooling 4 Compare subcooling values with those in table 1 if subcooling is greater than...

Page 26: ...9 310 147 305 142 95 35 0 353 151 349 151 356 148 352 146 105 40 6 403 153 397 153 407 150 405 148 115 46 1 460 155 461 157 466 152 459 150 Cooling Second Stage High Capacity 65 18 3 240 143 239 139 2...

Page 27: ...21 20 19 19 18 17 16 15 14 13 74 21 21 21 20 19 19 18 17 16 16 15 14 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...

Page 28: ...outdoor unit for charge information CHARGING METHOD NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the...

Page 29: ...dditional charge for line set and or match up 10 If subcooling value is greater than shown in tables under indoor unit matchups for the applicable unit remove refrigerant if less than shown add refrig...

Page 30: ...CBX32MV 036 12 9 0 10 CBX32M 036 17 8 2 4 CX34 60D 6F 18 4 0 2 CH33 25B 17 4 0 0 CBX32MV 024 030 17 6 0 0 CX34 62D 6F 16 8 0 2 CH33 36A 2F 12 6 0 10 CBX32MV 036 17 8 2 4 XP16XP16 060 lb oz CH33 36B 2...

Page 31: ...53 397 153 407 150 405 148 115 45 460 155 461 157 466 152 459 150 Cooling Second Stage High Capacity 65 18 240 143 239 139 244 140 241 134 75 24 279 145 278 141 283 141 280 136 85 29 322 147 322 143 3...

Page 32: ...40UHV 024 030 13 9 1 12 CBX32MV 036 17 8 2 4 CX34 60D 6F 18 4 0 2 CBX40UHV 036 12 9 0 10 CBX40UHV 024 030 17 6 0 0 CX34 62D 6F 16 8 0 2 CH33 25B 17 4 0 0 CBX40UHV 036 042 17 8 2 4 XP16 060 lb oz CH33...

Page 33: ...153 397 153 407 150 405 148 115 45 460 155 461 157 466 152 459 150 Cooling Second Stage High Capacity 65 18 240 143 239 139 244 140 241 134 75 24 279 145 278 141 283 141 280 136 85 29 322 147 322 143...

Page 34: ...CBX40UHV 030 17 7 1 3 CX34 50 60C 29 9 2 11 XP16 060 CBX40UHV 036 17 7 1 3 XP16 048 CBX26UH 060 20 9 4 13 CH33 31B 31 8 1 12 CBX26UH 048 10 8 1 4 CBX27UH 060 2 30 10 6 2 3 CR33 30 36A B C 45 4 0 0 CBX...

Page 35: ...56 444 156 450 155 453 149 Second Stage High Ca pacity Pressure 65 18 3 241 140 232 129 238 138 232 131 75 23 9 279 142 269 136 278 140 276 133 85 29 4 321 144 312 140 321 142 320 136 95 35 0 369 146...

Page 36: ...oor ambient temperature is below the selected compressor lock in temperature the second stage compressor solenoid output will be energized without the Y2 input If the jumper is not connected to one of...

Page 37: ...reset trip at 25 psig reset at 40 PRESSURE SWITCH 5 STRIKE LOCKOUT The internal control logic of the board counts the pressure switch trips only while the Y1 Input line is active If a pressure switch...

Page 38: ...hermostat demand if 5 strikes occur the board will lockout the unit Defrost board 24 volt power R must be cycled OFF or the TEST pins on board must be shorted between 1 to 2 seconds to reset the board...

Page 39: ...control will attempt to self calibrate after this and all other defrost cycle s Calibration success depends on stable system temperatures during the 20 minute calibration period If the board fails to...

Page 40: ...n TEST pins for longer than one second but less than two seconds Clears any short cycle lockout and five strike fault lockout function if applicable No other functions will be executed and unit will c...

Page 41: ...at code s counter 5 strikes per code LOCKOUT OFF SLOW Flash Low Pressure Fault 1 Restricted air flow over indoor or outdoor coil 2 Improper refrigerant charge in system 3 Improper metering device inst...

Page 42: ...is in at any given time By sensing the position of the rotor and then switching the motor windings on and off in sequence the rotor shaft turns the blower RED YELLOW BLACK RED BLUE motor control modul...

Page 43: ...urning off power to unit Troubleshooting If first or second stage thermostat call for cool is present and the variable speed condenser fan motor does not energize check voltage at the breaker box If v...

Page 44: ...pressures and temperatures to stabilize before taking measurements may take up to 10 minutes 7 Record all of the readings for the Y1 demand 8 Close switch to energize Y2 demand Verify power is going...

Page 45: ...may contain high levels of corrosive chemicals such as salts D Outdoor Coil The outdoor coil may be flushed with a water hose D Outdoor Coil Sea Coast Moist air in ocean locations can carry salt which...

Page 46: ...Page 46 XP16 Unit Wiring Diagrams and Sequence of Operations Figure 30 Unit Wiring Diagram All Sizes XP16 XXX 230 01 through 04...

Page 47: ...Page 47 XP16 Figure 31 Unit Wiring Diagram 024 036 and 048 Sizes XP16 XXX 230 05...

Page 48: ...Page 48 XP16 Figure 32 Unit Wiring Diagram 060 Size Only XP16 XXX 230 05...

Page 49: ...board checks for open low or high pressure switches and proper coil ambient and discharge sensor readings D If checks show no issues the defrost board sends 24 volts through Y1 OUT signal to the K1 c...

Page 50: ...contacts on the defrost board D The compressor runs on high capacity D XP16 060 05 only The 24 volt input to the yellow and blue wires of the outdoor fan will provide high speed operation Defrost Mod...

Page 51: ...ype 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 1st Stage 2nd Stage COOLIN...

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