Lennox XP25-024-230-01 Installation And Service Procedure Download Page 5

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Page 5

XP25

Typical Unit Parts Arrangement

GROUND LUGS

OUTDOOR

CONTROL

INVERTER REACTOR,

230V, 4KW

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

XP25-024 AND -036

CONTROL PANEL FOR

XP25-048 AND -060

VARIABLE-CAPACITY

INVERTER CONTROL

VARIABLE-CAPACITY

INVERTER CONTROL

Figure 1. Control Panel Components

Summary of Contents for XP25-024-230-01

Page 1: ...e agency TABLE OF CONTENTS I OVERVIEW Model Number Identification 2 Typical Serial Number Identification 2 Specifications 2 Electrical Data 3 Unit Dimensions 4 Typical Unit Parts Arrangement 5 General...

Page 2: ...arge2 Number of Blades Diameter inches Maximum Minimum XP25 024 230 01 68 58 11 lbs 5 oz 3 26 Model Number Unit Outdoor Fan Sound Rating Number dB 1 Factory Refrigerant Charge2 Number of Blades Diamet...

Page 3: ...18 00 1 3 4130 1865 850 390 214 40 2 80 208 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 Ra...

Page 4: ...ngle pole contactors Disconnect all remote electric power supplies before opening access panel Unit may have multiple power supplies WARNING Electrical Hazard High Voltage Wait 5 Minutes Electrical co...

Page 5: ...ONTACTOR 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 XP25 024 AND 036 C...

Page 6: ...S DROP BELOW 418 15 PSIG HR1 CRANKCASE HEATER 40W 240VAC COMPRESSOR TOP CAP SWITCH THERMAL VARIABLE CAPACITY COMPRESSOR SPEED HFC 410A 60HZ 3 PHASE CRANKCASE HEATER THERMOSTAT LIQUID LINE SENSOR Typic...

Page 7: ...ghtened Table 1 lists torque values for fasteners IMPORTANT Only use hex wrenches of sufficient hardness 50Rc Rockwell Harness Scale minimum Fully insert the wrench into the valve stem recess Service...

Page 8: ...112 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 sized wren...

Page 9: ...ting the Unit Units are outfitted with elongated support feet as illustrated in figure 6 detail C If additional elevation is necessary raise the unit by extending the height of the unit support feet U...

Page 10: ...it comes into contact with oil The rubber will then bubble and could cause leaks Protect the roof surface to avoid exposure to refrigerant and oil during service and installation Failure to follow thi...

Page 11: ...TIC 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 BU...

Page 12: ...ANEL 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 GUI...

Page 13: ...ir conditioning system use a regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa IMPORTANT If this unit is being matched with an approved line set or indoor unit coil that was...

Page 14: ...t Line Set Up to 50 Linear Feet Inches mm Model Number xx Valve Size Connections Recommended Line Sets Liquid Line Suction Line L15 Line Set Model Line Set Length Catalog Number XP25 024 230 XX XP25 0...

Page 15: ...D 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...

Page 16: ...to your health 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...

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: ...E 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...

Page 19: ...LD 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...

Page 20: ...APPLICATION 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...

Page 21: ...dry nitrogen to pressurize a refrigeration or air conditioning system use a regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa IMPORTANT If this unit is being matched with an...

Page 22: ...ITROGEN 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 O...

Page 23: ...OES 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: ...pleting 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 Segment di...

Page 25: ...o bundle 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 exce...

Page 26: ...he unit the control and the technician at the same electrostatic potential Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface before performing any service pro...

Page 27: ...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 commo...

Page 28: ...of inverter Outdoor control communication receive pin P6 Pin 4 Inv 5V Inverter 5VDC volts Inverter 5VDC volts LIQ Liquid line temperature sensor supply N A N A N A LIQ Liquid line temperature sensor...

Page 29: ...ould be energized 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 connec...

Page 30: ...ases errors are re lated to electrical noise Make sure high voltage power is separated from RSBus Check for mis wired and or loose connections between the stat indoor unit and outdoor unit Check for a...

Page 31: ...seconds or after a power reset E 410 N A N A N A Moderate The outdoor unit low pres sure switch has closed Unit pressure is below the lower limit The system is shutdown The low pressure switch opens a...

Page 32: ...in unit installation instruc tions Replace sensor pack if necessary At the begin ning of any configuration furnace or air handler con trol detects the presence of the sensor s If detected reading in...

Page 33: ...connection at compressor harness im proper winding resistance locked compressor rotor or flooded compressor To clear disconnect power to outdoor unit and restart E 431 27 2 flashes 7 flashes Moderate...

Page 34: ...hin an hour system is locked out To clear disconnect power to outdoor unit and restart Issue Feedback from supplier tear down of inverter in dicates that the screws that hold the inverter to the inver...

Page 35: ...to demand percentage rather than the actual Hz Alarm is automatically cleared Issue Possible issue is system running at high pres sures Check for high pressure trips or other alert codes in room therm...

Page 36: ...H OR These are just examples of firmware version unit type unit nominal capacity and unit codes UNIT CODE UNIT TYPE SIZE AND MODEL NOT PROGRAMMED 2 TON HEAT PUMP XP25 024 3 TON HEAT PUMP XP25 036 4 TO...

Page 37: ...g is repeated if defrost is active pause Diagnostic recall Shows the last 10 stored diagnostic error codes If first error is second pause pause Next codes up to 10 are show using same method Fault mem...

Page 38: ...version pause or unit pause unit capacity in BTUs pause unit code If 3 horizontal bars are displayed during any sequence of this display string it indicates that the specific parameter is not configur...

Page 39: ...or 10 minutes has passed whichever comes first When this mode is selected all installed temperature sensor valves non open and non short is shown on the 7 segment display The following system status...

Page 40: ...outdoor sensor on the outdoor unit Example pause pause If enabled in the display string represents the outdoor coil temperature in F at the sensor on the outdoor unit Example pause pause pause pause A...

Page 41: ...DOOR COIL AND LIQUID LINE TEMPERATURE INFORMATION ALL TEMPER ATURES ARE DISPLAYED IN FAHRENHEIT Outdoor control is either in IDLE mode or heating cooling demand To enable temperature display push and...

Page 42: ...figuring 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 capacity an...

Page 43: ...ure switch status Compressor top cap switch status Liquid line temperature Outdoor ambient temperature Coil temperature Time since last defrost Calibration delta T Current delta T Outdoor fan RPM Comp...

Page 44: ...nal Range Temperature Event C F Above 20 C Above 4 F Room thermostat controls operation of outdoor unit NOTE Below 65 F 18 3 C the liquid line temperature sensor controls the outdoor fan speed RPM to...

Page 45: ...per intervals procedures for your geographic area or service contract Indoor Unit 1 Clean or change filters 2 Lennox blower motors are factory lubricated and permanently sealed No more lubrication is...

Page 46: ...Page 46 XP25 Typical Unit Wiring Diagrams Figure 24 Typical Unit Wiring XP25 024 and 036...

Page 47: ...Page 47 XP25 Figure 25 Typical Unit Wiring XP25 048 and 060...

Page 48: ...Page 48 XP25 NOTE For more information on Load Shedding see Electrical on page 24 Figure 26 Load Shedding Feature Wiring Diagram...

Page 49: ...Page 49 XP25 Factory Wiring Diagrams OUTDOOR CONTROL INVERTER REACTOR INVERTER Figure 27 Typical Factory Wiring XP25 024 and 036...

Page 50: ...Page 50 XP25 OUTDOOR CONTROL INVERTER REACTOR INVERTER INVERTER NOISE FILTER Figure 28 Typical Factory Wiring XP25 048 and 060...

Page 51: ...error codes outdoor control sends 24 volts out on the CNTCTR terminals to pull in the contactor coil Note These checks take about 60 seconds 4 The contactor contacts pull IN and main power is applied...

Page 52: ...g range Check for status or fault codes in outdoor control or room thermostat Note Refer to low pressure and high pres sure switch flow charts for sequence of opera tion Outdoor Control Diagnostics Sc...

Page 53: ...d to satisfy all heat calls during heat pump lock out Defrost in the last 30 minutes Heat pump ran for at least 30 minutes From modu lating heat pump heat Back to modulating heat pump heat Go to auxil...

Page 54: ...sensors closed and within operating range Check for status or fault codes in out door control Emergency heat selected Go to auxiliary heating Balance point region Balance point region Balance point r...

Page 55: ...r run time is more than six 6 hours a defrost is to be initiated Coil sensor below 35 F 2 C No attempt to calibrate 30 35 minutes compressor run time Accumulated compressor run time while outdoor coil...

Page 56: ...acity Inverter Control Operation Checkout and Status Error Codes 79 Emergency 24VAC Operation 84 High and Low Pressure Switch Operation Checkout and Status Error Codes OPERATION The unit s pressure sw...

Page 57: ...ER 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...

Page 58: ...DEMAND 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 CLOS...

Page 59: ...ch opens at 40PSIG and resets at 90PSIG Confirm that the system is properly charged with refri gerant Check for clogged TXV blockage to indoor unit blower motor dirty filters or clogged refrigerant fi...

Page 60: ...ating in the winter The valve consists of a main body and a solenoid coil Note The reversing valve solenoid is energized in the cooling mode Figure 37 Reversing Valve L1 CHECKOUT Using a multimeter se...

Page 61: ...S BACK TO THE COMPRESSOR 2 WHEN THE SOLENOID IS DE ENERGIZED OFF REFRIGERANT PRESSURE IS DIRECTED FROM THE CONDENSER OUTDOOR COIL C TO THE SUCTION S BACK TO THE COMPRESSOR REVERSING VALVE OPERATION Fi...

Page 62: ...ertz is dependent on compressor size The compressor speed is determined by demand from the room thermostat CHECKOUT Figure 40 Compressor Operation Checkout and Status Error Codes IMPORTANT If compress...

Page 63: ...flash 2 flashes Moderate Compressor slowdown due to high input current Input current is approaching a high limit Com pressor speed automatically slows The control continues sending the inverter speed...

Page 64: ...s and is located on the liquid line see figure 2 on page 6 for location 1 When liquid line temperature drops below 50 F the thermostat closes which results in the heater being energized 2 When liquid...

Page 65: ...in table 18 on page 78 may be performing as designed However if a shorted or open circuit is detected the sensor is faulty the sensor needs to be replaced Figure 43 Checking Crankcase Heater Thermosta...

Page 66: ...S HOTTER THAN THE LIQUID LINE STORED LIQUID IS HEATED BOILED AND FORCE BACK INTO CIRCULATION VAPOR LINE TO OUTDOOR COIL COOLING MODE HEATING MODE VAPOR LINE TO OUTDOOR COIL EXCESS REFRIGERANT TO BE CO...

Page 67: ...d the outlet side of the filter drier is cooler than the inlet side Some filter driers have an access port which allows you to measure the pressure drop with a pressure gauge If it is restrictive Grea...

Page 68: ...bulb location 11 Incorrect equalizer location 12 Charge migration 13 wax 14 Wrong equalizer type valve 15 Rod leakage balanced port valve 16 Heat damaged power head 1 Add correct amount refrigerant 2...

Page 69: ...ressure normal or high 1 Oversized valve 2 Incorrect superheat setting 3 Moisture 4 Dirt or foreign material 5 Incorrect charge selection 6 Incorrect bulb location 7 Incorrect equalizer location 8 Plu...

Page 70: ...the switch is closed Figure 50 Top Cap Thermal Sensor Switch Checkout S173 STATUS None ERROR Table 15 Outdoor Control 7 Segment Display Alert Codes Top Cap Switch NOTE System fault and lockout codes...

Page 71: ...51 XC XP 25 024 and 036 Reactor 208 240 Voltage IN 208 240 Voltage OUT Figure 52 XC XP 25 048 and 060 Reactor STATUS CODES None ERROR CODES None Line Filter Electromagnetic Compatibility Circuit EMC...

Page 72: ...ODES None Outdoor Fan Operation and Checkout OPERATION These units use an integrated control and motor that is programmed for variable capacity operation The fan speed is controlled by the iComfort Wi...

Page 73: ...Page 73 XP25 Perform DC volt checks 19 23 VDC between FAN PWM and COM Figure 54 VAC Voltage Check...

Page 74: ...re 55 VDC Voltage Check STATUS CODES None ERROR CODES None NOTE If the outdoor fan does not operate at the correct RPM or does not start the system is be down by other protection components such as th...

Page 75: ...ontrol Operation STATUS CODES Table 16 Outdoor Control 7 Segment Display Alert Codes Outdoor Control Status NOTE System fault and lockout codes take precedence over system status codes cooling heating...

Page 76: ...unicating The alarm fault clears after communication is re established E 125 Critical There is a hardware problem with the outdoor control There is a control hardware problem Replace the outdoor contr...

Page 77: ...tance across the sensor changes Table 18 on page 78 shows how the resistance varies as the temperature changes for both type of sensors Check sensor operation by reading ohms across pins shown in figu...

Page 78: ...10 4 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...

Page 79: ...sensor readings or after a power reset E 424 Moderate The liquid line temperature sensor has malfunctioned In normal operation after outdoor control recognizes sensors the alarm is sent if valid temp...

Page 80: ...Codes Code Inverter LED Flash Code number of flashes Priority Alarm Description Possible Causes and Clearing Alarm Red LED Green LED E 423 40 4 flashes OFF Moderate Critical The inverter has detec ted...

Page 81: ...detects an over current condition of 100A the control will display a moderate code If condi tion is detected outdoor unit will stop Com pressor and fan Anti short cycle is initiated In verter is unav...

Page 82: ...de 13 first then slows down to allow the heat sink to cool If temperature re mains high outdoor unit stops compressor and fan Anti short cycle is initiated If condition oc curs 5 times within an hour...

Page 83: ...ual Hz Alarm is automatically clear See E428 E 440 13 1 flash 3 flashes Moderate Heat sink temperature is approaching limit The compressor speed auto matically slows to re duce heat sink temperat ure...

Page 84: ...ystem with the XP25 running in emergency mode 24VAC inputs to outdoor unit Communicating Air Handler or Furnance 24VAC Thermostat RSBus Communicating Air Handler or Furnance iComfort Wi Fi THERMOSTAT...

Page 85: ...d line filter drier is approved for use with HFC 410A only Do not replace it with components designed for use with HCFC 22 COOLING MODE INDOOR AIRFLOW CHECK Check airflow using the Delta T DT process...

Page 86: ...EMPERATURE USING DRY BULB A AND WET BULB B DT IS THE INTERSECTING VALUE OF A AND B IN THE TABLE SEE TRIANGLE 2 FIND TEMPERATURE DROP ACROSS COIL MEASURE THE DRY BULB AIR TEMPERATURE ENTERING AND LEAV...

Page 87: ...USE COOLING MODE USE HEATING MODE 60 F 15 C SAT LIQ SC SUBCOOLING 6 READ THE LIQUID LINE TEMPERATURE RECORD IN THE LIQ SPACE 7 READ THE LIQUID LINE PRESSURE THEN FIND ITS CORRESPONDING TEMPERATURE IN...

Page 88: ...7 130 475 6 146 579 8 38 113 6 54 152 8 69 197 3 85 254 1 100 317 2 116 396 0 131 481 6 147 586 8 39 115 8 55 155 5 70 200 6 86 258 0 101 321 8 117 401 3 132 487 8 148 593 8 40 118 0 56 158 2 71 203 9...

Page 89: ...Page 89 XP25 Figure 67 XP25 Charging Sticker...

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