Lennox XPG15 Series Installation Instructions Manual Download Page 3

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XPG15 SERIES

Model Number Identification

15 036

−

Unit Type

P = Heat Pump

Series

Nominal Cooling Capacity

024 = 2 tons
030 = 2.5 tons
036 = 3 tons
043 = 3.5 tons
048 = 4 tons
060 = 5 tons

Minor Revision Number

230

Voltage

230 = 208/230V−1ph−60hz

Refrigerant Type

X = R−410A

−

G= Green Technology

Typical Parts Arrangement

SOUND DOME COVER (SEE SOUND REDUCTION

COVER ON PAGE 55 FOR FURTHER DETAILS)

VAPOR VALVE AND

GAUGE PORT

DISCHARGE LINE

REVERSING VALVE

BI−FLOW FILTER DRIER

HIGH PRESSURE SWITCH

LIQUID VALVE AND

GAUGE PORT

TRUE SUCTION LINE PORT

MUFFLER

LOW PRESSURE SWITCH

CRANKCASE HEATER THERMOSTAT

CHECK EXPANSION
VALVE

TRUE SUCTION
LINE

Figure 1. Typical Parts Arrangement

Summary of Contents for XPG15 Series

Page 1: ...ficient use of fuel sources INSTALLATION INSTRUCTIONS Dave Lennox Signature Collection XPG15 Units DUAL FUEL HEAT PUMP UNITS 506212 01 11 10 Supersedes 10 09 TABLE OF CONTENTS General 1 Unit Dimensions 2 Model Number Identification 2 Unit Parts Arrangement 4 Control Panel Parts Arrangement 4 Shipping and Packing List 5 Operating Gauge Set and Service Valves 5 Recovering Refrigerant from Existing S...

Page 2: ...s product and or the indoor unit it is matched with may contain fiberglass wool Disturbing the insulation during installation maintenance or repair will expose you to fiberglass wool dust Breathing this may cause lung cancer Fiberglass wool is known to the State of California to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or ...

Page 3: ...hz Refrigerant Type X R 410A X 2 G G Green Technology Typical Parts Arrangement SOUND DOME COVER SEE SOUND REDUCTION COVER ON PAGE 55 FOR FURTHER DETAILS VAPOR VALVE AND GAUGE PORT DISCHARGE LINE REVERSING VALVE BI FLOW FILTER DRIER HIGH PRESSURE SWITCH LIQUID VALVE AND GAUGE PORT TRUE SUCTION LINE PORT MUFFLER LOW PRESSURE SWITCH CRANKCASE HEATER THERMOSTAT CHECK EXPANSION VALVE TRUE SUCTION LINE...

Page 4: ... TIE MODELS 024 030 036 AND 042 MODELS 048 AND 060 12 TUBES UP DISCHARGE SENSOR Not required for this application DEFROST COIL SENSOR Clip coil temperature sensor from the demand defrost control on the return bend shown on models as follows DETAIL A DETAIL B SENSORS LOCATIONS Figure 2 Sensor Locations Typical Control Panel Parts Arrangement GROUND LUG CONTACTOR 1POLE K1 1 DEMAND DEFROST CONTROL A1...

Page 5: ...tion TORQUE REQUIREMENTS When servicing or repairing heating ventilating and air conditioning components ensure the fasteners are appropriately tightened Table 1 shows torque values for fasteners IMPORTANT Only use Allen wrenches of sufficient hardness 50Rc Rockwell Harness Scale minimum Fully insert the wrench into the valve stem recess Service valve stems are factory torqued from 9 ft lbs for sm...

Page 6: ...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 wrench 2 Connect gauge set to service port 3 When testing is completed replace service port cap and tighten as follows S With torque wrench Finger tighten and torque cap per table 1 S Without torque wrench Fing...

Page 7: ...ls compressor stops pumping when the pressure 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 will result in overheating of the scrolls and permanent damage to the scroll tips drive bearings and internal seals Once the compressor can not pump down to ...

Page 8: ...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 6 Detail A PLACING UNIT ON SLAB When installing unit at grade level the top of the slab should be high enough above grade so that water from higher ground will not collect around the unit The slab should have a slope tolerance...

Page 9: ...f two 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 AS SLAB SIDE MOUNTING IMPORTANT To help stabilize an outdoor unit some installations may require strapping the unit to the pad using brackets and anchors commonly available in the marketplace DETAI...

Page 10: ...RRIER PREVAILING WINTER WINDS INLET AIR INLET AIR INLET AIR Figure 7 Rooftop Application and Wind Barrier NOTICE Roof Damage This system contains both refrigerant and oil Some rubber roofing material may absorbed oil and cause the rubber to swell when 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 d...

Page 11: ...firmly throughout this procedure Rotate bottom corner of panel away from hinged corner post until lower three tabs clear the slots as illustrated in detail B 3 Move panel down until lip of upper tab clears the top slot in corner post as illustrated in detail A LOUVERED PANEL INSTALLATION Position the panel almost parallel with the unit as illustrated in detail Dwith the screw side as close to the ...

Page 12: ...8 10 7 8 22 3 8 10 7 8 22 L15 65 15 50 feet 5 15 meters 042 048 060 3 8 10 1 1 8 29 3 8 10 1 1 8 29 Field Fabricated NOTE When installing refrigerant lines longer than 50 feet see the Lennox Refrigerant Piping Design and Fabrication Guidelines or contact Lennox Technical Support Product Applications for assistance To obtain the correct information from Lennox be sure to communicate the following i...

Page 13: ... LINE TO THE VAPOR LINE FLOOR JOIST OR ROOF RAFTER REFRIGERANT LINE SET INSTALLING HORIZONTAL RUNS NOTE Similar installation practices should 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 WOOD BLOCK BETWEEN STUDS STRAP WOOD BLOCK STRAP SLEEVE WIRE ...

Page 14: ...ns Perform 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 Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve IMPORTANT Allow braze joint to coo...

Page 15: ...exit point NITROGEN HIGH LOW B A C PIPING PANEL REMOVAL AND PREPARING LINE SET CAP AND CORE REMOVAL Remove piping panel for easier access to service valves Cut ends of the refrigerant lines square free from nicks or dents and debur the ends The pipe must remain round Do not crimp end of the line Remove service cap and core from both the suction vapor and liquid line service ports 1 2 LIQUID LINE S...

Page 16: ...3C on previous page and below for manifold gauge setup 5 SUCTION VAPOR LINE WHEN BRAZING LINE 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 service valve bodies and copper tube stub while brazing in the line set The braze when complete must be que...

Page 17: ...distributor tubes during this process G Remove and discard check 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 MANIFOLD INVERTED HCFC 22 CYLINDER CONTAINS CLEAN HCFC 22 TO BE USED FOR FLUSHING LIQUID LINE SERVICE VALVE INLET DISCHARGE TANK RETURN CLO...

Page 18: ...onnected the liquid line to the indoor unit s distributor assembly B Install one of the provided Teflon rings around the stubbed end of the check expansion valve and lightly lubricate the connector threads and expose surface of the Teflon ring with refrigerant oil C Attach the stubbed end of the check expansion valve to the liquid line orifice housing Finger tighten and use an appropriatelysized w...

Page 19: ... 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 set and indoor unit Weigh in a trace amount of HFC 410A A trace amount is a maximum of two ounces 57 g refrigerant or three pounds 31 kPa pressure Close the valve on the HFC 410A cylinder and the valve on the high...

Page 20: ... set and 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 When the absolute pressure requirement above has been met disconnect the manifold hose from the vacuum pump and connect it to an upright cylinder of HFC 410A refrigerant Open the manifold gauge v...

Page 21: ...power 24VAC 40 VA minimum SERVICE DISCONNECT SWITCH MAIN FUSE BOX BREAKER PANEL 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 Units are approved for use only with copper conductors Ground unit at disconnect switch or to an earth ground SIZE CIRCUIT AND INSTALL DISCONNECT SWITC...

Page 22: ...lectric 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 CAUTION ELECTROSTATIC DISCHARGE ESD Precautions and Procedures Ele...

Page 23: ...Page 23 XPG15 SERIES Figure 16 XPG15 024 030 036 042 and 048 Wiring using ComfortSense 5000 7000 Thermostats ...

Page 24: ...Page 24 506212 01 11 10 Figure 17 XPG15 060 Wiring using ComfortSense 5000 7000 Thermostats ...

Page 25: ...NSTALLER SETUP NAME SELECT 0170 SYSTEM TYPE 7 Two Heat One Cool Heat Pump Heat pump with auxiliary or back up heat 0200 AUXILIARY HEAT SOURCE 0 Electric Heat is used as auxiliary heat source in heat pump application Factory setting DO NOT USE FOSSIL FUEL SETTING 0340 REMOTE OUTDOOR TEMPERATURE SENSOR 0 No remote outdoor temperature sensor or 1 Outdoor temperature sensor used for display ONLY Use W...

Page 26: ...g X4147 W2 W2 Required for two stage furnaces with 7000 Series ROOM THERMOSTAT CONFIGURATION 7000 Series 3 Heat 1 Cool 3H 1C 2 Heat 1 Cool 2H 1C 5000 Series 2 Heat 1 Cool 2H 1C Use W2 stage time feature for two stage furnace WIRE NUT JUMPERED O O Cut W951 link on variable speed furnace control E JUMPERED See the ComfortSense 5000 or 7000 series thermostats installation instruction for complete the...

Page 27: ... hand side of the screen Use the up and down arrows on the right hand side of the display to select the proper setting for that particular set up number 6 After the proper selection has been made see table 3 use the up arrow in the center of the thermostat to advance to the next setup screen 7 When all setup selections have been made press the DONE key to save your settings Thermostat display will...

Page 28: ...SOR DEFAULT NO NO If outdoor sensor is used select LOW and HIGH balance points to the OFF option as follows LOW BALANCE POINT Default 25 F heat pump only and if outdoor sensor installed If outdoor temperature is below programmed low balance point compressor heating is not allowed The options are OFF or any point from 40 F to the High Balance Point setting in 1 0 F steps LOW BALANCE POINT OFF DEFAU...

Page 29: ...Refer to installation instructions packaged with the unit as well as XPG15 service manual Both documents are available from www LennoxDaveNet net Field Installed Relay K229 De energizes Y1 and G inputs to furnace factory provided and field installed at indoor unit NOTES 1 For proper operation the demand defrost control must have 24VAC between R system power input and C system common The above char...

Page 30: ...ten as specified in Operating Gauge Set and Service Valves on page 5 5 Check voltage supply at the disconnect 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 corrected 6 Set the thermostat for a cooling demand Turn on power to the indoor unit and close the...

Page 31: ...e into the delta plate between the coil slabs 2 Drill one 5 16 8 mm air test hole into the duct above the top of the coil 3 Connect the instrument for static pressure measurement hoses to the air entering side of coil Insert the hoses so that 1 4 6 mm extends inside the duct or end seal Seal around holes with Permagum 4 Turn on electrical power to the furnace and set the thermostat to initiate a c...

Page 32: ... nameplate on 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 liquid line or when pressure drop is equal to or greater than 20 psig CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE If the system is void of refrigerant first locate and repa...

Page 33: ... for line set and or match up 9 If subcooling value is greater than shown in table 5 for the applicable unit remove refrigerant if less than shown add refrigerant 10 If refrigerant is added or removed repeat steps 4 through 5 to verify charge 11 Disconnect gauge set and re install both the liquid and vapor service valve caps USING COOLING MODE When the outdoor ambient temperature is 60 F 15 C and ...

Page 34: ...0 5 15 4 CX34 31 0 0 21 4 0 0 23 4 0 0 22 4 CX34 38 1 4 18 4 0 2 20 3 0 5 15 4 CX34 43 1 4 13 4 1 8 16 4 0 11 13 4 CX34 44 48B 0 2 14 3 0 5 15 4 CX34 49 2 5 11 7 1 5 10 8 CX34 50 60C 1 8 16 4 0 11 13 4 Model Number XPG15 042 XPG15 048 XPG15 060 Add Charge Target SC Add Charge Target SC Add Charge Target SC lb oz Heat Cool lb oz Heat Cool lb oz Heat Cool CH33 43 0 5 17 5 CH33 44 48B 0 5 17 5 CH33 4...

Page 35: ... 3 439 152 453 146 468 147 444 150 451 145 459 145 115 46 1 469 152 483 148 501 149 479 152 482 148 492 147 These are most popular match up pressures Indoor match up indoor air quality and indoor load cause pressures to vary Temperature of the air entering the outdoor coil Table 7 HFC 410A Temp F Pressure Psig 5F Psig 5F Psig 5F Psig 5F Psig 5F Psig 32 100 8 56 158 2 79 231 6 103 331 0 127 457 6 3...

Page 36: ... light emitting diodes on the demand defrost control DS1 Red and DS2 Green indicate diagnostic conditions that are described in table 9 DEMAND DEFROST CONTROL A108 PRESSURE SWITCH CONNECTIONS The unit s pressure switches LO PS S87 and HI PS S4 are factory wired into the demand defrost control on the LO PS and HI PS terminals respectively Low Pressure Switch LO PS When the low pressure switch trips...

Page 37: ...r termination pin is factory set at 50 F 10 C If the temperature jumper is not installed the default termination temperatureis 90 F 32 C P2 RL 24VAC output for external K229 relay to control blower operation during defrost heat pump inactive mode and a call for second stage gas heat furnace operations C 24VAC system common W Out 24VAC output to furnace control to begin furnace heating operation R ...

Page 38: ...r to the demand defrost control Y1 Active Place a jumper on 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 continue in the mode it was operating Place a jumper on TEST pins for more than two seconds Clears any short cycle lockout and five strike faul...

Page 39: ...gas furnace heat 1 Code will reset when outdoor temperature raises above 35ºF for a calculated time period 2 Room thermostat demand is satisfied by furnace gas heat FAULT and LOCKOUT CODES Each fault adds one strike to that code s counter five strikes per code per room thermostat demand LOCKOUT OFF Slow Flash Low Pressure Fault 1 Restricted air flow over indoor or out door coil 2 Improper refriger...

Page 40: ...t coil sensor is open shorted or out of the temperature range of the sensor the demand defrost control will not perform demand or time temperature defrost operation and will display the appropriate fault code Heating and cooling operation will be allowed in this fault condition Ambient Sensor RT13 The ambient sensor shown in figure 2 Detail B considers outdoor temperatures below 35 F 37 C or above...

Page 41: ...0 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 7890 39 9 26195 7 7 67000 30 4 237941 85 7 8115 39 3 26626 7 2 68128 31 3 245667 84 5 8343 38 7 27063 6 7 69281 32 2 253834 83 4 8573 38 1 27505 6 1 70458 33 2 262482 82 3 8806 37 5 27954 5 6 71661 ...

Page 42: ...ntrol s TEST pins will not activate the heat pump out of inactive mode Power 24VAC must be cycled to the demand defrost control to activate the heat pump out of inactive mode CALIBRATION MODE The demand defrost control is considered uncalibrated when S 24VAC power is applied to demand defrost control during initial start up or any other time that power is reapplied to the demand defrost control S ...

Page 43: ... REQUESTED A NATURAL DEFROST HEAT PUMP GOES INACTIVE GAS HEAT ACTIVE MORE THAN 30 MINUTES BEFORE DEMAND DEFROST CONTROL REQUESTED A NATURAL DEFROST HEAT PUMP GOES INTO NATURAL DEFROST MODE CONTROL CALIBRATED CONTROL IN DEMAND MODE The demand defrost control is considered uncalibrated when S 24VAC power is applied to demand defrost control during initial start up or any other time that power is rea...

Page 44: ...Mode OFF X X Cooling X X X X X X X X X DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS 1 K1 relay contact remain closed 2 K2 relay contact two sets remain open 3 Reversing valve is energized through room thermostat 4 K3 relay contact close to energize compressor contactor 5 K4 relay contact remain open EXCEPTIONS Low or high pressure switch open or five 5 strike pressure switch lockout or ant...

Page 45: ... W1 W2 O G E L Y1 Y2 W1 W2 G O Y1 W IN RL K229 O Y1 OUT W OUT Heating Mode Outside Temperature above 32ºF First Stage Heat ing Heat Pump X X X X X X DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS 1 K1 relay contact remain closed 2 K2 relay contact two sets remain open 3 K3 relay contact close to energize compressor contactor 4 K4 relay contact remain open 5 K229 relay normally closed contact...

Page 46: ... X X X X X X X X DEMAND DEFROST CONTROL INTERNAL RELAY CONTACT STATUS 1 K1 relay contact remain closed 2 K2 relay contact two sets close and output 24VAC to RL output to energize K229 field installed relay 3 K3 relay contact open and de energize compressor contactor 4 K4 relay contact remain closed 5 K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from t...

Page 47: ...act remain closed 2 K2 relay contact close and output 24VAC to RL output to energize K229 field installed relay 3 K2 relay contact close and energize reversing valve 4 K3 relay contact open and de energize compressor contactor due to outdoor temperature being below 32ºF 0ºC Heat pump goes into inactive mode 5 K4 relay contact close and send 24VAC to W out terminal Gas furnace will satisfy Y1 heat ...

Page 48: ... outdoor fan 2 K2 relay contact close and output 24VAC to RL output to energize K229 field installed relay 3 K2 relay contact close and energize reversing valve 4 K3 relay contact close and energize compressor contactor 5 K4 relay contact remain open 6 K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from the room thermostat to the furnace control Indoor ...

Page 49: ...ycle OFF outdoor fan 2 K2 relay contact close and output 24VAC to RL output to energize K229 field installed relay 3 K2 relay contact close and energize reversing valve 4 K3 relay contact open and de energize compressor contactor 5 K4 relay contact remain open 6 K229 relay with normally closed contacts is now open and removes the Y1 and G signals going from the room thermostat to the furnace contr...

Page 50: ...F 5th Trip in this Cooling Demand No Hi Ps Lockout Display Code Yes Lo Ps Trip No Yes K1 K2 K3 and K4 OFF 5th Trip in this Cooling Demand No Lo Ps Lockout Display Code Yes Cooling Demand Satisfied No Yes K1 K2 K3 and K4 OFF No No K1 Outdoor Fan Normally Closed K2 Reversing valve RL output K3 Compressor Y1 out K4 W out ASCD Anti short Cycle Delay DEFROST CONTROL ON BOARD RELAYS Figure 26 Cooling Mo...

Page 51: ...active K1 K2 K3 OFF K4 ON Yes No Return from Inactive criteria satisfied and Y1 Active New Thermostat Heat Demand No No Yes K1 K2 K3 ON and K4 OFF Power Defrost Yes Ambient Temperature less than 32 F Hi Ps Trip No Lo Ps Trip No Demand Satisfied No No Yes De energize K3 Comp Contactor Fifth Trip in this Heating Demand Hi Ps Lockout Display Code Yes Yes De energize K3 Comp Contactor Fifth Trip in th...

Page 52: ...on No Was coil temperature stable during calibration attempt Board enters power defrost after 45 minutes of accumulated compressor run time with coil temperature less than 35 F K1 K2 K3 ON and K4 OFF No Demand Mode i 0 Yes Criteria to initiate Natural Defrost Met NO Initiate First Natural Defrost K1 K2 K3 K4 OFF and i 1 Set T1 Duration 150 seconds Yes Criteria to initiate Natural Defrost Met Does ...

Page 53: ...ither at the indoor unit installed internal or external to the cabinet or behind a return air grille in the wall or ceiling Check the filter monthly and clean or replace it as needed 2 Disposable Filter Disposable filters should be replaced with a filter of the same type and size NOTE If you are unsure about the filter required for your system call your Lennox dealer for assistance IMPORTANT Turn ...

Page 54: ...auxiliary heat during the defrost cycle to satisfy a heating demand however the unit will return to normal operation at the conclusion of the defrost cycle EXTENDED POWER OUTAGE The heat pump is equipped with a compressor crankcase heater which protects the compressor from refrigerant slugging during cold weather operation If power to your unit has been interrupted for several hours or more set th...

Page 55: ... remove sound reduction cover reverse order the above procedure XPG15 Start Up and Performance Checklist Customer Address Indoor Unit Model Serial Outdoor Unit Model Serial Notes START UP CHECKS Refrigerant Type Rated Load Amps Actual Amps Rated Volts Actual Volts Condenser Fan Full Load Amps Actual Amps COOLING MODE Vapor Pressure Liquid Pressure Supply Air Temperature Ambient Temperature Return ...

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