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Page 6

XP25

VAPOR VALVE

AND GAUGE

PORT

REVERSING

VALVE

LIQUID LINE BI-FLOW

FILTER DRIER

(HFC-410A)

LIQUID VALVE AND

GAUGE PORT

TRUE SUCTION LINE

PORT

HR1 CRANKCASE
HEATER (40W, 240VAC)

MUFFLER

CHECK EXPANSION
VALVE - (HFC-410A)

EXPANSION VALVE SENSING
BULB

CHARGE
C0MPENSATOR
(INTERNAL VOLUME
30.0 CUBIC INCHES)

LIQUID LINE SENSOR

VARIABLE-CAPACITY
COMPRESSOR SPEED - HFC-410A,
3-PHASE

VAPOR VALVE

AND GAUGE

PORT

REVERSING

VALVE

LIQUID LINE BI-FLOW

FILTER DRIER

LIQUID VALVE AND

GAUGE PORT

TRUE SUCTION LINE

PORT

MUFFLER

DISCHARGE LINE

CHECK EXPANSION VALVE SENSING BLUB

HIGH PRESSURE SWITCH - NORMALLY CLOSED, SWITCH
OPENS WHEN SYSTEM PRESSURES REACH 590+15 PSIG,
CLOSES WHEN PRESSURES 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

Typical Plumbing Components (-024 and -048)

Typical Plumbing Components (-036 and -060)

CRANKCASE HEATER
THERMOSTAT (S40) OPENS AT
70ºF, CLOSES AT 50ºF

COMPRESSOR TOP CAP

SWITCH (THERMAL)

HIGH PRESSURE SWITCH - NORMALLY CLOSED, SWITCH OPENS
WHEN SYSTEM PRESSURES REACH 590+15 PSIG, CLOSES
WHEN PRESSURES DROP BELOW 418+15 PSIG

LOW PRESSURE SWITCH - NORMALLY OPEN, SWITCH CLOSES

WHEN SYSTEM PRESSURES GO ABOVE 40±5 PSIG. OPENS

WHEN SYSTEM PRESSURES GO BELOW 25±5 PSIG

CHECK EXPANSION
VALVE - (HFC-410A)

LOW PRESSURE SWITCH - NORMALLY OPEN, SWITCH CLOSES

WHEN SYSTEM PRESSURES GO ABOVE 40±5 PSIG. OPENS

WHEN SYSTEM PRESSURES DROP BELOW 25±5 PSIG

Figure 2. Plumbing (Component Locations and Specifications)

Содержание XP25-024-230-01

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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