XP13 Series - HvacPartsShop.com
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1. 4 R 410A Temperature Pressure Psig oa 2908 25 4455 _ 308 2 129 469 5 312 7 130 475 6 317 2 321 8 132 487 8 133 494 0 07 gt ojo N aaj a aj RY 360 0 i 140 539 0 141 545 6 112 375 1 113 380 2 142 5523 385 4 143 559 1 144 15 390 7 396 0 565 9 145 572 8 17 401 3 406 7 146 579 8 150 608 1 151 615 4 147 586 8 148 593 8 417 7 423 2 152 622 7 278 2 122 428 8 153 630 1 ajo wo e oo o cdo 149 601 0 434 5 154 637 5 440 2 155 645 0 124 4 Subtract the liquid line temperature from the saturation temperature according to the chart to determine the subcooling value Compare the subcooling value with those in table 5 If subcooling value is greater than shown recover some refrigerant if less add some refrigerant TABLE 5 XP13 Subcooling Values for Charging Saturation Temperature Liquid Line Temperature Subcooling Value Charge Using the Approach Method Outdoor Temperature gt 65 F 18 The following procedure is intended as a general guide and is for use on expansion valve systems only For best results indoor temperature should be 70 F 21 C to 80 F 26 Monitor system pressures while charg2. LENNOX UNT INFORMATION XP13 Service Literature Revised 05 2008 XP13 SERIES UNITS The XP13 is a high efficiency residential split system heat pump unit which features a scroll compressor and R 410A refrigerant XP13 units are available in sizes ranging from 1 1 2 through 5 tons The series is designed for use with an indoor unit with an expansion valve approved for R 410A This manual is divided into sections which discuss the ma jor components refrigerant system charging procedure maintenance and operation sequence Information contained in this manual is intended for use by qualified service technicians only All specifications are subject to change A IMPORTANT Operating pressures of this R 410A unit are higher than pressures in R 22 units Always use service equipment rated for R 410A WARNING Warranty will be voided if covered equipment is re moved from original installation site Warranty will not cover damage or defect resulting from Flood wind lightning or installation and opera tion in a corrosive atmosphere chlorine fluorine salt recycled waste water urine fertilizers or oth er damaging chemicals AWARN TABLE OF CONTENTS Improper installation adjustment alteration service Specifications Electrical Page 2 or maintenance can cause property damage person Sepen al injury or loss of life Installation and service must Unit Information Page 3
3. 1 NY COIL SENSOR REVERSING VALVE EXPANSION CHECK VALVE 4 BIFLOW G FILTER DRIER OUTDOOR COIL INTERNAL COMPRESSOR LOW HIGH LIMIT INDOOR UNIT PRESSURE PRESSURE MUFFLER lt xX SUCTION SERVICE PORT 1 1 Hocemo H LIQUID LINE R4104 SERVICE DRUM PORT NOTE ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW FIGURE 11 XP13 HEATING CYCLE SHOWING MANIFOLD GAUGE CONNECTIONS OUTDOOR UNIT COIL SENSOR REVERSING VALVE EXPANSION CHECK VALVE BIFLOW FILTER DRIER OUTDOOR COIL INTERNAL COMPRESSOR LOW HIGH LIMIT INDOOR UNIT PRESSURE PRESSURE MUFFLER E xX cance manon TH suction SERVICE PORT LIQUID LINE SERVICE EXPANSION CHECK NOTE ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW FIGURE 12 Page 8 A Plumbing Field refrigerant piping consists of liquid and vapor lines from the outdoor unit sweat connections Use Lennox L15 sweat series line sets as shown in table 3 TABLE 3 Refrigerant Line Sets Field Recommended Line Set Liquid Vapor Liquid Vapor L15 Line Line Line Line Line Sets 3 8 in 3 4in 3 8in ud can 10 mm 19 mm 10 mm 19 mm 4 6 m 15 m 7 8in 3 8in 7 8in 15 65 22 mm 10 mm 22 mm dem PSI 3 8 in 1 1 8 in 3 8 in 1 1 8 in Field 10 mm 29 mm 10 mm 29 mm Fabricated B Service Valves A IMPORTA
4. 208 230V 208 230V 3 Maximum overcurrent protection amps 20 30 30 35 35 40 50 60 2 Minimum circuit ampacity 11 9 17 5 18 4 21 6 21 9 23 2 28 9 34 6 Compressor Rated load amps 8 97 13 46 14 1 26 28 Locked rotor amps 48 58 73 134 Power factor 0 98 0 98 0 98 i 0 99 Outdoor Fan Full load amps 0 7 0 7 0 7 0 7 1 1 1 1 1 7 1 7 Motor Locked Rotor Amps 1 4 14 14 14 2 1 2 1 2 1 3 1 OPTIONAL ACCESSORIES must be ordered extra Compressor Hard Start Kit 10J42 cl MEIN CRI Compressor Crankcase Heater 93M04 Factory Compressor Low Ambient 45F08 pepe es Cut Off Compressor Sound Cover 69J03 R EL Freezestat 3 8 in tubing 93G35 5 8 in tubing 50A93 Low Ambient Kit 54M89 Low Pressure Switch Bypass ot Thermostat Mild Weather Kit 33M07 Monitor Kit Service Light 76F53 Outdoor Thermostat 56A87 Thermostat Kit Mounting Box 31461 e Refrigerant L15 41 20 L15 41 40 Line Sets L15 41 30 L15 41 50 L15 65 40 L15 65 30 L15 65 50 Field Fabricate eo Time Delay Relay NOTE Extremes of operating range are plus 1096 and minus 59 of line voltage 1 Refrigerant charge sufficient for 15 ft length of refrigerant lines 2 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements 3 HACR type breaker or fuse Page 2 I UNIT INFORMATION ELECTROSTATIC DISCHARGE ESD Precautions
5. 14 IV CHARGING A Leak Testing After the line set has been connected to the indoor and out door units check the line set connections and indoor unit for leaks A WARNING Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may result in personal injury or death A WARNING Fire Explosion and Personal Safety Hazard Failure to follow this warning could result in damage personal injury or death Never use oxygen to pressurize or purge refrigeration lines Oxygen when exposed to a spark or open flame can cause damage by fire and or an explosion that can re sult in personal injury or death A WARNING Danger of explosion When using a high pressure gas such as dry nitrogen to pressurize a refriger ant or air conditioning system use a regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa Using an Electronic Leak Detector or Halide 1 Connect a cylinder of R 410A to the center port of the manifold gauge set 2 With both manifold valves closed open the valve on the R 410A cylinder vapor only 3 Open the high pressure side of the manifold to allow the R 410A into the line set and indoor unit Weigh in a trace amount of R 410A A trace amount is a maximum of 2 ounces 57 g or 3 pounds 31 kPa pressure Close the valve on the R 410A cylinder and the valve on the high pressure side of the m
6. DEFROST o CONTROL 108 FIGURE 2 Electrical openings are provided under the control box cov er Field thermostat wiring is made to a 24V terminal strip located on the defrost control board located in the control box See figure 3 24V THERMOSTAT TERMINAL STRIP gag FIGURE 3 1 Compressor Contactor K1 The compressor is energized by a contactor located in the control box See figure 2 Single pole contactors are used in all XP13 series units K1 is energized through the con trol board by the indoor thermostat terminal Y1 24V when thermostat demand is present DANGER Electric Shock Hazard May cause injury or death Line voltage is present at all compo nents when unit is not in operation on units with single pole contactors Disconnect all remote electrical power supplies before opening unit panel Unit may have multiple power supplies 2 Dual Capacitor C12 The compressor and fan in XP13 series units use permanent split capacitor motors The capacitor is located inside the unit control box see figure 2 A single dual capacitor C12 is used for both the fan motor and the compressor see unit wir ing diagram The fan side and the compressor side of the ca pacitor have different MFD ratings See side of capacitor for ratings 3 Defrost Control The XP13 defrost system includes two components a de frost t
7. HIGH PRESSURE SWITCH sIsIsIsIsIsIs TST PS DF C R O YI FIGURE 4 Defrost Control Timing Pins Each timing pin selection provides a different accumu lated compressor run time period for one defrost cycle This time period must occur before a defrost cycle is initi ated The defrost interval can be adjusted to 30 60 or 90 minutes see figure 4 The defrost timing jumper is facto ry installed to provide a 60 minute defrost interval If the timing selector jumper is not in place the control defaults to a 90 minute defrost interval The maximum defrost pe riod is 14 minutes and cannot be adjusted A TEST option is provided for troubleshooting The TEST mode may be started any time the unit is in the heating mode and the defrost thermostat is closed or jump ered If the jumper is in the TEST position at power up the control will ignore the test pins When the jumper is placed across the TEST pins for two seconds the control will enter the defrost mode If the jumper is removed before an addi tional 5 second period has elapsed 7 seconds total the unit will remain in defrost mode until the defrost thermostat opens or 14 minutes have passed If the jumper is not re moved until after the additional 5 second period has elapsed the defrost will terminate and the test option will not function again until the jumper is removed and re ap plied Compressor Delay The defrost board has a f
8. N O closes energizing compressor B1 and out door fan motor B4 3 Compressor B1 and outdoor fan motor B4 begin immediate operation END OF COOLING DEMAND 4 Cooling demand is satisfied Terminal Y1 is de ener gized 5 Compressor contactor K1 is de energized 6 K1 1 opens and compressor B1 and outdoor fan motor B4 are de energized and stop immediately Terminal O is de energized when indoor room thermo stat is out of cooling mode de energizing the reversing valve L1 Heating demand initiates at Y1 in the thermostat FIRST STAGE HEATING See steps 1 2 and 3 END OF HEATING DEMAND See steps 4 5 and 6 7 Page 16 DEFROST MODE When a defrost cycle is initiated the control ener gizes the reversing valve solenoid and turns off the condenser fan The control will also put 24VAC on the W1 auxiliary heat line The unit will stay in this mode until either the defrost thermostat S6 tem perature is above the termination temperature of 70 the defrost time of 14 minutes has been com pleted or the room thermostat demand cycle has been satisfied If the room thermostat demand cycle terminates the cycle the defrost cycle will be held until the next room thermostat demand cycle If the defrost thermostat S6 temperature is still below the termination temperature the control will continue the defrost cycle until the cycle is terminated in one of the methods mentioned above
9. and Procedures CAUTION Electrostatic discharge can affect electronic components Take precautions during unit instal lation and service to protect the unit s electronic controls Precautions will help to avoid control exposure to electrostatic discharge by putting the unit the control and the technician at the same electrostatic potential Neutralize electro static charge by touching hand and all tools on an unpainted unit surface before performing any service procedure All major components indoor blower and coil must be matched according to Lennox recommendations for the compressor to be covered under warranty Refer to the En gineering Handbook for approved system matchups A misapplied system will cause erratic operation and can re sult in early compressor failure AIMPORTANT This unit must be matched with an indoor coil as specified in Lennox Engineering Handbook Il UNIT COMPONENTS Unit components are illustrated in figure 1 XP13 UNIT COMPONENTS OUTDOOR FAN COMPRESSOR SERVICE LIQUID LINE SERVICE VALVE FIGURE 1 LINE HIGH PRESSURE SWITCH Page 3 A Control Box Figure 2 XP13 units are not equipped with a 24V transformer All 24 VAC controls are powered by the indoor unit Refer to wir ing diagram SINGLE PHASE UNIT CONTROL BOX r DUAL CAPACITOR C12 COMPRESSOR CONTACTO K1
10. be performed by a qualified installer or service agency Unit Components Page 3 Ill Refrigerant System Page 8 AWARNING IV Charging owsa 10 Electric shock hazard Can cause injury V Service and Recovery Page 13 or death Before attempting to perform any service or maintenance turn the VI Maintenance Page 14 electrical power to unit OFF at discon nect switch es Unit may have multiple VII Brazing Procedure Page 14 power supplies VIII Wiring Diagram Page 15 Technical ene 1 2005 Lennox Industries Inc SPECIFICATIONS General Model No XP13 018 XP13 024 XP13 030 XP13 036 XP13 037 XP13 042 XP13 048 XP13 060 Data Nominal Tonnage 1 5 2 2 5 3 3 3 5 4 5 Connections Liquid line o d in 3 8 3 8 3 8 3 8 3 8 3 8 3 8 sweat Vapor line o d 3 4 3 4 3 4 3 4 7 8 7 8 1 1 8 Refrigerant 1 R 410A charge furnished 10 Ibs 11 Ibs 15 Ibs 15 oz 7 OZ 10 oz 2 oz 10 oz 10 oz 0 oz Outdoor Net face area Outer coil 24 50 Coil sq ft Inner coil 23 64 Tube diameter 5 16 No of Rows 2 Fins per inch 22 Outdoor Diameter 22 Fan No of blades 4 Motor hp 1 4 Cfm 3980 Rpm 836 Watts 305 Shipping Data Ibs 1 pkg 235 305 ELECTRICAL DATA Line voltage data 60hz 1 phase 208 230V 208 230V 208 230V 208 230V 208 230V 208 230V
11. in the top of the compressor can and the motor is located just below The oil level is immediately below the motor The scroll is a simple compression concept centered around the unique spiral shape of the scroll and its inherent properties Figure 6 shows the basic scroll form Two identical scrolls are mated together forming concentric spiral shapes figure 7 One scroll remains stationary while the other is allowed to or bit figure 8 Note that the orbiting scroll does not rotate or turn but merely orbits the stationary scroll SCROLL COMPRESSOR FIGURE 5 NOTE During operation the head of a scroll compressor may be hot since it is in constant contact with discharge gas Page 5 SCROLL FORM FIGURE 6 CROSS SECTION OF SCROLLS DISCHARGE STATIONARY SCROLL D d DISCHARGE 9 SUCTION N NJ OPA SSS A 4 Y YA SSSSSASSANM VZEFZZZ SUE SANAAAANASSY LP ELL Led VL kL h hhh MSS N SS 3 SS A NA N S SS n TIPS SEALED BY ORBITING SCROLL DISCHARGE PRESSURE FIGURE 7 The counterclockwise orbiting scroll draws gas into the outer crescent shaped gas pocket created by the two scrolls figure 8 1 The centrifugal action of the orbiting scroll seals off the flanks of the scrolls figure 8 2 As the orbiting motion contin ues the gas is forced toward the center of the scroll and the gas pocket becomes compressed figure 8 3 When the compressed gas
12. with an optional by pass switch wired in parallel with the low pressure switch S87 This by pass switch prevents nuisance trips when ambient conditions drop below 15 F NOTE The defrost control board ignores input from the low pressure switch terminals as follows during the TEST mode during the defrost cycle during the 90 second start up period and for the first 90 seconds each time the reversing valve switches heat cool modes Diagnostic LEDs The defrost board uses two LEDs for diagnostics The LEDs flash a specific sequence according to the condition Page 4 TABLE 1 Defrost Control Board Diagnostic LED Green LED DS2 Red LED DS1 Mode No power to con ol OFF OFF Normal operation Simultaneous Slow FLASH power to control Anti short cycle lockout Alternating Slow FLASH Low pressure OFF Slow FLASH switch fault Low pressure OFF ON switch lockout High pressure Slow FLASH switch fault High pressure ON switch lockout B Compressor The scroll compressors in all XP13 model units are de signed for use with R 410A refrigerant and operation at high pressures Compressors are shipped from the factory with 3MA 32MMMA P O E oil See electrical section in this manual for compressor specifications The scroll compressor design is simple efficient and requires few moving parts A cutaway diagram of the scroll compressor is shown in figure 5 The scrolls are located
13. INTERMEDIATE PRESSURE 2 adi GAS CRESCENT SHAPED GAS POCKET FLANKS SEALED 7 BY CENTRIFUGAL FORCE J MOVEMENT OF ORBIT 3 HIGH PRESSURE GAS SUCTION DISCHARGE POCKET FIGURE 8 C Outdoor Fan Motor All units use single phase PSC fan motors which require a run capacitor In all units the condenser fan is controlled by the compressor contactor ELECTRICAL DATA tables in this manual show specifi cations for condenser fans used in XP 13 s Access to the condenser fan motor on all units is gained by removing the four screws securing the fan assembly See figure 9 The grill fan assembly can be removed from the cabinet as one piece See figure 10 The condenser fan motor is removed from the fan guard by removing the four nuts found on top of the grill See figure 10 if con denser fan motor replacement is necessary A DANGER Make sure all power is disconnected before beginning electrical service procedures Remove Screws q screws FIGURE 9 ALIGN FAN HUB FLUSH WITH END OF SHAFT FIGURE 10 D Reversing Valve L1 and Solenoid A refrigerant reversing valve with electromechanical so lenoid is used to reverse refrigerant flow during unit op eration The reversing valve requires no maintenance It is not repairable If the reversing valve has failed it must be replaced Page 6 E Drier A filter drier designed for all XP13 model units is factory installed in the liquid line The fi
14. NT Only use Allen wrenches of sufficient hardness 50Rc Rockwell Harness Scale min Fully in sert the wrench into the valve stem recess Service valve stems are factory torqued from 9 3 8 in 10 mm ft Ibs for small valves to 25 ft Ibs for large valves to prevent refrigerant loss during ship ping and handling Using an Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench or stripping the valve stem recess Service valves figures 13 and 14 and gauge ports are ac cessible from the outside of the unit Use the service ports for leak testing evacuating charging and checking charge Each valve is equipped with a service port which has a fac tory installed Schrader valve A service port cap protects the Schrader valve from contamination and serves as the primary leak seal To Access Schrader Port 1 Remove service port cap with an adjustable wrench 2 Connect gauge to the service port 3 When testing is complete replace service port cap Tight en finger tight then an additional 1 6 turn To Open Service Valve 1 Remove the stem cap with an adjustable wrench 2 Use a service wrench with a hex head extension to back the stem out counterclockwise as far as it will go NOTE Use a 3 16 hex head extension for 3 8 line sizes or a 5 16 extension for large line sizes Page 9 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn T
15. ST eo LES LOW PRESSURE DUAL DO CAPACITOR DEFROST CONTROL THERMOSTAT COMPRESSOR CONTACTOR FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVER CURRENT PROTECTION SIZE A S4 TO BE MOUNTED IN CONTROL BOX AND WIRED IN PARALLEL WITH LOW PRESSURE SWITCH Page 15 BLACK pu d BLACK eam BLACK om 208 230 60 THERMOSTAT LO PS AMBIENT PRESSURE HERMO SWITCH HI PS S4 HIGH PRESSURE SWITCH CONNECTION MUST BE JUMPERED WHEN OPTIONAL SWITCH IS NOT USED WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES DENOTES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED CLASS VOLTAGE FIELD INSTALLED New Form No 534 774M Litho U S A XP13 OPERATING SEQUENCE This is the sequence of operation for XP13 series units The sequence is outlined by numbered steps which correspond to circled numbers on the adjacent diagram NOTE The thermostat used may be electromechan ical or electronic NOTE Transformer in indoor unit supplies power 24 VAC to the thermostat and outdoor unit controls COOLING Indoor room thermostat wiring energizes terminal O by cooling mode selection energizing the reversing valve L1 Cooling demand initiates at Y1 in the thermostat 1 24VAC energizes compressor contactor K1 2 K1 1
16. TANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns Use an instrument that reads from 50 microns to at least 10 000 microns 1 Connect manifold gauge set to the service valve ports e low pressure gauge to vapor line service valve e high pressure gauge to iquid line service valve 2 Connect micron gauge 3 Connect the vacuum pump with vacuum gauge to the center port of the manifold gauge set 4 Open both manifold valves and start the vacuum pump 5 Evacuate the line set and indoor unit to an absolute pressure of 23 000 microns 29 01 inches of mercu ry During the early stages of evacuation it is desirable to close the manifold gauge valve at least once to deter mine if there is a rapid rise in absolute pressure A rapid rise in pressure indicates a relatively large leak If this occurs repeat the leak testing procedure NOTE The term absolute pressure means the total actual pressure within a given volume or system above the absolute zero of pressure Absolute pres sure in a vacuum is equal to atmospheric pressure mi nus vacuum pressure O 1 When the absolute pressure reaches 23 000 microns 29 01 inches of mercury close the manifold gauge valves turn off the vacuum pump and disconnect the manifold gauge center port hose from vacuum pump Attach the manifold center port hose to a nitrogen cylin der with pressure regulator set to 150 psig 1034 kPa and purge
17. VII BRAZING Before brazing remove access panels and any piping pan els to avoid burning off paint Be aware of any components ie service valves reversing valve pressure switches that may be damaged due to brazing heat When making line set connections use 1 to 2 psig dry nitro gen to purge the refrigerant piping This will help to prevent oxidation into the system AWARNING Danger of explosion Can cause equipment damage injury or death When using a high pressure gas such as 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 1 Cut ends of copper square free from nicks or dents Debur the ends The pipe must remain round do not pinch end of line 2 Wrap wet rag around any components that may be da maged 3 Use silver alloy brazing rods 5 or 6 percent minimum silver alloy for copper to copper brazing or 45 percent silver alloy for copper to brass or copper to steel braz ing which are rated for use with R 22 and R 410A re frigerant 4 After brazing quench the joints with a wet rag to prevent possible heat damage to any components Page 14 VIII WIRING DIAGRAM AND SEQUENCE OF OPERATION OUTDOOR AR FAN ei E 8 COMPRESSOR CRANKCASE HEATER DEFROST THERMOSTAT LI 208 230 60 L2 EQUIPMENT GROUND ey OR O DOOR N Cl2 CMCIICONTROL DEFRO
18. anifold gauge set Disconnect the R 410A cylinder 4 Connect a cylinder of nitrogen with a pressure regulat ing valve to the center port of the manifold gauge set 5 Connect the manifold gauge set high pressure hose to the vapor valve service port Normally the high pres sure hose is connected to the liquid line port however connecting it to the vapor port better protects the man ifold gauge set from high pressure damage 6 Adjust the nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set which will pressurize line set and indoor unit 7 After a few minutes open a refrigerant port to ensure the refrigerant you added is adequate to be detected Amounts of refrigerant will vary with line lengths Check all joints for leaks Purge nitrogen and R 410A mixture Correct any leaks and recheck B Evacuating the System Evacuating the system of noncondensables is critical for proper operation of the unit Noncondensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system Noncondensables and water vapor combine with refrigerant to produce substances that corrode copper pip ing and compressor parts NOTE This evacuation process is adequate for a new installation with clean and dry lines If excessive mois ture is present the evacuation process may be re quired more than once Page 10 A IMPOR
19. ct the outdoor coil The coil may be flushed with a water hose Ensure the power is turned off before you clean the coil 2 Condenser fan motor is prelubricated and sealed No further lubrication is needed 3 Visually inspect connecting lines and coils for evidence of oil leaks 4 Check wiring for loose connections 5 Check for correct voltage at unit unit operating 6 Check amp draw condenser fan motor Unit nameplate Actual NOTE If owner complains of insufficient cooling the unit should be gauged and refrigerant charge checked Refer to section on refrigerant charging in this instruction 1 Clean and inspect condenser coil Coil may be flushed with a water hose after disconnecting power 2 Visually inspect all connecting lines joints and coils for evidence of oil leaks B Indoor Coil 1 Clean coil if necessary 2 Check connecting lines and coils for evidence of oil leaks 3 Check the condensate line and clean it if necessary C Indoor Unit 1 Clean or change filters 2 Adjust blower speed for cooling Measure the pressure drop over the coil to determine the correct blower CFM Refer to the unit information service manual for pressure drop tables and procedure 3 Belt Drive Blowers Check belt for wear and proper ten sion 4 Check all wiring for loose connections 5 Check for correct voltage at unit blower operating 6 Check amp draw on blower motor Unit nameplate Actual
20. door Temperature Approach Temperature Model 018 024 030 036 037 042 048 060 oF 12 6 7 7 11 3 9 6 11 6 15 8 3 11 6 12 9 5 67 NOTE For best results use the same electronic thermometer to check both outdoor ambient and liquid line temperatures F 1 0 C 0 5 Model 018 024 030 036 E 6 3 7 4 3 3 17 3 9 22 1 0 0 5 12 7 XP13 Normal Operating Pressures Values below are typical pressures indoor unit match up indoor air quality equipment and indoor load will cause the pressures to vary Temp F C Cooling Operation Liquid Line Pressure Vapor Line Pressure 105 41 402 149 412 148 419 146 429 145 443 145 423 146 423 144 420 148 440 136 115 45 458 152 464 152 474 I 153 486 147 508 149 486 148 484 147 484 150 500 140 Heating Operation Temperature of the air entering the outdoor coil V SERVICE AND RECOVERY AWARNING Polyol ester POE oils used with R 410A refriger ant absorb moisture very quickly It is very impor tant that the refrigerant system be kept closed as much as possible DO NOT remove line set caps or service valve stub caps until you are ready to make connections A IMPORTANT Use recovery machine rated for R410 refrigerant If the XP13 system must be opened f
21. hermostat and a defrost control Defrost Thermostat Defrost Switch S6 The defrost thermostat is located on the liquid line between the check expansion valve and the distributor When de frost thermostat senses 42 5 5 C or cooler the thermo stat contacts close and send a signal to the defrost control board to start the defrost timing It also terminates defrost when the liquid line warms up to 70 F 21 Defrost Control The defrost control board includes the combined functions of a time temperature defrost control defrost relay diag nostic LEDs and terminal strip for field wiring connections The control provides automatic switching from normal heat ing operation to defrost mode and back During compressor cycle call for defrost the control accumulates compressor run times at 30 60 or 90 minute field adjustable inter vals If the defrost thermostat is closed when the selected compressor run time interval ends the defrost relay is ener gized and defrost begins XP13 Outdoor Unit Defrost Control Board OPNS KI RELAY FIELD SELECT 4 TIMING PINS TEST PINS DIAGNOSTIC LEDS COMPRESSOR DELAY PINS REVERSING VALVE K2 RELAY 24V TERMINAL STRIP CONNECTIONS S87 LOW PRESSURE SWITCH DEFROST THERMOSTAT elelelelele S4 K3 RELAY
22. ield selectable function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode The compressor will be cycled off for 30 seconds going in and out of the defrost mode when the compressor delay jumper is removed NOTE The 30 second compressor feature is ignored when the defrost test pins are jumpered Time Delay The timed off delay is five minutes long The delay helps to protect the compressor from short cycling in case the pow er to the unit is interrupted or a pressure switch opens The delay is bypassed by placing the timer select jumper across the TEST pins for 0 5 seconds Pressure Switch Circuit The defrost control incorporates two pressure switch cir cuits The high pressure switch S4 is factory connected to the board s HI PS terminals see figure 4 The board also includes a low pressure or loss of charge pressure switch S87 Switches are shown in the unit wiring diagram Dur ing a single demand cycle the defrost control will lock out the unit after the fifth time that the circuit is interrupted by any pressure switch wired to the control board In addition the diagnostic LEDs will indicate a locked out pressure switch after the fifth occurrence of an open pressure switch see Table 1 The unit will remain locked out until power to the board is interrupted then re established or until the jumper is applied to the TEST pins for 0 5 seconds Some XP13 units will be equipped
23. ing 1 2 3 Check the outdoor ambient temperature using a digital thermometer and record in table 6 Attach high pressure gauge set and operate unit for several minutes to allow system pressures to stabilize Compare stabilized pressures with those provided in table 7 Normal Operating Pressures Minor varia tions in these pressures may be expected due to differ ences in installations Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system Pressures higher than those listed indicate that the sys tem is overcharged Pressures lower than those listed indicate that the system is undercharged Continue to check adjusted charge using approach values Use the same digital thermometer used to check out door ambient temperature to check liquid line tempera ture and record in table 6 Verify the unit charge using the approach method The difference between the am bient and liquid temperatures should match values giv en in table 6 Add refrigerant to lower the approach tem perature and remove it to increase the approach tem perature Loss of charge results in low capacity and ef ficiency If the values do not agree with those in table 6 add re frigerant to lower the approach temperature or recover refrigerant from the system to increase the approach temperature TABLE 6 XP13 Approach Values for Charging Liquid Line Temperature Out
24. lter drier is designed to re move moisture and foreign matter which can lead to com pressor failure Moisture and or Acid Check Because POE oils absorb moisture the dryness of the system must be verified any time the refrigerant sys tem is exposed to open air A compressor oil sample must be taken to determine if excessive moisture has been introduced to the oil Table 2 lists kits available from Lennox to check POE oils If oil sample taken from a system that has been exposed to open air does not test in the dry color range the filter drier MUST be replace IMPORTANT Replacement filter drier MUST be approved for R 410A refrigerant and POE application Foreign Matter Check It is recommended that a liquid line filter drier be replaced when the pressure drop across the filter drier is greater than 4 psig To safeguard against moisture entering the system follow the steps in section IV sub section B Evacuating the System when replacing the drier F High Low Pressure Switch A IMPORTANT Pressure switch settings for R 410A refrigerant will be significantly higher than units with R 22 An auto reset single pole single throw high pressure switch is located in the liquid line This switch shuts off the compres sor when liquid line pressure rises above the factory setting The switch is normally closed and is permanently adjusted to trip open at 590 15 psi An auto reset single pole single throw low press
25. nd repair any leaks and then weigh in the refrigerant charge into the unit 1 Recover the refrigerant from the unit 2 Conduct leak check evacuate as previously outlined 3 Weigh in the unit nameplate charge If weighing facili ties are not available or if charging the unit during warm weather use one of the following procedures Charge Using the Subcooling Method Outdoor Temperature lt 65 F 18 C When the outdoor ambient temperature is below 65 F 18 C use the subcooling method to charge the unit If necessary restrict the air flow through the outdoor coil to achieve pressures in the 325 375 psig 2240 2585 kPa range These higher pressures are necessary for checking the charge Block equal sections of air intake panels and move obstructions sideways until the liquid pressure is in the 325 375 psig 2240 2585 kPa range See figure 15 Blocking Outdoor Coil BLOCK OUTDOOR COIL ONE SIDE AT A TIME WITH CARDBOARD OR PLASTIC SHEET UNTIL PROPER TESTING PRESSURES ARE REACHED CARDBOARD OR PLASTIC SHEET FIGURE 15 1 With the manifold gauge hose still on the liquid service port and the unit operating stably use a digital ther mometer to check the liquid line temperature and re cord in table 5 2 At the same time record the liquid line pressure reading 3 Use a temperature pressure chart for R 410A table 4 to determine the saturation temperature for the liquid pressure reading record in table 5
26. o Close Service Valve 1 Remove the stem cap with an adjustable wrench 2 Use a service wrench with a hex head extension to turn the stem clockwise to seat the valve Tighten the stem firmly NOTE Use a 3 16 hex head extension for 3 8 line sizes or a 5 16 extension for large line sizes 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn Service Valve Valve Closed stem cap service K port PA insert hex gt wrench here to outdoor coil service port cap Schrader valve open to line set when valve is closed front seated valve front seated Service Valve Valve Open insert hex stem cap wrench here service port to outdoor coil service port cap to indoor coil Schrader valve FIGURE 13 Vapor Line Ball Valve 5 Ton Only Vapor line service valves function the same way as the oth er valves the difference is in the construction If a valve has failed you must replace it A ball valve is illustrated in figure 14 The ball valve is equipped with a service port with a factory installed Schrader valve A service port cap protects the Schrader valve from contamination and assures a leak free seal Ball Valve Valve Open Use Adjustable Wrench To open rotate Stem Clockwise 90 To close rotate Stem Counter clockwise 90 44A stem to outdoor coil ball shown open service port cap Schrader valve FIGURE
27. or any kind of service such as compressor or drier replacement you must take extra precautions to prevent moisture from entering the system The following steps will help to minimize the amount of moisture that enters the system during recovery of R 410A 1 Use a regulator equipped nitrogen cylinder to break the system vacuum Do not exceed 5 psi The dry nitro gen will fill the system and will help purge any mois ture Page 13 2 Remove the faulty component and quickly seal the sys tem using tape or some other means to prevent addi tional moisture from entering the system 3 Do not remove the tape until you are ready to install new component Quickly install the replacement com ponent 4 Evacuate the system to remove any moisture and other non condensables The XP13 system MUST be checked for moisture any time the sealed system is opened Any moisture not absorbed by the polyol ester oil can be re moved by triple evacuation Moisture that has been ab sorbed by the compressor oil can be removed by replacing the drier A IMPORTANT Evacuation of system only will not remove mois ture from oil Drier must be replaced to eliminate moisture from POE oil VI MAINTENANCE In order to maintain the warranty on this equipment the XP13 system must be serviced annually and a record of service maintained The following should be checked be tween annual maintenance A Outdoor Unit 1 Clean and inspe
28. reaches the center it is discharged vertically into a chamber and discharge port in the top of the compressor figure 7 The discharge pressure forcing down on the top scroll helps seal off the upper and lower edges tips of the scrolls figure 7 During a single orbit several pockets of gas are compressed simultaneously providing smooth continuous compression The scroll compressor is tolerant to the effects of liquid return If liquid enters the scrolls the orbiting scroll is allowed to separate from the stationary scroll The liquid is worked toward the cen ter of the scroll and is discharged If the compressor is re placed conventional Lennox cleanup practices must be used Due to its efficiency the scroll compressor is capable of draw ing a much deeper vacuum than reciprocating compres sors Deep vacuum operation can cause internal fusite arcing resulting in damaged internal parts and will result in compressor failure Never use a scroll compressor for evacuating or pumping down the system This type of damage can be detected and will result in denial of war ranty claims The scroll compressor is quieter than a reciprocating com pressor however the two compressors have much differ ent sound characteristics The sounds made by a scroll compressor do not affect system reliability performance or indicate damage SS SUCTION ORBITING SCROLL STATIONARY SCROLL SUCTION POCKET SUCTION SUCTION y
29. the hose Open the manifold gauge valves to break the vacuum in the line set and indoor unit Close the manifold gauge valves A CAUTION Danger of Equipment Damage Avoid deep vacuum operation Do not use compres sors to evacuate a system Extremely low vacuums can cause internal arcing and compressor failure Damage caused by deep vacuum operation will void warranty 7 Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder Open the manifold gauge valves to release the nitrogen from the line set and indoor unit Page 11 8 Reconnect the manifold gauge to the vacuum pump turn the pump on and continue to evacuate the line 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 When the absolute pressure requirement above has been met disconnect the manifold hose from the vacu um pump and connect it to an upright cylinder of R 410A refrigerant Open the manifold gauge valves to break the vacuum from 1 to 2 psig positive pressure in the line set and indoor unit Close manifold gauge valves and shut off the R 410A cylinder and remove the manifold gauge set C Charging Charge Using the Weigh in Method Outdoor Temperature lt 65 F 18 C If the system is void of refrigerant or if the outdoor ambient temperature is cool first locate a
30. ure switch is located in the suction line This switch shuts off the compressor when suction pressure drops below the factory setting The switch is closed during normal operating pres sure conditions and is permanently adjusted to trip open at 25 5 psi The switch automatically resets when suction line pressure rises above 40 5 psi Under certain condi tions the low pressure switch is ignored See Pressure Switch Circuit in the Defrost Control description G Crankcase Heater Crankcase heater prevents migration of liquid refrigerant into compressor and ensures proper compressor lubrica tion The heaters are standard on the XP 037 042 048 and 060 and an option for all other models TABLE 2 KIT CONTENTS TUBE SHELF LIFE 10N46 Refrigerant Analysis Checkmate RT700 Boc TU 10N45 Acid Test Tubes 74N40 Easy Oil Test Tubes pack 10N44 Moisture Test Tubes c poenitet dE Checkmate RT750A three pack temperature 3t 6 12 months room temperature 2 years refrigerated Checkmate RT752C Tubes three 2 3 years room temperature 3 years refrigerated 74N39 Acid Test Kit Sporian One Shot TA 1 7 Ill REFRIGERANT SYSTEM Refer to figure 11 and 12 for refrigerant flow in the heat ing and cooling modes The reversing valve is energized during cooling demand and during defrost XP13 COOLING CYCLE SHOWING MANIFOLD GAUGE CONNECTIONS OUTDOOR UNIT DISTRIBUTOR
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