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1. C33 38 SNA before SN 6007K 31 7 0 0 ww ee A C33 38 SN 6007K and after 10 8 0 0 115 46 1 473 155 7 a C33 44 48 14 6 0 7 Heating First Stage Low Capacity Pressure C33 49 6 6 1 5 40 4 4 316 99 50 10 nae aaa C33 50 60C 12 5 0 13 7 3 C33 60D 8 5 0 15 Heating Second Stage High Capacity Pressure3 20 7 0 294 64 1 62D 9 30 1 0 313 77 CH33 44 48B 12 5 0 13 40 4 4 329 89 CH33 48 12 5 0 13 50 10 344 109 C33 50 60C 60D 6 6 1 5 Most popular match up pressures Indoor match up CR33 48 30 5 0 0 indoor air quality and indoor load cause pressures to CR33 50 60 60 15 4 1 5 vary l Amount of charge required in addition to charge shown Temperature of the air entering the outdoor coil on unit nameplate Remember to consider line set length Liquid 10 and Vapor 5 psig difference Page 32 Table 12 HFC 410A Temperature Pressure Chart Cee Y l Psig x 33 ai 4029 7 pss 1050 m ed 3 1092 3 ma as me ne Es o 44 1273 x 45 m7 d 1322 A 1346 E 49 os s 55 8 ares poso 442 81 290 42 35 jJ tas 591 5 446 J se 227 J s 362 Jj 44 5659 52 tra 8 2465 j 114 354 145 j 528 53 44 ss 2503 J 45 saoz jJ 446 5798 54 428 j es 241 46 3060 jJ 447 5868 5 14555 jJ 3 2580 j 47 413 jJ tas 59368 5 1482 Jj er 22o J ns 467 J 449 601
2. Later in the procedure the HFC 410A container will be replace bv the nitrogen container With both manifold valves closed connect the cylinder of HFC 410A refrigerant to the center port of the manifold gauge set Open the valve on the HFC 410A cvlinder suction oniv 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 JA 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 pressure side of the manifold gauge set Disconnect the HFC 410A cvlinder Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set Adjust dry nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor unit After a few minutes open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector After leak testing disconnect gauges from service ports Page 26 B Evacuating Evacuating the system of non condensables is critical for proper operation of the unit Non condensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system Non condensables and water suction combine with refri
3. FIGURE 30 Page 28 DT Temperature of air 80 24 24 24 23 23 22 22 22 20 19 18 17 16 15 entering indoor 78 2323232222212120191817161514 coil F 76 22 22 22 21 21 20 19 19 18 17 16 1514 13 74 21 212120191918 17 16 16 1514 13 12 72 20 2019181717 164315 14 13121110 A 701919181817171615151413121110 Wet bulb F 57 58 59 60 61 62 63 64 65 66 67 68 69 70 DRV BULB INDOOR COIL All temperatures are expressed in F 1 Determine the desired DT Measure entering air temperature using dry bulb A and wet bulb B DT is the intersecting value of A and B in the table see triangle Find temperature drop across coil Measure the coil s dry bulb entering and leaving air temperatures A and C Temperature Drop Formula Tprop A minus C Determine if fan needs adjustment If the difference between the measured Tprop and the desired DT Tprop DT is within 3 no adjustment is needed See example below Assume DT 15 and A temp 72 these C temperatures would necessitate stated actions ce Tprop DT F ACTION 555 19 15 4 Increase the airflow 5 14 15 1 within 3 range no change 622 10 15 5 Decrease the airflow Changing air flow affects all temperatures recheck temperatures to confirm that the temperature drop and DT are within 3 4 Adjust the fan speed See indoor unit instructions to increase decrease fan sp
4. Resistance values Pins Wire range ohms Color 280 000 to 3750 384 Black Coil 35 37 to 120 280 000 to 3750 5 amp 6 48 Brown Discharge if 24 4 to 350 41 000 to 103 1 amp 2 applicable 176 Yellow Temperature Range F C 35 37 to 120 48 Sensor Outdoor Note Sensor resistance increases as sensed temperature decreases Page 15 Ambient and Coil Sensor TEMPERATURE F 10000 30000 50000 70000 RESISTANCE OHMS Discharge Sensor TEMPERATURE F 2000 3000 4000 5000 6000 RESISTANCE OHMS FIGURE 19 Sensor Locations WIRE TIE SLEEVE AMBIENT SENSOR Extend tip of plastic sensor just outside of plastic sleeve Place ambient sensor and wire from defrost board inside of plastic sleeve and route thru gap between corner post and coil support as shown Secure with wire tie DISCHARGE SENSOR 12 tubes up COIL SENSOR Clip coil temperature sensor from the defrost board on the return bend 12 tubes up from the bottom 11 1 2 FIGURE 20 Ambient Sensor The ambient sensor shown in detail A figure 20 consider
5. LENNOX J UNIT INFORMATION XPG20 Corp 0907 L3 Service Literature XPG20 SERIES UNITS The XPG20 036 is a high efficiency residential split system heat pump unit which features a solar assisted DC motor two step scroll compressor and HFC 410A refrigerant The XPG20 is designed for use with an expansion valve only approved for use with HFC 410A in the indoor unit This manual is divided into sections which discuss the major components refrigerant system charging procedure maintenance and operation sequence A CAUTION Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury Be aware of and use caution when working nearby these areas during installation or while servicing this equipment A CAUTION To prevent personal injury or damage to panels unit or structure be sure to observe the following While installing or servicing this unit carefully stow all removed panels out of the way so that the panels will not cause injury to personnel nor cause damage to objects or structures nearby nor will the panels be subjected to damage e g being bent or scratched While handling or stowing the panels consider any weather conditions especially windy conditions that may cause panels to be blown around and bat tered 4 WARNING Improper installation adjustment alteration service or maintenance can cause personal injury loss of life or damage
6. Test Mode When Y1 is energized and 24V power is be ing applied to the board a test cycle can be initiated by placing the termination temperature jumper across the Test pins for 2 to 5 seconds If the jumper remains across the Test pins longer than 5 seconds the control will ignore the test pins and revert to normal operation The jumper will initiate one cycle per test Enter the TEST mode by placing a shunt jumper across the TEST pins on the board after power up The TEST pins are ignored and the test function is locked out if the shunt is applied on the TEST pins before power up Board timings are reduced the low pressure switch and loss of charge detection fault is ignored and the board will clear any active lockout condition Each test pin shorting will result in one test event For each TEST the shunt jumper must be removed for at least 1 second and reapplied Refer to flow chart figure 21 for TEST operation Note The Y1 input must be active ON and the O room thermostat terminal into board must be inactive Defrost Board Diagnostics See table 5 to determine defrost board operational condi tions and to diagnose cause and solution to problems Test Mode Y1 Active 0 line inactive Y Short test pins for longer Short test pins for more than 2 0 seconds than 1 second but less than 2 0 seconds Y Clear an
7. XPG20 COOLING CVCLE Showing Gauge Manifold Connections OUTDOOR UNIT DISTRIBUTOR NOTE ARROWS INDICATE DIRECTION OF REFRIGERANT FLOW REFRIGERANT WILL FLOW IN OPPOSITE REVERSING VALVE DIRECTION IN HEATING CYCLE EXPANSION CHECK VALVE sA LOW HIGH INDOOR UNIT PRESSURE PRESSURE BIFLOW FILTER DRIEROUTDOOR COIL MUFFLER lt xX SUCTION SERVICE SERVIC COMPRESSOR PORT INDOOR COIL LIQUID LINE NOTE Use gauge ports on vapor line valve and liquid valve for evacuating refrigerant lines and indoor coil Use suction gauge port to measure suction pressure during charging FIGURE 27 Page 24 A Service Valves Access the liquid line and vapor line service valves figures 28 and 29 and gauge ports are used for leak testing eva cuating charging and checking charge See table 8 for torque requirements 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 TABLE 8 Pat Recommended Torque 44 IMPORTANT Service valves are closed to the outdoor unit and open to line set connections Do not open the valves until refrigerant lines have been leak tested and evacuated All precautions should be exercised to keep the svstem free from dirt moisture and air To Access Schrader Por
8. Operational Description The defrost control board has three basic operational modes normal calibration and defrost Normal Mode The demand defrost board monitors the O line to determine the system operating mode heat cool outdoor ambient temperature coil temperature outdoor coil and compressor run time to determine when a defrost cycle is required Calibration Mode The board is considered uncalibrated when power is applied to the board after cool mode opera tion or if the coil temperature exceeds the termination tem perature when it is in heat mode Calibration of the board occurs after a defrost cycle to en sure that there is no ice on the coil During calibration the temperature of both the coil and the ambient sensor are measured to establish the temperature differential which is required to allow a defrost cycle See figure 22 for calibra tion mode sequence Defrost Mode The following paragraphs provide a de tailed description of the defrost system operation Detailed Defrost System Operation Defrost Cycles The demand defrost control board initi ates a defrost cycle based on either frost detection or time Frost Detection Iif the compressor runs longer than 34 minutes and the actual difference between the clear coil and frosted coil temperatures exceeds the maxi mum difference allowed by the control a defrost cycle will be initiated Time f 6 hours of heating mode compressor run time has elap
9. insert the screws and tighten Removing Installing Louvered Panels IMPORTANTI Do not allow panels to hang on unit bv top tab Tab is for alignment and not designed to support weight of panel I Panel shown slightly ro tated to allow top tab to exit or enter top slot for removing or instal ling panel A Y i a A Y LIP SCREW HOLES i A Y Y Y Al Detail A Ni Y Al Detail B Y 2 l Y l A Y 5 ES ROTATE IN THIS DIRECTION vv THEN DOWN TO REMOVE PANEL MAINTAIN MINIMUM PANEL ANGLE AS CLOSE TO PARALLEL WITH THE UNIT AS POSSIBLE WHILE INSTALLING PANEL HOLD DOOR FIRMLY TO THE HINGED ANGLE MAY BE TOO Soe Ve SIDE TO MAINTAIN EXTREME eee PSS FULLY ENGAGED TABS I PREFERRED ANGLE L SSA AN I ili Detail D FIGURE 2 AC FAN MOTOR AC FAN MOTOR MOUNT CONTACTOR E OUTDOOR FAN SOLAR ASSIST DC MOTOR COUPLER DEFROST CONTROL SOLAR ASSIST DC MOTOR LENNOX SYSTEM OPERATION Bs MONI
10. 1st stage 2500 1180 2nd stage 2800 1320 Rpm 1st stage 700 2nd stage 820 Watts 1st stage 70 2nd stage 105 Shipping Data Ibs kg 1 pkg 315 143 ELECTRICAL DATA Line voltage data 60hz 208 230V 1ph 3 Maximum overcurrent protection amps 40 2 Minimum circuit ampacity 23 7 Compressor Rated load amps 16 7 Locked rotor amps 82 Power factor 0 98 Outdoor Coil Full load amps 2 8 Fan Motor OPTIONAL ACCESSORIES must be ordered extra Compressor Hard Start Kit 10J42 81J69 Compressor Low Ambient Cut Off 45F08 Freezestat 3 8 in tubing 93G35 1 2 in tubing 39H29 5 8 in tubing 50A93 Indoor Blower Relay 40K58 Low Ambient Kit 68M04 Monitor Kit Service Light 76F53 Mounting Base 69J07 Outdoor Thermostat 56A87 Thermostat Mounting Box US 31461 e Kit Canada 33A09 SignatureStat Home Comfort Control 81M28 Refrigerant L15 65 15 L15 65 40 Line Sets L15 65 30 L15 65 50 Field Fabricate Time Delay Relay 58M81 NOTE Extremes of operating range are plus 10 and minus 5 of ine voltage 1 Refrigerant charge sufficient for 15 ft 4 6 m length of refrigerant lines 2 RefertoNational or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements 3 HACR type breaker or fuse I APPLICATION All major components indoor blower and coil must be matched according to Le
11. Sequence Occurs after power up after cooling operation or if the coil temperature exceeds the termination temperature while in Heat Mode DCB defaults to 34 minutes Time Temperature Mode Reset Compressor Runtime Reset Three Five Strike Counter DEMAND MODE Accumulate compressor run time while coil temperature is below 35 F 2 C When the accumulated compres sor time exceeds 6 hours or if the coil sensor indicates frost is present on coil go to Defrost Coil temperature was above 35 F 2 C for 4 min of the 14 min de frost OR reached defrost termination temp 34 MIN TIME TEMP MODE Accumulate compressor run time while coil temperature is below 35 F 2 C When the accumulated compressor time exceeds 34 minutes go to Defrost DEFROST OUTDOOR FAN Off Reversing Valve ON W1 line ON Monitor coil temperature and time in defrost mode y HOW DID DEFROST TERMINATE Defrosted for 14 min with out the coil temp going above 35 F 2 C for 4 min and coil did not reachi DCB s 60L3901 and 46M8201 LO PS Termination Option selected Defrost terminated bv pressure At termination of defrost the compressor runtime counter is reset Turn on Outdoor FAN Rev Valve 8 W1 turn off Attempt to Calibration Temperature measurements are not taken for the first few minutes of each heat demand This is to allow coil temperatures to stabilize DCB has a maximum of 20 minutes of accumulated compressor runti
12. alert LED at the unit Y2 DC Solenoid Connector DC SOL The 24VDC so lenoid which is internal to the compressor will not op erate properly if 24VAC is applied to the compressor solenoid terminals A voltmeter attached to the DC SOL output will measure 4 18 VDC when the sole noid is be energized Installation verification LSOM To verify correct LSOM installation two functional tests can be performed Dis connect power from the compressor and force a ther mostat call for cooling The red trip LED should turn on indicating a compressor trip as long as 24VAC is mea sured at the Y terminal If the red LED does not function as described refer to table 3 to verify the wiring Dis connect power from the compressor and 24VAC power from LSOM Remove the wire from the Y terminal of LSOM and reapply power to the compressor allowing the compressor to run The yellow alert LED will begin flashing a code 8 indicating a welded contactor Dis connect power from the compressor and 24VAC power from the LSOM While the LSOM is off reattach the wire to the Y terminal Reapply power to the compres sor and 24VAC power to the LSOM the yellow alert LED will flash the previous code 8 for one minute and then turn off If the yellow LED does not function as de scribed refer to table 3 to verify the wiring Resetting alert codes Alert codes can be reset manual ly or automatically Manual reset Cycle the 24VAC power to LSOM off and on Aut
13. clean if necessary 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 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 HFC 22 and HFC 410A refrigerant 4 After brazing quench the joints with a wet rag to prevent possible heat damage to any components Page 34 VIII DIAGRAM OPERATING SEQUENCE KI COMPRESSOR OO CONTACTO
14. for switch location E Capacitor C12 The compressor uses a permanent split capacitor see unit wiring diagram The capacitor is located inside the unit con trol box Ratings are on capacitor side F Condenser Fan with Variable Speed Motor B4 The variable speed condenser fan motor figure 11 used in all units is a three phase electronically controlled d c brushless motor controller converts single phase a c to three phase d c with a permanent magnet type rotor manufactured by GE Because this motor has a permanent magnet rotor it does not need brushes like conventional D C motors The motors consist of a control module and motor Internal components are shown in figure 12 The stator windings are split into three poles which are electrically connected to the controller This ar rangement allows motor windings to be turned on and off in sequence by the controller Page 9 The controller is primarily an a c to d c converter Con verted d c power is used to drive the motor The control ler contains a microprocessor which monitors varying conditions inside the motor such as motor workload The controller uses sensing devices to know what position the rotor is in at any given time By sensing the position of the rotor and then switching the motor windings on and off in sequence the rotor shaft turns the blower VARIABLE SPEED CONDENSER FAN MOTOR ANVLYOdH motor control module FIGURE 11 B
15. from the thermostat but no current to the compressor is detected by the module Flash code number corresponds to a number of LED flashes followed by a pause and then repeated Trip amp Alert LEDs flashing simultaneously indicates that the control circuit voltage is too low for operation Reset ALERT flash code by removing 24VAC power from moni tor Last ALERT flash code will display for 1 minute after monitor is powered on Thermostat Second Stage Cooling The Lennox system operation monitor LSOM requires a two stage room thermostat to operate properly Y2 room thermostat connection While the compressor is not running LSOM will not power the solenoid re gardless of the state of Y2 If alert codes 1 or 9 see table 3 appear while the compressor is running LSOM will turn off the solenoid to prevent solenoid damage from overheating conditions L terminal connection The L connection is used to com municate alert codes to the room thermostat On se lected Lennox SignatureStat thermostats a blinking check LED will display on the room thermostat and on select White Rodgers room thermostats an icon on the display will flash Either will flash at the same rate as the LSOM yellow alert LED NOTE ROOM THERMOSTAT WITH SERVICE OR CHECK LIGHT FEATURE The room thermostat may blink the Check or Service LED or it may come on solid Confirm fault by observing and interpreting the code from the LSOM yellow
16. lockout mode and displays the appropri ate code This code detects shorted sensor or high dis charge temperatures Code on board is Discharge Line Temperature Fault and Lockout Page 16 4 If the board recognizes five temperature sensor range faults during a single Y1 compressor demand it re verts to a lockout mode and displays the appropriate code The board detects open sensor or out of tem perature sensor range This fault is detected by allow ing the unit to run for 90 seconds before checking sen sor resistance If the sensor resistance is not within range after 90 seconds the board will count one fault After 5 faults the board will lockout Code on board is Discharge Sensor Fault and Lockout The discharge line sensor which covers a range of 150 F 65 C to 350 F 176 C is designed to mount on a Y re frigerant discharge line NOTE Within a single room thermostat demand if 5 strikes occur the board will lockout the unit Defrost board 24 volt power R must be cycled OFF or the TEST pins on board must be shorted between 1 to 2 sec onds to reset the board Second Stage Operation If the board receives a call for second stage compressor operation Y2 in heating or cooling mode and the first stage compressor output is ac tive the second stage compressor solenoid output will be energized by the LSOM NOTE The LSOM has a 5 second delay between Y2 being powered
17. problem is with external solenoid plug power TABLE 1 Unit Readings Compressor Operation Y1 1st Stage Y2 Expected Results 2nd Stage Compressor Voltage Same Amperage Higher Condenser Fan motor Amperage Same or Higher Temperature Ambient Same Outdoor Coil Discharge Air Higher in Cooling Lower in Heating Compressor Discharge Line Higher Indoor Return Air Same Indoor Coil Discharge Air Lower in Cooling Higher in Heating Pressures Suction Vapor Lower Liquid STEP 2 Confirm DC voltage output on compressor solenoid plug 1 Shut power off to the outdoor unit 2 Insert lead wires from voltmeter into back of the red and black wire plug jack that feeds power to compres sor solenoid coil Set voltmeter to DC volt scale to read DC voltage output from LSOM II plug See figure 10 FIGURE 10 3 Apply a Y1 and Y2 demand from the indoor thermostat to the LSOM II 4 Turn power back on to unit 5 Compressor should cycle ON when VI is calling 6 With Y2 calling 5 seconds after compressor cycles ON LSOM II will output 24 volt DC signal to the com pressor solenoid plug Once the solenoid has pulled in the LSOM II will reduce the DC voltage to a pulsating 6 to 18 volt DC output to the solenoid to allow the sole noid to remain energized Higher A IMPORTANT When checking compressor f
18. tem peratures to detect when the system is performing poorly because of ice build up on the outdoor coil The controller self calibrates when the defrost system starts and after each system defrost cycle The defrost control board com ponents are shown in figure 18 Defrost Control Board Note Component Locations Vary by Board Manufacturer TEST PINS rest PI P3 FAN DEFROST q Oo LOW TERMINATION 4 AMBIENT PIN SETTINGS THERMOSTAT al o PINS SENSOR PLUG IN COIL AMBIENT 8 DISCHARGE SENSORS KI DIAGNOSTIC LEDS DELAV PINS tsa P5 REVERSING VALVE 7 24V TERMINAL STRIP CONNECTIONS O LO PS PRESSURE SWITCH CIRCUIT COMMON CONNECTIONS ica o Y2 OUT HI PS o elelelelelele FIGURE 18 The control monitors ambient temperature outdoor coil temperature and total run time to determine when a de frost cycle is required The coil temperature probe is de signed with a spring clip to allow mounting to the outside coil tubing The location of the coil sensor is important for proper defrost operation NOTE The demand defrost board accurately measures the performance of the system as frost accumulates on the outdoor coil This typically will translate into longer running time between defrost cycles as more frost accumu
19. that the control circuit voltage is too low for operation Yellow Alert Flash Code 1 Long Run Time Compres sor is running extremely long run cycles 1 Low refrigerant charge 2 Evaporator blower is not running 3 Evaporator coil is frozen 4 Faulty metering device 5 Condenser coil is dirty 6 Liquid line restriction filter drier blocked if present 7 Thermostat is malfunctioning Vellow Alert Flash Code 2 System Pressure Trip or Discharge Sensor Fault Discharge or suction pres sure out of limits or compressor overloaded 1 Check high head pressure or discharge line sensor 2 Condenser coil poor air circulation dirty blocked damaged 3 Condenser fan is not running 4 Return air duct has substantial leakage 5 If low pressure switch is present see Flash Code 1 information Yellow Alert Flash Code 3 Short Cycling Compres sor is running only briefly 1 Thermostat demand signal is intermittent 2 Time delay relay or control board is defective 3 If high pressure switch is present see Flash Code 2 information 4 If discharge sensor is present see Flash Code 2 information Yellow Alert Flash Code 4 Locked Rotor 1 Run capacitor has failed 2 Low line voltage contact utility if voltage at disconnect is low 3 Excessive liquid refrigerant in the compressor 4 Compressor bearings are seized Yellow Alert Flash Code 5 Open Circuit 1 Outdo
20. to property Installation and service must be performed by a licensed professional installer or equivalent or a service agency A DANGER Shock Hazard Remove all power at disconnect before removing access panel XPG20 units use single pole contac tors Potential exists for electrical shock resulting in injury or death Line voltage exists at all components even when unit is not in operation Table of Contents General x uy e e a Paci aS asas ee Sa 1 Specifications Electrical Data 2 I Application a uy Esa S A 3 II Unit Components 3 III Refrigerant System 18 r Technical Publications Page 1 IV Charging Sl 26 V Service and Recovery LL 34 VI Maintenance 34 VII Brazing Procedure 0 eee eee eee 34 VIII Diagrams and Operating Sequence 35 2009 Lennox Industries Inc SPECIFICATIONS General Model No XPG20 036 Data Nominal Tonnage kW 3 10 6 Connections Liquid line o d in mm 3 8 9 5 sweat Vapor line o d in mm 7 8 22 2 Refrigerant 1 R 410A charge furnished 12 Ibs 5 oz 5 6 kg Outdoor Net face area sq ft m2 Outer coil 20 50 1 90 Coil Inner coil 19 86 1 85 Tube diameter in mm 5 16 0 52 No of rows 2 Fins per inch m 22 866 Outdoor Diameter in mm 26 660 Fan No of blades 3 Motor hp W 1 3 249 Cfm L s
21. to unit Troubleshooting If first or second stage thermostat call for cool is present and the variable speed condenser fan motor does not ener gize check voltage at the breaker box If voltage is present do the following and reference figure 13 1 Check for 240 volts between the compressor RED wi res 2 Initiate a first stage call for cool Check for 24 volts be tween the fan motor YELLOW wire and fan motor BLACK wire 3 Initiate a second stage call for cool Check for 24 volts between the fan motor YELLOW wire and fan motor BLACK wire then check for 24 volts between the fan motor BLUE wire and fan motor BLACK 4 Repeat steps 1 and 2 with a HEAT call 1st Stage low capacity 700 rpm RED 240V YELLOW Y1 2nd Stage High capacity 820 rpm 240V RED ra 240V YELLOW NI 24V 24V BLACK common 24V FIGURE 13 Page 10 Replacement Follow the steps below if condenser fan motor replacement is necessary 1 Disconnect power at the main disconnect switch or main fuse box breaker panel K1e1 COMPRESSOR CONTACTOR x N W LU x a o EQUIPMENT GROUND COMPRESSOR CONTACTOR 2 Disconnect DC solar motor wires and AC outdoor fan motor wires highlted in figure 14 COMFORTSENSE CS7000 A2 IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION LINE VOLTAGE FIELD INSTALLED CLASS II VOLT
22. 0 sr teo j ss 26o j 49 422 J 150 684 ss 439 J s 200 J 1207 477 J 151 654 59 tez jJ o 2741 J 424 4232 J 42 627 6 tes e 282 J 42 488 jJ 43 6301 6 me J o2 223 43 4345 J 44 6375 62 15 es 25 j 44 4602 j 155 650 Page 33 V SERVICE AND RECOVERY AWARNING Polyol ester POE oils used with HFC 410A refrig erant 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 IMPORTANT Use recovery machine rated for R410 refrigerant If the XPG20 system must be opened for any kind of ser vice such as compressor or filter drier replacement you must take extra precautions to prevent moisture from en tering the system The following steps will help to minimize the amount of moisture that enters the system during re covery of HFC 410A 1 Use a regulator equipped nitrogen cylinder to break the system vacuum Do not exceed 5 psi The dry ni trogen will fill the system and will help purge any mois ture 2 Remove the faulty component and quickly seal the system using tape or some other means to prevent additional 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 remov
23. 03 wa XPG20 CONTROL BOX WATERTIGHT FLEXIBLE CONDUIT FIELD GROUND LUG CONTACTOR E PROVIDED ROUTE THROUGH WIRE TIE WATERTIGHT FLEXIBLE CONDUIT IMPORTANT This should be the last wiring connection made in the solar cir cuit DC disconnect must be OFF when connection photovoltaic module to circuit Never open electrical connections or unplug connectors while the circuit is under load NOTE Solar electric modules have no on off switch Modules can be rendered inoperative only by removing them from light Ful ly cover the front module surface with opaque material or working with the module face down on a smooth flat surface WATERTIGHT CONDUIT FITTING NEGATIVE TERMINALS O O 24VDC SOLAR TERMINAL BLOCK FIGURE 25 Page 22 TO SOLAR DC MOTOR 24VDC SOLAR TERMINAL BLOCK POSITIVE TERMINALS MOTOR ALIGNMENT ADJUSTMENT Before start up of the XPG20 unit perform the procedure outlined in Figure 26 ADN aS Loosen the torque arm nut under the compressor top wrapper panel Allow the mo
24. AGE FIELD WIRING DENOTES OPTIONAL COMPONENTS FIGURE 14 3 Remove 4 screws on top of grille Remove alignment nut Lift assembly up and out screw location coupler dc motor alignment nut A CAUTION Outdoor fan assembly is heavy and awkward to handle 71 A TE ji ZA IRA A 1 FIGURE 15 Page 11 4 When replacing outdoor fan assembly make note of fan location See figure 16 Fan to Motor Shaft Dimension U GED y is ERED 7 U m 3 Ly fan blade 1 125 G Crankcase Heater HR1 Compressors in all units are equipped with a 70 watt belly band type crankcase heater HR1 prevents liquid from ac cumulating in the compressor HR1 is controlled by the crankcase heater thermostat H Crankcase heater Thermostat S40 Thermostat S40 controls the crankcase heater in all units S40 is located on the liquid line When liquid line tempera ture drops below 50 F the thermostat S40 closes energizing HR1 The thermostat will open de energizing HR1 once liq uid line temperature reaches 70 F l Drier A filter drier designed for the XPG20 is factorv installed in the liquid line The filter drier is designed to remove mois ture and foreign matter which can lead to compressor fail ure Moisture and or Acid Chec
25. FC 410A cvlinder Reinstall service valve cores bv removing manifold hose from service valve Quickiv install cores with core tool while maintaining a positive svstem pressure Replace the stem caps and secure finger tight then tighten an additional one sixth 1 6 of a turn as illustrated A IMPORTANT 4 WARNING Use a thermocouple or thermistor electronic vacuum Danger of Equipment Damage Avoid deep vacuum gauge that is calibrated in microns Use an operation Do not use compressors to evacuate a instrument capable of accurately measuring down to system Extremely low vacuums can cause internal arcing and compressor failure Damage 50 microns l a caused by deep vacuum operation will void warrantv Page 27 C Charging TESTING CHARGE TEMPERATURE MANIFOLD SENSOR GAUGE SET OUTDOOR UNIT t REFRIGERANT TO SUCTION TANK SERVICE VALVE CHARGE IN LIQUID PHASE DIGITAL SCALE TO LIQUID LINE SERVICE wy TEMPERATURE SENSOR VALVE LIQUID LINE Close manifold gauge set valves and connect the center hose to a cvlinder of HFC 410A Set for liquid phase charging Connect the manifold gauge set s low pressure side to the suction line service port Connect the manifold gauge set s high pressure side to the liquid line service port Position temperature sensor on liquid line near liquid line service port
26. LOWER MOTOR COMPONENTS STATOR WINDINGS BEARING FIGURE 12 Internal Operation The condenser fan motor is a variable speed motor with RPM settings at 700 Y1 and 820 Y2 The variation in speed is accomplished each time the controller switches a stator wind ing figure11 on and off it is called a pulse The length of time each pulse stays on is called the pulse width By vary ing the pulse width the controller varies motor speed called pulse width modulation This allows for precise control of motor speed and allows the motor to compensate for varying load conditions as sensed by the controller In this case the controller monitors the static workload on the motor and var ies motor rpm in order to maintain constant airflow cfm Motor rpm is continually adjusted internally to maintain constant static pressure against the fan blade The control ler monitors the static work load on the motor and motor amp draw to determine the amount of rpm adjustment Blower rpm is adjusted internally to maintain a constant cfm The amount of adjustment is determined by the incre mental taps which are used and the amount of motor load ing sensed internally The motor constantly adjusts rpm to maintain a specified cfm Initial Power Up When line voltage is applied to the motor there will be a large inrush of power lasting less than 1 4 second This in rush charges a bank of DC filter capacitors inside the con tro
27. R RT21 RT13 RT28 A NOTE SOARES DEFROST AMBIENT DISCHARGE FOR USE WITH COPPER CONDUCTORS COIL SENSOR SENSOR ONLY REFER TO UNIT RATING PLATE GROUND K228 K227 SENSOR FOR MINIMUM CIRCUIT AMPACITY AND LUG 0 O MAXIMUM OVERCURRENT PROTECTION SIZE 9 ZA REFER TO COMPRESSOR IN UNIT FOR OIDO ACTUAL TERMINAL ARRANGEMENT O s Bi A DEFROST HIGH N WARNING CONTROL PRESSURE COMPRESSOR ELECTRIC SHOCK HAZARD CAN CAUSE INJURY A132 OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE DIAGNOSTIC SWITCH O O O WITH NATIONAL AND LOCAL CODES MODULE A REMOVE JUMPER FOR TWO STAGE COOL A RT14 SENSOR OUTDOOR TEMP OPTIONAL A 134 SOLENOID IS LOCATED IN COMPRESSOR COIL IS 24VDC DO NOT CONNECT 24VAC TO COIL TERMINALS 024 AND 036 UNITS COME FACTORY WIRED FOR LOW OUTDOOR FAN SPEED ONLY HIGH SPEED Y2 BLUE WIRE IS NOT CONNECTED L34 S87 LOW L1 c12 PRESSURE REVERSING CAPACITOR SWITCH VALVE COMFORTSENSE CS7000 K1e1 COMPRESSOR CONTACTOR CRANKCASE O HR1 CRANKCASE HEATER COMPRESSOR NOTEs IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION LINE VOLTAGE FIELD INSTALLED CLASS Il VOLTAGE FIELD WIRING GROUND DENOTES OPTIONAL COMPONENTS SOLAR FAN RELAY COMPRESSOR CONTACTOR SOLAR MOTOR Page 35 Sequence of Operation XPG20 1 A 1 2 3 4 NOTE Solar motor will assist outdoor fan motor B1 once a minimum 16 VDC is achie
28. SERVICE PORT CAP SERVICE PORT 1 Valve Shown Closed Insert hex wrench here VALVE front seated To indoor coil To outdoor coil SCHRADER SERVICE PORT CAP VALVE SERVICE Valve Shown Open insert hex wrench here indoor coil To outdoor coil FIGURE 28 Vapor Line Ball Type Service Valve Valve Open To indoor coil Use Adjustable Wrench To close rotate Stem Counter clockwise 90 To open rotate Stem BALL Clockwise 90 Shown closed STEM STEM CAP SERVICE PORT SCHRADER VALVE SERVICE PORT CAP To outdoor coil FIGURE 29 IV CHARGING Units are factory charged with the amount of R410A refrig IM PORTANT erant indicated on the unit rating plate This charge is Leak detector must be capable of sensing HFC based on a matching indoor coil and outdoor coil with 15 ft refrigerant 4 6m line set For varying lengths of line set refer to table 9 for refrigerant charge adjustment TABLE 9 Liquid Line Set Ozs per 5 ft grams per 1 5m adjust Diameter from 15 ft 4 6m line set AWARNING When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system use a regulator that can 3 ounces per 5 feet 9 5mm 85g per 1 5m ee control the pressure down to 1 or 2 If line length is greater than 15 ft 4 6m add this amount psig 6 9 to 13 8 kPa If line length is less than 15 ft 4 6 subtract this amount A Le
29. TOR LSOM a RUN CAPACITOR x BLOCK VAPOR VALVE AND GAUGE PORT TWO STAGE COMPRESSOR DISCHARGE LINE REVERSING VALVE BI FLOW FILTER DRIER HIGH PRESSURE SWITCH LOW PRESSURE SWITCH FIGURE 3 SOLAR FAN RELAY 24VAC K228 DEFROST RELAY SOLAR FAN K227 GROUND LUG f i HIGH VOLTAGE FIELD CONNECTIONS CONTACTOR 1POLE 25A K1 1 AA DEFROST CONTROL BOARD A108 CAPACITOR C12 LOW VOLTAGE CONTROL WIRE TIE LSOM MODULE A132 TERMINAL BLOCK TWO POSITION SOLAR FIGURE 4 Page 4 ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A 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 andall tools on an unpainted unit surface before performing anv service procedure A Two Stage Scroll Compressor B1 The scroll compressor design is simple efficient and re quires few moving parts A cutawav diagram of the scroll compressor is shown in figure 1 The scrolls are located in the top of the compressor can and the motor is located just below The oil level is immediatelv below the motor The scroll is a simple compression concept centere
30. ak Testing 4 WARNING 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 Fire Explosion and Personal Safety Hazard Failure to follow this warning could re sult in damage personal injury or death Never use oxygen to pressurize or fu purge refrigeration lines Oxvgen Y when exposed to a spark or open flame can cause damage by fire and or an explosion that could result in personal injury or death LEAK TESTING THE SYSTEM After the line set has been connected to the indoor unit and air conditioner check the line set connections and indoor unit for leaks Use the following procedure to test for leaks NOTE Normally the high pressure hose is con MANIFOLD nected to the liquid line port however connecting it CW K_AINLA HIGHGAUGE SET to the suction port better protects the manifold a O gauge set from high pressure damage BE T OUTDOOR UNIT USE REGULATOR TO FLOW NITROGEN AT 1 TO 2 PSIG TO SUCTION NITROGEN SERVICE VALVE HFC 410A Connect an HFC 410A manifold gauge set high pressure hose to the suction valve service port With both manifold valves closed connect the cylinder of HFC 410A refrigerant to the center port of the manifold gauge set NOTE
31. and the solenoid energizing If first stage compressor output is active in heating mode and the outdoor ambient temperature is below the selected compressor lock in temperature the second stage com pressor solenoid output will be energized without the Y2 room thermostat input If the jumper is not connected to one of the temperature selection pins on P3 40 45 50 55 F the default lock in temperature of 40 F 4 5 C will be used The board de energizes the second stage compressor so lenoid output immediately when the Y2 signal is removed or the outdoor ambient temperature is 5 F above the se lected compressor lock in temperature or the first stage compressor output is de energized for any reason Defrost Temperature Termination Shunt Jumper Pins The defrost board selections are 50 70 90 and 100 F 10 21 32 and 38 C The shunt termination pin is factory set at 50 F 10 C If the temperature shunt is not installed the default termination temperature is 90 F 32 C Delay Mode The defrost board has a field selectable function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode When a jumper is installed on the DELAY pins the compressor will be cycled off for 30 seconds going in and out of the defrost mode Units are shipped with jumper installed on DELAY pins NOTE The 30 second off cycle is NOT functional when jumpering the TEST pins
32. ccess panel Install refrigeration gauges on unit Attach the amp meter to the common black wire wire of the compressor harness Attach thermometer to discharge line as close as possible to the compressor 4 Turn toggle switch OFF and install switch in series with Y2 wire from room thermostat 5 Cycle main power ON 6 Allow pressures and temperatures to stabilize before taking any measured reading may take up to 10 min utes NOTE Block outdoor coil to maintain a minimum of 375 psig during testing 7 Record all of the readings for the Y1 demand on table 1 8 Close switch to energize Y2 demand 9 Allow pressures and temperatures to stabilize before taking any measured reading this may take up to 10 minutes 10 Record all of the readings of Y2 demand on table 1 NOTE On new installations or installations that have shut down for an extended period of time if the com pressor does not cycle from low stage to high stage on the first attempt it may be necessary to recycle the com pressor back down to low stage and back up to high stage a few times in order to get the bypass seals to properly seat Compare Y1 readings with Y2 readings in table 1 Some readings should be higher lower or the same If the readings follow what table 1 specifies the compressor is operating and shifting to high capacity as designed If the readings do not follow what table1 specifies continue to step 2 to determine if
33. d around the unique spiral shape of the scroll and its inherent properties Figure 6 shows the basic scroll form Two iden tical scrolls are mated together forming concentric spiral shapes figure 7 One scroll remains stationarv while the other is allowed to orbit figure 8 Note that the orbiting scroll does not rotate or turn but merelv orbits the station arv scroll TWO STAGE MODULATED SCROLL slider ring solenoid actuator coil FIGURE 5 SCROLL FORM FIGURE 6 Page 5 CROSS SECTION OF SCROLLS DISCHARGE DISCHARGE PRESSURE STATIONARY SCROLL Ys SUCTION 2 Ye A kk y l AW bi bi NS A KE SS L TIPS SEALED BV A DISCHARGE PRESSURE OPBITING SCROLL FIGURE 7 de EXA 777 a AAA Z AMAIA b ka AAT lt YW YW WAY NAC The counterclockwise orbiting scroll draws gas into the out er 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 continues the gas is forced toward the center of the scroll and the gas pocket becomes compressed figure 8 3 When the compressed gas reaches the center it is dis charged vertically into a chamber and discharge port in the top of the compressor figure 8 4 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 or b
34. dule will continue pulsing 6 to 18 volt DC signal to the solenoid to keep it energized during the Y2 opera tion The 24volt inputs to the yellow and blue wires of the outdoor fan motor will provide high speed operation 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 coil sensor temperature is above the selected termination temperature the de frost time of 14 minutes has been completed or the room thermostat demand cycle has been satisfied If the temperature select shunt is not installed the default termination temperature will be 90 F If the room thermostat demand cycle terminates the cycle the defrost cycle will be held until the next room thermostat demand cycle If the coil sensor temperature is still below the selected termination temperature the control will continue the defrost cycle until the cycle is terminated in one of the meth ods mentioned above If a defrost is terminated by time and the coil temperature did not remain above 35 F 2 C for 4 minutes the control will go to the 34 minute Time Temperature mode
35. e If a pres sure switch opens and closes four times during a Y1 In put the control logic will reset the pressure switch trip counter to zero at the end of the Y1 Input If the pressure switch opens for a fifth time during the current Y1 Input the control will enter a lockout condition The 5 strike pressure switch lockout condition can be reset by cycling OFF the 24 volt power to the control board or by shorting the TEST pins between 1 and 2 seconds All timer functions run times will also be reset If a pressure switch opens while the V1 Out line is engaged a 5 minute short cycle will occur after the switch closes Defrost Svstem Sensors Sensors connect to the defrost board through a field re placeable harness assembiv that plugs into the board Through the sensors the board detects outdoor ambient coil and discharge temperature fault conditions As the de tected temperature changes the resistance across the sensor changes Sensor resistance values can be checked bv ohming across pins shown in table 4 The graph in figure 19 shows sensor temperature to resistance range NOTE When checking the ohms across a sensor be aware that a sensor showing a resistance value that is not within the range shown in table 4 mav be performing as de signed However if a shorted or open circuit is detected then the sensor mav be faultv and the sensor harness will need to be replaced TABLE 4 Sensor Temperature Resistance Range
36. e any moisture and oth er non condensables The XPG20 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 filter drier A IMPORTANT Evacuation of system only will not remove mois ture from oil Filter drier must be replaced to elimi nate moisture from POE oil VI MAINTENANCE AWARNING Electric shock hazard Can cause inju ry or death Before attempting to per form any service or maintenance turn III the electrical power to unit OFF at dis g connect switch es Unit may have multiple power supplies Maintenance and service must be performed by a quali fied installer or service agency At the beginning of each cooling or heating season the system should be checked as follows Outdoor Unit 1 Clean and inspect outdoor coil may be flushed with a water hose Ensure power is off before cleaning 2 Outdoor unit fan motor is prelubricated and sealed No further lubrication is needed 3 Visually inspect all connecting lines joints and coils for evidence of oil leaks 4 Check all wiring for loose connections 5 Check for correct voltage at unit unit operating 6 Check amp draw on outdoor fan motor and compres sor high and low capacitv N Inspect drain holes in coil compartment base and
37. e discharge tempera Flash ture LOCKOUT ture has dropped below 225 F 107 C OFF Fast Discharge Sensor Fault The board detects open sensor or out of temperature sensor range This fault is Flash detected by allowing the unit to run for 90 seconds before checking sensor resist Fast OFF Discharge Sensor ance If the sensor resistance is not within range after 90 seconds the board will Fa LOCKOUT count one fault After 5 faults the board will lockout L Solar Module OVERVIEW The Lennox SunSource Comfort System solar assisted heat pump utilizes a single solar module to offset the utility power consumed by the outdoor fan The heart of the Sun Source is a 24VDC Electronically Commutated Motor ECM that is coupled directly to the AC powered ECM mo tor used in the XPG20 heat pump This DC motor is wired directly to the output of the single solar module When the solar module produces electricity and the heat pump fan is running the DC motor applies a torque on the fan shaft and reduces the load of the AC motor The AC motor inverter control senses this reduction in load and realize that the AC motor does not have to work as hard to achieve its desired speed Thus it reduces the power the AC motor consumes The more sunlight that is available the more assist the DC motor will produce and the less utility power is consumed by the AC motor SOLAR MODULE MOUNTING AND TILT ANGLE The solar module should be mounted in a location wher
38. e it will receive maximum sunlight throughout the year When choosing a site avoid trees buildings or obstructions which could cast shadows on the solar module especially during the winter months when the arc of the sun is lowest over the horizon Page 20 LONGITUDE 100 W 110 W 130 W 120 W FIGURE 23 SOLAR MODULE N TILT ANGLE EXAMPLE 30 HORIZONTAL FIGURE 24 For the SunSource Comfort System a fixed solar module should be oriented facing southwest and be tilted at an angle that is equal to about 2 3 s of the local latitude This is at variance with typical solar system design and the reason is that this orientation gives better coincidence of peak so lar module output with the heat pump s cooling mode op eration Summer offers a better match between solar availability and heat pump power needs so we suggest biasing solar module orientation to take advantage of this The above guidance is intended to aid in optimization Lo cating and mounting solar modules frequently involves compromises many times homeowners wish to have the module located in a sub optimal location orientation for es thetic reasons The pitch of the roof may be what deter mines the tilt of the module and the orientation of the home itself may dictate the direction the module faces Solar module should be mounted with proper gap for ven tilation air to flow under the solar module for cooling See solar module
39. eed FIGURE 31 Page 29 AIMPORTANT Mineral oils are not compatible with R410A If oil must be added it must be a polyol ester oil This system uses HFC 410A refrigerant which operates at much higher pressures than HCFC 22 The pre installed liquid line filter drier is approved for use with HFC 410A only Do not replace it with components designed for use with HCFC 22 This unit is NOT approved for use with coils which use capillary tubes as a refrigerant metering device COOLING MODE INDOOR AIRFLOW CHECK Check airflow using the Delta T DT process using the il lustration in Figure 31 WEIGH IN Refrigerant Charge per Line Set Length Ounces per 5 feet g per 1 5 m Liquid Line adjust from 15 feet 4 6 m line set Set Diameter 3 8 9 5 mm 3 ounce per 5 85 g per 1 5 m NOTE lf line length is greater than 15 ft 4 6 m add this amount If line length is less than 15 ft 4 6 m subtract this amount HEATING MODE INDOOR AIRFLOW CHECK Blower airflow CFM may be calculated by energizing electric heat and measuring Temperature rise between the return air and supply air tem peratures at the indoor coil blower unit Measuring voltage supplied to the unit Measuring amperage being drawn by the heat unit s Then apply the measurements taken in following formula to determine CFM Amps x Volts x 3 41 1 08 x Temperature rise F CHARGING METHOD Use either WEIGH IN or SUBCOOLING to char
40. ge or adjust a charge to a system CFM Check Liquid and suction line pressures Compare unit pressures with table 10 Normal Operating Pressures Conduct leak check evacuate as previously outlined 4 Weigh in the unit nameplate charge plus any charge required for line set differences over feet LENN0X DALLAS TEXAS M N TSA036H4N41G S N PPYYMNNNNN DESIGN PRESSURE CONTAINS HFC 410A FACTORY CHARGE ELECTRICAL RATING HI 446 PSIG 8 LBS 9 ozs LO 236 PSIG NOMINAL VOLTS 460 3 PH 60 Hz MIN 414 MAX 506 NOTE The above nameplate is for illustration purposes only Go to actual nameplate on outdoor unit for charge information FIGURE 32 Page 30 SUBCOOLING 1 Check the airflow as illustrated in Figure 31 to be sure the indoor airflow is as required Make any air flow adjustments before continuing with the following procedure Measure outdoor ambient temperature determine whether to use cooling mode or heating mode to check charge SE COOLING MODE ewe Connect gauge set USE HEATING A a J MODE Check liquid and vapor line pressures Compare pressures with either heat or cooling mode normal operating pressures in table 10 second stage high capacity NOTE The reference table is a general guide Expect minor pressure variations Significant differences may mean improper charge or other system problem 5 Set thermostat for heat cool demand de
41. gerant to produce substances that corrode copper piping and compressor parts MANIFOLD GAUGE SET LOW HIGH A34000 1 4 C e SAE TEE Le BB WITH SWIVEL MICRON COUPLER GAUGE TO LIQUID LINE SERVICE VALVE OUTDOOR UNIT TO SUCTION SERVICE VALVE USE REGULATOR TO FLOW NITROGEN AT 1 TO 2 PSIG Q RECOMMEND MINI MUM 3 8 HOSE Connect low side of manifold gauge set with 1 4 SAE in line tee to suction line service valve Connect high side of manifold gauge set to liquid line service valve Connect micron gauge available connector on the 1 4 SAE in line tee NITROGEN VACUUM Connect the vacuum pump with vacuum gauge to the center port of the manifold PUMP HFC 410A gauge set The center port line will be used later for both the HFC 410A and nitrogen containers NOTE Remove cores from service valves if not alreadv done 1 Open both manifold valves and start the vacuum pump 2 Evacuate the line set and indoor unit to an absolute pressure of 23 000 microns 29 01 inches of mercurv NOTE During the early stages of evacuation it is desirable to close the manifold gauge valve at least once to determine if there is a rapid rise in sure indicates a relativelv large leak If this occurs repeat the leak testing procedure NOTE The term absolute pressure means the total actua
42. it several pockets of gas are compressed simultaneously providing smooth continuous compression The scroll compressor is tolerant to the effects of liquid re turn If liquid enters the scrolls the orbiting scroll is allowed to separate from the stationary scroll The liquid is worked toward the center of the scroll and is discharged Due to its efficiency the scroll compressor is capable of drawing a much deeper vacuum than reciprocating com pressors Deep vacuum operation can cause internal fusite arcing resulting in damaged internal parts and will result in compressor failure This type of damage can be detected and will result in denial of warranty claims The scroll com pressor can be used to pump down refrigerant as long as the pressure is not reduced below 7 psig NOTE During operation the head of a scroll compressor may be hot since it is in constant contact with discharge gas The scroll compressors in all XPG20 model units are de signed for use with R410A 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 TWO STAGE OPERATION The two stage scroll compressor operates like any stan dard scroll compressor with the exception the two stage compressor modulates between first stage low capacity approximately 67 and second stage high capacity Modulation occurs when gas is bypassed through b
43. k Because POE oils absorb moisture the drvness of the svstem must be verified anv time the refrigerant svs 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 drv color range the filter drier MUST be replaced A IMPORTANT Replacement filter drier MUST be approved for HFC410A 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 TABLE 2 KIT CONTENTS SHELF LIFE 10N46 Refrigerant Analysis Checkmate RT700 10N45 Acid Test Tubes Checkmate RT750A three pack Tag oe Ta room temperature3 years 10N44 Moisture Test Tubes Checkmate RT751 Tubes three pack eer room temperature 2 years 74N40 Easy Oil Test Tubes Checkmate RT752C Tubes three pack 2 3 years room temperature 3 years refrigerated 74N39 Acid Test Kit Sporlan One Shot TA 1 Page 12 J Lennox System Operation Monitor A132 The Lennox system operation monitor LSOM is a 24 volt powered module see diagnostic module A132 on wiring diagram and figure 17 wired directly to the indoor unit The LSOM is located in the control box and is used to trouble shoo
44. l pressure within a given volume or system above the absolute zero of pressure Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure When the absolute pressure reaches 23 000 microns 29 01 inches of mercurv 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 drv nitrogen cvlinder with pressure regulator set to 150 psig 1034 kPa and purge the hose Open the manifold gauge valves to break the vacuum in the line set and indoor unit Close the manifold gauge valves Shutoff the drv nitrogen cvlinder and remove the manifold gauge hose from the cvlinder Open the manifold gauge valves to release the drv nitrogen from the line set and indoor unit 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 1 6 TURN 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 valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit Perform the following Close manifold gauge valves Shut off H
45. lates on the outdoor coil before the board initiates defrost cycles Diagnostic LEDs The state Off On Flashing of two LEDs on the defrost board DS1 Red and DS2 Green indicate diagnostics conditions that are described in table 5 Defrost Board Pressure Switch Connections The unit s automatic reset pressure switches LO PS S87 and HI PS S4 are factory wired into the defrost board on the LO PS and HI PS terminals respectively Low Pressure Switch LO PS When the low pressure switch trips the defrost board will cycle off the compressor and the strike counter in the board will count one strike The low pressure switch is ignored under the following condi tions ojejo OF C R GO o YI y during the defrost cycle and 90 seconds after the termina tion of defrost when the average ambient sensor temperature is below 15 F 9 C for 90 seconds following the start up of the compressor during test mode High Pressure Switch HI PS When the high pressure switch trips the defrost board will cycle off the compressor and the strike counter in the board will count one strike Defrost Board Pressure Switch Settings High Pressure auto reset trip at 590 psig reset at 418 psig Low Pressure auto reset trip at 25 psig reset at 40 psig 5 Strike Lockout Feature The internal control logic of the board counts the pressure switch trips only while the Y1 Input line is activ
46. ller If the disconnect switch is bounced when the discon nect is closed the disconnect contacts may become welded Try not to bounce the disconnect switch when ap plying power to the unit The DC filter capacitors inside the controller are connected electrically to the speed tap wires The capacitors take approximately 5 minutes to discharge when the disconnect is opened For this reason it is necessary to wait at least 5 minutes after turning off power to the unit before attempting to service motor 4 DANGER Disconnect power from unit and wait at least five minutes to allow capacitors to discharge before attempting to service motor Failure to wait may cause personal injury or death Motor Start Up At start up the motor may gently rock back and forth fora moment This is normal During this time the electronic controller is determining the exact position of the rotor Once the motor begins turning the controller slowly eases the motor up to speed this is called soft start The motor may take as long as 10 15 seconds to reach full speed If the motor does not reach 200rpm within 13 seconds the motor shuts down Then the motor will im mediately attempt a restart The shutdown feature pro vides protection in case of a frozen bearing or blocked fan blade The motor may attempt to start eight times If the motor does not start after the eighth try the controller locks out Reset controller by momentarily turning off power
47. manufacturer s recommendations Solar module should be mounted according to manufactur er s recommendations Stainless Steel hardware nuts and bolts is recommended for longevity Two solar module mounting kits are available See Field Supplied Components Table 6 for catalog numbers for cat alog numbers Solar modules produce the most power when they are pointed directly at the sun The module tilt angle is mea sured between the solar modules and the ground as illus trated in Figure 24 SOLAR MODULE WIRING The wire typically used to interconnect the solar module should be single or two conductor from 10 AWG 5 26 mm up to 14 2 08 mm gauge copper wire in a SUNLIGHT RE SISTANT jacket UF B cable This cable is suitable for ap plications where wiring is exposed to outdoor conditions See wiring diagram at the back of this manual for connec tion requirements Solar module should be wired per the manufacturer s rec ommendations and the National Electric Code Article 690 Conductor ampacitv should be at least 15690 of the solar module s short circuit current Solar module comes pre wired with locking connectors multi contact MC connectors Mating connectors should be utilized See Field Supplied Components Ta ble 6 for catalog numbers The 2008 NEC requires a DC rated disconnect and a DC ground fault protection device be installed with the module Check with the local code official for local re quirements The
48. me in heat mode to calibrate DCB This may involve more than one heating demand YES calibration occurred Was stable coil temp attained within 20 minutes FIGURE 22 Page 19 45 MIN TIME TEMP MODE 90 min for 1 to 4 boards Accumulate compressor run time while coil temperature is below 35 F 2 C When the accumulated compressor time exceeds 90 minutes go to Defrost termination temp At Termination of Defrost the compressor runtime counter is reset Turn on Outdoor FAN Rev valve amp W turn OFF NO DCB reverts to 45 min 90 min for 1 to 4 boards time temp TABLE 5 Defrost Control Board Diagnostic LEDs DS1 Power problem No power 24V to board termi 1 Check control transformer power 24V nals R amp C or board failure 2 f power is available to board and LED s do not light replace board Simultaneous Normal operation Unit operating normally or in None required SLOW Flash standby mode Alternating 5 minute anti short cycle Initial power up safety trip end of None required Jumper TEST pins to override SLOW Flash delay room thermostat demand Simultaneous Ambient Sensor Problem Sensor being detected open or shorted or out of temperature range Board will re FAST Flash vert to time temperature defrost operation System will still heat or cool Alternating Coil Sensor Problem Sensor being detected open or shorted or out of temperature range Board will not FAST Flash perform demand
49. n compressor temperature If no resistance replace compressor b Measure the resistance from each fusite pin to ground There should not be continuity to ground If so lenoid coil is grounded replace compressor Good Solenoid a Seals not shifting replace compressor b Slider ring not shifting replace compressor B Contactor K1 The compressor is energized by a contactor located in the control box Units are single phase and use single pole con tactors C Low Pressure Switch S87 The XPG20 is equipped with an auto reset low pressure switch which is located on the suction line The switch shuts off the compressor when the suction pressure falls below the factory setting This switch is ignored during the first 90 seconds of compressor start up during defrost operation 90 seconds after defrost operation during test mode and when the outdoor temperature drops below 15 F The switch closes when it is exposed to 55 psig and opens at 25 psig It is not adjustable D High Pressure Switch S4 A IMPORTANT Pressure switch settings for R410A refrigerant will be significantly higher than units with R22 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 and close at 418 15 psi See fig ure 3
50. nect 24VAC outdoor motor common black wire from the AC motor x Apply 24VAC input to Y1 of demand defrost control oe x Check DC motor for proper operation and rotation Reconnect 24VAC outdoor motor common black wire NOTE Field test requires solar module output of 16VDC or more at DC motor 0 to 28VDC operating range TABLE 6 Parts Solar Module see Figure 25 for specifications Solar Module Mounting Kit Roof applications Solar Module Mounting Kit Pole applications DC rated disconnect 15A Lennox Catalog Numbers 48W00 48W01 48W02 48W03 Page 23 IIl REFRIGERANT SYSTEM Separate liquid and suction service ports are provided at the service valves for connection of gauge manifold during charging procedure Figure 27 shows XPG20 refrigerant A IM PORTANT flow and gauge manifold connections The Clean Air Act of 1990 bans the intentional vent TABLE 7 Valve Field Size P Recommended Line Set Connections ing of CFC s and HFC s as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration my be levied for noncompliance L15 a Vapor Liquid Vapor Line Sets Field refrigerant piping consists of liquid and vapor lines Line Line Line from the outdoor unit sweat connections Use Lennox 036 3 8 in 7 8 in 3 8 in 7 8 in L15 65 EN l 10mm 22 mm 10mm 22 mm 15 ft 50 ft L15 series line sets as shown in table 7 46m 15m
51. nnox 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 Il Unit Components Remove 4 screws to remove panel for accessing compressor and controls Install by positioning panel with holes aligned install screws and tighten FIGURE 1 Removing Access Panels Remove and reinstall the access panel as described in fig ure 1 Remove the louvered panels as follows 1 Remove 2 screws allowing the panel to swing open slightly 2 Hold the panel firmly throughout this procedure Rotate bottom corner of panel away from hinge corner post until lower 3 tabs clear the slots see figure 2 De tail B 3 Move panel down until lip of upper tab clears the top slot in corner post see figure 2 Detail A Position and Install Panel Position the panel almost parallel with the unit figure 2 Detail D with the screw side as close to the unit as possible Then in a continuous motion Slightly rotate and guide the LIP of top tab inward figure 2 Details A and C then upward into the top slot of the hinge corner post Rotate panel to vertical to fully engage all tabs Page 3 Holding the panel s hinged side firmly in place close the right hand side of the panel aligning the screw holes When panel is correctly positioned and aligned
52. omatic reset After an alert is detected the LSOM con tinues to monitor the compressor and system When if conditions return to normal the alert code is turned off automatically Page 13 TABLE 3 System Operation Monitor LED Troubleshooting Codes Status LED Condition Green Power LED ON Status LED Description Module has power Status LED Troubleshooting Information 24VAC control power is present at the module terminal Green Power LED OFF Module not powering up Determine verify that both R and C module terminals are connected and voltage is present at both terminals Red Trip LED ON System and compressor check out OK Thermostat demand signal Y1 is present but compres sor not running NOTE During 5 minute delay in defrost board the red trip LED will be on 1 Verify Y terminal is connected to 24VAC at contactor coil 2 Verify voltage at contactor coil falls below 0 5VAC when off 3 Verify 24VAC is present across Y and C when thermostat demand signal is present if not present Y and C wires are reversed 1 Compressor protector is open 2 Outdoor unit power disconnect is open 3 Compressor circuit breaker or fuse s is open 4 Broken wire or connector is not making contact 5 Low pressure switch open if present in the system 6 Compressor contactor has failed to close Red Trip amp Yellow Alert LEDs Flashing Simultaneous flashing Indicates
53. or time temperature defrost operation System will still heat or cool Circuit Board Failure Indicates that board has internal component failure Cycle 24 volt power to board If code does not clear replace board FAULT 8 LOCKOUT CODES Each fault adds 1 strike to that code s counter 5 strikes per code LOCKOUT OFF SLOW Low Pressure Fault 1 Restricted air flow over indoor Flash or outdoor coil 2 Improper refrigerant charge in Improper metering device HN installed or incorrect operation SLOW OFF High Pressure Fault of metering device Flash 4 Incorrect or improper sensor location or connection to sys 1 Remove any blockages or restrictions from coils and or fans Check indoor and outdoor fan motor for proper current draws 2 Check system charge using approach amp sub cooling temperatures 3 Check system operating pressures and compare to unit charging charts 4 Make sure all pressure switches and sensors have secure connections to system to prevent refrigerant leaks or errors in pressure and temperature measurements SLOW ON Discharge Line Tempera Line Tempera This code detects shorted sensor or high discharge temperatures If the discharge Flash ture Fault line temperature exceeds a temperature of 285 F 140 C during compressor op eration the board will de energize the compressor contactor output and the de FAST JON Discharge Line Tempera frost output if active The compressor will remain off until th
54. or two stage operation always cycle Y1 to Y2 from terminals on the LSOMII or room thermostat connections DO NOT cycle sec ond stage Y2 of compressor by unplugging the 24VDC solenoid LSOM Il end of plug The LSOM III will only output a 6 to 18VDC signal which will be insuffi cient voltage to pull the solenoid coil in for second stage If compressor solenoid is still not shifting to high capac ity this check will verify that DC power is being fed from the LSOM Il 7 Shut power off to unit main and low voltage 8 Unplug the 2 pin solenoid plug from the fusite connec tion on the compressor and the plug end from the LSOM Il Using an OHM meter check for continuity on the plug harness wire ends red to red black to black Wires should have continuity between same colors and no continuity between opposite color wires If the above checks verify that the solenoid plug is pro viding power to cycle into high capacity operation con tinue to step 3 to determine if problem is with solenoid coil in compressor STEP 3 Confirm internal unloader solenoid has proper resistance 1 Shut all power off to unit main and low voltage 2 Unplug the molded plug from the compressor solenoid 2 pin fusite 3 Using a volt meter set on the 200 ohm scale Replace the Compressor under these conditions Page 8 Bad Solenoid a Measure the resistance at the 2 pin fusite The resist ance should be 32 to 60 ohms depending o
55. or unit power disconnect is open 2 Unit circuit breaker or fuse s is open 3 Unit contactor has failed to close 4 High pressure switch is open and requires manual reset 5 Open circuit in compressor supply wiring or connections 6 Unusually long compressor protector reset time due to extreme ambi ent temperature 7 Compressor windings are damaged Yellow Alert Flash Code 6 Open Start Circuit Cur rent only in run circuit 1 Run capacitor has failed 2 Open circuit in compressor start wiring or connections 3 Compressor start winding is damaged Yellow Alert Flash Code 7 Open Run Circuit Current only in start circuit 1 Open circuit in compressor start wiring or connections 2 Compressor start winding is damaged Yellow Alert Flash Code 8 Welded Contactor Com pressor always runs 1 Compressor contactor failed to open 2 Thermostat demand signal not connected to module Yellow Alert Flash Code 9 Low Voltage Control cir cuit lt 17VAC 1 Control circuit transformer is overloaded 2 Low line voltage contact utility if voltage at disconnect is low Flash code number corresponds to a number of LED flashes followed by a pause and then repeated Reset ALERT flash code by removing 24VAC power from monitor last code will display for 1 minute after monitor is powered on Page 14 K Defrost System The demand defrost controller measures differential
56. ove refrigerant if less than shown add refrigerant 11 If refrigerant is added or removed repeat steps 4 through 5 to verify charge 12 Disconnect gauge set and re install both the liquid and suction service valve caps FIGURE 33 Page 31 TABLE 10 TABLE 11 HFC 410A Normal Operating Pressures XPG20 036 Matchups a F I Target Subcooling This table is used to perform maintenance checks and is INDOOR HEAT Heating Cooling Add not a procedure for charging the system Minor variations MATCHUP RUMP GSF UP charge in these pressures may be due to differences in installa Ib oz tions Significant deviations could mean that the svstem is CH23 51 14 6 0 5 not properly charged or that a problem exists with some com i CH23 65 12 5 0 13 ponent in the system Ti i a E ES F C 2 Vap Liq Vap CBX27UH 042 230 6 6 1 5 Cooling First Stage Low Capacity Pressure CB29M 51 6 6 1 5 Sc TP oo i oes E ES mes aw ems DEAE sea e e s s ys sea ee em fos fol wwa fe ces s L s Pi G BAG MEZZ 14 s o 7 3 Cooling Second Stage High Capacity Pressure CBX32M 042 230 14 6 0 7 65 183 A 2 1 A caxszw 048 200 6 s EE Bea 25 u CBxS2MV 086 230 14 6 o 5 85 29 4 318 148 soe Waaa O omuz o 6 tals 95 35 0 365 150 seso
57. pending on mode being used USING COOLING MODE When the outdoor ambient temperature is 60 F 15 C and above Target subcooling values second stage high capacity in table 10 are based on 70 to 80 F 21 27 C indoor return air temperature if necessary operate heating to reach that temperature range then set thermostat to cooling mode setpoint to 68 F 20 C which should call for second stage high capacity cooling When pressures have stabilized continue with step 6 USING HEATING MODE When the outdoor ambient temperature is below 60 F 15 C Target subcooling values second stage high capacity in table 10 are based on 65 75 F 18 24 C indoor return air temperature if necessary operate cooling to reach that temperature range then set thermostat to heating mode setpoint to 77 F 25 C which should call for second stage high capacity heating When pressures have stabilized continue with step 6 Read the liquid line temperature record in the LIQ space Read the liquid line pressure then find its corresponding temperature in the tem perature pressure chart listed in table 12 and record it in the SAT space Subtract LIQ temperature from SAT temperature to determine subcooling re cord it in SC space Compare SC results with table 11 being sure to note any additional charge for line set and or match up If subcooling value is greater than shown in table 11 for the applicable unit re m
58. s outdoor temperatures below 35 F 37 C or above 120 F 48 C as a problem If the ambient sensor is detected as being open shorted or out of the tem perature range of the sensor the board will not perform de mand defrost operation The board will revert to time tem perature defrost operation and will display the appropriate fault code Heating and cooling operation will be allowed in this fault condition Coil Sensor The coil temperature sensor shown in de tail B figure 20 considers outdoor temperatures below 35 F 37 C or above 120 F 48 C as a problem If the coil temperature sensor is detected as being open shorted or out of the temperature range of the sensor the board 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 Discharge Line Sensor If the discharge line tempera ture shown in figure 20 exceeds a temperature of 2857F 140 C during compressor operation the board will de en ergize the compressor contactor output and the defrost output if active The compressor will remain off until the discharge temperature has dropped below 225 F 107 C and the 5 minute anti short cycle delay has been satisfied This sensor has two fault and lockout codes 3 If the board recognizes five high discharge line temper ature faults during a single Y1 compressor demand it reverts to a
59. sed since the last defrost cycle while the coil tem perature remains below 35 F 2 C the demand de frost control will initiate a defrost cycle Page 17 Actuation When the reversing valve is de energized the Y1 circuit is energized and the coil temperature is below 35 F 2 C the board logs the compressor run time If the board is not calibrated a defrost cycle will be initiated after 34 minutes of heating mode compressor run time The con trol will attempt to self calibrate after this and all other de frost cycle s Calibration success depends on stable system tempera tures during the 20 minute calibration period If the board fails to calibrate another defrost cycle will be initiated after 45 minutes 90 minutes for 1 to 4 boards of heating mode compressor run time Once the defrost board is calibrated it initiates a demand defrost cycle when the difference be tween the clear coil and frosted coil temperatures exceeds the maximum difference allowed by the control OR after 6 hours of heating mode compressor run time has been logged since the last defrost cycle NOTE If ambient or coil fault is detected the board will not execute the TEST mode Termination The defrost cycle ends when the coil tem perature exceeds the termination temperature or after 14 minutes of defrost operation If the defrost is terminated by the 14 minute timer another defrost cycle will be initiated after 34 minutes of run time
60. slide ring mecha nism to open low capacity or close high capacity two by pass ports in the first compression pocket of the scrolls in the compressor The internal solenoid is activated by a 24 volt direct current solenoid coil The internal wires from the solenoid in the compressor are routed to a 2 pin fusite connection on the side of the compressor shell The external electrical connection is made to the compressor with a molded plug assembly The molded plug receives 24 volt DC power from the LSOM II If it is suspected the unloader is not operating properly check the following A IMPORTANT This performance check is ONLY valid on systems that have clean indoor and outdoor coils proper air flow over coils and correct system refrigerant charge All components in the system must be func tioning proper to correctly perform compressor modulation operational check Accurate measure ments are critical to this test as indoor system load ing and outdoor ambient can affect variations be tween low and high capacity readings STEP 1 Confirm low to high capacity compressor operation Tools required Refrigeration gauge set Digital volt amp meter Electronic temperature thermometer On off toggle switch Page 7 Procedure 1 Turn main power OFF to outdoor unit 2 Adjust room thermostat set point above heating op eration on heat pump or below cooling operation the room temperature 5 F 3 Remove control a
61. solar module should be grounded according to NEC 690 Section V or local code requirements Page 21 SOLAR MODULE FIELD PROVIDED REQUIREMENTS PEAK POWER VOLTAGE 180 205W PEAK POWER CURRENT lt 28 VDC OPEN CIRCUIT VOLTAGE lt 33 2 VDC SHORT CIRCUIT CURRENT lt 8 36A LENNOX CATALOG 48W00 SOLAR MODULE GROUND WIRE FIELD PROVIDED MULTI CONTACT MC CONNECTORS INCLUDED WITH SOLAR MODULE USE PHOTOVOLTAIC PV WIRING OR TWO WIRES WITH MC CONNECTORS FIELD PROVIDED CAT 48W04 NOTE 1 WEATHER PROOF JUNCTION BOX FIELD PROVIDED CONDUIT FIELD PROVIDED FIELD WIRING FIELD PROVIDED WEATHERPROOF ELECTRICAL ENCLOSURE FIELD PROVIDED a TO EARTH GROUND PER NEC 690 SECTION V IMPORTANT The AC and DC grounding sys tems for a photovoltaic system where both are present should tie to a common grounding elec trode or grounding system FIELD WIRING FIELD PROVIDED COMPLETE BOX AVAILABLE AS DC POSITIVE TERMINAL ON SWITCHED SIDE OF DISCONNECT GROUND FAULT IF REQUIRED BY LOCAL CODE NEC FIELD PROVIDED DC RATED 15A DISCONNECT IF REQUIRED BY LOCAL CODE NEC FIELD PROVIDED GROUND BUS BAR TERMINAL FOR EARTH GROUND DC NEGATIVE BUS BAR FROM SOLAR MODULE TO EARTH GROUND PER NEC 690 SECTION V SURGE ARRESTOR TO UNIT CONDUIT ELBOWS FIELD PROVIDED PIPING MODULE CAT 48W
62. t 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 Tighten finger tight then an additional 1 6 turn To Open Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and hex head extension back the stem out counterclockwise as far as it will go NOTE Use a 3 16 hex head extension for liquid line size 3 Replace stem cap and tighten it firmly Tighten finger tight then tighten an additional 1 6 turn To Close Service Valve 1 Remove stem cap with an adjustable wrench 2 Using service wrench and hex head extension turn stem clockwise to seat valve Tighten it firmly NOTE Use a 3 16 hex head extension for liquid line size 3 Replace stem cap Tighten finger tight then tighten an additional 1 6 turn Vapor Line Ball Type Valve Vapor line service valves function the same way as the oth er valves the difference is in the construction These valves are not rebuildable If a valve has failed you must replace it A ball valve valve is illustrated in figure 29 Page 25 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 Front Seated Liquid Line Service Valve SCHRADER VALVE open to line set when valve is closed front seated
63. t problems in the system The module has three LED s for troubleshooting GREEN indicates power status YEL LOW indicates an abnormal condition and RED indicates thermostat demand but compressor not operating See table 3 for troubleshooting codes The diagnostic indicator detects the most common fault conditions in the heat pump system When an abnormal condition is detected the module communicates the spe cific condition through its ALERT and TRIP lights The module is capable of detecting both mechanical and elec trical system problems See figure 17 for the system opera tion monitor Lennox System Operation Monitor POWER LED Y2 1 DATA OUTPUT Y CONNECTOR AT 25 SPADE L CONNECTOR 5 ol SOLENOID CONNECTOR L R C OU ALERT LED TRIP LED FIGURE 17 IMPORTANT The LSOM is not a safety component and cannot shutdown or control the XPG20 The LSOM is a monitoring device only LED Functions Alert LED green Indicates voltage within the range of 19 28VAC is present at the system monitor connections Alert LED yellow communicates an abnormal system condition through a unique Flash Code the alert LED flashes a number of times consecutively then pauses then repeats the process This consecutive flashing corre lates to a particular abnormal condition Trip LED red indicates there is a demand signal
64. the compres sor Once the solenoid is energized the diagnostic module will continue pulsing 6 to 18 volt DC signal to the solenoid to keep it energized during the Y2 room thermostat demand The 24volt inputs to the yellow and blue wires of the outdoor fan motor will provide high speed operation High Capacity Ambient temperature below de frost board Y2 lock in temperature TE N Room thermostat in heating mode Room thermostat outputs Y1 signal to the defrost board in the heat pump and to the indoor unit The defrost board checks for open low or high pres sure switches and proper coil ambient and discharge sensor readings If checks show no issues the defrost board sends 24 volts through Y1 OUT signal to the K1 compressor contactor coil the Y1 terminal on the diag nostic module A132 and the yellow wire to the out door fan motor The defrost board Y2 locks in sends 24 volts through Y2 OUT signal to the Y2 terminal on the diagnostic module A132 and the blue wire to the outdoor fan mo tor K1 1 closes energizing the compressor and puts 240 volts into the outdoor fan motor through the normally closed fan relay contacts on the defrost board The compressor will run on low capacity for 5 seconds The diagnostic module LSOM will confirm low stage operation and then output a 24volt DC signal to the L34 internal high capacity solenoid valve in the compres sor Once the solenoid is energized the diagnostic mo
65. tor K1 1 closes energizing the compressor and puts 240 volts into the outdoor fan motor through the normally closed fan relay contacts on the defrost board The compressor will run on low capacity and the 24volt input on the yellow wire to the outdoor fan motor will al low it to run on low speed High Capacity Ambient temperature above de frost board Y2 lock in temperature 1 N Room thermostat in heating mode Room thermostat outputs Y1 and Y2 if applicable to that room thermo stat signal to the defrost board in the heat pump and to the indoor unit The defrost board checks for open low or high pres sure switches and proper coil ambient and discharge sensor readings If checks show no issues the defrost board sends 24 volts through Y1 OUT signal to the K1 compressor contactor coil the Y1 terminal on the diag nostic module A132 and the yellow wire to the out door fan motor The defrost board sends 24 volts through Y2 OUT sig nal to the Y2 terminal on the diagnostic module A132 and the blue wire to the outdoor fan motor Page 36 4 5 6 B K1 1 closes energizing the compressor and puts 240 volts into the outdoor fan motor through the normally closed fan relay contacts on the defrost board The compressor will run on low capacity for 5 seconds The diagnostic module LSOM will confirm low stage operation and then output a 24volt DC signal to the L34 internal high capacity solenoid valve in
66. tor assembly to self align and then re tighten the nut FIGURE 26 OPERATIONS The DC motor is an electronically commutated brushless DC external rotor motor The motor is rated at 1 5 HP and 8 5A FLA The motor requires a 24 VDC nominal input 16 min to 28 max The DC voltage is applied to the motor on the red and blue motor leads The yellow motor lead is the speed control input SunSource Comfort System utilizes the motor at full speed only The solar module out put is tied directly into the speed control input thus when the K228 relay closes and the control voltage is present the motor is always asked to run full speed 875 rpm max The K227 Defrost relav switches the solar assist motor off when the heat pump is in defrost mode The relav has a 240VAC Coil that is wired in parallel with the K1 Fan relay on the defrost control board Thus 240 VAC is present at the relay coil at all times except when the defrost control board K1 relay opens The K227 relay makes or breaks the 24VDC from the solar module to the input to the DC motor The K228 Fan relay switches the fan on and off with a Y1 call The relay has a 24VAC coil that is energized by the Y1 signal The K228 relay makes or breaks the 24 VDC from the solar module to the speed control input of the DC motor TROUBLESHOOTING SOLAR MOTOR TROUBLESHOOTING Main and Solar Power Disconnects Steps to check direct current DC motor operation Discon
67. ved and passed through from A132 diagnostic module First Stage Cool low capacity Transformer from indoor unit supplies 24 VAC power to the thermostat and outdoor unit controls Internal wiring energizes terminal O by cooling mode selection energizing the reversing valve Cooling de mand initiates at Y1 in the thermostat 24VAC passes through high pressure switch S4 and discharge thermostat switch S5 energizing compres sor contactor K1 K1 1 N O closes energizing compressor B1 and out door fan motor B4 Solenoid L34 is NOT energized The slider ring re mains open limiting compressor to low capacity Second Stage Cool high capacity Second stage thermostat demand sends voltage to the LSOM After a 5 second delay the LSOM converts the AC voltage to DC voltage and energizes solenoid L34 L34 then closes the slider ring allowing the compres sor to operate at high capacity Variable speed outdoor fan operates on high speed blue tap Heating Low Capacity Room thermostat in heating mode Room thermostat outputs Y1 signal to the defrost board in the heat pump and to the indoor air handler The defrost board checks for open low or high pres sure switches and proper coil ambient and discharge sensor readings If checks show no issues the defrost board sends 24 volts through Y1 OUT signal to the K1 compressor contactor coil the Y1 terminal on the diag nostic module A132 and the yellow wire to the out door fan mo
68. y short cycle lockout and 5 strike fault lockout function if applicable Y Y Clear any short cycle lockout If in COOLING Mode If in HEATING Mode If in DEFROST Mode and 5 strike fault lockout y The unit will terminate defrost and enter Heat Mode uncalibrated with defrost timer set for 34 minute test No further test mode operation will be executed until the test short is removed and reapplied y The controller will check for ambient and coil faults open or shorted If a fault exists the unit will remain in Heat Mode and no further test mode operation will be executed until the test short is removed and re applied If no fault exists the unit will go into Defrost mode Y U Test pin short REMAINS in place for more than 5 seconds Test pins short REMOVED before a 7 maximum of 5 seconds Y No further test mode operation will be executed until the test short is removed and reapplied function if applicable No other functions will be executed and unit will continue in the mode it was operating The unit will return to Heat mode uncalibrated with defrost Y The unit will remain in Defrost mode until termination on time or temperature timer set for 34 minutes No further test mode operation will be executed until the test short is removed and re applied FIGURE 21 Page 18 Calibration Mode
69. ypass ports figure 9 bypass ports open in the first suction pock et This bypassing of gas allows the compressor to operate on first stage low capacity if thermostat demand allows Indoor thermostat setting will determine first or second stage operation The compressor will operate on first stage until demand is satisfied or the indoor temperature reaches the thermostat set point calling for second stage Second stage high capacity is achieved by blocking the bypass ports figure 9 bypass ports closed with a slider ring The slider ring begins in the open position and is con trolled by a 24VDC internal solenoid On a Y2 call the inter nal solenoid closes the slider ring blocking the bypass ports and bringing the compressor to high capacity Two stage modulation can occur during a single thermostat de mand as the motor runs continuously while the compressor modulates from first stage to second stage HOW A SCROLL WORKS W MOVEMENT OF ORBIT RUE a GAS CRESCENT SHAPED GAS POCKET ANKS 7 ED SUCTION ORBITING f SCROL sucTIONY POCKET ny en PRESSURE GAS x L STATIONARY SCROLL c FL SEALED BY ENTRIFUGAL FORCE NN G DISCHARGE POCKET FIGURE 8 TWO STAGE MODULATION Bvpass Ports Closed High Capacitv FIGURE 9 Bvpass Ports Open Low Capacitv Page 6 INTERNAL SOLENOID L34 The internal unloader solenoid controls the two stage op eration of the compressor by shifting a

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