user manual

ManualsBrandsLennox International Inc. ManualsAir ConditionerAir Conditioner 06/11 50672801

06/11 506728−01

*2P0611* *P506728-01*

Page 1

2011 Lennox Industries Inc.

Dallas, Texas, USA

These instructions are intended as a

general guide and do not supersede

local codes in any way. Consult

authorities having jurisdiction before

installation.

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

NOTICE TO INSTALLER

BRAZING LINE SET TO SERVICE VALVES

It is imperative to follow the brazing technique illustrated starting on

page 12 to avoid damaging the service valve’s internal seals.

WARNING

Improper installation, adjustment, alteration, service or

maintenance can cause personal injury, loss of life, or

damage to property.

Installation and service must be performed by a licensed

professional installer (or equivalent) or a service agency.

IMPORTANT

The Clean Air Act of 1990 bans the intentional venting of

refrigerant (CFCs, HFCs, and HCFCs) as of July 1,

1992. Approved methods of recovery, recycling or

reclaiming must be followed. Fines and/or incarceration

may be levied for noncompliance.

IMPORTANT

This unit must be matched with an indoor coil as

specified in Lennox’ Engineering Handbook. Coils

previously charged with HCFC−22 must be flushed.

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 near these areas during installation or while

servicing this equipment.

INSTALLATION

INSTRUCTIONS

Elite

Series XP13 Units

HEAT PUMPS

506728−01

06/11

Supersedes 04/11

Litho U.S.A.

TABLE OF CONTENTS

Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .

General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Number Identification 2. . . . . . . . . . . . . . . . . . . .

Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . . . .

Caps and Fasteners Torque Requirements 4. . . . . . . .

Operating Gauge Set and Service Valves 4. . . . . . . . .

Recovering Refrigerant from Existing System 6. . . . .

New Outdoor Unit Placement 7. . . . . . . . . . . . . . . . . . .

Removing and Installing Panels 9. . . . . . . . . . . . . . . . .

Line Set Requirements 10. . . . . . . . . . . . . . . . . . . . . . . . .

Brazing Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Indoor Refrigerant Metering Device Removal and

Flushing Line Set and Indoor Coil 15. . . . . . . . . . . . . . . .

Installing New Indoor Metering Device 16. . . . . . . . . . . .

Leak Test Line Set and Indoor Coil 17. . . . . . . . . . . . . . .

Evacuating Line Set and Indoor Coil 18. . . . . . . . . . . . .

Electrical Connections 19. . . . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing and Weighing In Refrigerant for Units

Delivered Void of Charge 22. . . . . . . . . . . . . . . . . . . . . . .

Optimizing System Refrigerant Charge 24. . . . . . . . . . .

System Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defrost System 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance (Dealer and Homeowner) 30. . . . . . . . . . .

Start−up and Performance Checklist 32. . . . . . . . . . . . . .

Shipping and Packing List

Check the unit for shipping damage and listed times below

are intact. If damaged, or if parts are missing, immediately

contact the last shipping carrier.

1  Assembled XP13 outdoor unit

General

The XP13 outdoor unit uses HFC−410A refrigerant. This

unit must be installed with a matching indoor blower coil

and line set as outlined in the XP13 Engineering

Handbook. These outdoor units are designed for use in

check / expansion valve (CTXV) systems only and are not

to be used with other refrigerant flow control devices. An

indoor coil check / expansion valve approved for use with

HFC−410A must be ordered separately and installed prior

to operating the unit.

Summary of content (32 pages)

PAGE 1
INSTALLATION INSTRUCTIONS 2011 Lennox Industries Inc. Dallas, Texas, USA Elite® Series XP13 Units HEAT PUMPS 506728−01 06/11 Supersedes 04/11 These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation. TABLE OF CONTENTS Shipping and Packing List . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Number Identification . . . .
PAGE 2
Model Number Identification X P 13 −036 − 230 −0 8 Refrigerant Type X = HFC−410A Minor Revision Number Voltage 230 = 208/230V−1ph−60hz Unit Type P = Heat Pump Outdoor Unit Nominal Cooling Capacity 018 = 1.5 tons 024 = 2 tons 030 = 2.5 tons 036 = 3 tons 042 = 3.
PAGE 3
Typical Unit Parts Arrangement CONTROL PANEL CAPACITOR (C12) CONTACTOR− 1POLE (K1−1) DEFROST CONTROL (CMC1) THERMAL PROTECTION SWITCH (S173) GROUND LUG SWITCH COVER ONLY ON UNITS USING EXTERNAL SWITCH COMPRESSOR MUFFLER 5−TON UNIT EXAMPLED HERE DEFROST THERMOSTAT (S6) TRUE SUCTION PORT CHECK EXPANSION VALVE REVERSING VALVE REVERSING VALVE SOLENOID CRANKCASE HEATER (−042, −048 AND 060 UNITS ONLY) LIQUID LINE FILTER DRIER (BI−FLOW) CRANKCASE HEATER THERMOSTAT (S40) (−042, −048 AND 060 UNITS ONLY)
PAGE 4
Caps and Fasteners Torque Requirements Operating Gauge Set and Service Valves IMPORTANT IMPORTANT To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening. Only use Allen wrenches of sufficient hardness (50Rc − Rockwell Harness Scale minimum). Fully insert the wrench into the valve stem recess.
PAGE 5
Operating Angle−Type Service Valve: 1. Remove stem cap with an appropriately sized wrench. HEX−HEAD 2 INSERT EXTENSION HERE 2. Use a service wrench with a hex−head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve sizes) to back the stem out counterclockwise as far as it will go to open the service valve.
PAGE 6
Recovering Refrigerant from Existing System 1 DISCONNECT POWER Disconnect all power to the existing outdoor unit at the disconnect switch and/or main fuse box/breaker panel. 2 CONNECT MANIFOLD GAUGE SET Connect a manifold gauge set, clean recovery cylinder and a recovery machine to the service ports of the existing unit.. NOTE Use the recovery machine instructions to make the correct manifold gauge set connections for recovery refrigerant. The illustration below is a typical connection.
PAGE 7
New Outdoor Unit Placement higher ground will not collect around the unit. The slab should have a slope tolerance as described in figure 5, detail B. NOTE If necessary for stability, anchor unit to slab as described in figure 5, detail D. CAUTION In order to avoid injury, take proper precaution when lifting heavy objects. Remove existing outdoor unit prior to placement of new outdoor unit. See Unit Dimensions on page 2 for sizing mounting slab, platforms or supports.
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DETAIL A Outside Unit Placement Install unit away from windows. DETAIL B Slab Mounting at Ground Level Install unit level or, if on a slope, maintain slope tolerance of two (2) degrees (or two inches per five feet [50 mm per 1.5 m]) away from building structure. BUILDING STRUCTURE MOUNTING SLAB TWO 90° ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION.
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Removing and Installing Panels LOUVERED PANEL REMOVAL Remove the louvered panels as follows: 1. Remove two screws, allowing the panel to swing open slightly. 2. Hold the panel firmly throughout this procedure. Rotate bottom corner of panel away from hinged corner post until lower three tabs clear the slots as illustrated in detail B. 3. Move panel down until lip of upper tab clears the top slot in corner post as illustrated in detail A. IMPORTANT! DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB.
PAGE 10
Line Set Requirements This section provides information on: installation of new or replacement line set. Adding Polyol ester oil requirements New or replacement line set installation Using existing line set. Model (XP13) and size of unit (e.g. −036). Line set diameters for the unit being installed as listed in table 2 and total length of installation. Number of elbows vertical rise or drop in the piping.
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Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation: REFRIGERANT LINE SET INSTALLING VERTICAL RUNS (NEW CONSTRUCTION SHOWN) REFRIGERANT LINE SET TRANSITION FROM VERTICAL TO HORIZONTAL ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE MUFFLER-TYPE HANGER NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greate
PAGE 12
Brazing Connections Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves. WARNING IMPORTANT Polyol Ester (POE) oils used with HFC−410A refrigerant absorb moisture very quickly. It is very important 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. Allow braze joint to cool before removing the wet rag from the service valve.
PAGE 13
1 CUT AND DEBUR Cut ends of the refrigerant lines square (free from nicks or dents) and debur the ends. The pipe must remain round. Do not crimp end of the line. 2 CAP AND CORE REMOVAL Remove service cap and core from both the suction / vapor and liquid line service ports.
PAGE 14
4 5 6 WRAP SERVICE VALVES To help protect service valve seals during brazing, wrap water saturated cloths around service valve bodies and copper tube stubs. Use additional water saturated cloths underneath the valve body to protect the base paint. FLOW NITROGEN Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and out of the suction / vapor valve stem port.
PAGE 15
Indoor Refrigerant Metering Device Removal and Flushing Line Set and Indoor Coil Flushing is only required when the existing system used HCFC−22 refrigerant. If the existing system used HFC−410a, then remove the original indoor coil metering device and proceed to Installing New Indoor Metering Device on page 16.
PAGE 16
Installing New Indoor Metering Device This outdoor unit is designed for use in HFC−410A systems that use a check / expansion valve metering device (purchased separately) at the indoor coil. See the Lennox XP13 Engineering Handbook for approved check / expansion valve kit match−ups. The check / expansion valve device can be installed either internal or external to the indoor coil.
PAGE 17
Leak Test Line Set and Indoor Coil IMPORTANT Leak detector must be capable of sensing HFC refrigerant. CONNECT GAUGE SET A B Connect an HFC−410A manifold gauge set high pressure hose to the vapor valve service port. LOW NOTE Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the vapor port better protects the manifold gauge set from high pressure damage.
PAGE 18
Evacuating Line Set and Indoor Coil 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 refrigerant to produce substances that corrode copper piping and compressor parts. CONNECT GAUGE SET 1 NOTE Remove cores from service valves (if not already done).
PAGE 19
Electrical IMPORTANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns. WARNING Danger of Equipment Damage. Avoid deep vacuum operation. Do not use compressors to evacuate a system. Extremely low vacuums can cause internal arcing and compressor failure. Damage caused by deep vacuum operation will void warranty.
PAGE 20
Figure 14.
PAGE 21
Figure 15. Typical Factory Wiring Unit Start−Up IMPORTANT If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start−up to prevent compressor damage as a result of slugging. have consulted with the power company and the voltage condition has been corrected. 6. Open both the liquid and vapor line service valves to release the refrigerant charge contained in outdoor unit into the system. 7. Use figure 16 to determine next step in system preparation.
PAGE 22
Service and Weigh In Refrigerant for Outdoor Units Delivered Void of Charge The following procedures are only required if it has been determine that the new outdoor unit is void of charge. Skip to the next section if refrigerant charge is present. LEAK CHECK, REPAIR AND EVACUATE If the outdoor unit is void of refrigerant, clean the system using the procedure described below. 1. Leak check system using procedures provided on page 17. Repair any leaks discovered during leak test. 1.
PAGE 23
WEIGH−IN CHARGING CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE If the system is void of refrigerant, first, locate and repair any leaks and then weigh in the refrigerant charge into the unit. To calculate the total refrigerant charge: Additional charge specified per match indoor air handler or coil Adjust amount. for variation in line set Amount specified on Total Charge listed in table 3. length listed on line set length table below.
PAGE 24
Optimizing System Refrigerant Charge This section provides instructions on optimizing the system charge. This section includes: Optimizing procedure Adjusting indoor airflow Using subcooling method Approved matched components, targeted subcooling (SC) values and add charge values Normal operating pressures Temperature pressures OPTIMIZING PROCEDURE 1. Move the low−side manifold gauge hose from the vapor line service valve to the true suction port (see figure 17). 2.
PAGE 25
OPTIMIZE CHARGE USING SUBCOOLING 1. Check liquid and vapor line pressures. Compare pressures with either second−stage heat or cooling mode normal operating pressures listed in table 4. Table 4 is a general guide and expect minor pressures variations. Significant pressure differences may indicate improper charge or other system problem. USE COOLING MODE 2.
PAGE 26
APPROVED MATCHED SYSTEM COMPONENTS, TARGETED SUBCOOLING (SC) VALUES AND ADD CHARGE VALUES Listed below are the approved matched system Subcooling values listed in the following tables are based components (air handlers and indoor coils), targeted on outdoor ambient air temperature of: subcooling and add charge values for the XP13. This 60°F (15.5°C) and above for cooling mode information is also listed on the unit charging sticker 59°F (15.0°C) and below for heating mode.
PAGE 27
Liquid Pressure Model Number Heating Cooling ºF (ºC)* 20 (−7) 30 (−1) 40 (4.
PAGE 28
System Operation IMPORTANT Some scroll compressor have internal vacuum protector that will unload scrolls when suction pressure goes below 20 psig. A hissing sound will be heard when the compressor is running unloaded. Protector will reset when low pressure in system is raised above 40 psig. DO NOT REPLACE COMPRESSOR. Bi−Flow Liquid Line Filter Drier The unit is equipped with a large−capacity biflow filter drier which keeps the system clean and dry.
PAGE 29
Compressor Delay (P5) The defrost control has a field−selectable function to reduce occasional sounds that may occur while the unit is cycling in and out of the defrost mode. Units with defrost control 100269−02: The compressor will be cycled off for 30 seconds going in and out of the defrost mode when the compressor delay jumper is removed.
PAGE 30
Maintenance DEALER Maintenance and service must be performed by a qualified installer or service agency. At the beginning of each cooling season, the system should be checked as follows: Outdoor Unit 1. Clean and inspect the outdoor coil. The coil may be flushed with a water hose. Ensure the power is turned off before you clean the coil. 2. Outdoor fan motor is prelubricated and sealed. No further lubrication is needed. 3. Visually inspect connecting lines and coils for evidence of oil leaks. 4.
PAGE 31
Thermostat Operation See the thermostat homeowner manual for instructions on how to operate your thermostat. Heat Pump Operation Your new Lennox heat pump has several characteristics that you should be aware of: Heat pumps satisfy heating demand by delivering large amounts of warm air into the living space. This is quite different from gas- or oil-fired furnaces or an electric furnace which deliver lower volumes of considerably hotter air to heat the space.
PAGE 32
Start−Up and Performance Checklist Job Name Job no. Date Job Location City State Installer City State Unit Model No. Serial No. Service Technician Nameplate Voltage Rated Load Ampacity Compressor Amperage: Maximum Fuse or Circuit Breaker Electrical Connections Tight? Indoor Blower RPM Indoor Filter clean? S.P. Drop Over Indoor (Dry) Supply Voltage (Unit Off) Outdoor Coil Entering Air Temp.