Lennox XP25-024-230-01 Installation And Service Procedure
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Lennox XP25-024-230-01 Installation And Service Procedure

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Service Literature
Dave Lennox Signature
IMPORTANT
This unit has refrigerant piping requirements that are
unique to this this model. Size and install the refrigerant
piping per table 2 (page 14) to ensure proper unit operation.
IMPORTANT: Before applying any power (main, solar or low
voltage) to the outdoor unit, confirm iComfort Wi-Fi
has Version 2.1 or higher software. (Reference iComfort Wi-Fi
thermostat manual.)
This unit is an integral component of a system that requires an
®
iComfort Wi-Fi
thermostat and iComfort
or furnace.
XP25 Heat
Pump
WARNING
mproper installation, adjustment, alteration, service or
I
Maintenance can cause personal injury, loss of life, or
damage to property.
Installation and service must be
performed by a licensed
equivalent) or a service agency.
INSTALLATION AND SERVICE
PROCEDURE
July 24, 2013 (Revised on Dec. 11, 2014)
®
thermostat
®
-enabled air handler
®
iComfort Wi-Fi
Thermostat
™
iComfort
-enabled
air handler or
furnace
professional installer (or
Corp. 1252-L11
®
Collection XP25 Series Units

TABLE OF CONTENTS

I. OVERVIEW
General
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II. INSTALLATION
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Servicing Unit Delivered Void of Charge
III. SYSTEM OPERATION AND SERVICE
®
Outdoor Control Push-Button Operation
Configuring Unit
Reconfiguring Outdoor Control using iComfort Wi-Fi
Thermostat
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Overview
Maintenance
®
SunSource
The Clean Air Act of 1990 bans the intentional venting of
refrigerant (CFCs, HCFCs AND HFCs) as of July 1, 1992.
Approved methods of recovery, recycling or reclaiming
must be followed. Fines and/or incarceration may be
levied for noncompliance.
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IMPORTANT
2013 Lennox Industries Inc.
XP25
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Summary of Contents for Lennox XP25-024-230-01

  • Page 1 Installation and service must be Approved methods of recovery, recycling or reclaiming performed by a licensed professional installer (or must be followed. Fines and/or incarceration may be equivalent) or a service agency. levied for noncompliance. Page 1 2013 Lennox Industries Inc.

  • Page 2: Model Number Identification

    Outdoor Fan Model Number Sound Rating Number (dB) Factory Refrigerant Number of Blades Diameter - inches. Charge Maximum Minimum XP25-024-230-01 11 lbs., 5 oz. Unit Outdoor Fan Model Number Sound Rating Number (dB) Factory Refrigerant Number of Blades Diameter - inches.

  • Page 3: Electrical Data

    Model Number Load Rotor Motor Load current Circuity Amps Amps Amps Protection Ampacity (RLA) (LRA) (FLA) (amps) XP25-024-230-01 15.7 10.30 18.00 2580 1845 2.80 208/230V-60 Hz-1 Ph Unit Compressor Outdoor Fan (RPM varies with compressor RPM) Maximum Rated Locked WATTS Full...

  • Page 4: Unit Dimensions

    Unit Dimensions -- Inches (mm) UNIT SUPPORT FEET 16-7/8 26-7/8 (429) (683) 8-3/4 (222) 3-3/4 (95) 30-3/4 3-1/8 4-5/8 (781) (79) (117) BASE WITH ELONGATED LEGS CAUTION WARNING Physical contact with metal edges and corners while Electric Shock Hazard. Can cause injury or death. Unit applying excessive force or rapid motion can result in must be grounded in accordance with national and local personal injury.

  • Page 5: Typical Unit Parts Arrangement

    Typical Unit Parts Arrangement CONTROL PANEL FOR XP25-024 AND -036 CONTACTOR-SPST (25FLA/35RES) GROUND LUGS INVERTER REACTOR, 230V, 4KW VARIABLE-CAPACITY OUTDOOR INVERTER CONTROL CONTROL CONTROL PANEL FOR XP25-048 AND -060 INVERTER NOISE FILTER FOR 6KW INVERTER (208/240V, 60HZ, CURRENT RANGE 30A MAXIMUM, INDUCTANCE 4.3MH GROUND LUGS CONTACTOR-SPST...
  • Page 6 Typical Plumbing Components (-024 and -048) COMPRESSOR TOP CAP SWITCH (THERMAL) VARIABLE-CAPACITY COMPRESSOR SPEED - HFC-410A, 3-PHASE MUFFLER REVERSING VALVE CHARGE C0MPENSATOR (INTERNAL VOLUME 30.0 CUBIC INCHES) VAPOR VALVE AND GAUGE PORT CHECK EXPANSION VALVE - (HFC-410A) LIQUID VALVE AND GAUGE PORT HR1 CRANKCASE HEATER (40W, 240VAC)

  • Page 7: General

    See the Lennox Service and Application Notes #C-08-1 for personal injury. Be aware of, and use caution when further details and information.

  • Page 8: Service Valves

    SERVICE VALVES ANGLE AND BALL-TYPE Operating Angle-Type Service Valve: Remove stem cap with an appropriately sized wrench. 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.

  • Page 9: Unit Placement

    II. INSTALLATION PLACING UNIT ON SLAB Unit Placement When installing unit at grade level, the top of the slab should be high enough above grade so that water from higher ground will not collect around the unit. The slab should have CAUTION a slope tolerance as described in figure 6, detail B.
  • Page 10 STABILIZING UNIT ON UNEVEN SURFACES unit above a load-bearing wall or area of the roof that can adequately support the unit. Consult local codes for rooftop IMPORTANT applications. If unit coil cannot be mounted away from prevailing Unit Stabilizer Bracket Use (field-provided): winter winds, a wind barrier should be constructed.
  • Page 11 DETAIL A DETAIL B INSTALL UNIT AWAY FROM WINDOWS INSTALL UNIT LEVEL OR, IF ON A SLOPE, MAINTAIN SLOPE TOLERANCE OF 2 DEGREES (OR 2 INCHES PER 5 FEET [50 MM PER 1.5 M]) AWAY FROM BUILDING STRUCTURE. BUILDING STRUCTURE MOUNTING SLAB TWO 90°...

  • Page 12: Removing And Installing Panels

    Removing and Installing Panels ACCESS PANEL REMOVAL PANELS REMOVE AND INSTALL THE ACCESS PANEL AS ILLUSTRATED. ACCESS AND LOUVERED WARNING REMOVE 4 SCREWS TO REMOVE PANEL FOR ACCESSING COMPRESSOR To prevent personal injury, or damage to panels, unit or structure, be AND CONTROLS.

  • Page 13: New Or Replacement Line Set

    Brazing must be flushed prior to installation. Take care to empty all Connections on page 16. existing traps. Polyol ester (POE) oils are used in Lennox IMPORTANT units charged with HFC-410A refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer.
  • Page 14 COOLING SYSTEM (HFC-410A) Vertical vapor riser must be sized per table 3 on systems with line sets longer than 51 feet. Use tables 3 and 4 to • Total equivalent length equals 180 feet (piping and all determine the correct liquid and vapor line sizes. fittings included).
  • Page 15 LINE SET IMPORTANT - Refrigerant lines must not contact structure. REFRIGERANT LINE SET — INSTALLING INSTALLATION VERTICAL RUNS (NEW CONSTRUCTION SHOWN) Line Set Isolation — The following illustrations are examples of proper NOTE - INSULATE LIQUID LINE WHEN IT IS ROUTED THROUGH AREAS refrigerant line set isolation: WHERE THE SURROUNDING AMBIENT TEMPERATURE COULD BECOME HIGHER THAN THE TEMPERATURE OF THE LIQUID LINE OR WHEN...

  • Page 16: Brazing Connections

    Brazing Connections WARNING Use the procedures outlined in figures 9 and 10 for brazing Fire, Explosion and Personal Safety Haz­ line set connections to service valves. ard. WARNING Failure to follow this warning could result in damage, personal injury or death. When using a high pressure gas such as Never use oxygen to pressurize or purge dry nitrogen to pressurize a refrigeration or...
  • Page 17 CAP AND CORE REMOVAL PIPING PANEL REMOVAL AND LINE SET PREPARATION Remove service cap and core from both the suction and liquid line service ports. Remove piping panel for easier access to service valves. SERVICE PORT CAP Cut ends of the refrigerant lines square (free from nicks or dents) and debur the ends.
  • Page 18 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 WARNING Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection FIRE, PERSONAL INJURY, OR PROPERTY on the liquid service valve and out of the suction / vapor...

  • Page 19: Flushing The System

    Flushing the System LINE SET AND INDOOR COIL (1 OF 2) TYPICAL EXISTING EXPANSION VALVE REMOVAL PROCEDURE (UNCASED COIL SHOWN) STUB END TWO PIECE PATCH PLATE LIQUID LINE CHECK TYPICAL EXISTING FIXED ORIFICE (UNCASED COIL ONLY) ORIFICE EXPANSION HOUSING REMOVAL PROCEDURE VALVE DISTRIBUTOR (UNCASED COIL SHOWN)
  • Page 20 FLUSHING LINE SET AND INDOOR COIL (2 OF 2) TYPICAL NEW CHECK EXPANSION VALVE INSTALLATION PROCEDURE THIS OUTDOOR UNIT IS DESIGNED FOR USE IN SYSTEMS THAT USE A CHECK EXPANSION VALVE METERING DEVICE. SEE THE LENNOX XP25 PRODUCT SPECIFICATION FOR APPROVED EXPANSION VALVE KIT MATCH-UPS AND APPLICATION INFORMATION.

  • Page 21: Leak Testing The System

    Take care to REAR VIEW OF UNIT EXTERIOR empty all existing traps. Polyol ester (POE) oils are used in Lennox units charged with HFC-410A refrigerant. Residual mineral oil can act as an insulator, preventing Figure 11. Isolation Grommets proper heat transfer.

  • Page 22: Leak Test

    LEAK TEST LINE SET AND INDOOR COIL 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. CONNECT GAUGE SET CONNECT AN HFC-410A MANIFOLD GAUGE SET HIGH HIGH PRESSURE HOSE TO THE VAPOR VALVE...

  • Page 23: Evacuating The System

    Evacuating the System LINE SET AND INDOOR COIL MANIFOLD GAUGE SET CONNECT GAUGE SET HIGH NOTE - REMOVE CORES FROM SERVICE VALVES (IF NOT ALREADY DONE). CONNECT LOW SIDE OF MANIFOLD GAUGE SET WITH 1/4 SAE IN-LINE TEE TO VAPOR LINE SERVICE VALVE. CONNECT HIGH SIDE OF MANIFOLD A34000 1/4 SAE TEE WITH GAUGE SET TO LIQUID LINE SERVICE...

  • Page 24: Electrical

    for minimum circuit ampacity and maximum over-current IMPORTANT protection size. 24VAC TRANSFORMER Use a thermocouple or thermistor electronic vacuum Use the transformer provided with the furnace or air handler gauge that is calibrated in microns. Use an instrument for low‐voltage control power (24VAC - 40 VA minimum). capable of accurately measuring down to 50 microns.
  • Page 25 ROUTE CONTROL WIRES ELECTRICAL (CONTROL WIRING) AND LINE SET INLETS USE Maximum length of wiring (18 gauge) for all connections on TYPICAL CONTROL BOX BUSHING AND GROMMETS the RSBus is 1500 feet (457 meters). Wires should be col­ PROVIDED IN BAG º...
  • Page 26 ELECTRICAL (Continued) -- Outdoor Unit Control CAUTION Electrostatic discharge can affect electronic components. Take precautions during unit installation and service to protect the unit's electronic controls. ELECTROSTATIC DISCHARGE Precautions will help to avoid control exposure to electrostatic discharge by (ESD) putting the unit, the control and the technician at the same electrostatic potential.
  • Page 27 Data Data 24VAC nominal board 24VAC nominal power input. main power input. Factory test 26Vdc transistor output to Lennox TOUT factory OEM tester Factory test pin. In each terminal box: 24VAC nominal 17ma @ P2 ­ Terminal 1 ­ TEST 30VAC P2 ­...
  • Page 28 Table 5 continued. Outdoor Control Terminal Designations and Input /Outputs WARNING - Electric Shock Hazard. Can cause injury or death. Unit must be grounded in accordance with national and local codes. The 4 pins in P6 have the potential of transferring up to 250 volts to the unit cabinet ground. Designator Description Input...

  • Page 29: Servicing Unit Delivered Void Of Charge

    1. Rotate fan to check for binding. Servicing Units Delivered Void of Charge If the outdoor unit is void of refrigerant, clean the system 2. Inspect all factory- and field-installed wiring for loose using the procedure described below. connections. 1. Leak check system using procedure outlined on page 21.
  • Page 30 III. SYSTEM OPERATION AND SERVICE • Disconnecting R wire from the outdoor control R 7-Segment Alert and System Status Codes terminal. Alert codes are displayed using the 7-segment display located on the outdoor control. • Turning the indoor unit off and back on again NOTE - System fault and lockout codes take precedence After power up, all currently displayed codes are over system status codes (cooling, heating operating...
  • Page 31 Lennox is enlarging the cut-outs in the plate firms this operational se­ so MOV2 will clear the fixture. Corrective action com­...
  • Page 32 Table 6. Outdoor Control 7-Segment Display Alert Codes and Inverter LED Flash Codes NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 33 Table 6. Outdoor Control 7-Segment Display Alert Codes and Inverter LED Flash Codes NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 34 Table 6. Outdoor Control 7-Segment Display Alert Codes and Inverter LED Flash Codes NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 35 Table 6. Outdoor Control 7-Segment Display Alert Codes and Inverter LED Flash Codes NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 36 POWER-UP / RESET: 7-SEGMENT POWER-UP DISPLAY STRING FIRMWARE VERSION: During initial power-up or reset, the first item displayed is the outdoor control firmware version. Example to the right shows firmware version 2.3. UNIT TYPE: The next item displayed is the self discovery unit type.
  • Page 37 Table 7. Outdoor Control 7-Segment Unit Status Displays Description Example of Display Idle Mode: Decimal point flashes at 1 Hz (0.5 second on, 0.5 second off). Idle Mode: Decimal point flashes at 1 Hz Display OFF. Soft Disabled: Top and bottom horizontal line and decimal point Soft Disabled: Top and bottom horizontal line and decimal point flash at 1 flash at 1 Hz.
  • Page 38 PUSH - BUTTON OPERATION Outdoor control must be in IDLE mode (no heating or Allows field access to Diagnostic, Fan, Defrost and Error Code Re­ cooling operation) call modes. NOTE - See table 6 for explanation of codes. Push and hold button until mode To enter mode options, push and hold button next to 7­seg­...
  • Page 39 Error Code Recall Mode (Note - control must be in idle mode) To enter error code recall mode, push and hold button until solid E appears, then release button. Control displays up to 10 error codes stored in memory. If E 0 0 0 is displayed, there are no stored error codes. —...
  • Page 40 Table 8. Field Test, Diagnostic Recall and Program Menu Options Display Display and action (normal operation) No Change - idle No Change - idle (*) Solid . Enter or exit field test and program mode. Solid A Puts unit in diagnostic mode. (Displays ambient, coil, liquid sensor temperatures and any active error codes.) Solid c Clears error history (**) Solid E...
  • Page 41 How to enable liquid line temperature information on a 7-segment display NOTE - IF SYSTEM POWER IS RECYCLED, DISPLAY STRING Both coil and liquid line temperatures can be enabled for display REVERTS BACK TO DEFAULT. THE ABOVE PROCEDURE either during normal demand operation or while in idle mode. NEEDS TO BE REPEATED TO ENABLE OUTDOOR COIL AND LIQUID LINE TEMPERATURE INFORMATION.

  • Page 42: Configuring Unit

    Configuring Unit When installing a new or replacement outdoor control, the unit selection code may have to be manually assigned using the 7-segment display and push button on the control. The unit code sets unit type, capacity and outdoor fan RPM. Configuring Unit Selection Code Power-up - Unit selection code (two-digit number) displayed represents unit size code (outdoor unit capacity).

  • Page 43: Reconfiguring Outdoor Control Using Icomfort Wi-Fi Thermostat

    • Low pressure switch status Reconfiguring Outdoor Control using ® iComfort Wi-Fi Thermostat • Compressor top cap switch status • Liquid line temperature If any component of the HVAC system is changed, ( e.g. an outdoor sensor is replaced), reconfigure the system. To •...

  • Page 44: Outdoor Temperature Operational Range

    COMPRESSOR SHORT-CYCLING DELAY reduces sounds that occur while the unit is cycling in and out The outdoor control protects the compressor from: of the defrost mode. • Short-cycling (five minutes) when there is initial power When enabled, there is a 30-second compressor shift delay which de-energizes the contactor output and ECM •...

  • Page 45: Maintenance

    Heavy snow and/or freezing rain can interfere with the installer or service agency. At the beginning of each cooling performance of the outdoor fan assembly. Lennox season, the system should be checked as follows: recommends use of the optional snow guard (X8782) in 1.

  • Page 46: Unit Wiring Diagrams

    Typical Unit Wiring Diagrams Figure 24. Typical Unit Wiring (XP25-024 and -036) XP25 Page 46...
  • Page 47 Figure 25. Typical Unit Wiring (XP25-048 and -060) XP25 Page 47...
  • Page 48 NOTE - For more information on Load Shedding, see Electrical on page 24. Figure 26. Load Shedding Feature Wiring Diagram XP25 Page 48...

  • Page 49: Factory Wiring Diagrams

    Factory Wiring Diagrams Figure 27. Typical Factory Wiring (XP25-024 and -036) XP25 Page 49...
  • Page 50 Figure 28. Typical Factory Wiring (XP25-048 and -060) XP25 Page 50...

  • Page 51: Unit Sequence Of Operations

    Unit Sequence of Operations The following figures illustrate the overall unit sequence of operation along with the operation of various pressure switches and temperature sensors. The figures also illustrate the use of the compressor anti-short-cycle function in relation to unit Status, unit Fault and lock out LED Codes and unit system operation interactions.
  • Page 52 On 24 VAC power-up or outdoor reset, the outdoor unit control shall perform the following tasks: 1. Start the anti-short cycle 3 minute delay in the outdoor control. 2. Check status of the temperature sensor and pressure devices. 3. If the outdoor unit control does not detect any error codes, it sends 24 volts out on the CNTCTR terminals to pull in the contactor coil.
  • Page 53 From modu­ lating heat pump heat. Heat pump ran for at least 30 minutes? Defrost in the last 30 minutes? Auxiliary heat is used to satisfy all heat calls during heat pump lock­ Back to modulating out. heat pump heat. Go to auxiliary heat.
  • Page 54 Auxiliary heat (while demand exists) Check for status or All sensors closed fault codes in out­ Dual Fuel? and within operating door control range? Turn off heat pump. Heat only using gas heat. Emergency Go to auxiliary heat selected? heating. Balance Balance Balance...
  • Page 55 Defrost Calibration Heat pump control monitors mode Coil sensor detects temperature below 35°F {2°C} during of operation through outdoor ambient temperature, outdoor coil either initial power-up, after loss of power or after cooling temperature compressor mode, a sacrificial defrost is used to ensure there is a clear run-time to determine when a coil before attempting calibration.

  • Page 56: Component Testing

    Component Testing Section Table of Contents High and Low Pressure Switch Operation, Checkout and Reactor Operations, Checkout and Status / Status / Error Codes ......Error Codes .
  • Page 57 INITIAL TRIP PRESSURE CONTACTOR SWITCH IS Y1 DEMAND CLOSED SWITCH (S87) ENERGIZED IGNORED FOR 90 SECONDS SWITCH IS CLOSED OR OUTDOOR PRESSURE CLOSED AMBIENT TEMPERATURE IS 15ºF OPEN SWITCH (S87) OR BELOW CONTACTOR The thermostat terminates demand when the contactor is DE-ENERGIZED de-energized.
  • Page 58 HIGH CONTACTOR TOP CAP PRESSURE CLOSED ENERGIZED CLOSED Y1 DEMAND SWITCH (S173) SWITCH (S4) HIGH PRESSURE CLOSED OPEN SWITCH (S4) CONTACTOR DE-ENERGIZED The thermostat terminates demand when the contactor is de-energized. If demand is satisfied when alarm is not active, the 5-strike counter resets.
  • Page 59 High and Low Pressure Switch Errors Table 12. Outdoor Control 7-Segment Display Alert Codes - High and Low Pressure Switches NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 60 Reversing Valve Operation, Checkout and Status / Error Codes OPERATION: The reversing valve switches the system between cooling and heating modes. By switching the flow of refrigerant, the heat pump can incorporate the functions of cooling in the summer and heating in the winter. The valve consists of a main body and a solenoid coil.
  • Page 61 IMPORTANT - ENSURE NEW REVERSING VALVE IS INSTALLED EXACTLY AS ORIGINAL VALVE. REVERSING VALVE SOLENOID OPERATION WHEN THE SOLENOID IS ENERGIZED (ON), THE EVAPORATOR (INDOOR COIL – E) REFRIGERANT PRESSURE IS DIRECTED TO THE SUCTION (S) BACK TO THE COMPRESSOR. TO COMPRESSOR DISCHARGE LINE WHEN THE SOLENOID IS DE-ENERGIZED (OFF),...
  • Page 62 Compressor Operation, Checkout and Status / Error Codes OPERATION: The compressor is a 380VAC three-phase variable-capacity scroll compressor that is approved for use with HFC­410A refrigerant. The compressor, when connected to an inverter, is capable of operating in a running frequency range from 22 hertz up to a maximum of 70 Hertz (maximum hertz is dependent on compressor size).
  • Page 63 ERROR CODES: Table 13. Outdoor Control 7-Segment Display Alert Codes - Compressor NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 64 Crankcase Heater, Checkout and Status / Error Codes OPERATION: CRANKCASE HEATER (HR1) Compressors in all units are equipped with a 40 or 70 watt (depending on unit size) belly-band type crankcase heater. The heater prevents liquid from accumulating in the compressor. The heater is controlled by the crankcase heater thermostat. CRANKCASE HEATER THERMOSTAT (S40) Crankcase heater thermostat S40 controls the crankcase heater in all units and is located on the liquid line (see figure 2 on page 6 for location).
  • Page 65 Crankcase Heater Thermostat: As the detected temperature changes the resistance across the sensor changes. Table 18 on page 78 shows how the resistance varies as the temperature changes for this sensor. 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 18 on page 78, may be performing as designed.
  • Page 66 Charge Compensator (XP25-024-230-XX and XP25-048-230-XX only) The XP25­024 and XP25­048 units come with a factory-installed refrigerant charge compensator. The compensator helps manage the refrigerant charge in the heating and cooling modes. COOLING MODE HEATING MODE VAPOR LINE - TO VAPOR LINE - TO OUTDOOR COIL OUTDOOR COIL COMPENSATOR TANK - DURING...
  • Page 67 Liquid Line Bi-Flow Filter Drier (Heat Pumps only) Filter-driers come in a variety of sizes, connection types, and materials of construction, but they essentially perform the same function. All filter-driers contain the same functional parts. They contain desiccants to remove the water and acids, and they contain a filtration system to remove the solid contaminants.
  • Page 68 Check Expansion Valve (Heat Pumps only) The thermostatic expansion valve (TEV) controls the flow of liquid refrigerant by maintaining superheat of the refrigerant vapor at the outlet of the outdoor coil during heating mode. CHECKOUT: Table 14. Expansion Valve Checks Problem Causes Corrective Action...
  • Page 69 Table 14 Continued Problem Causes Corrective Action Symptoms 1. Make necessary modification to bal­ ance the load 1. Unequal circuit loading 2. Correct piping 2. Flow from one coil effecting an­ 3. Correct conditions causing the condi­ Superheat appears nor­ other coil tion 1.
  • Page 70 Top Cap Switch Operation, Checkout and Status / Error Codes OPERATION: Some units are equipped with a compressor-mounted normally closed temperature switch that prevents compressor damage due to overheating caused by internal friction. The switch is located on top of the compressor casing. This switch senses the compressor casing temperature and opens at 239-257°F to shut off compressor operation.
  • Page 71 Reactor Operations, Checkout and Status / Error Codes OPERATION: Reactor (Inductor or choke) is a passive two­terminal electrical component that stores energy in its magnetic field. Reactors are one of the basic components used in electronics where current and voltage change with time, due to the ability of inductors to delay and reshape alternating currents.
  • Page 72 208/240 Voltage “OUT” 208/240 Voltage “IN” Figure 53. XP25 4- and 5-ton filter board (EMC) CHECKOUT: Voltage IN should read the same value as the Voltage OUT. With filter isolated from system, resistance between L1 and L2 should be the same as resistance between N1 and N2. STATUS CODES: None ERROR CODES:...
  • Page 73 Perform DC volt checks (19 -23 VDC between FAN PWM and COM). Figure 54. VAC Voltage Check XP25 Page 73...
  • Page 74 VDC Voltage Check: Check for VDC out of Fan PWM and COM. VDC output reading is determined by the percentage of room thermostat demand (see figure 55). 1. No voltage present – Remove wires from control and check for VDC. If there is no voltage present then replace outdoor control.
  • Page 75 Outdoor Control Operation, Checkout and Status / Error Codes OPERATION: The outdoor control is a microprocessor-based device for use with variable-capacity compressors up to 5-tons in capacity operating on 24VAC residential power. The outdoor control integrates the functionality of maintaining compressor speed, demand, defrost and fan PWM controls.
  • Page 76 ERROR CODES: Table 17. Outdoor Control 7-Segment Display Alert Codes - Outdoor Control Errors NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 77 PIN# / WIRE RESISTANCE VALUES TEMP RANGE ºF SENSOR SLEEVE COLOR RANGE (OHMS) (ºC) 6 AND 5 COIL (BROWN) 336,000 to 2,487 (see -40 (-40) TO table 18 on page 78 for OUTDOOR 4 AND 3 140 (60) exact temperature to AMBIENT (BLACK) ohm readings)
  • Page 78 Table 18. Ambient, Coil and Liquid Line Sensors Temperature / Resistance Range Degrees Fahr­ Degrees Fahr­ Degrees Fahr­ Degrees Fahr­ Resistance Resistance Resistance Resistance enheit enheit enheit enheit 136.3 2680 56.8 16657 21.6 44154 -11.3 123152 133.1 2859 56.0 16973 21.0 44851 -11.9...
  • Page 79 ERROR CODES: Table 19. Outdoor Control 7-Segment Display Alert Codes - Outdoor Control Errors NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 80 Heat Sink Intelligent Power Module Converter Power Factor Correction Circuit Communication Control Figure 61. 4- and 5-Ton Unit Inverter STATUS CODES: Table 20. Outdoor Control 7-Segment Display Alert Codes, DC Inverter and Outdoor Control LED Flash Codes NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present).
  • Page 81 Inverter LED Flash Code Alert (number of flashes) Code Priority Alarm Description Possible Causes and Clearing Alarm Codes Red LED Green LED If condition is detected, is detected, outdoor unit compressor and fan stop. Anti­short cycle is initi­ ated. If condition occurs 5 times within an hour, The inverter has detec­...
  • Page 82 Table 21. Outdoor Control 7-Segment Display Alert Codes and Inverter LED Flash Codes NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 83 Table 21. Outdoor Control 7-Segment Display Alert Codes and Inverter LED Flash Codes NOTE - System fault and lockout codes take precedence over system status codes (cooling, heating operating percentages or defrost/dehumidification). Only the latest active fault or lockout codes are displayed (if present). If no fault or lockout codes are active, then system status codes are displayed. Alert ®...
  • Page 84 Emergency 24VAC System Operation The Y and O terminals located on the outdoor control allow the outdoor unit to be cycled ON and OFF using 24VAC inputs. The outdoor unit will operate at 100% capacity in this configuration. NOTE - Defrost operation will not have any indoor discharge air tempering due to the lack of a W1 out terminal. The following wiring diagrams display the wiring changes needed to switch a full communicating system to a partial communicating system with the XP25 running in emergency mode (24VAC inputs to outdoor unit).

  • Page 85: System Refrigerant

    System Refrigerant IMPORTANT - Unit must be operating at 100% input to IMPORTANT ! charge properly. The system must be operating at full capacity during ADDING OR REMOVING REFRIGERANT charging. Increase (heat) or decrease (cooling) the This system uses HFC-410A refrigerant which operates at thermostat setting by 5°F to create system demand.
  • Page 86 AIRFLOW INDOOR COIL TEMPERATURE OF AIR 80 24 24 24 23 23 22 22 22 20 19 18 17 16 15 ENTERING INDOOR COIL ºF 78 23 23 23 22 22 21 21 20 19 18 17 16 15 14 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13 74 21 21 21 20 19 19 18 17 16 16 15 14 13 12 72 20 20 19 18 17 17 16 15 15 14 13 12 11 10...
  • Page 87 WEIGH-IN SUBCOOLING method for adding initial refrigerant charge, then use method for for verifying refrigerant charge. WEIGH-IN NOTE - Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than CHARGING METHOD FOR LONG LINE SETS the temperature of the liquid line or when pressure drop is equal 64ºF (17.7ºC) and Below to or greater than 20 psig.
  • Page 88 Table 22 HFC-410A Temperature (°F) - Pressure (Psig) °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig 100.8 137.1 178.5 231.6 290.8 365.0 545.6 445.9 102.9 139.6 181.6 235.3 295.1 370.0 451.8 552.3 105.0 142.2 184.3...
  • Page 89 Figure 67. XP25 Charging Sticker XP25 Page 89...

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Xp25-036-230-01Xp25-048-230-01Xp25-060-230-01

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