EasyManua.ls Logo

Lennox Signature XP21 Series

Lennox Signature XP21 Series
81 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Loading...
Page 1
2012 Lennox Industries Inc.
Corp. 1031−L7
Revised August 17, 2012
XP21
INSTALLATION AND SERVICE
PROCEDURE
Service Literature
Dave Lennox Signature
®
Collection XP21 Series Units
NOTICE
A thermostat is not included and must be ordered
separately.
The Lennox icomfort thermostat must be used in
communicating applications.
In non−communicating applications, the Lennox
ComfortSense
®
7000 thermostat may be used, as well
as other non−communicating thermostats.
In all cases, setup is critical to ensure proper system
operation.
Field wiring examples for non−communicating
applications begin on page 22.
See the icomfort thermostat Quick Start Guide for
communicating and partial communicating field wiring
connections.
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, 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.
TABLE OF CONTENTS
I. OVERVIEW
Model Number Identification 2. . . . . . . . . . . . . . . . . . . .
Typical Serial Number Identification 2. . . . . . . . . . . . . .
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Data 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Unit Parts Arrangement 5. . . . . . . . . . . . . . . . .
Operating Gauge Set 6. . . . . . . . . . . . . . . . . . . . . . . . . .
General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II. INSTALLATION
Unit Placement 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and Installing Panels 11. . . . . . . . . . . . . . . . .
New or Replacement Line Set 12. . . . . . . . . . . . . . . . . .
Brazing Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing the System 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing the System 19. . . . . . . . . . . . . . . . . . . . . . .
Evacuating the System 19. . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Control Wiring 24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Unit Delivered Void of Charge 26. . . . . . . . . .
Unit Start−Up 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Refrigerant 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Handler / Indoor Coil Match ups and Targeted
Subcooling Values 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and Temperature Pressures 30. . . . . . . . . .
III. SYSTEM OPERATION AND SERVICE
OUTDOOR CONTROL − PART NUMBER 101796−XX
Heat Pump Control (A175) Jumpers and Terminals 31
System Status, Fault and Lockout LED Codes 33. . . .
Component Field Configuration and
Troubleshooting 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTDOOR CONTROL − PART NUMBER 103369−XX
Jumpers and Links 47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Unit 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7−Segment Alert and System Status Codes 51. . . . . . .
Reconfiguring Outdoor Control using icomfort
Thermostat 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPLICABLE TO ALL VERSIONS
Compressor Information and Testing 57. . . . . . . . . . . . .
System Overview 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defrost System 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SunSource
®
Home Energy System 67. . . . . . . . . . . . . .
Checklists 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Wiring Diagrams 69. . . . . . . . . . . . . . . . . . . . . . . . . .
Factory Wiring Diagrams 72. . . . . . . . . . . . . . . . . . . . . . .
Unit Sequence of Operations 75. . . . . . . . . . . . . . . . . . .
Question and Answer IconNeed help?

Do you have a question about the Lennox Signature XP21 Series and is the answer not in the manual?

Lennox Signature XP21 Series Specifications

General IconGeneral
TypeHeat Pump
SEER RatingUp to 21
RefrigerantR-410A
Cooling Capacity (BTU/h)Up to 60, 000
Heating Capacity (BTU/h)Up to 60, 000
Warranty10 years on compressor and parts
CabinetGalvanized steel with a powder-coated finish

Summary

INSTALLATION AND SERVICE PROCEDURE

I. OVERVIEW

General introduction to unit components and identification.

II. INSTALLATION

Procedures for installing the unit, including placement and clearances.

III. SYSTEM OPERATION AND SERVICE

Details on operating and servicing the unit, including controls and troubleshooting.

I. OVERVIEW

Model Number Identification

Explains how to identify unit model numbers and their components.

Specifications

Lists technical specifications for various unit models.

I. OVERVIEW

Electrical Data

Provides electrical characteristics and ratings for unit components.

I. OVERVIEW

Unit Dimensions

Details the physical dimensions and clearance requirements of the unit.

I. OVERVIEW

Typical Unit Parts Arrangement

Illustrates the location of major unit components and their connections.

IMPORTANT SAFETY INFORMATION

TORQUE REQUIREMENTS

Specifies torque values for proper fastener tightening during service.

USING MANIFOLD GAUGE SET

Guidance on selecting and using manifold gauge sets for HVAC systems.

OPERATING SERVICE VALVES

Instructions for operating the liquid and vapor line service valves.

SERVICE VALVES ANGLE AND BALL

Operating Angle Type Service Valve

Procedure for operating angle type service valves.

Operating Ball Type Service Valve

Procedure for operating ball type service valves.

To Access Service Port

Steps to access the service port for gauge connections.

II. INSTALLATION

Unit Placement

Guidance on positioning the unit, considering sound and clearances.

POSITIONING CONSIDERATIONS

Factors to consider when placing the unit for optimal performance.

PLACING UNIT ON SLAB

Instructions for placing the unit on a foundation slab.

II. INSTALLATION

STABILIZING UNIT ON UNEVEN SURFACES

How to stabilize the unit on uneven surfaces using brackets.

ROOF MOUNTING

Considerations for mounting the unit on a roof structure.

II. INSTALLATION

Outside Unit Placement

Details and diagrams for placing the unit outdoors.

Slab Mounting at Ground Level

Diagram illustrating slab mounting at ground level.

Stabilizing Unit on Uneven Surfaces

Visual guide for stabilizing the unit using mounting brackets.

II. INSTALLATION

Removing and Installing Panels

Procedure for removing and installing access and louvered panels.

II. INSTALLATION

New or Replacement Line Set

Information on installing or replacing refrigerant line sets.

LINE SET INSTALLATION

REFRIGERANT LINE SET - INSTALLING VERTICAL RUNS

How to install vertical refrigerant line runs.

REFRIGERANT LINE SET - TRANSITION FROM VERTICAL TO HORIZONTAL

Guidance for transitioning refrigerant line sets.

REFRIGERANT LINE SET - INSTALLING HORIZONTAL RUNS

How to install horizontal refrigerant line runs.

II. INSTALLATION

Brazing Connections

Procedures for making brazed connections to service valves.

II. INSTALLATION

II. INSTALLATION

BRAZE LINE SET

Steps for brazing the refrigerant line set connections.

II. INSTALLATION

Flushing the System

Procedures for flushing the refrigerant lines and indoor coil.

II. INSTALLATION

TYPICAL NEW CHECK EXPANSION VALVE INSTALLATION PROCEDURE

Procedure for installing a new check expansion valve.

SENSING BULB INSTALLATION

Instructions for installing the sensing bulb correctly.

EQUALIZER LINE INSTALLATION

Procedure for installing the equalizer line.

II. INSTALLATION

INSTALLING ISOLATION GROMMETS

Installing isolation grommets to protect refrigerant lines.

Leak Testing the System

Procedure for testing the system for refrigerant leaks.

II. INSTALLATION

LEAK TEST LINE SET AND INDOOR COIL

Detailed steps for performing a system leak test.

II. INSTALLATION

Evacuating the System

Procedures for evacuating the system to remove air and moisture.

II. INSTALLATION

Electrical

Electrical installation requirements and codes.

INSTALL THERMOSTAT

Guidelines for installing the room thermostat.

Electrostatic Discharge (ESD) Precautions and Procedures

ESD safety measures to protect electronic components.

II. INSTALLATION

A. ROUTE CONTROL WIRES - NON-COMMUNICATING

Routing control wires for non-communicating systems.

B. ROUTE CONTROL WIRES - COMMUNICATING

Routing control wires for communicating systems.

ROUTE HIGH VOLTAGE AND GROUND WIRES

Routing high voltage and ground wires.

II. INSTALLATION

Field Control Wiring

Examples of control wiring for thermostats and air handlers.

II. INSTALLATION

Field Control Wiring

Examples of control wiring for thermostats and furnaces.

II. INSTALLATION

Servicing Units Delivered Void of Charge

Procedures for servicing units delivered without refrigerant.

Unit Start-Up

Steps for starting the unit, including pre-start checks.

System Refrigerant

Procedures for testing and charging the system with refrigerant.

II. INSTALLATION

ADDING OR REMOVING REFRIGERANT

Procedures for adding or removing refrigerant for charging.

COOLING MODE INDOOR AIRFLOW CHECK

Checking indoor airflow in cooling mode using the Delta-T process.

II. INSTALLATION

WEIGH IN CHARGING METHOD

Method for weighing in the initial refrigerant charge.

SUBCOOLING CHARGING METHOD

Method for verifying refrigerant charge using subcooling.

II. INSTALLATION

Air Handler Indoor Coil Matchups and Targeted Subcooling Values

Lists indoor coil matchups and targeted subcooling values for charging.

II. INSTALLATION

Operating and Temperature Pressures (All Builds)

Lists normal operating pressures for various conditions.

III. SYSTEM OPERATION AND SERVICE

OUTDOOR CONTROL - PART NUMBER 101796-XX

Details on the outdoor control unit, part number 101796-XX.

HEAT PUMP CONTROL (A175) Jumper and Terminals

Jumpers and terminals for the heat pump control (A175).

III. SYSTEM OPERATION AND SERVICE

Table 10. Heat Pump Control (A175) Jumper and Terminal Descriptions

Description of heat pump control jumpers and terminals.

III. SYSTEM OPERATION AND SERVICE

System Status, Fault and Lockout LED Codes

Explains LED status, fault, and lockout codes for system diagnostics.

RESETTING FAULT AND LOCKOUT LED CODES

Procedures for resetting fault and lockout codes.

III. SYSTEM OPERATION AND SERVICE

III. SYSTEM OPERATION AND SERVICE

Table 11. System Status, Fault and Lockout LED Codes and Related icomfort Thermostat Alert Codes

Continued list of LED codes and icomfort thermostat alert codes.

III. SYSTEM OPERATION AND SERVICE

Table 12. Compressor Fault and Alarm LED Codes and Related icomfort Thermostat Alert Codes

Compressor fault and alarm LED codes with related thermostat alerts.

III. SYSTEM OPERATION AND SERVICE

III. SYSTEM OPERATION AND SERVICE

Component Field Configuration and Troubleshooting

Procedures for configuring and troubleshooting unit components.

FAN MOTOR CONTROL (A177)

Information on the fan motor control unit (A177).

Verifying Jumper Settings (J2)

Verifying fan motor control jumper settings for correct operation.

III. SYSTEM OPERATION AND SERVICE

III. SYSTEM OPERATION AND SERVICE

Figure 20. Fan Motor Control (A177) OneTwo Stage and EDA LED Sequence of Operation

Sequence for fan motor control LEDs indicating operational stages.

III. SYSTEM OPERATION AND SERVICE

Figure 21. Fan Motor Control, Wiring, Jumper Settings, Testing and LED Location

Visual guide to fan motor control, including wiring and testing.

III. SYSTEM OPERATION AND SERVICE

Figure 22. Testing for External Power to Fan Motor Control (A177)

Testing external power supply to the fan motor control.

III. SYSTEM OPERATION AND SERVICE

Fan Motor Test Procedure

Procedure for testing the operation of the fan motor.

III. SYSTEM OPERATION AND SERVICE

HEAT PUMP CONTROL (A175) UNIT NOMINAL CAPACITY CODE CONFIGURATION

Configuring unit capacity codes for the heat pump control.

Figure 24. Heat Pump Control (A175) Unit Nominal Capacity Code Configuration

Flowchart for configuring heat pump control capacity codes.

III. SYSTEM OPERATION AND SERVICE

MULTI-FUNCTION TEST PINS (E33)

Using the multi-function test pins for various diagnostic tests.

Figure 25. Heat Pump Controls Multi-Function Test Pins (E33) (101796-XX Only)

Sequence for performing tests using the heat pump control's test pins.

III. SYSTEM OPERATION AND SERVICE

FAN MOTOR SURGE PROTECTION (XP21-XXX-230-01 only)

Information on surge protection for the fan motor.

FAN MOTOR SURGE PROTECTION (XP21-XXX-230-02 and later)

Information on surge protection for later fan motor models.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Jumper Settings

Details on jumper settings for the outdoor control unit.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Configuring Unit

Steps to configure the outdoor control unit for proper operation.

Auto-Detection of Unit Type (air conditioner or heat pump and number of stages)

Auto-detection of unit type based on wiring connections.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Configuring Unit Type

Procedure for manually configuring the unit type and stages.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Configuring Unit Capacity or Fan Profile

Setting unit capacity and outdoor fan profile.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Seven-Segment Alert and System Status Codes

Alert codes displayed on the seven-segment display.

Reconfiguring Outdoor Control using icomfort Thermostat

Reconfiguring the outdoor control via the icomfort thermostat.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Table 19. Seven-Segment Display Alert Codes

Detailed list of seven-segment display alert codes and causes.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Table 21. Outdoor Control Seven-Segment Unit Status Displays

Displays for outdoor control seven-segment unit status.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Table 8. Outdoor Control Seven-Segment Unit Status Displays (continued)

Continued list of outdoor control seven-segment unit status displays.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Table 23. Field Test and Program Menu Options

Field test and program menu options for the control.

OUTDOOR CONTROL - PART NUMBER 103369-XX

Configuring Outdoor Fan Speed

Setting the outdoor fan speed profile.

Configuring Unit Capacity

Setting the unit capacity.

APPLICABLE TO ALL VERSIONS

Compressor Information and Testing

Information and testing procedures for compressors.

K4 COMPRESSOR MODULATING SOLENOID

Details on the K4 compressor modulating solenoid.

APPLICABLE TO ALL VERSIONS

K5 COMPRESSOR MODULATING SOLENOID

Details on the K5 compressor modulating solenoid.

COMPRESSOR INTERNAL SOLENOID (L34) TEST PROCEDURE

Testing the compressor internal solenoid.

APPLICABLE TO ALL VERSIONS

STEP 2 - Verify Compressor Solenoid has Correct Ohm Values

Verifying the compressor solenoid coil has correct ohm values.

STEP 3 - Verify solenoid plug has DC output voltage

Verifying the DC output voltage at the solenoid plug.

APPLICABLE TO ALL VERSIONS

Table 27. Two-Stage Modulation Compressors Field Operational Checklist

Checklist for two-stage compressor field operational verification.

III. SYSTEM OPERATION AND SERVICE

System Overview and Compressor Protection

General overview, compressor protection features, and anti-short cycle delay.

Pressure Switches and Defrost System

Details on pressure switches and the defrost system operation.

III. SYSTEM OPERATION AND SERVICE

UNIT SENSORS

Information on unit sensors including ambient, coil, and discharge temperature.

SECOND-STAGE OPERATION

Explanation of how second-stage compressor operation works.

Second Stage Lock-in

Explanation of the second-stage lock-in feature.

III. SYSTEM OPERATION AND SERVICE

Table 29. Ambient (RT13) and Coil (RT21) Sensors Temperature Resistance Range

Sensor resistance data for ambient and coil sensors.

III. SYSTEM OPERATION AND SERVICE

Table 30. High Discharge Sensor (RT28) Temperature Resistance Range

Sensor resistance data for the high discharge line sensor.

II. INSTALLATION

TOP GRILLE OR FAN MOTOR MOUNT ADJUSTMENT FOR FAN CLEARANCE

Adjusting top grille or fan motor mount for fan blade clearance.

III. SYSTEM OPERATION AND SERVICE

CRANKCASE HEATER (HR1)

Information on the crankcase heater and its function.

REVERSING VALVE (L1)

Components and operation of the reversing valve.

Maintenance

Outdoor Unit

Maintenance procedures for the outdoor unit.

Indoor Unit Maintenance

Maintenance procedures for the indoor unit.

Locations with Possibility of Heavy Snow or Freezing Rain Accumulation

Recommendations for areas with heavy snow or freezing rain.

Checklists

TWO STAGE COMPRESSOR CHECKOUT

Procedure to verify part- and full-load capacity of two-stage compressors.

XP21 Field Operational Checklist

Checklist for field operational verification of the XP21 unit.

Unit Wiring Diagrams

Figure 35. Typical XP21 Wiring (XP21-XXX-230-01 only)

Wiring diagram for XP21 model XP21-XXX-230-01.

Unit Wiring Diagrams

Unit Wiring Diagrams

Factory Wiring Diagrams

Figure 38. Typical Factory Wiring (XP21-XX-230-01)

Factory wiring diagram for XP21-XX-230-01 model.

Factory Wiring Diagrams

Factory Wiring Diagrams

Unit Sequence of Operations

Figure 41. One- and Two-Stage Cooling Sequence of Operations (101796-XX Only)

Cooling sequence for specific outdoor control part number.

Unit Sequence of Operations

Figure 42. One- and Two-Stage Cooling Sequence of Operations (103369-01 Only)

Cooling sequence for a different outdoor control part number.

III. SYSTEM OPERATION AND SERVICE

Figure 43. Low Pressure Switch (S87) Sequence of Operation (All Versions)

Sequence of operation for the low pressure switch.

III. SYSTEM OPERATION AND SERVICE

Figure 44. High Pressure Switch (S4) Sequence of Operation (All Versions)

Sequence of operation for the high pressure switch.

III. SYSTEM OPERATION AND SERVICE

Figure 45. High Discharge Temperature Sensor (RT28) Sequence of Operation (All Versions)

Sequence of operation for the high discharge temperature sensor.

III. SYSTEM OPERATION AND SERVICE

III. SYSTEM OPERATION AND SERVICE

Figure 47. W Input Fault or Miswire Sequence of Operation (All Versions)

Sequence of operation for W input faults or miswires.

Related product manuals