Caution Caution Warning

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. 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. 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. DANGER Shock Hazard Remove all power at disconnect before WARNING removing access panel. Improper installation, adjustment, alteration, service XPG20 units use single-pole contac- or maintenance can cause personal injury, loss of tors. Potential exists for electrical life, or damage to property. shock resulting in injury or death. Line voltage exists at all components Installation and service must be performed by a (even when unit is not in operation). licensed professional installer (or equivalent) or a service agency. Table of Contents General. 1 IV Charging. 26 Specifications / Electrical Data. 2 V Service and Recovery. 34 I Application. 3 VI Maintenance. 34 II Unit Components. 3 VII Brazing Procedure. 34 III Refrigerant System. 18 VIII Diagrams and Operating Sequence. 35 Page 1 © 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 lbs. 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) 1st stage 2500 (1180) 2nd stage 2800 (1320) Rpm − 1st stage 700 2nd stage 820 Watts − 1st stage 70 2nd stage 105 Shipping Data − lbs. (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 S 81J69 Compressor Low Ambient Cut−Off 45F08 S Freezestat 3/8 in. tubing 93G35 S 1/2 in. tubing 39H29 S 5/8 in. tubing 50A93 S Indoor Blower Relay 40K58 S Low Ambient Kit 68M04 S Monitor Kit − Service Light 76F53 S Mounting Base 69J07 S Outdoor Thermostat 56A87 S Thermostat Mounting Box − US 31461 S Kit Canada 33A09 S SignatureStatt Home Comfort Control 81M28 S Refrigerant L15−65−15 L15−65−40 S Line Sets L15−65−30 L15−65−50 Field Fabricate Time Delay Relay 58M81 S NOTE − Extremes of operating range are plus 10% and minus 5% of line voltage. 1 Refrigerant charge sufficient for 15 ft. (4.6 m) length of refrigerant lines. 2 Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements. 3 HACR type breaker or fuse. Page 2 I−APPLICATION Holding the panel’s hinged side firmly in place, close the All major components (indoor blower and coil) must be right−hand side of the panel, aligning the screw holes. matched according to Lennox recommendations for the When panel is correctly positioned and aligned, insert the compressor to be covered under warranty. Refer to the En- screws and tighten. gineering Handbook for approved system matchups. A Removing/Installing Louvered Panels misapplied system will cause erratic operation and can re- IMPORTANT! Do not allow panels to hang on unit by top tab. Tab sult in early compressor failure. is for alignment and not designed to support weight of panel. II−Unit Components Panel shown slightly ro- tated to allow top tab to Access Panel exit (or enter) top slot for removing (or installing) panel. LIP SCREW HOLES Detail A Remove 4 screws to remove panel for accessing compressor and controls. Install by positioning Detail B panel with holes aligned; install screws and tighten. FIGURE 1 Removing Access Panels Detail C Remove and reinstall the access panel as described in fig- ROTATE IN THIS DIRECTION; ure 1. THEN DOWN TO REMOVE PANEL MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT Remove the louvered panels as follows: AS POSSIBLE) WHILE INSTALLING PANEL. 1−. Remove 2 screws, allowing the panel to swing open HOLD DOOR FIRMLY TO THE HINGED ANGLE MAY BE TOO SIDE TO MAINTAIN slightly. EXTREME FULLY−ENGAGED TABS 2−. Hold the panel firmly throughout this procedure. PREFERRED ANGLE Rotate bottom corner of panel away from hinge corner FOR INSTALLATION 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 PanelPosition the panel almost Detail D 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. FIGURE 2 Page 3 AC FAN MOTOR AC FAN MOTOR MOUNT OUTDOOR FAN CONTACTOR SOLAR ASSIST DC MOTOR COUPLER DEFROST CONTROL SOLAR ASSIST DC MOTOR LENNOX SYSTEM OPERATION MONITOR (LSOM) RUN CAPACITOR SOLAR PANEL TERMINAL BLOCK VAPOR VALVE AND GAUGE PORT TWO−STAGE COMPRESSOR DISCHARGE LINE REVERSING VALVE COMPRESSOR TERMINAL PLUG BI−FLOW FILTER DRIER HIGH PRESSURE SWITCH LOW PRESSURE SWITCH FIGURE 3 SOLAR FAN RELAY (24VAC) (K228) DEFROST RELAY SOLAR FAN (K227) GROUND LUG HIGH VOLTAGE FIELD CONNECTIONS CONTACTOR−1POLE,25A (K1−1) 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) CROSS−SECTION OF SCROLLS Precautions and Procedures DISCHARGE DISCHARGE PRESSURE STATIONARY CAUTION SCROLL Electrostatic discharge can affect electronic components. Take precautions during unit instal- SUCTION 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 electrostatic charge by touching hand and all tools on an TIPS SEALED BY ORBITING SCROLL unpainted unit surface before performing any DISCHARGE PRESSURE service procedure. FIGURE 7 A−Two−Stage Scroll Compressor (B1) The counterclockwise orbiting scroll draws gas into the out- The scroll compressor design is simple, efficient and re- er crescent shaped gas pocket created by the two scrolls quires few moving parts. A cutaway diagram of the scroll (figure 8 − 1). The centrifugal action of the orbiting scroll compressor is shown in figure 1.The scrolls are located in seals off the flanks of the scrolls (figure 8 − 2). As the orbiting the top of the compressor can and the motor is located just below. The oil level is immediately below the motor. motion continues, the gas is forced toward the center of the The scroll is a simple compression concept centered scroll and the gas pocket becomes compressed (figure 8 around the unique spiral shape of the scroll and its inherent −3). When the compressed gas reaches the center, it is dis- properties. Figure 6 shows the basic scroll form. Two iden- charged vertically into a chamber and discharge port in the tical scrolls are mated together forming concentric spiral top of the compressor (figure 8 − 4). The discharge pressure shapes (figure 7). One scroll remains stationary, while the other is allowed to orbit" (figure 8). Note that the orbiting forcing down on the top scroll helps seal off the upper and scroll does not rotate or turn but merely orbits" the station- lower edges (tips) of the scrolls (figure 7). During a single or- ary scroll. bit, several pockets of gas are compressed simultaneously providing smooth continuous compression. TWO−STAGE MODULATED SCROLL slider ring 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- solenoid actuator coil pressor can be used to pump down refrigerant as long as FIGURE 5 the pressure is not reduced below 7 psig.

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