INSTALLATION AND SERVICE XP25

PROCEDURE
Service Literature Corp. 1252-L11
July 24, 2013 (Revised on Dec. 14, 2016)

Dave Lennox Signature ® Collection XP25 Series Units

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
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating Service Valves . . . . . . . . . . . . . . . . . . . . . . . 7
II. INSTALLATION
Unit Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IMPORTANT Removing and Installing Panels . . . . . . . . . . . . . . . . .
New or Replacement Line Set . . . . . . . . . . . . . . . . . .
12
13
This unit has refrigerant piping requirements that are Brazing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
unique to this this model. Size and install the refrigerant Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
piping per table 2 (page 14) to ensure proper unit operation. Leak Testing the System . . . . . . . . . . . . . . . . . . . . . . . 21
Evacuating the System . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Servicing Unit Delivered Void of Charge . . . . . . . . . . 29
IMPORTANT: Before applying any power (main, solar or low Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
voltage) to the outdoor unit, confirm iComfort Wi-Fi® thermostat III. SYSTEM OPERATION AND SERVICE
has Version 2.1 or higher software. (Reference iComfort Wi-Fi®
thermostat manual.) 7-Segment Alert and System Status Codes . . . . . . . 30
This unit is an integral component of a system that requires an
Outdoor Control Push-Button Operation . . . . . . . . . . 38
iComfort Wi-Fi® thermostat and iComfort®-enabled air handler Configuring Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
or furnace. Reconfiguring Outdoor Control using iComfort Wi-Fi®
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . 43
Defrost Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
iComfort Wi-Fi® Outdoor Temperature Operational Range . . . . . . . . . 44
Thermostat Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
iComfort™-enabled
SunSource® Home Energy System . . . . . . . . . . . . . . 45
air handler or Unit Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 46
XP25 Heat furnace Factory Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . 49
Pump
Unit Sequence of Operations . . . . . . . . . . . . . . . . . . . 51
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
System Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

WARNING IMPORTANT
Improper installation, adjustment, alteration, service or The Clean Air Act of 1990 bans the intentional venting of
maintenance can cause personal injury, loss of life, or refrigerant (CFCs, HCFCs AND HFCs) as of July 1, 1992.
damage to property. 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 2016 Lennox Industries Inc.

 I. OVERVIEW

Model Number identification

X P 25 - XXX - 230 -02
Refrigerant Type Minor Revision Number
X = R-410A
Voltage
Unit Type 230 = 208/230V-1ph-60hz
P = Heat Pump Nominal Cooling Capacity
024 = 2 tons
Series 036 = 3 tons
048 = 4 tons
060 = 5 tons

Typical Serial Number Identification

58 09 C 05716
Location Code
19 = Saltillo, Mexico
58 = Marshalltown, IA
5 (or 6) Digit Unique Number
Year Code Month Code
08 = 2008 A = January
09 = 2009 B = February
10 = 2010 C = March

Specifications
Unit Outdoor Fan
Model Number Sound Rating Number (dB)1 Factory Refrigerant Number of Blades Diameter - inches.
Maximum Minimum Charge2
XP25-024-230-01 68 58 11 lbs., 5 oz. 3 26

Unit Outdoor Fan

Model Number Sound Rating Number (dB)1 Factory Refrigerant Number of Blades Diameter - inches.
Maximum Minimum Charge2
XP25-036-230-01 73 58 11 lbs., 8 oz. 3 26

Unit Outdoor Fan

Model Number Sound Rating Number (dB)1 Factory Refrigerant Number of Blades Diameter - inches.
Maximum Minimum Charge2
XP25-048-230-01 74 64 13 lbs., 14 oz. 3 26

Unit Outdoor Fan

Model Number Sound Rating Number (dB)1 Factory Refrigerant Number of Blades Diameter - inches.
Maximum Minimum Charge2
XP25-060-230-01 74 64 13 lbs., 0 oz. 3 26
1 Tested according to AHRI Standard 270-2008 test conditions.
2 Factory charge is sufficient for refrigerant line lengths up to 15 feet.

XP25
Page 2
 Electrical Data
208/230V-60 Hz-1 Ph
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Maximum
Over- Minimum Rated Locked CFM RPM WATTS Full
Model Number Load Rotor Motor Load
current Circuity
Protection Ampacity2 Amps Amps HP Amps
1 (RLA) (LRA) MAX MIN MAX MIN MAX MIN (FLA)
(amps)
XP25-024-230-01 25 15.7 10.30 18.00 1/3 2580 1845 723 515 70 32 2.80

208/230V-60 Hz-1 Ph
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Maximum
Over- Minimum Rated Locked CFM RPM WATTS Full
Model Number Load Rotor Motor Load
current Circuity
Protection Ampacity2 Amps Amps HP Amps
(RLA) (LRA) MAX MIN MAX MIN MAX MIN (FLA)
(amps)1
XP25-036-230-01 25 20.3 14.00 18.00 1/3 4130 1865 850 390 214 40 2.80

208/230V-60 Hz-1 Ph
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Maximum
Over- Minimum Rated Locked CFM RPM WATTS Full
Model Number Load Rotor Motor Load
current Circuity
Protection Ampacity2 Amps Amps HP Amps
(RLA) (LRA) MAX MIN MAX MIN MAX MIN (FLA)
(amps)1
XP25-048-230-01 40 33.7 24.70 29.00 1/3 4040 3315 805 658 172 98 2.80

208/230V-60 Hz-1 Ph
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Maximum
Over- Minimum Rated Locked CFM RPM WATTS Full
Model Number Load Rotor Motor Load
current Circuity
Protection Ampacity2 Amps Amps HP Amps
1 (RLA) (LRA) MAX MIN MAX MIN MAX MIN (FLA)
(amps)
XP25-060-230-01 40 34.9 25.70 29.00 1/3 4240 3025 845 600 198 76 2.80
1 HACR type circuit breaker or fuse.
2 Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.

XP25
Page 3
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
Electrical Hazard
As with any mechanical equipment, contact with sharp
High Voltage
sheet metal edges can result in personal injury. Take care
while handling this equipment and wear gloves and pro­ Wait 5 Minutes
tective clothing. Electrical components may hold charge. Do
not remove this panel or service this area for
5 minutes after the power has been
WARNING removed.
Electric Shock Hazard. Can cause injury or death. Unit
must be grounded in accordance with national and local
codes.
Line voltage is present at all components when unit is not
in operation on units with single‐pole contactors.
Disconnect all remote electric power supplies before
opening access panel. Unit may have multiple power
supplies.

XP25
Page 4
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
INVERTER REACTOR,
(35FLA/40RES)
230V, 6KW

OUTDOOR CONTROL
VARIABLE-CAPACITY
INVERTER CONTROL

Figure 1. Control Panel Components

XP25
Page 5
 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
VAPOR VALVE 30.0 CUBIC INCHES)
AND GAUGE
PORT

CHECK EXPANSION
VALVE - (HFC-410A)
LIQUID VALVE AND
GAUGE PORT
HR1 CRANKCASE
HEATER (40W, 240VAC)

TRUE SUCTION LINE

PORT EXPANSION VALVE SENSING
BULB

LIQUID LINE SENSOR

CRANKCASE HEATER
LIQUID LINE BI-FLOW THERMOSTAT (S40) OPENS AT
FILTER DRIER 70ºF, CLOSES AT 50ºF
(HFC-410A)

LOW PRESSURE SWITCH - NORMALLY OPEN, SWITCH CLOSES HIGH PRESSURE SWITCH - NORMALLY CLOSED, SWITCH OPENS
WHEN SYSTEM PRESSURES GO ABOVE 40±5 PSIG. OPENS WHEN SYSTEM PRESSURES REACH 590+15 PSIG, CLOSES
WHEN SYSTEM PRESSURES GO BELOW 25±5 PSIG WHEN PRESSURES DROP BELOW 418+15 PSIG

Typical Plumbing Components (-036 and -060)

COMPRESSOR TOP CAP SWITCH (THERMAL)

DISCHARGE LINE

MUFFLER
VARIABLE-CAPACITY
COMPRESSOR SPEED - HFC-410A,
REVERSING
60HZ, 3-PHASE
VALVE

VAPOR VALVE CHECK EXPANSION

AND GAUGE VALVE - (HFC-410A)
PORT

LIQUID VALVE AND

GAUGE PORT

TRUE SUCTION LINE

PORT
HR1 CRANKCASE HEATER (40W,
240VAC)
LIQUID LINE SENSOR
CRANKCASE HEATER THERMOSTAT
LIQUID LINE BI-FLOW
FILTER DRIER CHECK EXPANSION VALVE SENSING BLUB

LOW PRESSURE SWITCH - NORMALLY OPEN, SWITCH CLOSES HIGH PRESSURE SWITCH - NORMALLY CLOSED, SWITCH
WHEN SYSTEM PRESSURES GO ABOVE 40±5 PSIG. OPENS OPENS WHEN SYSTEM PRESSURES REACH 590+15 PSIG,
WHEN SYSTEM PRESSURES DROP BELOW 25±5 PSIG CLOSES WHEN PRESSURES DROP BELOW 418+15 PSIG

Figure 2. Plumbing (Component Locations and Specifications)

XP25
Page 6
 IMPORTANT IMPORTANT
This unit must be matched with an indoor coil as Only use hex wrenches of sufficient hardness (50Rc -
specified in Lennox Product Specification bulletin. Coils Rockwell Harness Scale minimum). Fully insert the
previously charged with HCFC-22 must be flushed. wrench into the valve stem recess.
Service valve stems are factory-torqued (from 9 ft-lbs for
small valves, to 25 ft-lbs for large valves) to prevent
refrigerant loss during shipping and handling. Using a hex
WARNING wrench rated at less than 50Rc risks rounding or breaking
off the wrench, or stripping the valve stem recess.
Electric Shock Hazard. Can cause injury or See the Lennox Service and Application Notes #C-08-1 for
death. Unit must be grounded in further details and information.
accordance with national and local codes.
Line voltage is present at all components
when unit is not in operation on units with IMPORTANT
single‐pole contactors. Disconnect all To prevent stripping of the various caps used, the
remote electric power supplies before appropriately sized wrench should be used and fitted
opening access panel. Unit may have snugly over the cap before tightening.
multiple power supplies.
Table 1. Torque Requirements
Parts Recommended Torque

WARNING Service valve cap 8 ft.- lb. 11 NM

Sheet metal screws 16 in.- lb. 2 NM
This product contains a chemical known to the State of
California to cause cancer, birth defects, or other repro­ Machine screws #10 28 in.- lb. 3 NM
ductive harm. Compressor bolts 90 in.- lb. 10 NM
Gauge port seal cap 8 ft.- lb. 11 NM

General USING MANIFOLD GAUGE SET

When checking the system charge, only use a manifold
The XP25 is a high-efficiency residential split-system heat gauge set that features low loss anti-blow back fittings.
pump unit, which features a variable-capacity scroll Manifold gauge sets used with HFC-410A refrigerant
compressor and HFC-410A refrigerant. Units are available systems must be capable of handling higher system
in 2, 3, 4 and 5-ton sizes. The series is designed for use with operating pressures. The gauges should be rated for use
with pressures of 0 - 800 psig on the high side and a low side
a check expansion valve (approved for use with HFC-410A) of 30” vacuum to 250 psig, with dampened speed to 500 psi.
in the indoor unit only. Gauge hoses must be rated for use at or up to 800 psig of
pressure with a 4000 psig burst rating.
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities Operating Service Valves
who have jurisdiction before installation. The liquid and vapor line service valves are used for
removing refrigerant, flushing, leak testing, evacuating,
TORQUE REQUIREMENTS checking charge and charging.
Each valve is equipped with a service port which has a
When servicing or repairing HVAC components, ensure the
factory-installed valve stem. Figure 3 provides information
fasteners are appropriately tightened. Table 1 lists torque on how to access and operate both angle and ball-type
values for fasteners. service valves.

XP25
Page 7
SERVICE VALVES ANGLE AND BALL-TYPE
Operating Angle-Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
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.

SERVICE PORT CAP

SERVICE PORT CORE

(VALVE STEM SHOWN
CLOSED) INSERT HEX
(VALVE STEM SHOWN OPEN) WRENCH HERE
INSERT HEX WRENCH HERE

TO INDOOR
UNIT

STEM CAP

TO OUTDOOR UNIT
ANGLE-TYPE SERVICE VALVE ANGLE-TYPE SERVICE VALVE
(BACK-SEATED OPENED) (FRONT-SEATED CLOSED)

When service valve is OPEN, the service port is When service valve is CLOSED, the service port is open
open to line set, indoor and outdoor unit. to the line set and indoor unit.

Operating Ball-Type Service Valve: To Access Service Port:

A service port cap protects the service port core from contamination and
1. Remove stem cap with an appropriately sized wrench. serves as the primary leak seal.
2. Use an appropriately sized wrenched to open. To open valve,
1. Remove service port cap with an appropriately sized wrench.
rotate stem counterclockwise 90°. To close, rotate stem
clockwise 90°. 2. Connect gauge set to service port.
3. When testing is completed, replace service port cap and tighten as
follows:
TO INDOOR UNIT
1/6 TURN
• With torque wrench: Finger tighten and

11 12 1
torque cap per table 1.
• Without torque wrench: Finger tighten and 10 2
TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°. BALL (SHOWN use an appropriately sized wrench to turn 9 3
CLOSED) an additional 1/6 turn clockwise. 8 4
VALVE 7 6 5
TO CLOSE ROTATE STEM
CLOCKWISE 90°.
STEM Reinstall Stem Cap:
Stem cap protects the valve stem from damage and serves as the
SERVICE PORT primary seal. Replace the stem cap and tighten as follows: 1/12 TURN

SERVICE PORT • With torque wrench: Finger tighten and then

11 12
CORE torque cap per table 1.
1
SERVICE PORT
CAP
• Without torque wrench: Finger tighten and use 10 2
an appropriately sized wrench to turn an addi­ 9 3
TO OUTDOOR STEM CAP tional 1/12 turn clockwise. 8 4
UNIT 7 6 5

NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.

Figure 3. Angle- and Ball-Type Service Valves

XP25
Page 8
 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.
NOTE - If necessary for stability, anchor unit to slab as
In order to avoid injury, take proper precaution when lifting described in figure 6, detail D.
heavy objects.
Elevating the Unit
Units are outfitted with elongated support feet as illustrated
See Unit Dimensions on page 3 for sizing mounting slab, in figure 6, detail C.
platforms or supports. Refer to figure 4 for mandatory
installation clearance requirements. If additional elevation is necessary, raise the unit by
extending the height of the unit support feet. Use a 2-inch
POSITIONING CONSIDERATIONS (50.8mm) Schedule 40 female threaded adapter to raise the
height of the unit.
Consider the following when positioning the unit:
The specified coupling fits snugly into the recessed portion
• Some localities are adopting sound ordinances based of the feet. Use additional 2-inch (50.8mm) Schedule 40
on the unit sound level registered from the adjacent male threaded adaptors, which can be threaded into the
female threaded adaptors, to make additional adjustments
property, not from the installation property. Install the
to the level of the unit.
unit as far as possible from the property line.
NOTE - Keep the height of extenders short enough to
• When possible, do not install the unit directly outside a ensure a sturdy installation. If it is necessary to extend the
window. Glass has a very high level of sound height further than what is stable, consider a different type
transmission. For proper placement of unit in relation to of field-fabricated framework that is sturdy enough for
a window see figure 6, detail A. greater heights.

CLEARANCE ON ALL SIDES — INCHES (MILLIMETERS) MINIMUM CLEARANCE

ABOVE UNIT
6 (152)
ACCESS PANEL
NOTES:
CONTROL PANEL
ACCESS • CLEARANCE TO ONE OF THE THREE 48 (1219)
LOCATION SIDES MUST BE 36 INCHES (914MM).
30 (762)
12 (305)
• CLEARANCE TO ONE OF THE
REMAINING TWO SIDES MAY BE 12
INCHES (305MM) AND THE FINAL
SIDE MAY BE 6 INCHES (152MM).
LINE SET
36 (914) CONNECTIONS

Note - Dimensions are not to scale.

MINIMUM CLEARANCE BETWEEN

TWO UNITS ACCESS PANEL

24 (610)
LINE SET
CONNECTIONS

REAR VIEW OF UNIT

Figure 4. Installation Clearances

XP25
Page 9
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.
Unit Stabilizer Bracket Use (field-provided): If unit coil cannot be mounted away from prevailing
Always use stabilizers when unit is raised above the winter winds, a wind barrier should be constructed. Size
factory height. (Elevated units could become unstable in barrier at least the same height and width as outdoor
unit. Mount barrier 24 inches (610 mm) from the sides of
gusty wind conditions.)
the unit in the direction of prevailing winds.
Stabilizers may be used on factory height units when
mounted on unstable an uneven surface.
1. Remove the louvered panel from each side to expose PREVAILING WINTER
WINDS
the unit base.
2. Install the brackets as illustrated in figure 6, detail D
using conventional practices.
WIND BARRIER
3. Replace the panels after installation is complete.
ROOF MOUNTING INLET AIR 24”
(610)

NOTICE
Roof Damage! INLET AIR

This system contains both refrigerant and oil. Some

rubber roofing material may absorb oil and cause the
rubber to swell when it comes into contact with oil. The
rubber will then bubble and could cause leaks. Protect the
roof surface to avoid exposure to refrigerant and oil
INLET AIR
during service and installation. Failure to follow this
notice could result in damage to roof surface.
Install the unit a minimum of six inches (152 mm) above the Figure 5. Wind Barrier
roof surface to avoid ice build-up around the unit. Locate the (Rooftop or Ground Application)

XP25
Page 10
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° ELBOWS INSTALLED IN LINE SET
REDUCES LINE SET VIBRATION. GROUND LEVEL

Slab Mounting at Ground Level

Outside Unit Placement

DETAIL C DETAIL D
Slab Side Mounting
#10 1/2” LONG SELF-DRILLING
SHEET METAL SCREWS
COIL

STABILIZING BRACKET (18 GAUGE

METAL — 2” WIDTH; HEIGHT AS BASE PAN
REQUIRED)

#10 1-1/4” LONG HEX HEAD

SCREW AND FLAT WASHER

CORNER POST
BASE
CONCRETE SLAB — USE TWO PLASTIC
ANCHORS (HOLE DRILL 1/4”)
WOOD OR PLASTIC SLAB — NO PLASTIC ANCHOR
(HOLE DRILL 1/8”)

MINIMUM ONE
LEG DETAIL PER SIDE
Deck Top Mounting
2” (50.8MM) SCH 40 STABILIZING BRACKET (18 GAUGE METAL
FEMALE THREADED — 2” (50.8MM) WIDTH; HEIGHT AS
ADAPTER REQUIRED); BEND TO FORM RIGHT ANGLE

2” (50.8MM) SCH 40 FOR EXTRA

MALE THREADED SAME FASTENERS AS
SLAB SIDE MOUNTING. STABILITY
ADAPTER

ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY, TWO

BRACKETS PER SIDE, 2” (50.8MM) FROM EACH CORNER.
USE ADDITIONAL 2” SCH 40 MALE THREADED ADAPT­
ERS WHICH CAN BE THREADED INTO THE FEMALE Stabilizing Unit on Uneven Surfaces
THREADED ADAPTERS TO MAKE ADDITIONAL AD­
JUSTMENTS TO THE LEVEL OF THE UNIT.
IMPORTANT - To help stabilize an outdoor unit, some installations may require strap­
ping the unit to the pad using brackets and anchors commonly available in the
Elevated Slab Mounting using Feet marketplace.
Extenders

Figure 6. Placement and Slab Mounting

XP25
Page 11
Removing and Installing Panels

ACCESS PANEL REMOVAL

PANELS
ACCESS AND LOUVERED
REMOVE AND INSTALL THE ACCESS PANEL
AS ILLUSTRATED.

WARNING REMOVE 4 SCREWS TO

REMOVE PANEL FOR
ACCESSING COMPRESSOR
To prevent personal injury, or damage to panels, unit or structure, be AND CONTROLS.
sure to observe the following: ALIGN PANEL WITH SCREW
HOLES. INSTALL SCREWS
While installing or servicing this unit, carefully stow all removed AND TIGHTEN.
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 Detail A
conditions, especially windy conditions, that may cause panels to be
blown around and battered.
LIP

IMPORTANT - Do not allow panels to hang on unit by top tab. Tab

is for alignment and not designed to support weight of panel.
PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR ENTER) TOP SLOT FOR
REMOVING (OR INSTALLING) PANEL.

LOUVERED PANEL REMOVAL

Remove the louvered panels as follows: SCREW
HOLES
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.

LOUVERED PANEL INSTALLATION Detail B

Position the panel almost parallel with the unit as illustrated in detail D with the screw side
as close to the unit as possible. Then, in a continuous motion:
1. SLIGHTLY ROTATE AND GUIDE THE LIP OF TOP TAB INWARD AS ILLUSTRATED IN DETAIL
A AND C; THEN UPWARD INTO THE TOP SLOT OF THE HINGE CORNER POST.
2. ROTATE PANEL TO VERTICAL TO FULLY ENGAGE ALL TABS.
3. HOLDING THE PANEL'S HINGED SIDE FIRMLY IN PLACE, CLOSE THE RIGHT-HAND SIDE
OF THE PANEL, ALIGNING THE SCREW HOLES.
4. WHEN PANEL IS CORRECTLY POSITIONED AND ALIGNED, INSERT THE SCREWS AND
TIGHTEN.
Detail C
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT AS
POSSIBLE) WHILE INSTALLING PANEL. ROTATE IN THIS DIRECTION; THEN
DOWN TO REMOVE PANEL
Detail D
ANGLE MAY BE TOO EXTREME HOLD DOOR FIRMLY ALONG
THE HINGED SIDE TO MAINTAIN
FULLY-ENGAGED TABS

PREFERRED ANGLE FOR INSTALLATION

Figure 7. Removing and Installing Panels

XP25
Page 12
New or Replacement Line Set
IMPORTANT
REFRIGERANT LINE SET
If this unit is being matched with an approved line set or
This section provides information on installation or indoor unit coil that was previously charged with mineral
replacement of existing line set. If new or replacement line oil, or if it is being matched with a coil which was
set is not being installed, then proceed to Brazing manufactured before January of 1999, the coil and line set
Connections on page 16. must be flushed prior to installation. Take care to empty all
existing traps. Polyol ester (POE) oils are used in Lennox
units charged with HFC-410A refrigerant. Residual
IMPORTANT mineral oil can act as an insulator, preventing proper heat
Lennox highly recommends changing line set when transfer. It can also clog the expansion device and reduce
converting the existing system from HCFC-22 to system performance and capacity.
HFC-410A. If that is not possible and the line set is the Failure to properly flush the system per the XP25
proper size as reference in table 2, use the procedure Installation and Service Procedures will void the warranty.
outlined under Flushing the System on page 19.

If refrigerant lines are routed through a wall, seal and isolate

the opening so vibration is not transmitted to the building. Pay
WARNING
close attention to line set isolation during installation of any Refrigerant can be harmful if it is inhaled. Refrigerant
HVAC system. When properly isolated from building must be used and recovered responsibly.
structures (walls, ceilings, floors), the refrigerant lines will Failure to follow this warning may result in personal injury
not create unnecessary vibration and subsequent sounds. or death.
See figure 8 for recommended installation practices. Also,
consider the following when placing and installing a
high-efficiency outdoor unit. WARNING
Liquid lines that meter the refrigerant, such as RFC1 liquid
lines, must not be used in this application. Existing line set of Fire, Explosion and Personal Safety Haz­
proper size (as listed in table 3) may be reused. If system ard. Failure to follow this warning could re­
was previously charged with HCFC-22 refrigerant, the sult in damage, personal injury or death.
existing line set must be flushed (see Flushing the System Never use oxygen to pressurize or purge
on page 19). refrigeration lines. Oxygen, when exposed
to a spark or open flame, can cause fire
IMPORTANT and/or an explosion, that could result in
property damage, personal injury or death.
Mineral oils are not compatible with HFC-410A. If oil must
be added, it must be a Polyol ester oil.

Recommended topping-off POE oils are Mobil EAL ARCTIC

WARNING
22 CC or ICI EMKARATEt RL32CF. When using a high pressure gas such as
nitrogen to pressurize a refrigeration or air
conditioning system, use a regulator that
WARNING can control the pressure down to 1 or 2 psig
(6.9 to 13.8 kPa).
Danger of fire. Bleeding the refrigerant
charge from only the high side may result
in the low side shell and suction tubing
being pressurized. Application of a brazing
IMPORTANT
torch while pressurized may result in Some scroll compressors have an internal vacuum
ignition of the refrigerant and oil mixture - protector that will unload scrolls when suction pressure
check the high and low pressures before goes below 20 psig. A hissing sound will be heard when
unbrazing. the compressor is running unloaded. Protector will reset
when low pressure in system is raised above 40 psig. DO
NOT REPLACE COMPRESSOR.
WARNING
The XP25 is a variable-capacity cooling and heat pump
When using a high pressure gas such as
system utilizing variable-speed compressor technology.
dry nitrogen to pressurize a refrigeration or
With the variable-speed compressor and variable pumping
air conditioning system, use a regulator capacity, additional consideration must be given to
that can control the pressure down to 1 or refrigerant piping sizing and application. The following
2 psig (6.9 to 13.8 kPa). guidelines are to be used exclusively for the XP25 systems.

XP25
Page 13
COOLING SYSTEM (HFC-410A) Vertical vapor riser must be sized per table 3 on systems
• Total equivalent length equals 180 feet (piping and all with line sets longer than 51 feet. Use tables 3 and 4 to
fittings included). determine the correct liquid and vapor line sizes.
NOTE - This is a general guide. Lengths may be more or NOTE - See figure 65 on page 87 to calculate required
less, depending on remaining system design factors. refrigerant charge.
• Maximum linear (actual) length = 150 feet. • Line set lengths over 150 linear feet: Not
• Maximum linear liquid lift = 60 feet. recommended.
NOTE - Maximum lifts are dependent on total length, • Additional oil is not required for systems with line lengths
number of elbows, and other factors that contribute to total up to 150 feet except for the XP25-048 and XP25-060.
pressure drop. These units require 2 ounces of oil for every 10 feet
beyond 100 feet.
• Maximum linear length of vapor riser = 60 feet.
• Size vertical vapor riser per table 3. NOTE - Recommended POE oils are Mobil EAL ARCTIC 22
CC or ICI EMKARATE ® RL32CF.
• Line set lengths up to 50 linear feet: Use rated line
sizes listed in table 2. SUCTION TRAPS
• Line set lengths between 51 ­ 150 linear feet: In systems with the outdoor unit 5 to 60 feet above the
Crankcase heater and non­bleed port TXV indoor unit, one trap must be installed at the bottom of the
factory-installed. No additional components required. suction riser.
Table 2. Standard Refrigerant Line Set — Up to 50 Linear Feet

Inches (mm)
Valve Size Connections Recommended Line Sets
Model Number (-xx*) L15 Line Set Catalog
Liquid Line Suction Line Line Set Length Number
Model
L15-65-30 30 feet (9.1 m) 89J60
XP25-024-230-XX
XP25-036-230-XX 3/8” (10 mm) 7/8” (22 mm) L15-65-40 40 feet (12.2 m) 89J61
XP25-048-230-XX L15-65-50 50 feet (15.2 m) 89J62
XP25-060-230-XX 3/8” (10 mm) 1-1/8” (29 mm) ** Field-fabricated
* Applicable to all minor revision numbers unless otherwise specified.
** Some applications may require a field-provided 1-1/8” to 7/8” adapter.

Table 3. XP25 Piping Guidelines

Maximum Preferred Vapor Line
Maximum Total Maximum Linear Maximum Vapor Required Vapor
Model Linear Liquid Sizes for Horizontal
Equivalent Length (ft) (actual) Length (ft) Riser (ft) Riser Size
Lift (ft) Runs

­024 180 150 60 60 7/8” 5/8”

­036 180 150 60 60 7/8” 3/4”
­048 180 150 60 60 7/8” 7/8”
­060 180 150 60 60 7/8” 7/8”

Table 4. Liquid Line Diameter Selection Table

Total Linear Length (feet)
Unit Line Size
25 50 75 100 125 150
5/16” 25 50 55 48 40 33
(ft)
Max. Elevation

­024
3/8” 25 50 60 60 60 60
3/8” 25 50 60 56 51 45
­036
1/2” 25 50 60 60 60 60
3/8” 25 50 50 41 31 22
­048
1/2” 25 50 60 60 60 60
3/8” 25 50 36 22 8 NR
­060
1/2” 25 50 60 60 60 59
Note ­ Shaded rows indicate rated liquid line size. 4. The elevation listed in the table is the maximum allowed for the liquid
1. Find your unit on the left side of the table. line listed.
2. Start with the rated liquid line size (shaded row) for the outdoor unit. 5. Consider the larger liquid line size shown in the table if the elevation
3. Select the actual total linear length of your system shown at the top of does not meet your requirements.
the table.
XP25
Page 14
LINE SET INSTALLATION
IMPORTANT - Refrigerant lines must not contact structure.

REFRIGERANT LINE SET — INSTALLING

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
PRESSURE DROP IS EQUAL TO OR GREATER THAN 20 PSIG.
REFRIGERANT LINE SET — TRANSITION
FROM VERTICAL TO HORIZONTAL IMPORTANT - Refrigerant lines must not contact
ANCHORED HEAVY NYLON wall
WIRE TIE OR AUTOMOTIVE AUTOMOTIVE
MUFFLER‐TYPE HANGER MUFFLER‐TYPE HANGER
OUTSIDE WALL LIQUID LINE
VAPOR LINE

WALL WIRE TIE

STUD
INSIDE WALL

STRAP
WOOD BLOCK
STRAP LIQUID LINE TO NON-CORROSIVE
BETWEEN
VAPOR LINE METAL SLEEVE
STUDS
WIRE TIE
LIQUID LINE

NON-CORROSIVE
METAL SLEEVE WOOD BLOCK
VAPOR LINE - WRAPPED WIRE TIE
IN ARMAFLEX
STRAP

REFRIGERANT LINE SET — INSTALLING

HORIZONTAL RUNS SLEEVE

TO HANG LINE SET FROM JOIST OR RAFTER, USE EITHER METAL

STRAPPING MATERIAL OR ANCHORED HEAVY NYLON WIRE TIES.

WIRE TIE (AROUND

VAPOR LINE ONLY) VAPOR LINE WRAPPED
WITH ARMAFLEX
8 FEET (2.43 METERS)
OUTSIDE
STRAPPING WALL
LIQUID
MATERIAL (AROUND LINE
VAPOR LINE ONLY)
FLOOR JOIST OR
ROOF RAFTER
TAPE OR
WIRE TIE

8 FEET (2.43 METERS) PVC CAULK

PIPE
NON-CORROSIVE FIBERGLASS
METAL SLEEVE INSULATION

TAPE OR STRAP THE VAPOR LINE TO THE

WIRE TIE JOIST OR RAFTER AT 8 FEET (2.43
METERS) INTERVALS THEN STRAP NOTE - SIMILAR INSTALLATION PRACTICES SHOULD BE USED IF
THE LIQUID LINE TO THE VAPOR LINE. LINE SET IS TO BE INSTALLED ON EXTERIOR OF OUTSIDE WALL.

FLOOR JOIST OR
WARNING - Polyol ester (POE) oils used with
ROOF RAFTER 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.

Figure 8. Line Set Installation

XP25
Page 15
Brazing Connections
Use the procedures outlined in figures 9 and 10 for brazing
WARNING
line set connections to service valves. Fire, Explosion and Personal Safety Haz­
ard.
WARNING Failure to follow this warning could result in
damage, personal injury or death.
When using a high pressure gas such as
dry nitrogen to pressurize a refrigeration or Never use oxygen to pressurize or purge
air conditioning system, use a regulator refrigeration lines. Oxygen, when exposed
that can control the pressure down to 1 or to a spark or open flame, can cause a fire
2 psig (6.9 to 13.8 kPa). and/or an explosion, that could result in
property damage, personal injury or death.

CAUTION
Brazing alloys and flux contain materials which are
hazardous to your health.
Avoid breathing vapors or fumes from brazing operations.
Perform operations only in well-ventilated areas.
Wear gloves and protective goggles or face shield to
protect against burns.
Wash hands with soap and water after handling brazing
alloys and flux.

XP25
Page 16
1
PIPING PANEL REMOVAL AND LINE SET
PREPARATION
Remove piping panel for easier access to service valves.
2 CAP AND CORE REMOVAL
Remove service cap and core from both the suction and
liquid line service ports.
SERVICE PORT CAP
Cut ends of the refrigerant lines square (free from nicks or
dents) and debur the ends. The pipe must remain round. Do SERVICE
not crimp end of the line. PORT CORE

CUT AND DEBUR

LINE SET SIZE MATCHES

SERVICE VALVE CONNECTION

SERVICE VALVE
CONNECTION
COPPER TUBE
STUB

REDUCER

LIQUID LINE SERVICE VALVE

LINE SET SIZE IS SMALLER
THAN CONNECTION

REFRIGERANT LINE
SERVICE
PORT CORE

SERVICE
PORT CAP

SUCTION LINE SERVICE

VALVE
DO NOT CRIMP SERVICE
VALVE CONNECTOR WHEN
PIPE IS SMALLER THAN
CONNECTION

3 ATTACH THE MANIFOLD GAUGE SET FOR BRAZING

LIQUID AND SUCTION LINE SERVICE VALVES

A Connect gauge set low pressure side to liquid

line service valve (service port).
B Connect gauge set center port to bottle of
nitrogen with regulator.
LOW HIGH
C Remove the valve core from the suction line to
provide an exit point for the nitrogen flow.

ATTACH
GAUGES

SUCTION SERVICE PORT MUST BE OPEN AND

SERVICE PORT CORE REMOVED TO ALLOW B
EXIT POINT FOR NITROGEN FLOW C
SUCTION LINE
SERVICE VALVE
SUCTION LINE

INDOOR OUTDOOR
UNIT UNIT

NITROGEN
LIQUID LINE LIQUID LINE SERVICE
VALVE
A

Figure 9. Brazing Procedures

XP25
Page 17
 WRAP SERVICE VALVES
4 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.

5
FLOW NITROGEN
Flow regulated nitrogen (at 1 to 2 psig) through the WARNING
refrigeration gauge set into the valve stem port connection 1. FIRE, PERSONAL INJURY, OR PROPERTY
on the liquid service valve and out of the suction / vapor DAMAGE will result if you do not wrap a water-
valve stem port. See steps 3A, 3B and 3C on previous page saturated cloth around both liquid and suction
and below for manifold gauge setup. line service valve bodies and copper tube stub
while brazing in the line set! The braze, when

6 BRAZE LINE SET

Cloths must remain water-saturated throughout the
brazing and cool-down process. 2.
complete, must be quenched with water to
absorb any residual heat.
Do not open service valves until refrigerant lines
and indoor coil have been leak-tested and
A Braze liquid line to liquid line service valve. evacuated. Refer to procedures provided in this
B Braze suction / vapor line to suction / vapor supplement.
service valve.
WHEN BRAZING LINE SET TO
IMPORTANT ! SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
Use silver alloy brazing rods with 5%
minimum silver alloy for copper-to-copper
brazing and 45% alloy for copper-to-brass 6B
or copper-to-steel brazing.

SUCTION / VAPOR LINE

SUCTION / VAPOR SERVICE PORT
MUST BE OPEN AND SERVICE PORT
CORE REMOVED TO ALLOW EXIT
POINT FOR NITROGEN FLOW

WATER SATURATED CLOTHS

IMPORTANT !
Allow braze joint to cool. Apply additional
water-saturated cloths to help cool brazed
joints. Do not remove water-saturated cloths
until piping has cooled. Temperatures above
250ºF will damage valve seals.

6A

LIQUID LINE

WATER SATURATED
CLOTHS

7 PREPARATION FOR NEXT STEP

After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water-saturated
cloths to both services valves to cool piping. Once piping is cool, remove all water-saturated cloths. Refer to the unit installation
instructions for the next step in preparing the unit.

Figure 10. Brazing Procedures (Continued)

XP25
Page 18
Flushing the System

LINE SET AND INDOOR COIL (1 OF 2)

1B TYPICAL EXISTING EXPANSION VALVE
REMOVAL PROCEDURE (UNCASED COIL
SHOWN)
TWO PIECE PATCH PLATE
STUB END
LIQUID LINE CHECK

1A
TYPICAL EXISTING FIXED ORIFICE (UNCASED COIL ONLY) ORIFICE EXPANSION
REMOVAL PROCEDURE HOUSING VALVE
DISTRIBUTOR
(UNCASED COIL SHOWN) TUBES TEFLON®
RING
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING

TEFLON® RING TEFLON®

RING SENSING
FIXED ORIFICE LINE

BRASS NUT OR DISTRIBUTOR EQUALIZER

ASSEMBLY LINE

DISTRIBUTOR LIQUID LINE

ASSEMBLY ASSEMBLY WITH
REMOVE AND DISCARD BRASS NUT
WHITE TEFLON® SEAL
(IF PRESENT) LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
MALE EQUALIZER
LINE FITTING VAPOR
LINE LIQUID
SENSING BULB LINE
A ON FULLY CASED COILS, REMOVE THE COIL ACCESS AND PLUMBING
PANELS.
B REMOVE ANY SHIPPING CLAMPS HOLDING THE LIQUID LINE AND DIS­ A ON FULLY CASED COILS, REMOVE THE COIL ACCESS AND PLUMBING
TRIBUTOR ASSEMBLY. PANELS.
C USING TWO WRENCHES, DISCONNECT LIQUID LINE FROM LIQUID LINE B REMOVE ANY SHIPPING CLAMPS HOLDING THE LIQUID LINE AND DIS­
ORIFICE HOUSING. TAKE CARE NOT TO TWIST OR DAMAGE DISTRIBU­ TRIBUTOR ASSEMBLY.
TOR TUBES DURING THIS PROCESS. C DISCONNECT THE EQUALIZER LINE FROM THE CHECK EXPANSION
D REMOVE AND DISCARD FIXED ORIFICE, VALVE STEM ASSEMBLY (IF VALVE EQUALIZER LINE FITTING ON THE VAPOR LINE.
PRESENT) AND TEFLON® WASHER AS ILLUSTRATED ABOVE. D REMOVE THE VAPOR LINE SENSING BULB.
E USE A FIELD-PROVIDED FITTING TO TEMPORARILY RECONNECT THE E DISCONNECT THE LIQUID LINE FROM THE CHECK EXPANSION VALVE
LIQUID LINE TO THE INDOOR UNIT'S LIQUID LINE ORIFICE HOUSING. AT THE LIQUID LINE ASSEMBLY.
F DISCONNECT THE CHECK EXPANSION VALVE FROM THE LIQUID LINE
ORIFICE HOUSING. TAKE CARE NOT TO TWIST OR DAMAGE DISTRIBU­

2 CONNECT GAUGES AND EQUIPMENT FOR

FLUSHING PROCEDURE
INVERTED HCFC-22
CYLINDER CONTAINS
GAUGE
MANIFOLD
G

H
TOR TUBES DURING THIS PROCESS.
REMOVE AND DISCARD CHECK EXPANSION VALVE AND THE TWO TEF­
LON® RINGS.
USE A FIELD-PROVIDED FITTING TO TEMPORARILY RECONNECT THE
CLEAN HCFC-22* TO BE LIQUID LINE TO THE INDOOR UNIT'S LIQUID LINE ORIFICE HOUSING.
USED FOR FLUSHING.
A FLUSHING LINE SET

3
HIGH
1 LOW
CAUTION - This procedure should not be performed on systems
VAPOR LINE NEW which contain contaminants (Example, compressor burn out).
SERVICE VALVE OUTDOOR
UNIT
THE LINE SET AND INDOOR UNIT COIL MUST BE FLUSHED WITH AT
OPENED CLOSED LEAST THE SAME AMOUNT OF CLEAN REFRIGERANT* THAT PRE­
EXISTING VIOUSLY CHARGED THE SYSTEM. CHECK THE CHARGE IN THE
INDOOR FLUSHING CYLINDER BEFORE PROCEEDING.
UNIT B A
B
SET THE RECOVERY MACHINE FOR LIQUID RECOVERY AND
LIQUID LINE SERVICE START THE RECOVERY MACHINE. OPEN THE GAUGE SET
VALVE VALVES TO ALLOW THE RECOVERY MACHINE TO PULL A VACU­
RECOVERY UM ON THE EXISTING SYSTEM LINE SET AND INDOOR UNIT COIL.
CYLINDER TANK
B INVERT THE CYLINDER OF CLEAN HCFC-22* AND OPEN ITS
RETURN
VALVE TO ALLOW LIQUID REFRIGERANT TO FLOW INTO THE SYS­
C
VAPOR
LIQUID

TEM THROUGH THE VAPOR LINE VALVE. ALLOW THE REFRIGER­

INLET
D ANT TO PASS FROM THE CYLINDER AND THROUGH THE LINE SET
AND THE INDOOR UNIT COIL BEFORE IT ENTERS THE RECOVERY
DISCHARGE
MACHINE.
RECOVERY MACHINE
C AFTER ALL OF THE LIQUID REFRIGERANT HAS BEEN RECOV­
A INVERTED HCFC-22 CYLINDER WITH CLEAN REFRIGERANT* TO THE ERED, SWITCH THE RECOVERY MACHINE TO VAPOR RECOVERY
VAPOR SERVICE VALVE. SO THAT ALL OF THE HCFC-22 VAPOR IS RECOVERED. ALLOW
B HCFC-22 GAUGE SET (LOW SIDE) TO THE LIQUID LINE VALVE. THE RECOVERY MACHINE TO PULL SYSTEM DOWN TO 0.
C HCFC-22 GAUGE SET CENTER PORT TO INLET ON THE RECOVERY D CLOSE THE VALVE ON THE INVERTED HCFC-22 DRUM AND THE
MACHINE WITH AN EMPTY RECOVERY TANK TO THE GAUGE SET. GAUGE SET VALVES. PUMP THE REMAINING REFRIGERANT OUT
D CONNECT RECOVERY TANK TO RECOVERY MACHINES PER MACHINE OF THE RECOVERY MACHINE AND TURN OFF THE MACHINE.
INSTRUCTIONS.
*IMPORTANT - Clean refrigerant is any refrigerant in a system that has not had compressor burn out. If the system
has experienced burn out, it is recommended that the existing line set and indoor coil be replaced.
XP25
Page 19
FLUSHING LINE SET AND INDOOR COIL (2 OF 2)

4 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.
THE EXPANSION VALVE UNIT CAN BE INSTALLED INTERNAL OR
EXTERNAL TO THE INDOOR COIL. IN APPLICATIONS WHERE AN 1/2 TURN

TWO PIECE
UNCASED COIL IS BEING INSTALLED IN A FIELD-PROVIDED
PLENUM, INSTALL THE CHECK EXPANSION VALVE IN A MANNER 11 12 1
PATCH PLATE (Uncased Coil Shown) WHICH PROVIDES ACCESS FOR FIELD SERVICING OF THE 10 2
(UNCASED EXPANSION VALVE. REFER TO BELOW ILLUSTRATION FOR
COIL ONLY) LIQUID LINE STUB REFERENCE DURING INSTALLATION OF EXPANSION VALVE 9 3
END
ORIFICE
HOUSING EXPANSION UNIT.
8 4
DISTRIBUTOR
TUBES
VALVE 7 6 5
TEFLON®
RING

A REMOVE THE FIELD-PROVIDED FITTING THAT TEMPORARILY RECON­

NECTED THE LIQUID LINE TO THE INDOOR UNIT'S DISTRIBUTOR AS­
TEFLON® SEMBLY.
SENSING
RING B INSTALL ONE OF THE PROVIDED TEFLON® RINGS AROUND THE
LINE
STUBBED END OF THE EXPANSION VALVE AND LIGHTLY LUBRICATE
THE CONNECTOR THREADS AND EXPOSE SURFACE OF THE TEFLON®
DISTRIBUTOR EQUALIZER RING WITH REFRIGERANT OIL.
ASSEMBLY LINE C ATTACH THE STUBBED END OF THE EXPANSION VALVE TO THE LIQUID
LINE ORIFICE HOUSING. FINGER TIGHTEN AND USE AN APPROPRIATELY
SIZED WRENCH TO TURN AN ADDITIONAL 1/2 TURN CLOCKWISE AS IL­
LIQUID LINE LUSTRATED IN THE FIGURE ABOVE, OR 20 FT-LB.
ASSEMBLY WITH D PLACE THE REMAINING TEFLON® WASHER AROUND THE OTHER END
BRASS NUT OF THE EXPANSION VALVE. LIGHTLY LUBRICATE CONNECTOR
THREADS AND EXPOSE SURFACE OF THE TEFLON® RING WITH RE­
FRIGERANT OIL.
MALE EQUALIZER LINE E ATTACH THE LIQUID LINE ASSEMBLY TO THE EXPANSION VALVE. FIN­
VAPOR GER TIGHTEN AND USE AN APPROPRIATELY SIZED WRENCH TO TURN
FITTING (SEE LINE
EQUALIZER LINE AN ADDITIONAL 1/2 TURN CLOCKWISE AS ILLUSTRATED IN THE FIGURE
INSTALLATION FOR ABOVE OR 20 FT-LB.
FURTHER DETAILS) LIQUID LINE

9 O'CLOCK TO
3 O'CLOCK
SENSING BULB INSULATION IS REQUIRED
IF MOUNTED EXTERNAL TO THE COIL ON LINES SMALLER THAN
CASING. SEE SENSING BULB 12 7/8”, MOUNT SENSING
INSTALLATION FOR BULB POSITIONING. BULB BULB BULB BETWEEN THE 9
AND 3 O'CLOCK
POSITIONS.

SENSING BULB INSTALLATION

VAPOR LINE
A ATTACH THE VAPOR LINE SENSING BULB IN THE PROPER VAPOR LINE
ORIENTATION AS ILLUSTRATED TO THE RIGHT USING THE ON 7/8” AND LARGER LINES,
CLAMP AND SCREWS PROVIDED. MOUNT SENSING BULB AT
EITHER THE 4 OR 8 O'CLOCK
NOTE - CONFIRM PROPER THERMAL CONTACT BETWEEN VA­
POSITION. NEVER MOUNT
POR LINE AND CHECK EXPANSION BULB BEFORE INSULATING
12 THE SENSING BULB ON
THE SENSING BULB ONCE INSTALLED. BOTTOM OF LINE.
B CONNECT THE EQUALIZER LINE 1/8 TURN
BULB BULB
FROM THE EXPANSION VALVE TO

11 12 1
THE EQUALIZER VAPOR PORT ON
THE VAPOR LINE. FINGER
TIGHTEN THE FLARE NUT PLUS
1/8 TURN (7 FT-LBS) AS ILLUS­
10 2 NOTE - NEVER MOUNT THE SENSING BULB ON
BOTTOM OF LINE.
TRATED BELOW. 9 3
8 4
7 5 FLARE SEAL CAP FLARE NUT
6

OR COPPER FLARE
EQUALIZER LINE INSTALLATION SEAL BONNET

REMOVE AND DISCARD EITHER THE FLARE SEAL CAP OR FLARE

NUT WITH COPPER FLARE SEAL BONNET FROM THE EQUALIZER
LINE PORT ON THE VAPOR LINE AS ILLUSTRATED IN THE FIGURE MALE BRASS EQUALIZER
TO THE RIGHT. LINE FITTING

VAPOR LINE

XP25
Page 20
INSTALLING ISOLATION GROMMETS Leak Testing the System
Locate the isolation grommets (provided). Slide grommets
onto vapor and liquid lines. Insert grommets into piping
panel to isolate refrigerant lines from sheet metal edges.
WARNING
PIPING PANEL
SUCTION LINE
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).

LIQUID LINE
IMPORTANT
If this unit is being matched with an approved line set or
TWO ISOLATION GROMMETS indoor unit coil which was previously charged with
ARE PROVIDED FOR THE
LIQUID AND SUCTION LINE PIPE mineral oil, or if it is being matched with a coil which was
PANEL PASS THROUGH. manufactured before January of 1999, the coil and line
set must be flushed prior to installation. 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.
Figure 11. Isolation Grommets Residual mineral oil can act as an insulator, preventing
proper heat transfer. It can also clog the expansion
IMPORTANT device, and reduce the system performance and
capacity.
The Environmental Protection Agency (EPA) prohibits the Failure to properly flush the system per the instructions
intentional venting of HFC refrigerants during below will void the warranty.
maintenance, service, repair and disposal of appliance.
Approved methods of recovery, recycling or reclaiming
must be followed.
WARNING
IMPORTANT Refrigerant can be harmful if it is inhaled. Refrigerant
must be used and recovered responsibly.
Leak detector must be capable of sensing HFC Failure to follow this warning may result in personal injury
refrigerant. or death.

XP25
Page 21
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.

1 CONNECT GAUGE SET

A CONNECT AN HFC-410A MANIFOLD GAUGE SET
HIGH PRESSURE HOSE TO THE VAPOR VALVE
LOW HIGH
SERVICE PORT.
MANIFOLD GAUGE SET
B WITH BOTH MANIFOLD VALVES CLOSED, CONNECT
THE CYLINDER OF HFC-410A REFRIGERANT TO THE
CENTER PORT OF THE MANIFOLD GAUGE SET.

NOTE - LATER IN THE PROCEDURE, THE HFC-410A OUTDOOR UNIT

CONTAINER IS REPLACED BY THE NITROGEN
CONTAINER.

B A

TO VAPOR
SERVICE VALVE

NITROGEN
HFC-410A

2 TEST FOR LEAKS

AFTER THE LINE SET HAS BEEN CONNECTED TO THE INDOOR AND OUTDOOR UNITS, CHECK THE LINE SET CON­
NECTIONS AND INDOOR UNIT FOR LEAKS. USE THE FOLLOWING PROCEDURE TO TEST FOR LEAKS:

A 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 CYLINDER (VAPOR ONLY).
B 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. [A 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 CYLINDER.
C CONNECT A CYLINDER OF DRY NITROGEN WITH A PRESSURE REGULATING VALVE TO THE CENTER PORT OF THE MANIFOLD
GAUGE SET.
D 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.
E 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.
F AFTER LEAK TESTING, DISCONNECT GAUGES FROM SERVICE PORTS.

Figure 12. System Leak Test

XP25
Page 22
Evacuating the System
LINE SET AND INDOOR COIL
MANIFOLD
GAUGE SET

1 CONNECT GAUGE SET

NOTE - REMOVE CORES FROM SERVICE VALVES (IF
NOT ALREADY DONE).
LOW HIGH

A CONNECT LOW SIDE OF MANIFOLD

GAUGE SET WITH 1/4 SAE IN-LINE TEE
TO VAPOR LINE SERVICE VALVE.
B CONNECT HIGH SIDE OF MANIFOLD A34000 1/4 SAE TEE WITH
GAUGE SET TO LIQUID LINE SERVICE SWIVEL COUPLER
VALVE. A
C CONNECT MICRON GAUGE TO AN 500
AVAILABLE CONNECTOR ON THE 1/4
SAE IN-LINE TEE.
MICRON
D CONNECT THE VACUUM PUMP (WITH OUTDOOR
UNIT C GAUGE
VACUUM GAUGE) TO THE CENTER
PORT OF THE MANIFOLD GAUGE SET. TO VAPOR
THE CENTER PORT LINE IS USED LATER SERVICE VALVE
FOR BOTH THE HFC-410A AND
NITROGEN CONTAINERS.

HFC-410A
B
TO LIQUID LINE
SERVICE VALVE

VACUUM PUMP
D

NITROGEN RECOMMEND
MINIMUM 3/8” HOSE

2 EVACUATE THE SYSTEM

A
B
OPEN BOTH MANIFOLD VALVES AND START THE VACUUM PUMP.
EVACUATE THE LINE SET AND INDOOR UNIT TO AN ABSOLUTE PRESSURE OF 23,000 MICRONS (29.01 INCHES OF MERCURY).
NOTE - DURING THE EARLY STAGES OF EVACUATION, IT IS DESIRABLE TO CLOSE THE MANIFOLD GAUGE VALVE AT LEAST ONCE. A RAPID RISE
IN PRESSURE INDICATES A RELATIVELY LARGE LEAK. IF THIS OCCURS, REPEAT THE LEAK TESTING PROCEDURE.
NOTE - THE TERM ABSOLUTE PRESSURE REFERS TO THE TOTAL ACTUAL PRESSURE (ABOVE ABSOLUTE ZERO) WITHIN A GIVEN VOLUME OR
SYSTEM. ABSOLUTE PRESSURE IN A VACUUM IS EQUAL TO ATMOSPHERIC PRESSURE MINUS VACUUM PRESSURE.
C WHEN THE ABSOLUTE PRESSURE REACHES 23,000 MICRONS (29.01 INCHES OF MERCURY), 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 DRY NITROGEN CYLINDER 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.
D SHUT OFF THE DRY NITROGEN CYLINDER AND REMOVE THE MANIFOLD GAUGE HOSE FROM THE CYLINDER. OPEN THE MANIFOLD
GAUGE VALVES TO RELEASE THE DRY NITROGEN FROM THE LINE SET AND INDOOR UNIT.
E RECONNECT THE MANIFOLD GAUGE TO THE VACUUM PUMP, TURN THE PUMP ON, AND CONTINUE TO EVACUATE THE LINE SET AND IN­
DOOR 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.
F 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.
G PERFORM THE FOLLOWING: 1/6 TURN

11 12 1
1. Close manifold gauge valves.
2. Shut off HFC-410A cylinder.
3. Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with 10 2
core tool while maintaining a positive system pressure. 9 3
4. Replace the stem caps and secure finger tight, then tighten an additional one-sixth (1/6) of a turn as 4
illustrated. 8
7 5
6

Figure 13. System Evacuation

XP25
Page 23
 for minimum circuit ampacity and maximum over-current
IMPORTANT protection size.
Use a thermocouple or thermistor electronic vacuum 24VAC TRANSFORMER
gauge that is calibrated in microns. Use an instrument Use the transformer provided with the furnace or air handler
capable of accurately measuring down to 50 microns. for low‐voltage control power (24VAC - 40 VA minimum).
LOAD SHEDDING
WARNING Utility Load Shedding Mode ACTIVATED – The normally
closed set of contacts in the utility load shedding control
Danger of Equipment Damage. Avoid deep vacuum receiver OPEN. This removes 24VAC from the coil of the
operation. Do not use compressors to evacuate a field-provided relay (catalog # 69J79). The relay contacts
system. Extremely low vacuums can cause internal close (terminal 7 to terminal 2), completing the circuit
arcing and compressor failure. Damage caused by deep between terminals R and L on the outdoor control. The
vacuum operation will void warranty. 24VAC input to terminal L activates the load shedding mode
in the outdoor control, cycling the outdoor unit OFF. The
Evacuating the system of non-condensables is critical for 7-Segment display on the outdoor control displays a load
proper operation of the unit. Non-condensables are defined shedding alert code (E600) and an alert appears on the
as any gas that will not condense under temperatures and display of the iComfort Wi-Fi® thermostat. The customer
pressures present during operation of an air conditioning receives email notifications when the alert occurs, if the
system. Non-condensables combined with refrigerant to option to receive notifications is selected.
produce substances that corrode copper piping and Utility Load Shedding Mode DEACTIVATED
compressor parts. (Normal Equipment Operation) – When load shedding is
not required, the contacts in the utility load control receiver
Electrical are closed. This provides 24VAC to the coil of the
field-provided relay (catalog # 69J79).The relay contacts
In the U.S.A., wiring must conform with current local codes OPEN (terminal 7 to terminal 2) removing 24VAC from the L
terminal on the outdoor control. This deactivates the load
and the current National Electric Code (NEC). In Canada,
shedding mode in the outdoor control. The outdoor unit
wiring must conform with current local codes and the current
returns to normal operation and alert code clears once load
Canadian Electrical Code (CEC).
shedding mode is deactivated.
Refer to the furnace or air handler installation instructions for For more information, see the Load Shedding Feature
additional wiring application diagrams. See unit nameplate Wiring Diagram on page 48.

1
SIZE CIRCUIT AND INSTALL DISCONNECT
SWITCH
REFER TO THE UNIT NAMEPLATE FOR MINIMUM CIRCUIT AMPACITY,
AND MAXIMUM FUSE OR CIRCUIT BREAKER (HACR PER NEC).
2 INSTALL THERMOSTAT
INSTALL ROOM THERMOSTAT (ORDERED SEPARATELY) ON AN
INSIDE WALL APPROXIMATELY IN THE CENTER OF THE
CONDITIONED AREA AND 5 FEET (1.5M) FROM THE FLOOR. IT
SHOULD NOT BE INSTALLED ON AN OUTSIDE WALL OR WHERE IT
INSTALL POWER WIRING AND PROPERLY SIZED DISCONNECT CAN BE AFFECTED BY SUNLIGHT OR DRAFTS.
SWITCH.
SERVICE THERMOSTAT
DISCONNECT
SWITCH

5 FEET
(1.5M)

NOTE - UNITS ARE APPROVED FOR USE ONLY WITH COPPER

CONDUCTORS. GROUND UNIT AT DISCONNECT SWITCH OR TO AN NOTE - 24VAC, CLASS II CIRCUIT CONNECTIONS ARE MADE IN THE CON­
EARTH GROUND. TROL BOX.

Figure 14. Electrical

XP25
Page 24
 ROUTE CONTROL WIRES
3
ELECTRICAL (CONTROL WIRING)
Maximum length of wiring (18 gauge) for all connections on AND LINE SET INLETS USE TYPICAL CONTROL BOX
BUSHING AND GROMMETS
the RSBus is 1500 feet (457 meters). Wires should be col­ PROVIDED IN BAG
or-coded, with a temperature rating of 95ºF (35ºC) mini­
mum, and solid-core (Class II Rated Wiring). All low volt­
age wiring must enter unit through the provided field-
installed busing installed in the electrical inlet.
The iComfort Wi-Fi® thermostat requires four thermostat
wires between the thermostat and the furnace / air handler
BUSHING
iComfort® control and four wires between the outdoor unit
and the furnace/air handler iComfort® control. When a
thermostat cable with more than four wires is used, the ex­
tra wires must be properly connected to avoid electrical
noise (see below).
Use a wire nut to bundle the four unused wires at each end
of the cable. Each bundle should also include an additional
wire that should be connected on each end to the C termi­
GROMMETS
nal as shown in the figure below.
CONTROL WIRING
ROUTE (LOW VOLTAGE)

OUTDOOR CONTROL

Indoor Control

Provided Rast
6-PIN Connector Outdoor Control
iComfort Wi-Fi®
thermostat

Single Wire To C Terminal

Single Wire To
C Terminal Unused Wires

Unused Wires

4 ROUTE HIGH VOLTAGE AND GROUND WIRES

Any excess high voltage field wiring should be trimmed and secured away from any
low voltage field wiring. To facilitate a conduit, a cutout is located in the side panel of
the control box. Connect conduit to the control box using a proper conduit fitting.

GROUND LUGS

CONTACTOR

ELECTRICAL INLET
(HIGH VOLTAGE)

WATERTIGHT
FLEXIBLE CONDUIT

TO SERVICE
DISCONNECT BOX

Figure 15. Electrical (Continued)

XP25
Page 25
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.
Precautions and Procedures
Neutralize electrostatic charge by touching hand and all tools on an unpainted
unit surface before performing any service procedure

7-SEGMENT
DISPLAY

PUSH
BUTTON

PUMP DOWN - WHEN UNIT IS IN PUMP DOWN MODE,  IS

SHOWN ON THE 7-SEGMENT DISPLAY.
NOTE - The green LED located on the outdoor control
flashes when communication occurs between the outdoor TO ACTIVATE MODE, REFER TO PUMP DOWN CYCLE
control and either the thermostat or the inverter. SEQUENCE ON PAGE 39.

Figure 16. Outdoor Unit Control

XP25
Page 26
 TABLE 5
Outdoor Control Terminal Designations and Input /Outputs (see figure 16 for terminal locations)
Designator Description Input Output Common
Switched 24VAC
O OUT Reversing valve switched output N/A N/A
nominal
O Reversing valve return N/A N/A 24VAC common
LO PS Low Pressure switch N/A 5ma @18VAC N/A
Low Pressure switch sensing con­
LO PS 5ma @18VAC N/A N/A
nection
Hi PS High Pressure switch N/A 24VAC nominal N/A
High pressure switch sensing con­
Hi PS 24VAC nominal N/A N/A
nection
Top cap thermostat switch (in series
TP N/A 24VAC nominal N/A
with the HI PS)
Top Cap thermostat switch sensing
TP 24VAC nominal N/A N/A
connection
Control (Inverter power) contactor
Switched 24VAC
Cntctr switched output (in series with the HI N/A N/A
Nominal
PS and TC)
Cntctr Contactor common N/A 24VAC common
10­97% duty cycle,
Fan PWM PWM fan output N/A N/A
19­23 VDC peak
COM PWM Fan common connection N/A N/A Fan PWM common
PWM Fan Parking spot for unused
Fan Park N/A N/A N/A
terminal, not connected.
P2 Terminals
24VAC nominal from
O O (reversing valve) emergency input thermostat and loaded to N/A N/A
draw 17ma at 30VAC
24VAC nominal from
Y1 Y1 emergency input thermostat and loaded to N/A N/A
draw 17ma at 30VAC
C 24VAC nominal power return. N/A N/A 24VAC common
i­ Low data line. Data Data N/A
i+ High data line. Data Data N/A
24VAC nominal board
R 24VAC nominal power input. N/A N/A
main power input.
DF Factory test N/A N/A N/A
26Vdc transistor output to Lennox
TOUT N/A N/A N/A
factory OEM tester
Factory test pin.
In each terminal box:
P2 ­ Terminal 1 ­ TEST 24VAC nominal 17ma @
TST N/A N/A
P2 ­ Terminal 2 ­ TOUT 30VAC
P2 ­ Terminal 3 ­ DF
P2 ­ Terminal 4 ­ R

XP25
Page 27
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 Output Common
Outdoor control • Pin 1 to pin 2 should read 4.5 to 5.5
Transmit data to inverter, connects to Rx of
P6 - Pin 1 Tx communication transmit VDC when not communicating.
inverter.
pin. • Pin 3 to pin 2 should read 4.5 to 5.5
VDC when not communicating.
Inverter Inverter common
• Pin 4 to pin 2 should read 4.5 to 5.5
P6 - Pin 2 Com­ NOTE - This is a signal reference point and not Inverter common. VDC.
mon an earth ground. NOTE - Communication signals switch
Outdoor control off and on rapidly. This may cause volt
Receive data from the inverter. Connects to
P6 - Pin 3 Rx communication receive meter readings to fluctuate. This is nor­
Tx of inverter.
pin. mal. Communication signals will switch
P6 - Pin 4 Inv 5V Inverter 5VDC volts. Inverter 5VDC volts between this 5V and common (Pin 2).
LIQ Liquid line temperature sensor supply. N/A N/A N/A
LIQ Liquid line temperature sensor return. N/A N/A N/A
AMB Outdoor ambient temperature sensor supply. N/A N/A N/A
AMB Outdoor ambient temperature sensor return. N/A N/A N/A
COIL Outdoor coil temperature sensor supply. N/A N/A N/A
COIL Outdoor coil temperature sensor return. N/A N/A N/A
To initiate pump down function, place jumper
in the ON position. (See Pump Down Mode
Operation on Page 39.)
1. Place the jumper in the ON position to
activate pump down mode.
2. Place the jumper in the OFF position to ON ON
Pump Down deactivate pump down mode. OFF OFF
NOTE - If the pump down jumper is in the ON
PUMP PUMP
position during power-up, it is ignored.
DOWN DOWN
NOTE - The outdoor control stays in pump
down mode for five minutes, after which the
outdoor control initiates a compressor
shutdown sequence.
24VAC input to L ener­
L Load shedding input. gizes load shedding fea­ N/A N/A
ture.
Load shedding input reference. Refer to wir­
ing of load shedding terminals in the Unit Wir­ 24VAC com­
C N/A N/A
ing Diagram section of this manual on page mon
46.

XP25
Page 28
Servicing Units Delivered Void of Charge 1. Rotate fan to check for binding.

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. 3. After evacuation is complete, open both the liquid and
2. Evacuate the system using procedure outlined on vapor line service valves to release the refrigerant
page 23. charge contained in outdoor unit into the system.
3. Use nitrogen to break the vacuum and install a new filter
drier in the system. 4. Replace the stem caps and tighten to the value listed in
4. Evacuate the system again using procedure outlined on table 1.
page 23.
5. Check voltage supply at the disconnect switch. The
5. Weigh in refrigerant using procedure outlined in
voltage must be within the range listed on the unit's
figure 65 on page 87.
nameplate. If not, do not start the equipment until you
6. Monitor the system to determine the amount of moisture have consulted with the power company and the voltage
remaining in the oil. It may be necessary to replace the condition has been corrected.
filter drier several times to achieve the required dryness
level. If system dryness is not verified, the
compressor will fail in the future. 6. Set the thermostat for a cooling demand. Turn on power
to the indoor unit and close the outdoor unit disconnect
Unit Start-Up switch to start the unit.

IMPORTANT 7. Recheck voltage while the unit is running. Power must

be within range shown on the nameplate.
If unit is equipped with a crankcase heater, it should be
energized 24 hours before unit start-up to prevent 8. Check system for sufficient refrigerant by using the
compressor damage as a result of slugging. procedures listed under System Refrigerant.

XP25
Page 29
 III. SYSTEM OPERATION AND SERVICE
7-Segment Alert and System Status Codes  Disconnecting R wire from the outdoor control R
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
percentages or defrost/dehumidification). cleared.
The 7-segment display shows an abnormal condition (error 2. Automatic Reset
code) when detected in the system. A list of the codes are After an alert is detected, the outdoor control continues
shown in table 6.
to monitor the system and compressor operations.
RESETTING ALERT CODES
When/if conditions return to normal, the alert code turns
Alert codes can be reset manually or automatically:
off automatically.
1. Manual Reset
Use one fo the following methods to manually reset the NOTE - Error codes can be recalled by following information
system: in tables on 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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Inverter LED Flash

Alert Inverter Code (number of
flashes) Priority Alarm Description Possible Causes and Clearing Alarm
Codes Code
Red LED Green LED
N/A N/A ON OFF N/A XC/XP 25-024 and -036 only: Indicates inverter is operating normally.
N/A N/A ON ON N/A XC/XP 25-048 and -060 only: Indicates inverter is operating normally.
N/A N/A OFF OFF N/A Indicates inverter is NOT energized.
Equipment is unable to communicate. Indicates nu­
merous message errors. In most cases errors are re­
The outdoor control has lated to electrical noise. Make sure high voltage power
lost communication with is separated from RSBus. Check for mis­wired and/or
E 105 N/A N/A N/A Moderate
either the thermostat or in­ loose connections between the stat, indoor unit and
door unit. outdoor unit. Check for a high voltage source of noise
close to the system. Fault clears after communication
is restored.
Typically, this alarm/code does not cause any issues
There is a delay in the out­ and clears on its own. The alarm/code is usually
E 120 N/A N/A N/A Moderate door unit responding to the caused by a delay in the outdoor unit responding to the
system. thermostat. Check all wiring connections. Cleared
after unresponsive device responds to any inquiry.
Equipment lost communication with the thermostat.
The iComfort Wi­Fi® ther­ Check the wiring connections and resistance, then
mostat has lost communic­ cycle the system power. This alarm stops all associ­
E 124 N/A N/A N/A Critical
ation with the outdoor unit ated HVAC operations and waits for a signal from the
for more than 3 minutes. non-communicating unit. The alarm / fault clears after
communication is re­established.
There is a control hardware problem. Replace the out­
There is a hardware prob­
door control if the problem prevents operation and is
E 125 N/A N/A N/A Critical lem with the outdoor con­
persistent. The alarm / fault is cleared 300 seconds after
trol.
the fault recovers.

The outdoor unit control Reconfigure the system. Replace the control if heating or
E 131 N/A N/A N/A Critical
parameters are corrupted. cooling is not available.
E 132 N/A N/A N/A Critical Internal software error. Replace outdoor control.
Valid temperature reading is lost during normal opera­
tion and after outdoor control recognized sensors.
The outdoor unit ambient Compare outdoor sensor resistance to temperature/
temperature sensor has resistance charts in unit installation instructions. Re­
malfunctioned. As a result place sensor pack if necessary. At the beginning of
E 180 N/A N/A N/A Critical
the outdoor unit control will (any) configuration, furnace or air­handler control de­
not perform low ambient tects the presence of the sensor(s). If detected (reading
cooling. in range), appropriate feature is shown in the iComfort
Wi­Fi® thermostat About screen. The alarm / fault clears
upon configuration, or when normal values are sensed.
XP25
Page 30
 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
codes are also displayed on the iComfort Wi-Fi ® thermostat.
Inverter LED Flash
Alert Inverter Code (number of
flashes) Priority Alarm Description Possible Causes and Clearing Alarm
Codes Code
Red LED Green LED
Issue: Broken R50 will make the control board think
reversing valve output is always off regardless of state
of relay. (Supplier issue - We have found our functional
Heat Pump or Air Condition­ test fixture can bend over MOV2 and crush it into
er Alert Code - The "O" re­ R50.There are cut-outs in the plate of the fixture to let
lay on the outdoor board the two relays pass through as the plate with pogo pins
has failed. Either the pilot is moved to the board to make contact with the termin­
relay contacts did not close, als. There is a pocket milled out in the plate to let
E 345 N/A N/A N/A Critical MOV2 pass, but if MOV2 is not straight up, it could
the relay coil did not ener­
gize or the circuit that con­ catch the plate outside the pocket and be bent down to
firms this operational se­ the board. Lennox is enlarging the cut-outs in the plate
quence is not sensing prop­ so MOV2 will clear the fixture. Corrective action com­
erly. pleted on August 29,2013.
Corrective Actions: Short term fix: Converted the sys­
tem back to a 24 volt system to get unit operating. Long
term: Replace outdoor control.
Secondary voltage is below 18VAC. After 10 minutes,
operation is discontinued. Check the indoor line voltage
Outdoor control secondary
E 409 N/A N/A N/A Moderate and transformer output voltage. The alarm clears after
voltage is 18VAC or less.
the voltage is higher than 20VAC for 2 seconds or after
a power reset.
Unit pressure is below the lower limit. The system is
shut down. The low pressure switch for HFC-410A
closes above 90PSIG and opens below 40PSIG. Con­
The outdoor unit cycled off
firm that the system is properly charged with refriger­
E 410 N/A N/A N/A Moderate due to low pressure switch
ant. Check TXV, indoor unit blower motor, dirty filters or
opening.
clogged refrigerant filter. Confirm that the evaporator
coil is clean. The alarm clears after the pressure switch
closes or after a power reset.
Low pressure switch error count reached 5 strikes. The
low pressure switch opens at 40PSIG and resets at
The low pressure switch has
90PSIG. Confirm that the system is properly charged
opened 5 times within one
E 411 N/A N/A N/A Critical with refrigerant. Check for clogged TXV, blockage to
hour. As a result, the out­
indoor unit blower motor, dirty filters or clogged refriger­
door unit is locked out.
ant filter. Confirm that the evaporator coil is clean. The
alarm clears after a power reset.
Unit pressure is above the upper limit. System is shut
down. The high pressure switch opens at 590PSIG
and closes at 418PSIG. Confirm that the system is
properly charged with refrigerant. Check for clogged
The outdoor unit high pres­ TXV, blockage to indoor unit blower motor, clogged
E 412 N/A N/A N/A Moderate refrigerant filter. Confirm that the outdoor unit is clean.
sure switch has opened.
The alarm clears after the pressure switch closes or a
power reset.
For heating, indoor CFM may be set too low. For zon­
ing system, zone CFM may be set too low.
Open high pressure switch error count reached 5
strikes. System is shut down. The high pressure switch
for HFC­410A opens at 590PSIG and closes at
418PSIG. Confirm that the system is properly charged
The high pressure switch with refrigerant. Check condenser fan motor, for
has opened 5 times within clogged TXV, for blockage to indoor unit blower motor,
E 413 N/A N/A N/A Critical
one hour. As a result, the for stuck reversing valve or clogged refrigerant filter.
outdoor unit is locked out. Confirm that the outdoor unit is clean. The alarm clears
after a power reset.
For heating, indoor CFM may be set too low. For zon­
ing system, zone CFM may be set too low.

XP25
Page 31
 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
codes are also displayed on the iComfort Wi-Fi ® thermostat.
Inverter LED Flash
Alert Inverter Code (number of
flashes) Priority Alarm Description Possible Causes and Clearing Alarm
Codes Code
Red LED Green LED
Coil sensor being detected open or shorted, or temper­
ature is out of coil sensor range. Outdoor unit control
The outdoor coil sensor has will not perform demand or time/temperature defrost
Moderate malfunctioned. As a result operation. System is still able heat and cool. Check the
E 416 N/A N/A N/A
/ Critical the outdoor unit control will resistance of the coil sensor and compare to temperat­
not perform defrost. ure resistance chart. Replace coil sensor if needed.
The alarm clears when outdoor unit control detects
proper coil sensor readings or after a power reset.
Issue: One of the wires from the top cap switch had
pulled off one of the TP terminals on the outdoor con­
Compressor top cap switch
E 422 N/A N/A N/A Moderate trol board.
exceeding thermal limit.
Corrective Action: Reconnected wire onto top cap
terminal.
Moderate The inverter has detected a Control locks out after 10 strikes within an hour. To
E 423 40 4 flashes OFF
/ Critical circuit problem. clear, disconnect power to outdoor unit and restart.
In normal operation, after outdoor control recognizes
sensors, the alarm is sent if valid temperature reading
is lost. Compare liquid line sensor resistance to tem­
perature/resistance charts in unit installation instruc­
tions. Replace sensor pack if necessary. At the begin­
The liquid line temperature
E 424 N/A N/A N/A Moderate ning of (any) configuration, furnace or air­handler con­
sensor has malfunctioned.
trol detects the presence of the sensor(s). If detected
(reading in range), appropriate feature is shown in the
iComfort Wi­Fi® thermostat About screen. The alarm /
fault clears upon configuration, or when normal values
are sensed.
Outdoor control has in­
creased minimum com­
Outdoor ambient temperature is below system limit.
pressor speed to allow for
Control attempts to run at lowest allowed compressor
proper oil return due to low
E 425 N/A N/A N/A Minor speed to allow for proper oil return. Automatically
ambient temperature. NOTE -
clears when outdoor ambient temperature rises above
Minimum speed adjustments
limit for more than 5 minutes.
begin at 45°F and increase to
100% minimum at 17°F.
After ten faults within one hour, control is locked out,
indicating poor system operation. Review history of
alarms to resolve system setup. Check condenser fan
motor, TXV, indoor unit blower motor, over-charge, un­
E 426 N/A N/A N/A Critical Excessive inverter alarms dercharge, or clogged refrigerant filter.
To clear error, disconnect power to outdoor unit and
restart. Inverter alarms 12 to 14 and 53 do not count
toward this lock out condition.
The inverter has detected a DC peak fault condition. If condition (55A or higher) is
detected, outdoor unit compressor and fan stop. Anti-short cycle is initiated. If peak
Moderate
E 427 21 2 flashes 1 flash current (55A or higher) occurs 10 times within an hour, system is locked out. Indicates
/ Critical
high pressure, condenser fan failure, locked compressor rotor or overcharge. To clear,
disconnect power to outdoor unit and restart.
If condition is detected, is detected, outdoor unit com­
pressor and fan stop. Anti­short cycle is initiated. If
The inverter has detected a condition occurs 5 times within an hour, system is
Moderate locked out.
E 428 22 2 flashes 2 flashes high main input current con­
/ Critical Indicates high pressure, condenser fan failure or over­
dition.
charge.
To clear, disconnect power to outdoor unit and restart.

XP25
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.
Inverter LED Flash
Alert Inverter Code (number of
flashes) Priority Alarm Description Possible Causes and Clearing Alarm
Codes Code
Red LED Green LED
On a call for compressor op­ Issues:
eration, if DC link power in
(1) If DC link power in inverter does not rise above 180
inverter does not rise above
VDC for 2- and 3-ton models, 250 VDC for 4- and 5-ton
180 VDC for 2 and 3 ton
models, within 30 seconds, the outdoor control will dis­
models, 250 VDC for 4 and
play a moderate code.
5 ton models, within 30
seconds, the control will dis­ (2) Capacitors on inverter do not properly charge.
Moderate play a moderate code. If
E 429 23 2 flashes 3 flashes Corrective Actions:
/ Critical condition is detected, out­
door unit will stop (Com­
(1) check for proper main power to outdoor unit and for
pressor and fan). Anti-short
any loose electrical connections.
cycles is initiated. If condi­
tion occurs 10 times within a (2) Outdoor control boards with part # 103686-03 have
60 minute rolling time peri­ software update to delay the de-energizing of the re­
od, system will lock out and versing valve by four seconds when coming out of de­
display a critical code. frost.
If condition is detected, outdoor unit compressor and
fan stop. Anti­short cycle is initiated. If condition occurs
10 times within an hour, system is locked out.
Moderate
E 430 26 2 flashes 6 flashes Compressor start failure. Indicates poor connection at compressor harness, im­
/ Critical
proper winding resistance, locked compressor rotor, or
flooded compressor.
To clear, disconnect power to outdoor unit and restart.
Issues:
Error occurs when PFC de­
tects an over-current condi­ (1) Indicates power interruption, brownout, poor elec­
tion of 100A, the control will trical connection or loose inverter input wire.
display a moderate code. If (2) System testing was set up and code was gener­
condition is detected, out­ ated when the reversing valve is de-energized coming
door unit will stop (Com­ out of defrost (code appears with or without 30 com­
pressor and fan). Anti-short pressor delay).
Moderate
E 431 27 2 flashes 7 flashes cycle is initiated. Inverter is
/ Critical Corrective Actions:
unavailable to communicate
with the outdoor control for (1) Check for proper main power to outdoor unit and
3 minutes. If condition oc­ for any loose electrical connections.
curs 10 times within a 60
minute rolling time period, (2) Outdoor control boards with part # 103686-03 have
system will lock out and dis­ software update to delay the de-energizing of the re­
play a critical code. versing valve by four seconds when coming out of de­
frost.
Error occurs when the DC link capacitor voltage is greater
than 480VDC. If condition is detected, outdoor unit com­
The inverter has detected a
Moderate pressor and fan stop. Anti­short cycle is initiated. If condi­
E 432 28 2 flashes 8 flashes DC link high voltage condi­
/ Critical tion occurs 10 times within an hour, system is locked out.
tion.
System stops. To clear, disconnect power to outdoor unit
and restart.
Error occurs when compressor peak phase current is
greater than 28A. Inverter issues code 14 first and slows
The inverter has detected a down to try to reduce the current. If the current remains
Moderate
E 433 29 2 flashes 9 flashes compressor over-current high, outdoor unit compressor and fan stop. Anti­short
/ Critical
condition. cycle is initiated. If condition occurs five times within an
hour, system is locked out. To clear disconnect power to
outdoor unit and restart.

XP25
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.
Inverter LED Flash
Alert Inverter Code (number of
flashes) Priority Alarm Description Possible Causes and Clearing Alarm
Codes Code
Red LED Green LED
Outdoor control has lost
communications with the
inverter for greater than 3 Issues:
minutes. Outdoor control
will stop all compressor de­ (1) Loose electrical connections.
mands, recycle power to (2) Interruption of main power to inverter.
Moderate /
E 434 53 5 flashes 3 flashes the inverter by de-energiz­
Critical Corrective Actions:
ing the contactor for 2
minutes. If this occurs 3 (1) Check all electrical connections.
time in one thermostat call,
the outdoor unit will locked (2) Check for proper main power to inverter.
out and display a critical
code.
When this error occurs, the outdoor control cycles
power to the inverter by opening the contactor for two
Moderate /
E 435 60 6 flashes OFF Inverter internal error. minutes. Check that the EEPROM is properly seated.
Critical
After power is cycled to the inverter 3 times, the out­
door unit is locked out.
Inverter heat sink temperat­
ure exceeded limit. Occurs
when the heat sink temper­
ature exceeds the inverter Issue: Feedback from supplier tear down of inverter in­
limit. Inverter issues code dicates that the screws that hold the inverter to the invert­
13 first, then slows down to er board were loose causing poor contact between these
allow the heat sink to cool. If two components.
Moderate /
E 436 62 6 flashes 2 flashes temperature remains high,
Critical Corrective Action: Tighten screws that hold the heat
outdoor unit stops (com­
sink to the inverter control board.
pressor and fan). Anti-short
cycle is initiated. If condition NOTE: Wait five minutes to all capacitor to discharge be­
occurs 5 times within an fore checking screws.
hour, system is locked out.
To clear, disconnect power
to outdoor unit and restart.
Occurs when the temperature sensor detects a temperat­
Heat sink temperature ure less than 0.4ºF or greater than 264ºF after 10 minutes
sensor fault has occurred of operation. If condition is detected, outdoor unit will stop
Moderate /
E 437 65 6 flashes 5 flashes (temperature less than 4ºF (compressor and fan). Anti­short cycle is initiated. If con­
Critical
or greater than 264ºF after dition occurs 5 times within an hour, system will lock out.
10 minutes of operation). To clear disconnect power to outdoor unit and restart. If
problem persists, replace inverter.
The inverter has detected a
PFC over current condi­
tion.  This would be caused
by a high load condition,
high pressure, or outdoor
fan failure. Outdoor control
will display the code when
the inverter has the error.  Issue: Possible issue is system running at high pres­
Moderate /
E 438 73 7 flashes 3 flashes After 3 minutes, the inverter sures. Check for high pressure trips or other alert codes in
Critical
will reset and the com­ room thermostat and outdoor control.
pressor will turn on again. 
If it happens 10 times with­
in a 60 minute rolling time
period, the OD control will
lock out operation of the
outdoor unit and display a
critical code.
Input current is approaching a high limit. Compressor
speed automatically slows. The control continues send­
Compressor slowdown due ing the inverter speed demanded by the thermostat. The
E 439 12 1 flash 2 flashes Moderate
to high input current. control sets indoor CFM and outdoor RPM to values ac­
cording to demand percentage rather than the actual Hz.
Alarm is automatically cleared.

XP25
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.
Inverter LED Flash
Alert Inverter Code (number of
flashes) Priority Alarm Description Possible Causes and Clearing Alarm
Codes Code
Red LED Green LED
Heat sink temperature is
approaching limit. The Issue: Feedback from supplier tear down of inverter in­
compressor speed auto­ dicates that the screws that hold the inverter to the invert­
matically slows to reduce er board were loose causing poor contact between these
heat sink temperature. The two components.
E 440 13 1 flash 3 flashes Moderate control sets indoor CFM
and outdoor RPM to values Corrective action: Tighten screws that hold the heat sink
according to demand per­ to the inverter control board.
centage rather than the ac­ NOTE: Wait 5 minutes to all capacitor to discharge before
tual Hz. Alarm is automatic­ checking screws.
ally cleared.
Compressor slowdown due
to high compressor current.
Compressor current is ap­
proaching limit. The com­
pressor speed automatic­ Issue: Possible issue is system running at high pres­
E 441 14 1 flash 4 flashes Moderate ally slows. The control sets sures. Check for high pressure trips or other alert codes in
indoor CFM and outdoor room thermostat and outdoor control.
RPM to values according to
demand percentage rather
than the actual Hz. Alarm is
automatically cleared..
The top cap switch has
When compressor thermal protection sensor opens five
opened five times within
E 442 N/A N/A N/A Critical times within one hour, outdoor stops working. To clear,
one hour. As a result, the
disconnect power to outdoor unit and restart.
outdoor unit is locked out.
Check for proper configuring of unit size codes for out­
door unit in configuration guide or in installation instruc­
tions. If replacing inverter, verify inverter model
Incorrect appliance unit
E 443 N/A N/A N/A Critical matches unit size. The alarm/fault clears after the cor­
size code selected.
rect match is detected following a reset. Remove the
thermostat from the system while applying power and
reprogramming.
Load shedding function: Provides a method for a local
Compressor has been utility company to limit the maximum power level usage of
E 600 N/A N/A N/A Critical cycled OFF on utility load the outdoor unit. The feature is activated by applying 24
shedding. volts AC power to the L and C terminals on the outdoor
control.
Low temperature protection: Outdoor unit will not operate
when the outdoor temperature is at or below ­4°F
Outdoor unit has been (­20°C). If the unit is operating and the outdoor temper­
E 601 N/A N/A N/A Critical cycled OFF on low temper­ ature drops below ­4°F (­20°C), the unit continues to op­
ature protection. erate until the room thermostat is satisfied or the outdoor
temperature drops to ­15°F (­26°C). Outdoor unit ambi­
ent sensor provides temperature readings.

XP25
Page 35
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. AC = air conditioner and HP = heat pump. If the
unit type cannot be determined, three bars appear.
  OR   OR

UNIT NOMINAL CAPACITY: The next item to be displayed

is the self-discovery unit nominal capacity. Valid capacities

are 24 for 2-ton, 36 for 3-ton, 48 for 4-ton and 60 for 5-ton OR
units. If the unit type cannot be determined, three bars ap­
pear.

UNIT CODE: The next item to be displayed is the self discov­

ery unit code. (may be a single character or two characters).
If the unit code cannot be determined, three bars appear.
 THROUGH
OR

(These are just examples of firmware version, unit type,

UNIT CODE UNIT TYPE, SIZE AND MODEL unit nominal capacity and unit codes.)

NOT PROGRAMMED

 2-TON HEAT PUMP, XP25-024

7-SEGMENT POWER-UP DISPLAY STRING EXAMPLE

3-TON HEAT PUMP, XP25-036

 4-TON HEAT PUMP, XP25-048

 .    

.
FIRMWARE UNIT UNIT UNIT
 5-TON HEAT PUMP, XP25-060 VERSION TYPE CAPACITY CODE IDLE MODE

2-TON AIR CONDITIONER, XC25-024

3-TON AIR CONDITIONER, XC25-036

 4-TON AIR CONDITIONER, XC25-048

5-TON AIR CONDITIONER, XC25-060

Figure 17. Outdoor Control 7-Segment Unit Status Displays

XP25
Page 36
 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. Hz (0.5 second on, 0.5 second off). Note - Control should be replaced.

All segments flashing at 2 Hz (unless error is detected) Note - Control

Factory Test Mode
should be replaced.

The middle line flashes at 1 Hz for 2 seconds, followed by a 2-second dis­

play of the number of minutes left on the timer (value is rounded up: 2 min.
Anti-Short Cycle Delay
1 sec. is displayed as 3). If activated, the anti-short cycle delay time remain­
ing is displayed (default is 300 sec./5 min.).

The demand percentage is displayed first, followed by a pause, then the

Cooling Cycle: Shows current percentage of maximum cooling outdoor fan speed and the ambient temperature.
capacity. Example to the right indicates a cooling demand of 50
percent and a outdoor fan speed of 700 RPM.    pause     pause   

Following string is repeated if heat pump is active with outdoor fan speed
Heating Pump Cycle: Shows current percentage of maximum set at 600 RPM. Note -  - If available, displays outdoor ambient tempera­
heating capacity. Example to the right indicates a heating de­ ture.
mand of 33 percent and an outdoor fan speed of 600 RPM.
   pause     pause   
Following string is repeated if defrost is active.
Defrost Mode: Shown only while in an active defrost.   pause

If first error is    , second    pause     pause

Diagnostic recall: Shows the last 10 stored diagnostic error   
codes.
Next codes (up to 10) are show using same method.

If there are no error codes stored:  pause    . After the fault memory
is cleared, the following is displayed with 0.5 seconds character ON / OFF
Fault memory clears time:
    pause
Active error in outdoor control Idle mode: Show all active Following display string is repeated if Error E 125 and E 201 are present:
error(s) codes.    pause   
Following display string is repeated if Error E 440 is present while outdoor
Active error in run mode: Show current status and all active fan speed at 700RPM:
error(s) codes.
    pause 


Outdoor Ambient Temperature (OAT): Any time OAT is sensed Following display string is repeated if cooling is active with outdoor fan
in operating range, value is displayed if unit is in diagnostic and speed set at 650 RPM and OAT is 104ºF:
non-diagnostic modes.    pause     pause  
pause

Outdoor Coil Temperature (OCT): Any time OCT is sensed in Following display string is repeated if heat is active with outdoor fan speed
operating range, value is displayed if unit is in diagnostic mode set at 550 RPM and OCT is 25ºF:
or manually enabled for non-diagnostic modes.    pause     pause    pause

Liquid Line Temperature (LIQ): Any time LIQ is sensed in oper­ Following display string is repeated if cooling is active with outdoor fan
ating range, value is displayed if unit is in diagnostic mode or speed set at 650 RPM and LIQ is 105ºF:
manually enabled for non-diagnostic modes.   pause     pause    pause
Following display string is repeated:
Pump Down Mode: While the unit is in pump down mode,     pause  
is displayed repeatedly. Errors are shown if they exist.
  pause 

 pause   pause 



XP25
Page 37
 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
ment display until DASH symbol appears. Immediately re­ _
selection displays on the 7­seg­ 
ment display (, ,    ,  or
lease the button. Once dash starts flashing, proceed to
). Immediately release the button,
next step. proceed to next step.
_

Push and hold button until the selection stops flashing, then release button. The 7 seg­
ment display shows the selected mode and the control performs the selected function.


Figure 18. Push-Button Operation

Unit Selection Code for Outdoor Control
If the single-character display shows three (3) horizontal lines, the unit selection code needs to be programmed. Press and hold the button until the  
menu option is displayed, release button. The single­character display displays the selected mode per example in figure 17 on page 36. When the de­
sired unit selection code appears, press and hold the button until it stops flashing, then release.
Unit Code Unit Type Unit Model
 2-ton heat pump XP25-024

3-ton heat pump XP25-036

 4-ton heat pump XP25-048
7 5-ton heat pump XP25-060
2-ton air conditioner XC25-024

3-ton air conditioner XC25-036

 4-ton air conditioner XC25-048

5-ton air conditioner XC25-060

Idle mode — decimal flashes at 1 Hertz > 0.5 second ON, 0.5 second OFF. Idle mode is when the system is energized but no demand.
Display
Symbol or Display Fan Test and Display String Option
Character
Displayed
during start-up Display string shows outdoor control firmware version   > pause>   or   unit >pause>unit capacity in BTUs>pause >unit code.
or power If 3 horizontal bars are displayed during any sequence of this display string, it indicates that the specific parameter is not configured.
recycling.

. Idle mode — decimal flashes at 1 Hertz > 0.5 second ON, 0.5 second OFF.

 or  Indicates either cooling () or heating () mode and demand percentage.
Code displays when system is in defrost mode. To enter defrost mode, unit must be running in heating mode, outdoor ambient
  must be below 65F and outdoor coil temperature must be below defrost termination temperature.
Control must be in Idle mode: To enter fan test option -  mode, push and hold button
until solid – appears, release button. Display begins flashing. Within 10 seconds, push
and hold button until required symbol  displays, release button. Display begins flashing.
 Indicates outdoor fan RPM speed. Within 10 seconds, push and hold button until display stops flashing, release button.
Control outputs DC voltage on PWM and COM terminals. Outdoor fan cycles ON for 10
minutes at 490 RPM. To exit test – Push and hold button until three horizontal bars dis­
play. Release button, outdoor fan cycles OFF.
Control can be in Idle or demand mode: To enter display configuration option -  mode,
 indicates that the display is show­
push and hold button until solid – appears, release button. Display begins flashing. Within 10
ing the ambient temperature in F
(at the outdoor unit sensor). seconds, push and hold button until required symbol  displays, release button. Display be­
gins flashing. Within 10 seconds, push and hold button until display stops flashing, release
 button. Display shows error () code(s), ambient (), outdoor coil () and liquid () tempera­
 displayed during configuration tures in Fahrenheit.
mode, indicates the option to display
coil and liquid line temperatures is
NOTE - If button is not pushed in the 10-second time period, the control exits the test mode. If
enabled.
this occurs, test mode must be repeated.
XP25
Page 38
Error Code Recall Mode (Note - control must be in idle mode)

 To enter error code recall mode, push and hold button until solid  appears, then release button. Control displays up to 10 error codes
stored in memory. If     is displayed, there are no stored error codes.

— To exit error code recall mode, push and hold button until solid three horizontal bars appear, then release button. Note - Error codes
— are not cleared.
—
To clear error codes stored in memory, continue to push button while the 3 horizontal bars are displayed. Release button when solid 
 is displayed.
Push and hold for one (1) second, release button. 7-Segment displays
     and exits error recall mode.

FIELD TEST MODE OPERATION In this mode, the control energizes the outdoor fan at the
The field test mode allows the unit to be put into diagnostic highest speed. The control continuously displays the fan
mode and allows the installer to perform multiple tests on the RPM on the 7-segment display.
control / unit.
PUMP DOWN MODE OPERATION
Forced Defrost Mode 1. Turn room thermostat OFF.
This mode is available for heat pump units only. This mode 2. Install a set of refrigerant gauges on the system to
can only be selected when the unit is in heating mode and monitor the pressure.
the ambient sensor is reading a temperature below 65ºF.
NOTE - All operation monitoring devices: high pressure
• When in this mode, the coil and ambient sensor
switch, low pressure switch and compressor internal
readings are shown on the 7-segment display.
vacuum protection remain active in the system. This
• The control indicates an active defrost state. prevents the compressor from recovering all the system
• The menu mode automatically exits when forced defrost refrigerant into the outdoor unit.
is selected. The appropriate values are shown on the NOTE - If the pump down jumper is in the ON position during
7-segment display. power-up, it is ignored.
• The 7-segment display indicates defrost mode as 3. Move the Pump Down jumper (see page Page 75 for
described in table 7. location) from the OFF position to the ON position.
• Forced defrost mode exits under the following
conditions:
A Defrost period expired
B Defrost termination temperature reached ON ON
C Heating demand satisfied OFF
OFF
D Push button is pressed and released without
PUMP DOWN PUMP DOWN
entering the menus
Diagnostic Mode
Diagnostic mode is only available when the system is idle or
during an active / suspended call for heating or cooling. Figure 19. Pump Down Jumper
Diagnostic mode is terminated when the exit command is 4. Shut off the liquid line service valve to stop the flow of
given, the push button is pressed and released without refrigerant into the indoor coil.
entering the diagnostic menu, or 10 minutes has passed,
whichever comes first. 5. After a three-second delay, the compressor and outdoor
fan increases speed up to 100% capacity. (Indoor fan
When this mode is selected, all installed temperature sensor remains OFF.)
valves (non-open and non-short) is shown on the 7-segment
display. The following system status codes are displayed: 6. Monitor the low-side pressure at the outdoor unit. The
internal vacuum protection in the compressor and/or
• Heating / Cooling one of the pressure switches prevent full recovery of all
• Defrost Status of the refrigerant into the outdoor unit. When the system
reaches this condition,close the suction line service
• Percentage demand operation valve and move the Pump Down Jumper to the OFF
• Outdoor fan RPM position.
• Active error codes NOTE - The outdoor control stays in pump down mode for
Outdoor Fan Mode five minutes, after which the outdoor control initiates a
This mode is only available while the system is in idle mode. compressor shutdown sequence.
This mode can be exited with the proper command or after 7. Use a refrigerant recovery machine to recover the
10 minutes has passed. remaining refrigerant on the indoor side of the system.

XP25
Page 39
 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  Puts unit in diagnostic mode. (Displays ambient, coil, liquid sensor temperatures and any active error codes.)

Solid  Clears error history (**)

Solid  Enter diagnostic recall mode. Displays up to 10 error codes in memory.

Solid  Start forced defrost test

Solid  Starts outdoor fan.

String   Enter unit code programming.

*No change indicates the display continues to show whatever is currently being displayed for normal operations.

**Note - Once the error history is deleted, it cannot be recovered. After the history is deleted, the unit resets itself.

Table 9. Normal Operation Character Display String

Display Display and action (normal operation) Display and action (configuration and test mode)

. Idle mode — decimal flashes at 1 Hertz > 0.5 second ON, 0.5 second OFF
 Cooling operation. Shows  and the cooling demand percentage. Example:    pause     pause   
 Fan RPM. Shows  and the current fan RPM. Example:    pause     pause 

  in the display string represents the active error code or codes in the outdoor unit.
Example:    pause     pause 

pause 

 pause    pause
  in the display string represents the outdoor ambient temperature in F at the outdoor sensor on the outdoor unit.
Example:    pause     pause   
 If enabled,  in the display string represents the outdoor coil temperature in F at the sensor on the outdoor unit.
Example:    pause     pause    pause 
 pause. Air conditioning units do not require an outdoor coil sensor.
A 10K resistor, across pins 5 and 6 on the outdoor control sensor harness, prevents false outdoor coil sensor codes. The 10K
resistor causes the 7-segment display to show a constant 77ºF coil (c) temperature value.
 If enabled,  in the display string represents the outdoor liquid line temperature in F at the sensor on the outdoor unit.
Example:    pause     pause    pause 
 pause pause    pause
    displays when system is in pump down mode.

TYPICAL 7-SEGMENT ACTIVE COOLING OR HEATING DEMAND DISPLAY STRING

       

         
COOLING AT OUTDOOR ACTIVE ERROR OUTDOOR OUTDOOR OUTDOOR LIQUID
50% DEMAND FAN RPM CODE (IF PRESENT) AMBIENT AIR COIL TEMP(*) LINE TEMP
TEMP
BY DEFAULT, COOLING OR HEATING, DEMAND, OUTDOOR FAN RPM, ACTIVE ERROR CODES OUTDOOR COIL AND LIQUID LINE TEMPERATURES CAN BE
AND OUTDOOR AMBIENT TEMPERATURE ARE DISPLAYED. MANUALLY ENABLED. IF SYSTEM POWER IS RECYCLED, DISPLAY
STRING REVERTS BACK TO DEFAULT (SEE FIGURE 21 TO ENABLE)

* Air conditioning units do not require an outdoor coil sensor. A 10K resistor, across pins 5 and 6 on the outdoor control sensor harness, prevents
false outdoor coil sensor codes. The 10K resistor causes the 7-segment display to show a constant 77ºF coil (c) temperature value.

Figure 20. Typical 7-Segment Demand Display String

XP25
Page 40
 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. ALL TEMPER­
ATURES ARE DISPLAYED IN FAHRENHEIT.

Outdoor control is either in IDLE Wait until unit returns

Yes
mode or heating / cooling to a active demand or
demand) idle mode.

To enable temperature display, push

and hold button next to 7-segment _ _
display until dash symbol appears
and immediately release button.
Push and hold button until the

Once dash starts flashing, proceed
to next step. flashing  stops flashing then
release button. The display shows
the coil and liquid line temperature if
there is an active demand running. 
Push and hold the button until the solid
 appears on the 7-segment display. 
Then, immediately release the button.

During thermostat demand of the outdoor control, the 7-segment display shows the cooling or heating (percent demand), fan RPM, error codes if present, and
outdoor ambient, Coil and liquid line temperatures need to be manually enabled to be displayed.

       

         
PERCENTAGE OF FAN RPM ACTIVE ERRORS OUTDOOR OUTDOOR COIL OUTDOOR LIQUID
MAXIMUM CAPACITY ONLY AMBIENT TEMP (*) LINE TEMP
NOTE - The coil and liquid line temperature readings are temporarily shown on the outdoor 7-segment display when the iComfort Wi-Fi® diagnostic screen is
accessed.

Figure 21. Enabling Liquid Line Temperature Information

XP25
Page 41
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).
During initial power-up, firmware version, unit type, unit capacity
and unit selection code appears on the 7-segment display.

If three horizontal bars are shown in the 7-segment display

during power-up, the outdoor control did not store the last
−
−
configuration setting. If this happens, the configuration se­
quence for that setting must be repeated.
−

Outdoor control is in IDLE mode

Yes (No heating or cooling demand) No

To enter unit selection code,

push and hold button next
7-segment display until dash _
symbol appears and Turn room thermostat
immediately release button. to OFF
Once dash starts flashing, _
proceed to next step.

1. When the correct unit section code is displayed, release but­

Push and hold button until the solid ton immediately. [Display begins flashing]
UNIT SELECTION
 sequence is displayed on the CODE 2. Push and hold button until selection stops flashing during
7-segment display, then one of the three cycles. [Release push button]
immediately release the button. This 3. If selection is not made during those three cycles the control
configuration sequence allows the   returns to idle mode.
installer to choose the unit selection UNIT SELECTION
code (number combination) that CODES UNIT
matches the outdoor unit type and
inverter. 2 2-TON HEAT PUMP (XP25-024)
4 3-TON HEAT PUMP (XP25-036)
6 4-TON HEAT PUMP (XP25-048) NOT
SELECTED
7 5-TON HEAT PUMP (XP25-060)
9 2-TON AIR CONDITIONER (XC25-024)
11 3-TON AIR CONDITIONER (XC25-036)
Press and hold the button during
the  cycling display. 13 4-TON AIR CONDITIONER (XC25-048)
NOT 14 5-TON AIR CONDITIONER (XC25-060)
NOTE: The  sequence repeats SELECTED
5 times. If a selection is not made, SELECTED
the control returns to idle mode.

The outdoor control stores the unit type, automatically exits the con­
figuration mode and resets.

SELECTED

If three horizontal bars display in any

EXAMPLE 7-SEGMENT DISPLAY STRING
part of the 7-segment display string
during power-up, the outdoor
control did not store the unit −
−
 .    

.
selection code. If this occurs, the
configuration sequence for that
section of the display string must be
− FIRMWARE UNIT UNIT UNIT IDLE MODE
repeated.
VERSION TYPE CAPACITY CODE (NO DEMAND)

Figure 22. Configuring Unit Selection Code

XP25
Page 42
Reconfiguring Outdoor Control using • Low pressure switch status
iComfort Wi-Fi® Thermostat • Compressor top cap switch status
If any component of the HVAC system is changed, ( e.g. an • Liquid line temperature
outdoor sensor is replaced), reconfigure the system. To • Outdoor ambient temperature
begin reconfiguring a system, select the Setup tab.
• Coil temperature
System Overview • Time since last defrost
Refer to the iComfort Wi-Fi® Thermostat Installer Guide for • Calibration delta T
configuration procedures. • Current delta T
• Outdoor fan RPM
IMPORTANT • Compressor active alarm
Some scroll compressors have internal an vacuum • Compressor Hz
protector that unloads the scrolls when suction pressure
drops below 20 psig. A hissing sound is heard when the
• Inverter compressor short cycle
compressor is running unloaded. Protector resets when • Heat sink temperature
low pressure in system is raised above 40 psig. DO NOT
REPLACE COMPRESSOR. Installer Test
The outdoor control provides the following functions: Verify the proper operation of the system by running the
Installer Test feature through the thermostat interface. Refer
• Demand defrost algorithm to the iComfort Wi-Fi® Installer's System Setup Guide.
• Field-selectable defrost termination temperatures
through the thermostat interface Defrost Function
• Internal switching of outputs The outdoor unit control measures differential temperatures
• Anti-short-cycle delay (adjustable through the to detect when the system is performing poorly because of
ice build-up on the outdoor coil. The controller self-calibrates
thermostat interface
(see figure 33) when the defrost system starts and after each
• Five-strike lockout function system defrost cycle. The outdoor unit control monitors
• Ambient (RT13), coil (RT21) and liquid line (RT36) ambient temperature, outdoor coil temperature, and total
run-time to determine when a defrost cycle is required. The
temperatures monitoring and protection
coil temperature sensor is designed with a spring clip to
COMPRESSOR PROTECTION — FIVE-STRIKE secure the sensor to the outside coil tubing. The location of
LOCKOUT FUNCTION the coil sensor is important for proper defrost operation (see
The five-strike lockout function is designed to protect the figure 59 on page 77 for location of coil sensor).
unit's compressor from damage. The five-strike feature is NOTE - The outdoor unit control accurately measures the
used for high (S4) and low (S87) pressure switch trips. performance of the system as frost accumulates on the
Resetting Five-Strike Lockout outdoor coil. This typically translates into longer running time
Once the condition has been resolved, power to the outdoor between defrost cycles as more frost accumulates on the
control R terminal must be cycled OFF. outdoor coil before the outdoor control initiates defrost
cycles.
Diagnostic Information DEFROST OPERATING MODES
The outdoor control has three operational modes:
The following diagnostic information is available through the
thermostat user interface. Refer to the Wi-Fi® Installer • Defrost calibration (see figure 33)
System Setup Guide.
• Operation
• Compressor anti-short cycle delay timer status • Defrost test
• Cooling rate DEFROST TERMINATION TEMPERATURES
• Heating rate The defrost termination temperature setting selections (50,
70, 80, 90, and 100°F) are available through the thermostat
• Compressor shift delay timer status
interface. The factory default setting is 50°F (10°C).
• Defrost status
NOTE - Colder climates may require a higher discharge
• High pressure switch status termination temperature setting to maintain a clear coil.

XP25
Page 43
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
up delay which de-energizes the contactor output and ECM
• Interruption in power to the unit fan outputs. After the delay expires, the contactor and
• Pressure or sensor trips ECM, fan outputs are energized.
• Delay after demand is removed. * When disabled, the reversing valve is shifted by
The delay is set by default for 300 seconds (five minutes) but de-energizing the outputs.
can be changed through the thermostat interface.
Available settings are 60, 120, 180, 240 and 300 seconds. Outdoor Temperature Operational Range
COMPRESSOR SHIFT DELAY
The outdoor control has a field-selectable option (ON or Use the chart below to determine the operational limits in
OFF), selected through the thermostat interface, which reference to outdoor temperatures.
Table 10. Heat Pump Cooling Operational Range
Temperature
Event
C° F°
Room thermostat controls operation of outdoor unit.

Above Above NOTE - Below 65°F (18.3°C) the liquid line temperature sensor controls the outdoor fan speed (RPM)
(-) 20°C (-) 4°F to maintain a liquid line temperature between 58°F (14.4°C) and 55°F (12.8°C).

NOTE - Minimum fan RPM is 300.

At or Below At or Below Outdoor unit cooling operation stopped by low ambient temperature protection (Status Code 601).
(-) 20°C (-) 4°F

Table 11. Heat Pump Heating Operational Range

Temperature
Event
C° F°
Room thermostat controls operation of outdoor unit.

Above Above NOTE - If the outdoor unit is operating and the outdoor ambient temperature drops below -4°F
(-) 26°C (-) 15°F (-20°C), the unit continues to operate until the room thermostat demand is satisfied or the outdoor
temperature drops to -15°F (-26°C). If the outdoor unit stops running while the temperature is below
-4°F (-20°C), the unit remains OFF until outdoor temperature rises above -4°F (-20°C),
Outdoor unit heating operation stopped by low ambient temperature protection (Status Code 601).
At or Below At or Below
(-) 26°C (-) 15°F
NOTE - Room thermostat "Low Balance Point" minimum setting is -15°F (-26°C).
NOTE - If system conditions are outside the specified ranges, the outdoor control may reduce, terminate, or prevent system
operation.

XP25
Page 44
Maintenance 3. Check condensate line and clean if necessary.
Outdoor Unit Locations with Possibility of Heavy Snow or
Freezing Rain Accumulation
Maintenance and service must be performed by a qualified
installer or service agency. At the beginning of each cooling Heavy snow and/or freezing rain can interfere with the
season, the system should be checked as follows: performance of the outdoor fan assembly. Lennox
recommends use of the optional snow guard (X8782) in
1. Clean and inspect outdoor coil (may be flushed with a these areas.
water hose). Ensure power is off before cleaning.
2. Outdoor unit fan motor is factory-lubricated 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.
7. Inspect drain holes in coil compartment base and clean
if necessary.
NOTE - If insufficient heating or cooling occurs, the unit
should be gauged and refrigerant charge should be
checked.
Outdoor Coil
It may be necessary to flush the outdoor coil more frequently Figure 23. Snow Guard Top Cover — X8782
if it is exposed to substances which are corrosive or which
block airflow across the coil (e.g., pet urine, cottonwood
SunSource® Home Energy System
seeds, fertilizers, fluids that may contain high levels of
corrosive chemicals such as salts).
• Outdoor Coil — The outdoor coil may be flushed with a
water hose.
• Outdoor Coil (Sea Coast) — Moist air in ocean locations
can carry salt, which is corrosive to most metal. Units
that are located near the ocean require frequent
inspections and maintenance. These inspections
determine the need to wash the unit including the
outdoor coil. Consult your installing contractor for proper
intervals/procedures for your geographic area or
service contract.
Indoor Unit
1. Clean or change filters.
2. Lennox blower motors are factory-lubricated and
permanently sealed. No more lubrication is needed. This Dave Lennox Signature® Collection heat pump is
3. Adjust blower speed for cooling. Measure the pressure factory-equipped with components that make it SunSource®
drop over the coil to determine the correct blower CFM. Solar-Ready. These units can be matched with solar
Refer to the unit information service manual for pressure modules and other optional equipment so that they can
drop tables and procedure. become part of a SunSource® Home Energy System.
4. Check all wiring for loose connections. Units can be upgraded for use with solar equipment at the
5. Check for correct voltage at unit. (blower operating) time of installation or in the future.
6. Check amp draw on blower motor. Solar energy is first used to meet cooling/heating demands.
When the outdoor unit is not operating, the system powers
Indoor Coil lighting, appliances and other electronic devices in the
1. Clean coil if necessary. home. Any surplus power is sent back to the utility company
2. Check connecting lines, joints and coil for evidence of oil for a possible credit. Check with your local utility company for
leaks. availability.

XP25
Page 45
Typical Unit Wiring Diagrams

Figure 24. Typical Unit Wiring (XP25-024 and -036)

XP25
Page 46
Figure 25. Typical Unit Wiring (XP25-048 and -060)

XP25
Page 47
NOTE - For more information on Load Shedding, see Electrical on page 24.

Figure 26. Load Shedding Feature Wiring Diagram

XP25
Page 48
Factory Wiring Diagrams

INVERTER
OUTDOOR
CONTROL
INVERTER
REACTOR

Figure 27. Typical Factory Wiring (XP25-024 and -036)

XP25
Page 49
INVERTER
REACTOR

INVERTER
NOISE FILTER
INVERTER

OUTDOOR
CONTROL

Figure 28. Typical Factory Wiring (XP25-048 and -060)

XP25
Page 50
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.
On 24 VAC power-up or outdoor reset, the outdoor control shall perform the follow­
ing 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 control does not detect any error codes, outdoor control sends 24 volts
out on the CNTCTR terminals to pull in the contactor coil.
(Note - These checks take about 60 seconds.)
4. The contactor contacts pull IN and main power is applied to the compressor inverter.

System
Idle

No
Room
Thermostat Yes
Demand
All
switches
closed and Heating or
Yes sensors in Heating
Cooling
operating
range?

No

Cooling
Yes Go To Auxiliary Check for status or
Emer­ Heating fault codes in outdoor
gency control or room ther­
Heat Se­ mostat (Note - Refer to
lected? low pressure and high
Below Low pressure switch flow
BP charts for sequence of
operation).
Balance All
No Point switches
Region closed and
No sensors in
operating
Above the Low BP range?
or Not Applicable

Go To Primary
Heat Pump Yes
Heating

Go To Go To
Modulat­ Modu­
ing Heat lating
Pump Cooling
Heat

Figure 29. 24 VAC Power-Up or Outdoor Reset

XP25
Page 51
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. (Note - These checks take about 60 seconds).
4. The contact(s) of the contactor pull IN and main power is applied to the compressor inverter.

From idle mode

No

Room thermostat is sending a heating percentage of maximum

capacity demand to the main control board in the outdoor unit.

Yes
Yes

Check for status or fault

codes in outdoor control
or room thermostat.
All switches closed and (Note - Refer to low
sensors in operating No
No
pressure and high pres­
range. sure switch flow charts
for sequence of opera­
tion.)

Yes
Yes

Outdoor Control Diagnostics Screen

1. Sends a demand to the compressor inverter 1. View the Heat PUMP screen for
to start and run the compressor up to the re­ current compressor frequency in
quested pumping capacity (Frequency in hertz.
Hertz).
2. View the OUTDOOR CONTROL
2. Outputs a DC voltage on the FAN PWM and 7-Segment display to read the
COM terminals to start and run the outdoor RPM of the outdoor fan motor.
fan motor at the desired RPM.
3. View the AIR HANDLER screen
3. Sends a communication signal to the indoor for actual CFM of the indoor
unit to start and run the supply fan motor at blower motor.
the demand air volume(CFM).
4. Energizes the on-board reversing valve re­
lay to outputs 24 volts to the reversing valve.

Figure 30. Heat Pump Mode

XP25
Page 52
 From modu­
lating heat
pump heat.

Heat pump ran for

at least 30 minutes? No

Yes

Defrost in the last 30 No

minutes?

Yes

Auxiliary heat is
used to satisfy all
heat calls during
heat pump lock­ Back to modulating
out. heat pump heat.

Go to auxiliary
heat.

Figure 31. Transition to Auxiliary Heat

XP25
Page 53
 Auxiliary heat (while
demand exists)

All sensors closed Check for status or

Dual Fuel? No No fault codes in out­
and within operating
range? door control
Yes

Yes

Turn off heat pump.

Heat only using gas
heat.
Emergency Go to auxiliary
Yes
heat selected? heating.

No

Balance Balance
point region point region

Above the low balance point

Go to primary heat
pump heating.

Return to
modulating
heat pump
heat.

Figure 32. Auxiliary Heat

XP25
Page 54
 Heat pump control monitors mode Defrost Calibration
of operation through outdoor Coil sensor detects temperature below 35°F {2°C} during
ambient temperature, outdoor coil either initial power-up, after loss of power or after cooling
temperature and compressor mode, a sacrificial defrost is used to ensure there is a clear
run-time to determine when a coil before attempting calibration.
defrost cycle is required.
Note - No system alert codes can
be active during defrost
calibration.
Coil sensor
below 35°F {2°C} NO No attempt
to calibrate.

Notes: YES
When the HP enters defrost, the thermostat runs
auxiliary heat with the HP, stopping the auxiliary
heat when defrost ends.
Accumulated compressor run-time while outdoor
coil temperature sensor input is below 35°F (2°C)

Continue to
30-35 minutes
NO accumulate
compressor
run-time.
run-time

YES

Defrost Mode
Demand Mode
Initiate a defrost (Turn off outdoor fan, energize reversing
After the initial calibration, the outdoor control
valve and increase compressor to 100% capacity). Monitor
disables the defrost mode for 30-34 minutes in
coil temperature sensor input and accumulated defrost time.
order to avoid unnecessary defrosts. Beyond
this timing period, both the ambient coil
sensors are continuously monitored. If the coil
temperature is below 35°F (2°C) and the cal­
ibration delta is reached or accumulated com­
pressor run-time is more than six (6) hours, a
defrost is to be initiated.
How did defrost
terminate?
NO

Defrost for 14 minutes without

Coil temperature sensor input the coil temperature sensor in­
reached specified defrost ter­ put reaching defrost termina­
mination temperature as set tion temperature as set on out­
on outdoor control. door control.

YES

Calibration Attempted
(Unit Running in Heat Mode)

Calibration NO

Figure 33. Defrost Calibration and Defrost Mode Sequence of Operations (All Versions)
XP25
Page 55
 Component Testing

Section Table of Contents

High and Low Pressure Switch Operation, Checkout and Reactor Operations, Checkout and Status /
Status / Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Reversing Valve Operation, Checkout and Status / Error Line Filter (Electromagnetic Compatibility Circuit - EMC)
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Operations, Checkout and Status / Error Codes . . . 71
Compressor Operation, Checkout and Status / Error
Outdoor Fan Operation and Checkout . . . . . . . . . . . 72
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Compressor Sound Cover . . . . . . . . . . . . . . . . . . . . . . 65 Ferrites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Charge Compensator (XP25-024-230-XX and Outdoor Control Operation, Checkout and Status / Error
XP25-048-230-XX only) . . . . . . . . . . . . . . . . . . . . . . . . 66 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Discharge Muffler (Heat Pumps only) . . . . . . . . . . . . 66 Unit Sensor Operations, Checkout and Status / Error
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Liquid Line Bi-Flow Filter Drier (Heat Pumps only) . 67

Check Expansion Valve (Heat Pumps only) . . . . . . . 68 Variable-Capacity Inverter Control Operation, Checkout
and Status / Error Codes . . . . . . . . . . . . . . . . . . . . . . . 79
Top Cap Switch Operation, Checkout and Status / Error
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Emergency 24VAC Operation . . . . . . . . . . . . . . . . . . . 84

High and Low Pressure Switch Operation, Checkout and Status / Error Codes
OPERATION :
The unit's pressure switches (LO PS - S87 and HI PS - S4) are factory-wired into the control on the LO-PS and HI-PS
terminals, respectively.
Low Pressure Switch (LO-PS) — See figure 35 for low pressure switch sequence of operation.
High Pressure Switch (HI-PS) — See figure 36 for high pressure switch sequence of operation.
Pressure Switch Event Settings
The following pressures are the auto-reset event value triggers for low and high pressure thresholds:
• High Pressure (auto-reset) - trip at 590 psig; reset at 418.
• Low Pressure (auto-reset) - trip at 40 psig; reset at 90.
CHECKOUT
Using a multimeter set to ohms with the terminals disconnected from the control board, check the resistance between the
two terminals of the pressure switch. If the resistance reading is 0 ohms, the switch is closed.

S4 S87
HIGH LOW
PRESSURE PRESSURE
SWITCH SWITCH

Figure 34. Verifying High Pressure and Low Pressure Switch Operation

XP25
Page 56
 LOW
INITIAL TRIP
PRESSURE CONTACTOR
Y1 DEMAND CLOSED SWITCH IS
SWITCH (S87) ENERGIZED IGNORED FOR
90 SECONDS

LOW
SWITCH IS CLOSED OR OUTDOOR
PRESSURE
OPEN CLOSED AMBIENT TEMPERATURE IS 15ºF
SWITCH (S87)
OR BELOW3

CONTACTOR 1. The thermostat terminates demand when the contactor is

DE-ENERGIZED de-energized. If demand is satisfied when alarm is not active, the
5-strike counter resets.
2. Lockouts can be reset by cycling power off to the outdoor control
OPEN (A175) R terminal.
ANTI-SHORT 3. The low pressure switch is ignored by the system when the out­
CYCLE TIMER door temperature is below 15°F.
BEGINS

5-STRIKE
COUNTER
INCREMENT
REACHES 5
5-STRIKE
WITHIN A SINGLE
COUNTER1
Y1 DEMAND

LED ALERT
LOW
CODE / OR
PRESSURE
MODERATE
SWITCH (S87)
ALERT 410
LOCKOUT
DISPLAYED

LED ALERT
ANTI-SHORT CODE / OR
CYCLE TIMER CRITICAL SERVICE
ENDS ALERT 411 REQUIRED2
DISPLAYED

CONTACTOR
ENERGIZED

LED ALERT
LOW CODE / OR
PRESSURE NORMAL
CLOSED MODERATE OPERATION
SWITCH (S87) ALERT 410
DISPLAYED
SERVICE
REQUIRED2

WAITING FOR
PRESSURE
OPEN SWITCH TO CLOSED
CLOSE

Figure 35. Low Pressure Switch (S87) Sequence of Operation (All Versions)

XP25
Page 57
 HIGH
TOP CAP CONTACTOR
PRESSURE
Y1 DEMAND CLOSED SWITCH (S173) CLOSED ENERGIZED
SWITCH (S4)

HIGH
PRESSURE
OPEN CLOSED
SWITCH (S4)

CONTACTOR
DE-ENERGIZED
1. The thermostat terminates demand when the contactor is
de-energized. If demand is satisfied when alarm is not active, the
OPEN 5-strike counter resets.
2. Lockouts can be reset by cycling power off to the outdoor control
ANTI-SHORT
(A175) R terminal.
CYCLE TIMER
BEGINS

5-STRIKE
COUNTER
INCREMENT
REACHES 5
5-STRIKE
WITHIN A SINGLE
COUNTER1
Y1 DEMAND

LED ALERT
HIGH
CODE / OR
PRESSURE
MODERATE
SWITCH (S4)
ALERT 412
LOCKOUT
DISPLAYED

LED ALERT
ANTI-SHORT CODE / OR
CYCLE TIMER CRITICAL SERVICE
ENDS ALERT 413 REQUIRED2
CLEARED

LED ALERT
HIGH CODE / OR
PRESSURE NORMAL
CLOSED MODERATE OPERATION
SWITCH (S4) ALERT 412
DISPLAYED
SERVICE
REQUIRED2

WAITING FOR
OPEN PRESSURE
SWITCH TO CLOSED
CLOSE

Figure 36. High Pressure Switch (S4) Sequence of Operation (All Versions)
XP25
Page 58
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Alert
Priority Alarm Description Possible Causes and Clearing Alarm
Codes
Unit pressure is below the lower limit. The system is shutdown. The low pressure switch
opens at 25PSIG and closes at 40PSIG. Confirm that the system is properly charged
The outdoor unit low pressure
E 410 Moderate with refrigerant. Check TXV, indoor unit blower motor, dirty filters or clogged refrigerant
switch has tripped.
filter. Confirm that the evaporator coil is clean. The alarm clears after the pressure
switch opens or after a power reset.
Low pressure switch error count reached 5 strikes. The low pressure switch opens at
The low pressure switch has tripped 40PSIG and resets at 90PSIG. Confirm that the system is properly charged with refri­
E 411 Critical 5 times within one hour. As a result, gerant. Check for clogged TXV, blockage to indoor unit blower motor, dirty filters or
the outdoor unit is locked out. clogged refrigerant filter. Confirm that the evaporator coil is clean. The alarm clears
after a power reset.
Unit pressure is above the upper limit. System is shut down. The high pressure switch
opens at 590PSIG and closes at 418PSIG. Confirm that the system is properly charged
with refrigerant. Check for clogged TXV, blockage to indoor unit blower motor, clogged
The outdoor unit high pressure
E 412 Moderate refrigerant filter. Confirm that the outdoor unit is clean. The alarm clears after the pres­
switch has opened.
sure switch closes or a power reset.
For heating, indoor CFM may be set too low. For zoning system, zone CFM may be set
too low.
Unit pressure is above the upper limit. System is shut down. The high pressure switch
opens at 590PSIG and closes at 418PSIG. Confirm that the system is properly charged
The high pressure switch has
with refrigerant. Check for clogged TXV, blockage to indoor unit blower motor, clogged
opened 5 times within one hour. As
E 413 Critical refrigerant filter. Confirm that the outdoor unit is clean. The alarm clears after the pres­
a result, the outdoor unit is locked
sure switch closes or a power reset.
out.
For heating, indoor CFM may be set too low. For zoning system, zone CFM may be set
too low.

XP25
Page 59
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.
Note - The reversing valve solenoid is energized in the cooling mode.

Figure 37. Reversing Valve (L1)

CHECKOUT:
Using a multimeter set to ohms, with the solenoid terminals disconnected from the outdoor unit’s control, check the
resistance between the two terminals of the reversing valve solenoid. If the resistance reading is 0 ohms or infinite,
replace solenoid coil.

Figure 38. Reversing Valve Checkout

XP25
Page 60
 IMPORTANT - ENSURE NEW REVERSING VALVE IS INSTALLED EXACTLY AS ORIGINAL
VALVE.

SOLENOID REVERSING VALVE

OPERATION

1. 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

2. WHEN THE SOLENOID IS DE-ENERGIZED (OFF),

REFRIGERANT PRESSURE IS DIRECTED FROM THE
CONDENSER (OUTDOOR COIL – C) TO THE SUCTION
(S) BACK TO THE COMPRESSOR.

LINE TO OUTDOOR
COIL

SUCTION LINE (TO

COMPRESSOR)

VAPOR LINE (TO SERVICE VALVE)

IMPORTANT - CONFIRM CORRECT CONNECTIONS OF

REFRIGERANT LINES TO REVERSING VALVE BEFORE
BRAZING IN VALVE.

Figure 39. Typical Reversing Valve Components and Operation

STATUS CODE:
Diagnostic screen in room thermostat indicates when reversing valve is ON.
ERROR CODES:
There is no feedback from the reversing valve to the outdoor control therefore no error codes is displayed on the outdoor
control or iComfort Wi-Fi® room thermostat. (NOTE - If the reversing valve does not operate as designed, the system is
shut down by other controls.)

XP25
Page 61
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). The compressor speed is determined
by demand from the room thermostat.
CHECKOUT:

Figure 40. Compressor Operation, Checkout and Status/Error Codes

IMPORTANT: If compressor replacement is required, remove the compressor through the top of the unit. Removal through
the access panel is not possible.
STATUS CODES:
When the compressor is running, the 7­segment display on the outdoor control displays (strings) the room thermostat
demand to the compressor as a percentage. (Example: C 5 0 – compressor is running at 50% of maximum speed.)

XP25
Page 62
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Inverter LED Flash

Code (number of
Alert Inverter flashes)
Priority Alarm Description Possible Causes and Clearing Alarm
Codes Code
Red
Green LED
LED

If condition is detected, outdoor unit com­

pressor and fan stop. Anti­short cycle is initi­
ated. If condition occurs 10 times within an
hour, system is locked out.
Moderate /
E 430 26 2 flashes 6 flashes Compressor start failure. Indicates poor connection at compressor har­
Critical
ness, improper winding resistance, locked com­
pressor rotor, or flooded compressor.
To clear, disconnect power to outdoor unit and
restart.
Error occurs when compressor peak phase
current is greater than 28A. Inverter issues
code 14 first and slows down to try to reduce
Moderate / The inverter has detected a com­ the current. If the current remains high, out­
E 433 29 2 flashes 9 flashes Critical pressor over-current condition. door unit compressor and fan stop. Anti­short
cycle is initiated. If condition occurs 5 times
within an hour, system is locked out. To clear
disconnect power to outdoor unit and restart.
Input current is approaching a high limit. Com­
pressor speed automatically slows. The control
continues sending the inverter speed deman­
Compressor slowdown due to high ded by the thermostat. The control sets indoor
E 439 12 1 flash 2 flashes Moderate input current.
CFM and outdoor RPM to values according to
demand percentage rather than the actual Hz.
Alarm is automatically cleared.
Issue: Feedback from supplier tear down of
Heat sink temperature is approach­ inverter indicates that the screws that hold the
ing limit. The compressor speed inverter to the inverter board were loose caus­
automatically slows to reduce heat ing poor contact between these two compon­
sink temperature. The control sets ents.
E 440 13 1 flash 3 flashes Moderate
indoor CFM and outdoor RPM to Corrective action: Tighten screws that hold
values according to demand per­ the heat sink to the inverter control board.
centage rather than the actual Hz.
Alarm is automatically cleared. NOTE: Wait 5 minutes to all capacitor to dis­
charge before checking screws.
Compressor slowdown due to high
compressor current. Compressor
current is approaching limit. The
compressor speed automatically Issue: Possible issue is system running at high
pressures. Check for high pressure trips or oth­
E 441 14 1 flash 4 flashes Moderate slows. The control sets indoor CFM
er alert codes in room thermostat and outdoor
and outdoor RPM to values accord­
ing to demand percentage rather control.
than the actual Hz. Alarm is auto­
matically cleared..

Compressor has been cycled OFF Load shedding function: Provides a method for
E 600 N/A N/A N/A Critical on utility load shedding. a local utility company to limit the maximum
power level usage of the outdoor unit.

XP25
Page 63
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).
1. When liquid line temperature drops below 50°F, the thermostat closes which results in the heater being energized.
2. When liquid line temperature rises above 70°F, the thermostat opens which results in the heater being de-energized.

Belly-Band Crankcase Heater - 240VAC, Watts

40 or 70

Crankcase Heater Thermostat

Figure 41. Belly-Band Crankcase Heater Thermostat

CHECKOUT:
Belly-Band Crankcase Heater: Using meter set on ohms, check crankcase heater resistance. If resistance is 0 ohms or
infinite, replace the crankcase heater.

Figure 42. Checking Belly-Band Crankcase Heater

XP25
Page 64
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. However, if a shorted or open circuit is detected, the
sensor is faulty; the sensor needs to be replaced.

Figure 43. Checking Crankcase Heater Thermostat

STATUS CODE:
None
ERROR CODES:
None
Compressor Sound Cover
All units come with a soft-sided polyethylene molded outer shell compressor sound cover. The cover helps reduce any
unwanted operating sounds from the compressor. The cover features a hook/loop closure system for ease of installation on
the compressor.

Figure 44. Compressor Sound Cover

XP25
Page 65
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
COMPENSATOR TANK - HEATING MODE, THE VAPOR LINE IS
DURING COOLING COOLER THAN THE LIQUID LINE.
MODE, THE VAPOR LINE EXCESS REFRIGERANT IS FORCED
IS HOTTER THAN THE INTO THE CHARGE COMPENSATOR
LIQUID LINE. STORED WHERE IT CONDENSES AND
LIQUID IS HEATED COLLECTS.
(BOILED) AND FORCE
BACK INTO
CIRCULATION.

STORED LIQUID TO EXCESS REFRIGERANT

LIQUID LINE TO BE TO BE CONDENSED AND
CIRCULATED THROUGH STORED AS LIQUID.
INDOOR COIL.

VAPOR LINE VAPOR LINE (TO

(FROM COMPRESSOR COMPRESSOR SUCTION
DISCHARGE PORT) PORT)

Figure 45. Charge Compensator

Discharge Muffler (Heat Pumps only)

The discharge muffler absorbs unwanted harmonic resonance from the compressor.

Figure 46. Top Discharge Muffler

XP25
Page 66
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.
CHECKOUT:
If the filter drier becomes filled with debris, contaminants, or non-condensables, it restricts refrigerant flow. If the filter drier is
restricted, the outlet side of the filter drier is cooler than the inlet side. Some filter driers have an access port which allows you
to measure the pressure drop with a pressure gauge. If it is restrictive (Greater than 3 psig pressure difference), remove it from
the system and replace it.
Perform a moisture test on the system. If the test indicates moisture levels above what the moisture kit recommends, replace
the drier.
Note - Recommended practice is to replace the filter drier every time you open the system.
STATUS CODES:
None
ERROR CODES:
None
NOTE - If the drier is not operating correctly, the system is shut down by other controls, such as the high and low pressure
switches, which will generate a code.

Figure 47. Top Bi-Flow Filter Drier

XP25
Page 67
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 Symptoms Causes Corrective Action
1. Replace with correct size valve
2. Adjust the superheat to correct set­
ting
1. Oversized valve 3. Replace the filter / driers
2. Incorrect superheat setting 4. Evacuate the system and replace the
3. Moisture refrigerant
1. Liquid slugging
4. Dirt or foreign material 5. Clean out the material or replace the
Superheat is too low - 2. Low superheat
5. Incorrect charge selection valve
valve feeds too much 3. Suction pressure normal or
6. Incorrect bulb location 6. Select proper charge based on refri­
high
7. Incorrect equalizer location gerant type
8. Plugged equalizer (balanced 7. Relocate the bulb to proper location
ported valve) 8. Relocate the equalizer to proper loc­
ation
9. Remove any restriction in the equal­
izer tube

1. Low on refrigerant 1. Add correct amount refrigerant

2. High superheat 2. Change superheat setting
3. Flash gas in liquid line 3. Remove source of restriction
4. Low or lost bulb charge 4. Replace power element or valve
5. Moisture 5. Replace driers or evacuate the sys­
tem and replace refrigerant
6. Plugged equalizer (conventional
valve) 6. Remove any restriction in the equal­
izer tube
7. Insufficient pressure drop or
1. Evaporator temperature too valve to small 7. Replace existing valve with properly
Superheat is too high - high sized valve
Valve does not feed or 8. Dirt or foreign material
2. High superheat 8. Clean out the material or replace the
does not feed enough 9. Incorrect charge selection
3. Low suction pressure valve
10. Incorrect bulb location 9. Select the correct charge
11. Incorrect equalizer location 10. Move the bulb to the correct location
12. Charge migration 11. Move equalizer to correct location
13. wax 12. Move valve to a warmer location or
14. Wrong equalizer type valve apply heat tape to the power head
15. Rod leakage (balanced port 13. Use charcoal drier
valve) 14. Use externally equalized valve
16. Heat damaged power head 15. Replace power head or valve
1. Refrigerant drainage 1. Use Pump Down Control
2. Compressor or suction line in a 2. Install a trap at the top of the Evapor­
1. Liquid slugging cold location ator
No superheat at start- 3. Install Crankcase Heater
2. Zero super heat 3. Partially restricted or plugged
up only - valve feeds
3. Suction pressure higher external equalizer (balance port 4. Install Suction Solenoid
too much at start-up
than normal valve) 5. Remove restriction
4. Liquid line solenoid will not com­ 6. Disassemble/Clean Valve
pletely shut 7. Replace valve
1. Reposition bulb
1. Bulb location Incorrect
Superheat is erratic or 1. Suction pressure hunts 2. Replace existing valve with correct
2. Too large a valve
hunts - system hunts or 2. Superheat hunts sized valve
cycles 3. Incorrect superheat setting
3. Erratic valve feeding 3. Adjust superheat to correct setting
4. System design
4. Redesign system

XP25
Page 68
Table 14 Continued
Problem Symptoms Causes Corrective Action
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 1. Poor system performance other coil tion
mal - system performs 3. Low load 4. Correct match
2. Low or normal superheat
poorly - valve does not
feed properly 3. Low suction pressure 4. Mismatched coil / compressor 5. Hot gas bypass
5. Incorrect distributor 6. Add unloaded to compressor (if pos­
6. Evaporator oil­logged sible)
7. Install correct distributor
8. Increase gas velocity through the coil
1. Replace with correct size valve
2. Adjust the superheat to correct set­
ting
1. Oversized valve 3. Replace the filter / driers
2. Incorrect superheat setting 4. Evacuate the system and replace the
3. Moisture refrigerant
1. Liquid slugging
Superheat is too low - 4. Dirt or foreign material 5. Clean out the material or replace the
2. Low superheat
TEV feeds to much - 5. Incorrect charge selection valve
valve feeds too much 3. Suction pressure normal or
6. Incorrect bulb location 6. Select proper charge based on refri­
high
7. Incorrect equalizer location gerant type
8. Plugged equalizer (balance port 7. Relocate the bulb to proper location
valve) 8. Relocate the equalizer to proper loc­
ation
9. Remove any restriction in the equal­
izer tube
STATUS CODES:
None
ERROR CODES:
None
NOTE - If the drier is not operating correctly, the system is shut down by other controls, such as the high and low pressure
switches, which will generate a code.

CHECK EXPANSION
VALVE - (HFC-410A)

CHECK EXPANSION
VALVE - (HFC-410A)
MICRO:06L
MICRO:06L

Figure 48. Plumbing (Component Locations and Specifications)

XP25
Page 69
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. The auto-reset switch closes
when the compressor casing temperature falls to 151-187°F, and the compressor is re-energized. This single-pole,
single-throw (SPST) bi-metallic switch.

COMPRESSOR TOP CAP SWITCH

(SPST BI-METALLIC SWITCH,
NORMALLY OPENS AT 239-257ºF,
AND CLOSES AT 151-187ºF

SWITCH COVER

TOP OF COMPRESS0R

Figure 49. Top Cap Thermal Sensor Switch Operation

CHECKOUT:
Using a multimeter set to ohms, with the terminals disconnected from the system, check the resistance between the two
terminals of the top cap switch. If the resistance reading is 0 ohms, the switch is closed.

Figure 50. Top Cap Thermal Sensor Switch Checkout (S173)

STATUS:
None
ERROR:
Table 15. Outdoor Control 7-Segment Display Alert Codes - Top Cap Switch
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Alert
Priority Alarm Description Possible Causes and Clearing Alarm
Codes
Check condenser fan motor, TEV, indoor unit blower motor, stuck reversing valve,
E 422 Compressor top cap switch ex­ clogged refrigerant filter or undercharge. When error occurs with inverter slowdown
Moderate
ceeding thermal limit.
errors, check for system overcharge. Automatically clears when error is corrected.
The top cap switch has opened 5
times within one hour. As a result, When compressor thermal protection sensor opens 5 times within 1 hour, outdoor stops
E 442 Critical
working. To clear, disconnect power to outdoor unit and restart.
the outdoor unit is locked out.

XP25
Page 70
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.

CHECKOUT:
Main Power ON – Voltage IN reactor should be the same as the voltage OUT. With main power OFF and reactor
disconnected from system; resistance between leads should be the same (brown IN to brown OUT, blue IN to blue OUT).

Voltage “IN” same as Voltage “OUT”

Figure 51. XC/XP 25-024 and -036 Reactor

208/240 208/240
Voltage “IN” Voltage
“OUT”

Figure 52. XC/XP 25-048 and -060 Reactor

STATUS CODES:
None
ERROR CODES:
None
Line Filter (Electromagnetic Compatibility Circuit - EMC) Operations, Checkout and Status /
Error Codes
OPERATION:
The line filter is being used to reduce the unintentional conducted emission from the equipment to a level sufficiently to
minimize electrical interference.
The filter is rated at 208/230 volt, 30 amp maximum, 60 Hertz.

NOTE - The 2- and 3-ton inverters have the EMC built­in. The 4- and 5-ton units have an external device (see illustration
below).

NOTE - A line filter is an electronic filter which is placed between electronic equipment and an external power source in
order to attenuate conducted radio frequency interference (RFI). RFI is also known as electromagnetic interference (EMI).
XP25
Page 71
 L2

L1
208/240
Voltage “OUT”
208/240
Voltage “IN”

N1
N2

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:
None

Outdoor Fan Operation and Checkout

XP25 Fan Assembly
OPERATION:
These units use an integrated control and motor that is
programmed for variable-capacity operation. The fan speed is
controlled by the iComfort Wi-Fi® thermostat.

CHECKOUT:
VAC Voltage Check
Check for 208/240 VAC power at inverter contactor (red wires) (see figure 54).
With unit operating, check for main VAC to motor and outdoor control VDC output to motor:
1. No voltage present – Check main power
2. Voltage present – Perform DC volt checks (19 -23 VDC between FAN PWM and COM) (see figure 54).

XP25
Page 72
Perform DC volt checks (19 -23
VDC between FAN PWM and
COM).

Figure 54. VAC Voltage Check

XP25
Page 73
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.
2. Voltage present – Perform a 9-volt battery test (see below) on motor.

BROWN LEAD
BLACK LEAD

CONNECT B4 FAN MOTOR WIRE

TO 9V BATTERY POSITIVE
V
TERMINAL

CONNECT B4 FAN MOTOR BLACK

COMMON WIRE TO 9V BATTERY
NEGATIVE TERMINAL

NEGATIVE TERMINAL POSITIVE TERMINAL

FULLY CHARGED 9V BATTERY

Figure 55. VDC Voltage Check

STATUS CODES:
None
ERROR CODES:
None
NOTE - If the outdoor fan does not operate at the correct RPM, or does not start, the system is be down by other protection
components such as the high and low pressure switches which generate error code(s).
Ferrites
Electronic cabling and wires, by virtue of their length­to­width ratios, are perfect natural antennas. In the presence of
high­speed microprocessor signals, cables will conduct, radiate, and receive unwanted high­frequency signals. Use an
insertion-loss device, such as a ferrite suppressor as shown below, to control radio-frequency (RF) interference.

Ferrites are consistently stable over time and

over wide temperature ranges, and provide
RF suppression without causing large current
losses.

Figure 56. Ferrites

XP25
Page 74
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. The outdoor control is self-configuring. During start-up the outdoor control selects
one of two configurations ­ variable-capacity air conditioner or variable-capacity heat pump.

COMMUNICATION PLUG BETWEEN OUTDOOR

CONTROL AND INVERTER CONTROL

PUSH 7-SEGMENT
AMBIENT, COIL AND LIQUID
BUTTON DISPLAY
LINE SENSOR PLUG
PUMP DOWN - WHEN UNIT IS IN PUMP DOWN MODE,  WILL BE
NOTE - THE GREEN LED ON THE OUTDOOR CONTROL FLASHES DISPLAYED ON 7-SEGMENT.
WHEN COMMUNICATION OCCURS BETWEEN THE OUTDOOR TO ACTIVATE PUMP DOWN MODE, REFER TO PUMP DOWN
CONTROL AND EITHER THE THERMOSTAT OR THE INVERTER. CYCLE SEQUENCE ON PAGE 39.

Figure 57. Outdoor Control Operation

STATUS CODES:
Table 16. Outdoor Control 7-Segment Display Alert Codes - Outdoor Control Status
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Alert
Priority Alarm Description Possible Causes and Clearing Alarm
Codes
Compressor has been cycled OFF Load shedding function: Provides a method for a local utility company to limit the maxim­
E 600 Critical
on utility load shedding. um power level usage of the outdoor unit.
Low temperature protection: Outdoor unit will not operate when the outdoor temperat­
ure is at or below ­4°F (­20°C). If the unit is operating and the outdoor temperature
Outdoor unit has been cycled OFF
E 601 Critical drops below ­4°F (­20°C), the unit continues to operate until the room thermostat is sat­
on low temperature protection.
isfied or the outdoor temperature drops to ­15°F (­26°C). Outdoor unit ambient sensor
provides temperature readings.

XP25
Page 75
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Alert
Priority Alarm Description Possible Causes and Clearing Alarm
Codes

Equipment is unable to communicate. Indicates numerous message errors. In most

The outdoor control has lost com­ cases errors are related to electrical noise. Make sure high voltage power is separ­
E 105 Moderate munication with either the thermo­ ated from RSBus. Check for mis­wired and/or loose connections between the stat,
stat or indoor unit. indoor unit and outdoor unit. Check for a high voltage source of noise close to the
system. Fault clears after communication is restored.

Typically, this alarm/code does not cause any issues and will clear on its own. The
There is a delay in the outdoor unit alarm / code is usually caused by a delay in the outdoor unit responding to the ther­
E 120 Moderate responding to the system. mostat. Check all wiring connections. Cleared after unresponsive device responds to
any inquiry
Equipment lost communication with the thermostat. Check the wiring connections,
The iComfort Wi­Fi® thermostat has ohm wires and cycle power. The alarm stops all associated HVAC operations and
E 124 Critical lost communication with the out­ waits for a heartbeat message from the unit that's not communicating. The alarm /
door unit for more than 3 minutes. fault clears after communication is re­established.

There is a hardware problem with There is a control hardware problem. Replace the outdoor control if the problem pre­
E 125 Critical the outdoor control. vents operation and is persistent. The alarm / fault is cleared 300 seconds after the
fault recovers.
The outdoor unit control parameters
E 131 Critical are corrupted Reconfigure the system. Replace the control if heating or cooling is not available

E 132 Critical Internal software error. Replace outdoor control.

Unit Sensor Operations, Checkout and Status / Error Codes

OPERATION
Coil Temperature Sensor (RT21)
Coil temperatures, as read by the sensor (shown in figure 59), which are below -35°F (-37°C) or above 120°F (48°C) trigger a
fault condition. If the defrost coil sensor is open, shorted, or out of the temperature range, the outdoor control will not perform
defrost operation (demand or time/temperature) and displays the appropriate fault code (see table 19 on page 79). Heating
and cooling operation is allowed during this fault condition.
Ambient Temperature Sensor (RT13)
Ambient temperatures, as read by the ambient temperature sensor (shown in figure 59), which are below -35°F (-37°C) or
above 120°F (48°C) trigger a fault condition. If the ambient sensor is open, shorted, or out of the temperature range of the
sensor, the control does not perform demand defrost operation. The control reverts to time/temperature defrost operation and
displays the appropriate alert code (see table 19 on page 79). Heating and cooling operation is allowed in this fault condition.
Liquid Line Temperature Sensor (RT36)
Liquid line temperatures below -40°F (-40°C) or above 140°F (60°C) trigger a fault condition and result in the appropriate
alarm code (see table 19 on page 79). The outdoor control uses the liquid line sensor to change the fan speed, allowing cooling
operation at lowered ambient temperatures.

XP25
Page 76
 TEMP RANGE ºF RESISTANCE VALUES PIN# / WIRE
SENSOR
(ºC) RANGE (OHMS) SLEEVE COLOR
COIL 6 AND 5
336,000 to 2,487 (see (BROWN)
-40 (-40) TO table 18 on page 78 for
OUTDOOR 4 AND 3
140 (60) exact temperature to
AMBIENT (BLACK)
ohm readings)
2 AND 1
LIQUID LINE (YELLOW)
COIL

BLACK WIRES WITH

OUTDOOR BROWN SLEEVE
AMBIENT

BLACK WIRES WITH

LIQUID LINE BLACK SLEEVE
TEMPERATURE
SENSOR HARNESS
BLACK WIRES WITH
YELLOW SLEEVE

Figure 58. Temperature Sensor Specifications

CHECKOUT
Sensors connect to the outdoor control through a field‐replaceable harness assembly that plugs into the control. Through the
sensors, the control detects outdoor ambient, coil and liquid temperature fault conditions. 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 both type of sensors. Check sensor operation by reading ohms across pins shown in figure 58.
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. However, if a shorted or open circuit is detected, then the
sensor may be faulty and the sensor harness will need to be replaced.

(-048) COIL TEMPERATURE

SENSOR (RT21) - ON
RETURN BEND, 16 TUBES
(-024 AND -036) COIL UP FROM BOTTOM (15.50'
TEMPERATURE SENSOR UP)
(RT21) - ON RETURN BEND,
12 TUBES UP FROM (-060) COIL TEMPERATURE
BOTTOM (11.50' UP) SENSOR (RT21) - ON
RETURN BEND, 12 TUBES
UP FROM BOTTOM (11.50'
UP)

OUTDOOR AMBIENT
TEMPERATURE
SENSOR LIQUID LINE SENSOR

CRANKCASE HEATER
THERMOSTAT (S40) OPENS AT
70ºF, CLOSES AT 50ºF

Figure 59. Temperature Sensor Locations

XP25
Page 77
 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 125787
130.1 3040 55.3 17293 20.5 45560 -12.6 128508
127.3 3223 54.6 17616 20.0 46281 -13.2 131320
124.7 3407 53.9 17942 19.4 47014 -13.9 134227
122.1 3592 53.2 18273 18.9 47759 -14.5 137234
119.7 3779 52.5 18607 18.4 48517 -15.2 140347
117.5 3968 51.9 18945 17.8 49289 -15.9 143571
115.3 4159 51.2 19287 17.3 50074 -16.5 146913
113.2 4351 50.5 19633 16.8 50873 -17.2 150378
111.2 4544 49.9 19982 16.3 51686 -17.9 153974
109.3 4740 49.2 20336 15.7 52514 -18.6 157708
107.4 4937 48.5 20695 15.2 53356 -19.3 161588
105.6 5136 47.9 21057 14.7 54215 -20.1 165624
103.9 5336 47.3 21424 14.1 55089 -20.8 169824
102.3 5539 46.6 21795 13.6 55979 -21.5 174200
100.6 5743 46.0 22171 13.1 56887 -22.3 178762
99.1 5949 45.4 22551 12.5 57811 -23.0 183522
97.6 6157 44.7 22936 12.0 58754 -23.8 188493
96.1 6367 44.1 23326 11.5 59715 -24.6 193691
94.7 6578 43.5 23720 11.0 60694 -25.4 199130
93.3 6792 42.9 24120 10.4 61693 -26.2 204829
92.0 7007 42.3 24525 9.9 62712 -27.0 210805
90.6 7225 41.7 24934 9.3 63752 -27.8 217080
89.4 7444 41.1 25349 8.8 64812 -28.7 223677
88.1 7666 40.5 25769 8.3 65895 -29.5 230621
86.9 7890 39.9 26195 7.7 67000 -30.4 237941
85.7 8115 39.3 26626 7.2 68128 -31.3 245667
84.5 8343 38.7 27063 6.7 69281 -32.2 253834
83.4 8573 38.1 27505 6.1 70458 -33.2 262482
82.3 8806 37.5 27954 5.6 71661 -34.1 271655
81.2 9040 37.0 28408 5.0 72890 -35.1 281400
80.1 9277 36.4 28868 4.5 74147 -36.1 291774
79.0 9516 35.8 29335 3.9 75431 -37.1 302840
78.0 9757 35.2 29808 3.4 76745 -38.2 314669
77.0 10001 34.7 30288 2.8 78090 -39.2 327343
76.0 10247 34.1 30774 2.3 79465
75.0 10496 33.5 31267 1.7 80873
74.1 10747 33.0 31766 1.2 82314
73.1 11000 32.4 32273 0.6 83790
72.2 11256 31.9 32787 0.0 85302
71.3 11515 31.3 33309 -0.5 86852
70.4 11776 30.7 33837 -1.1 88440
69.5 12040 30.2 34374 -1.7 90068
68.6 12306 29.6 34918 -2.2 91738
67.7 12575 29.1 35471 -2.8 93452
66.9 12847 28.6 36031 -3.4 95211
66.0 13122 28.0 36600 -4.0 97016
65.2 13400 27.5 37177 -4.6 98870
64.4 13681 26.9 37764 -5.2 100775
63.6 13964 26.4 38359 -5.7 102733
62.8 14251 25.8 38963 -6.3 104746
62.0 14540 25.3 39577 -6.9 106817
61.2 14833 24.8 40200 -7.5 108948
60.5 15129 24.2 40833 -8.2 111141
59.7 15428 23.7 41476 -8.8 113400
59.0 15730 23.2 42130 -9.4 115727
58.2 16036 22.6 42794 -10.0 118126
57.5 16345 22.1 43468 -10.6 120600

XP25
Page 78
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Alert
Priority Alarm Description Possible Causes and Clearing Alarm
Codes

In normal operation, after outdoor control recognizes sensors, the alarm is sent if
The outdoor unit ambient temper­ valid temperature reading is lost. Compare outdoor sensor resistance to temperat­
ature sensor has malfunctioned. ure/resistance charts in unit installation instructions. Replace sensor pack if neces­
E 180 Critical As a result the outdoor unit control sary. At the beginning of (any) configuration, furnace or air­handler control detects
will not perform low ambient cool­ the presence of the sensor(s). If detected (reading in range), appropriate feature is
ing. shown in the iComfort Wi­Fi® thermostat About screen. The alarm / fault clears upon
configuration, or when normal values are sensed.

Coil sensor being detected open or shorted, or temperature is out of coil sensor
The outdoor coil sensor has mal­ range. Outdoor unit control will not perform demand or time/temperature defrost
Moderate/ functioned. As a result the out­ operation. System is still able heat and cool. Check the resistance of the coil sensor
E 416 and compare to temperature resistance chart. Replace coil sensor if needed. The
Critical door unit control will not perform
defrost. alarm clears when outdoor unit control detects proper coil sensor readings or after a
power reset.

In normal operation, after outdoor control recognizes sensors, the alarm is sent if
valid temperature reading is lost. Compare liquid line sensor resistance to temperat­
ure/resistance charts in unit installation instructions. Replace sensor pack if neces­
The liquid line temperature sensor sary. At the beginning of (any) configuration, furnace or air­handler control detects
E 424 Moderate has malfunctioned.
the presence of the sensor(s). If detected (reading in range), appropriate feature is
shown in the iComfort Wi­Fi® thermostat About screen. The alarm / fault clears upon
configuration, or when normal values are sensed.

Variable-capacity Inverter Control Operation, Checkout, Status / Error Codes

OPERATION OF COMPONENTS:
Electromagnetic compatibility circuit (EMC): EMC ensures the correct operation of different equipment items which use or
respond to electromagnetic phenomena, and the avoidance of any interference effects.
NOTE - The 2- and 3-ton DC inverter control has the EMC built­in. The 4- and 5-ton units have an external EMC.
CONVERTER:
Converts AC (alternating current) to DC (direct current).
POWER FACTOR CORRECTION (PFC) CIRCUIT:
The PFC module is an integrated part of the outdoor DC inverter control that monitors the DC bus for high, low and abnormal
voltage conditions. If any of these conditions are detected, the PFC function and compressor will stop.
INTELLIGENT (INVERTER) POWER MODULE (IPM):
The IPM inverts DC voltage into AC voltage. The control method is known as pulse width modulation (PWM). This means the
DC is switched on and off very quickly (chopped) by the transistor switches to make simulated AC at required frequency and
voltage.
COMMUNICATION CONTROL CIRCUIT:
Receives and sends message between the DC inverter control and the outdoor control.

Power Factor Correction Circuit Electromagnetic Compatibility Circuits

Converter

Intelligent Power Module Communication Control

Figure 60. 2- and 3-Ton Unit Inverter

XP25
Page 79
 Heat Sink
Converter Intelligent Power Module

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). If no fault or lockout codes are active, then system status codes are displayed. Alert
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Inverter LED Flash Code

Alert (number of flashes)
Code Priority Possible Causes and Clearing Alarm
Codes
Red LED Green LED
N/A N/A ON OFF N/A XC/XP 25-024 and -036 only: Indicates inverter is operating normally.
N/A N/A ON ON N/A XC/XP 25-048 and -060 only: Indicates inverter is operating normally.
N/A N/A OFF OFF N/A Indicates inverter is NOT energized.

ERROR CODES:
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.
Inverter LED Flash Code
Alert (number of flashes)
Code Priority Alarm Description Possible Causes and Clearing Alarm
Codes
Red LED Green LED
Control locks out after 10 strikes within an hour. To
Moderate / The inverter has detec­
E 423 40 4 flashes OFF clear, disconnect power to outdoor unit and re­
Critical ted a circuit problem.
start.
After ten faults within one hour, control is locked
out, indicating poor system operation. Review his­
tory of alarms to resolve system setup. Check con­
denser fan motor, TXV, indoor unit blower motor,
Excessive inverter over-charge, undercharge, or clogged refrigerant
E 426 N/A N/A N/A Critical
alarms filter.
To clear error, disconnect power to outdoor unit
and restart. Inverter alarms 12 to 14 and 53 do not
count towards this lock out condition.
The inverter has detected a DC peak fault condition. If condition (55A or high­
er) is detected, outdoor unit compressor and fan stop. Anti-short cycle is initi­
Moderate /
E 427 21 2 flashes 1 flash ated. If peak current (55A or higher) occurs 10 times within an hour, system is
Critical
locked out. Indicates high pressure, condenser fan failure, locked compressor
rotor or overcharge. To clear, disconnect power to outdoor unit and restart.

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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

XP25
Page 80
 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 system is locked out.
Moderate /
E 428 22 2 flashes 2 flashes ted a high main input cur­
Critical Indicates high pressure, condenser fan failure or
rent condition.
overcharge.
To clear, disconnect power to outdoor unit and re­
start.
On a call for compressor
operation, if DC link Issues:
power in inverter does
(1) If DC link power in inverter does not rise
not rise above 180 VDC
above 180 VDC for 2- and 3-ton models, 250
for 2 and 3 ton models,
VDC for 4- and 5-ton models, within 30 seconds,
250 VDC for 4 and 5 ton
the outdoor control will display a moderate code.
models, within 30
seconds, the control will (2) Capacitors on inverter do not properly charge.
Moderate / display a moderate code.
E 429 23 2 flashes 3 flashes Corrective Actions:
Critical If condition is detected,
outdoor unit will stop
(1) check for proper main power to outdoor unit
(Compressor and fan).
and for any loose electrical connections.
Anti-short cycles is initi­
ated. If condition occurs (2) Outdoor control boards with part # 103686-03
10 times within a 60 have software update to delay the de-energizing
minute rolling time period, of the reversing valve by four seconds when com­
system will lock out and ing out of defrost.
display a critical code.
Error occurs when PFC Issues:
detects an over-current
condition of 100A, the (1) Indicates power interruption, brownout, poor
control will display a electrical connection or loose inverter input wire.
moderate code. If condi­ (2) System testing was set up and code was gen­
tion is detected, outdoor erated when the reversing valve is de-energized
unit will stop (Com­ coming out of defrost (code appears with or
pressor and fan). Anti- without 30 compressor delay).
Moderate /
E 431 27 2 flashes 7 flashes short cycle is initiated. In­
Critical Corrective Actions:
verter is unavailable to
communicate with the (1) Check for proper main power to outdoor unit
outdoor control for 3 and for any loose electrical connections.
minutes. If condition oc­
curs 10 times within a 60 (2) Outdoor control boards with part # 103686-03
minute rolling time period, have software update to delay the de-energizing
system will lock out and of the reversing valve by four seconds when com­
display a critical code. ing out of defrost.
Error occurs when the DC link capacitor voltage is
greater than 480VDC. If condition is detected, out­
The inverter has detec­ door unit compressor and fan stop. Anti­short
Moderate /
E 432 28 2 flashes 8 flashes ted a DC link high voltage cycle is initiated. If condition occurs 10 times within
Critical
condition. an hour, system is locked out. System stops. To
clear, disconnect power to outdoor unit and re­
start.
Error occurs when compressor peak phase cur­
rent is greater than 28A. Inverter issues code 14
The inverter has detected first and slows down to try to reduce the current. If
Moderate / the current remains high, outdoor unit compressor
E 433 29 2 flashes 9 flashes a compressor over-cur­
Critical and fan stop. Anti­short cycle is initiated. If condi­
rent condition.
tion occurs 5 times within an hour, system is
locked out. To clear disconnect power to outdoor
unit and restart.

XP25
Page 81
 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
codes are also displayed on the iComfort Wi-Fi ® thermostat.

Inverter LED Flash Code

Alert (number of flashes)
Code Priority Alarm Description Possible Causes and Clearing Alarm
Codes
Red LED Green LED

Outdoor control has lost

communications with the
inverter for greater than Issues:
3 minutes. Outdoor con­
trol will stop all com­ (1) Loose electrical connections.
pressor demands, re­
Moderate / cycle power to the invert­ (2) Interruption of main power to inverter.
E 434 53 5 flashes 3 flashes
Critical er by de-energizing the Corrective Actions:
contactor for 2 minutes.
If this occurs 3 time in (1) Check all electrical connections.
one thermostat call, the
outdoor unit will locked (2) Check for proper main power to inverter.
out and display a critical
code.

When this error occurs, the outdoor control cycles

power to the inverter by opening the contactor for
Moderate /
E 435 60 6 flashes OFF Inverter internal error. 2 minutes. Check that the EEPROM is properly
Critical
seated. After power is cycled to the inverter 3
times, the outdoor unit is locked out.

Inverter heat sink tem­

perature exceeded limit.
Occurs when the heat
sink temperature ex­
ceeds the inverter limit. Issue: Feedback from supplier tear down of inverter
Inverter issues code 13 indicates that the screws that hold the inverter to the
first, then slows down to inverter board were loose causing poor contact
allow the heat sink to between these two components.
Moderate / cool. If temperature re­
E 436 62 6 flashes 2 flashes
Critical mains high, outdoor unit Corrective Action: Tighten screws that hold the
stops (compressor and heat sink to the inverter control board.
fan). Anti-short cycle is
initiated. If condition oc­ NOTE: Wait five minutes to all capacitor to dis­
curs 5 times within an charge before checking screws.
hour, system is locked
out. To clear, disconnect
power to outdoor unit
and restart.

This occurs when the temperature sensor detects

Heat sink temperature a temperature less than 0.4ºF or greater than
sensor fault has occurred 264ºF after 10 minutes of operation. If condition is
Moderate / (temperature less than 4 detected, outdoor unit compressor and fan stop.
E 437 65 6 flashes 5 flashes
Critical ºF or greater than 264ºF Anti­short cycle is initiated. If condition occurs 5
after 10 minutes of opera­ times within an hour, system is locked out. To clear
tion). disconnect power to outdoor unit and restart. If
problem persists, replace inverter.

The inverter has detec­

ted a PFC over current
condition.  This would be
caused by a high load
condition, high pressure,
or outdoor fan fail­
ure. Outdoor control will
display the code when
the inverter has the er­ Issue: Possible issue is system running at high
Moderate /
E 438 73 7 flashes 3 flashes ror.  After 3 minutes, the pressures. Check for high pressure trips or other
Critical
inverter will reset and alert codes in room thermostat and outdoor control.
the compressor will turn
on again.  If it happens
10 times within a 60
minute rolling time peri­
od, the OD control will
lock out operation of the
outdoor unit and display
a critical code.
XP25
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
codes are also displayed on the iComfort Wi-Fi ® thermostat.
Inverter LED Flash Code
Alert (number of flashes)
Code Priority Alarm Description Possible Causes and Clearing Alarm
Codes
Red LED Green LED
Input current is approaching a high limit. Com­
pressor speed will automatically slow down. The
Compressor slowdown control continues sending the inverter speed de­
E 439 12 1 flash 2 flashes Moderate due to high input cur­ manded by the thermostat. The control will set in­
rent. door CFM and outdoor RPM to values according
to demand percentage rather than the actual Hz.
Alarm is automatically clear. See E428.
Heat sink temperature is
approaching limit. The Issue: Feedback from supplier tear down of invert­
compressor speed auto­ er indicates that the screws that hold the inverter to
matically slows to re­ the inverter board were loose causing poor contact
duce heat sink temperat­ between these two components.
ure. The control sets in­
E 440 13 1 flash 3 flashes Moderate
door CFM and outdoor Corrective action: Tighten screws that hold the
RPM to values accord­ heat sink to the inverter control board.
ing to demand percent­
age rather than the actu­ NOTE: Wait 5 minutes to all capacitor to discharge
al Hz. Alarm is automat­ before checking screws.
ically cleared.
Compressor slowdown
due to high compressor
current. Compressor
current is approaching
limit. The compressor
speed automatically Issue: Possible issue is system running at high
E 441 14 1 flash 4 flashes Moderate slows. The control sets pressures. Check for high pressure trips or other
indoor CFM and outdoor alert codes in room thermostat and outdoor control.
RPM to values accord­
ing to demand percent­
age rather than the actu­
al Hz. Alarm is automat­
ically cleared..

XP25
Page 83
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).

iComfort Wi-Fi® Thermostat Emergency 24VAC

Communicating Air Handler and XP25 (Non-Communicating Mode)
Communicating Air
Handler or Communicating Air
Furnance Handler or
Furnance

iComfort Wi−Fi
THERMOSTAT
XP25 UNIT 24VAC Thermostat
C

R
RSBus
NOTE 1
O
Y

XP25 UNIT

NOTE 3
NOTE 2
XC25 XP25
DO NOT CUT CUT LINK

NOTES:
1. Move two wires on both indoor and outdoor controls from terminals i+ to Y1 and i- to O for 24VAC operation on heat pump and indoor unit.
2. Do not disconnect wires from the XP25 R and C terminals, both are required.
3. Cut R to O link on indoor control.

Figure 62. Thermostat Communication Mode

XP25
Page 84
System Refrigerant
IMPORTANT - Unit must be operating at 100% input to
IMPORTANT ! charge properly.
The system must be operating at full capacity during
charging. Increase (heat) or decrease (cooling) the ADDING OR REMOVING REFRIGERANT
thermostat setting by 5°F to create system demand. This system uses HFC-410A refrigerant which operates at
Confirm outdoor unit running capacity on the display much higher pressures than HCFC-22. The pre-installed
on the outdoor control. Value should be 100%. liquid line filter drier is approved for use with HFC-410A
This section outlines procedures for: only. Do not replace it with components designed for use
with HCFC-22.
1. Connecting gauge set for testing and charging as
illustrated in figure 63. COOLING MODE INDOOR AIRFLOW CHECK
2. Checking and adjusting indoor airflow as described in Check airflow using the Delta-T (DT) process using the
figure 64. illustration in figure 64.
3. Adding or removing refrigerant using the weigh-in The diagnostic screen on the thermostat or outdoor control
method shown in figure 65, and verifying charge using 7-Segment display shows indoor and outdoor motor CFMs
subcooling method described in figure 66. or RPMs.

MANIFOLD GAUGE SET

GAUGE SET
CONNECTIONS FOR TESTING AND CHARGING
LOW HIGH

TRUE SUCTION PORT

B CONNECTION OUTDOOR UNIT

REFRIGERANT TANK

CHARGE IN
LIQUID PHASE
A

DIGITAL SCALE

INSIDE OUTDOOR UNIT

C
TO LIQUID TEMPERATURE SENSOR
D LINE SERVICE (LIQUID LINE)
TEMPERATURE VALVE
SENSOR

A CLOSE MANIFOLD GAUGE SET VALVES AND CONNECT THE CENTER HOSE TO A CYLINDER OF HFC-410A. SET FOR LIQUID PHASE CHARGING.
B CONNECT THE MANIFOLD GAUGE SET'S LOW PRESSURE SIDE TO THE TRUE SUCTION PORT.
C CONNECT THE MANIFOLD GAUGE SET'S HIGH PRESSURE SIDE TO THE LIQUID LINE SERVICE PORT.
D POSITION TEMPERATURE SENSOR ON LIQUID LINE NEAR LIQUID LINE SERVICE PORT.

Figure 63. Gauge Set Connections

XP25
Page 85
 DT
AIRFLOW INDOOR COIL TEMPERATURE OF AIR
ENTERING INDOOR COIL ºF 80 24 24 24 23 23 22 22 22 20 19 18 17 16 15
78 23 23 23 22 22 21 21 20 19 18 17 16 15 14

DRY-BULB
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
A 72 20 20 19 18 17 17 16 15 15 14 13 12 11 10
70 19 19 18 18 17 17 16 15 15 14 13 12 11 10
WET-BULB ºF 57 58 59 60 61 62 63 64 65 66 67 68 69 70
DRY
BULB B
A
C USE THE FOLLOWING PROCEDURE TO ADJUST FOR OPTIMAL
TDROP 72º AIR FLOW ACROSS THE INDOOR COIL:
53º
1. DETERMINE THE DESIRED DT — MEASURE ENTERING AIR
19º B TEMPERATURE USING DRY BULB (A) AND WET BULB (B).
AIR DT IS THE INTERSECTING VALUE OF A AND B IN THE
AIR FLOW
FLOW 64º TABLE (SEE TRIANGLE).

DRY BULB 2. FIND TEMPERATURE DROP ACROSS COIL — MEASURE

THE DRY BULB AIR TEMPERATURE ENTERING AND LEAV­
ALL TEMPERATURES ARE INDOOR ING THE COIL (A AND C). TEMPERATURE DROP FORMULA:
EXPRESSED IN ºF COIL (TDROP) = A MINUS C.
WET
BULB
3. DETERMINE IF FAN NEEDS ADJUSTMENT — IF THE DIF­
FERENCE BETWEEN THE MEASURED TDROP AND THE DE­
ASSUME DT = 15 AND A TEMP. = 72º, BELOW C TEMPERATURES REQUIRE ACTION: SIRED DT (TDROP–DT) IS WITHIN +3º, NO ADJUSTMENT IS
NEEDED. SEE EXAMPLE AT LEFT:

Cº TDROP – DT = ºF ACTION NOTE - CHANGING AIR FLOW AFFECTS ALL TEMPERA­

TURES; RECHECK TEMPERATURES TO CONFIRM THAT THE
53º 19 – 15 = 4 INCREASE THE AIRFLOW
TEMPERATURE DROP AND DT ARE WITHIN +3º.
58º 14 – 15 = -1 (WITHIN +3º RANGE) NO CHANGE
62º 10 – 15 = -5 DECREASE THE AIRFLOW
4. ADJUST THE FAN SPEED — SEE INDOOR UNIT IN­
STRUCTIONS TO INCREASE/DECREASE FAN SPEED.

Figure 64. Checking Indoor Airflow over Evaporator Coil Using Delta-T Chart

XP25
Page 86
Use WEIGH-IN method for adding initial refrigerant charge, then use SUBCOOLING method for for verifying
refrigerant charge.

WEIGH-IN NOTE - Insulate liquid line when it is routed through areas where
CHARGING METHOD FOR LONG LINE SETS the surrounding ambient temperature could become higher than
the temperature of the liquid line or when pressure drop is equal
64ºF (17.7ºC) and Below to or greater than 20 psig.
Adjust amount for variation in
NOTE - The above nameplate is shown for illustration purposes
Amount specified line set length and liquid line
diameter using table below. Total charge only. Go to actual nameplate on outdoor unit for charge information.
on nameplate
+ =

Charging Formula for Liquid Line Charge Adjustments

Liquid Line HFC-410A [(Line set oz./ft. x total length) ­ (factory charge for line set)] = charge adjustment
Set Diameter (ounces per foot)
5/16” 0.40 Example: Units are factory­charged for 15 feet (4.6 meters) of 3/8" line set.
Factory charge for 3/8" is 0.60 oz/ft x 15 = 9.0 ounces.
3/8” 0.60
1/2” 1.00

Figure 65. Using HFC-410A Weigh In Method

(All charging MUST be performed while system is operating either at maximum speed or 100% demand.)
SUBCOOLING
CHARGING METHOD
1. THE DIAGNOSTIC SCREEN ON THE THERMOSTAT OR OUTDOOR CONTROL 7-SEGMENT DISPLAY WILL SHOW
INDOOR AND OUTDOOR MOTOR CFMS OR RPMS.
2. MEASURE OUTDOOR AMBIENT TEMPERATURE; DETERMINE WHETHER TO USE COOLING MODE OR HEATING MODE
TO CHECK CHARGE.

3. CONNECT GAUGE SET.

4. CHECK LIQUID AND VAPOR LINE PRESSURES. COMPARE PRESSURES WITH EITHER HEAT OR COOLING MODE
NORMAL OPERATING PRESSURES IN THE APPLICABLE CHARGING STICKER, NORMAL OPERATING PRESSURES,
HIGH STAGE.
USE
COOLING NOTE - THE REFERENCE TABLE IS A GENERAL GUIDE. EXPECT MINOR PRESSURE VARIATIONS. SIGNIFICANT
MODE DIFFERENCES MAY MEAN IMPROPER CHARGE OR OTHER SYSTEM PROBLEM.
60ºF 5. SET THERMOSTAT FOR HEAT/COOL DEMAND, DEPENDING ON MODE BEING USED:
(15ºC)
USE USING COOLING MODE — WHEN THE OUTDOOR AMBIENT TEMPERATURE IS 60°F (15°C) AND ABOVE. TARGET
HEATING SUBCOOLING VALUES (SECOND STAGE - HIGH CAPACITY) IN APPLICABLE CHARGING STICKER ARE BASED ON 70
MODE 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 68ºF (20ºC) WHICH SHOULD
CALL FOR SECOND-STAGE (HIGH STAGE) 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 APPLICABLE CHARGING STICKER 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 77ºF (25ºC) WHICH SHOULD
CALL FOR SECOND-STAGE (HIGH STAGE) HEATING. WHEN PRESSURES HAVE STABILIZED, CONTINUE WITH STEP
SATº
6.
LIQº – 6. READ THE LIQUID LINE TEMPERATURE; RECORD IN THE LIQº SPACE.
SCº =
7. READ THE LIQUID LINE PRESSURE; THEN FIND ITS CORRESPONDING TEMPERATURE IN THE TEMPERATURE/
PRESSURE CHART LISTED IN THE APPLICABLE CHARGING STICKER AND RECORD IT IN THE SATº SPACE.

8. SUBTRACT LIQº TEMPERATURE FROM SATº TEMPERATURE TO DETERMINE SUBCOOLING; RECORD IT IN SCº
SPACE.

9. COMPARE SCº RESULTS WITH APPLICABLE CHARGING STICKER, BEING SURE TO NOTE ANY ADDITIONAL
CHARGE FOR LINE SET AND/OR MATCH-UP.

10. IF SUBCOOLING VALUE IS GREATER THAN SHOWN IN APPLICABLE CHARGING STICKER FOR THE APPLICABLE
UNIT, REMOVE REFRIGERANT; IF LESS THAN SHOWN, ADD REFRIGERANT.

11. IF REFRIGERANT IS ADDED OR REMOVED, REPEAT STEPS 6 THROUGH 10 TO VERIFY CHARGE.

12. DISCONNECT GAUGE SET AND RE-INSTALL BOTH THE LIQUID AND SUCTION SERVICE VALVE CAPS.

Figure 66. Using HFC-410A Subcooling Method — High Speed (High Capacity)

XP25
Page 87
 Table 22. HFC-410A Temperature (°F) - Pressure (Psig)
°F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig
32 100.8 48 137.1 63 178.5 79 231.6 94 290.8 110 365.0 125 445.9 141 545.6
33 102.9 49 139.6 64 181.6 80 235.3 95 295.1 111 370.0 126 451.8 142 552.3
34 105.0 50 142.2 65 184.3 81 239.0 96 299.4 112 375.1 127 457.6 143 559.1
35 107.1 51 144.8 66 187.7 82 242.7 97 303.8 113 380.2 128 463.5 144 565.9
36 109.2 52 147.4 67 190.9 83 246.5 98 308.2 114 385.4 129 469.5 145 572.8
37 111.4 53 150.1 68 194.1 84 250.3 99 312.7 115 390.7 130 475.6 146 579.8
38 113.6 54 152.8 69 197.3 85 254.1 100 317.2 116 396.0 131 481.6 147 586.8
39 115.8 55 155.5 70 200.6 86 258.0 101 321.8 117 401.3 132 487.8 148 593.8
40 118.0 56 158.2 71 203.9 87 262.0 102 326.4 118 406.7 133 494.0 149 601.0
41 120.3 57 161.0 72 207.2 88 266.0 103 331.0 119 412.2 134 500.2 150 608.1
42 122.6 58 163.9 73 210.6 89 270.0 104 335.7 120 417.7 135 506.5 151 615.4
43 125.0 59 166.7 74 214.0 90 274.1 105 340.5 121 423.2 136 512.9 152 622.7
44 127.3 60 169.6 75 217.4 91 278.2 106 345.3 122 428.8 137 519.3 153 630.1
45 129.7 61 172.6 76 220.9 92 282.3 107 350.1 123 434.5 138 525.8 154 637.5
46 132.2 62 175.4 77 224.4 93 286.5 108 355.0 124 440.2 139 532.4 155 645.0
47 134.6 78 228.0 109 360.0 140 539.0

XP25
Page 88
XP25 HFC-410A CHARGING PROCEDURE

Figure 67. XP25 Charging Sticker

XP25
Page 89
 XP25 HFC-410A CHARGING PROCEDURE
FOR COMPLETE CHARGING DETAILS, REFER TO THE INSTALLATION AND SERVICE PROCEDURE (CORP 1252-L11)
IMPORTANT: Room thermostat must be turned down at least 5°F from set point for cooling or turned up 5°F for heating so charging occurs with system operating
at 100% capacity. Seven-segment display on outdoor control will show outdoor unit running capacity.
MAINTENANCE CHECKS USING THE NORMAL OPERATING PRESSURES Table 1 - Normal Operating Pressures (Liquid +10 and Suction +5 psig)
TABLE Cooling Heating
Table 1 may be used to help perform maintenance checks. This table is not a Size Min Speed Max Speed 5F Min Speed Max Speed
5F
procedure for charging the system and any minor variations in the pressures may Suc Liq Suc Liq 5F Suc Liq Suc Liq
be expected due to differences in installations. However, significant deviations 65 153 222 148 231 20 ­ ­ 65 308
could mean that the system is not properly charged or that a problem exists with 75 155 260 150 273 30 ­ ­ 79 337
some component in the system. The values in Table 2 are “most-popular-match-up” ­024 85 157 300 152 320 40 101 267 94 353
pressures; indoor match up, indoor air quantity, and indoor load will cause the 95 158 346 154 356 50 119 281 111 384
pressures to vary. Charge levels on the unit nameplate are based on 105 160 397 155 414 60 137 296 130 417
installations with 15 feet line sets; be sure to consider any difference in line 115 160 452 156 468
set length (see Installation Instructions for more details). 65 153 210 134 222 20 ­ ­ 62 308
CHARGE USING THE WEIGH‐IN METHOD 75 155 244 139 257 30 ­ ­ 75 326
85 158 285 142 304 40 101 291 89 350
If the system is void of refrigerant, locate and repair any leaks and then weigh in the ­036
95 160 330 144 350 50 121 306 107 363
refrigerant charge into the unit. For charge adjustments, be sure to consider line set
105 162 381 147 402 60 143 321 125 375
length differences and, referring to table 2, adjust for the matchup difference.
115 163 436 149 460
NOTE: See installation instruction for adding charge for longer line sets. 65 151 196 137 234 20 ­ ­ 56 318
1 - Recover the refrigerant from the unit. 75 152 247 138 271 30 ­ ­ 72 354
2 - Conduct leak check; evacuate as previously outlined. 85 154 291 140 314 40 95 271 86 370
­048
3 - Weigh in the unit nameplate charge, adjusting for matchup and line set length 95 156 333 142 361 50 112 282 104 394
differences. If weighing facilities are not available use the Subcooling method. 105 158 382 144 413 60 127 305 123 416
CHARGE USING THE SUBCOOLING METHOD 115 159 437 147 472
Cooling Mode—When the outdoor ambient temperature is 60°F and above, use 65 147 218 129 232 20 ­ ­ 60 333
the cooling mode to adjust the charge using the subcooling method. Target 75 149 254 132 269 30 ­ ­ 73 356
subcooling values in table 2 are based on 70 to 80°F indoor return air temperature. ­060 85 151 293 135 316 40 96 269 82 360
Heating Mode—When the outdoor ambient temperature is below 60°F, use the 95 153 340 136 365 50 121 285 106 397
heating mode to adjust the charge using the subcooling charge levels (table 2). 105 155 392 139 416 60 135 300 122 420
115 157 450 141 476
Target subcooling values in table 2 are based on 65-75°F indoor return air
temperature.
Table 2 - XP25 Indoor Units Match-ups and Subcooling Charge Levels
OD Unit ID Model Lbs Oz Cooling SC Heating SC OD Unit ID Model Lbs Oz Cooling SC Heating SC
CBX32MV­036 2.0 8.0 9 22 CBX40UHV­048 0.0 7.0 5 25
CBX40UHV­024 2.0 8.0 9 22 CBX40UHV­060 2.0 0.0 7 19
CBX40UHV­030 2.0 8.0 9 22 CX34­49 0.0 0.0 6 16
CX34­31 1.0 4.0 5 18 CX34­62C 2.0 13.0 11 27
CX34­38 2.0 3.0 8 17 CX34­62D 0.0 6.0 4 10
CX34­44/48 1.0 14.0 5 20 CR33­50/60 0.0 8.0 6 27
­024 -048
CR33­48 1.0 0.0 5 40 CR33­60D 0.0 8.0 6 27
CH33­31B 0.0 0.0 5 17 CH33­49C 2.0 4.0 7 22
CH33­42B 0.0 0.0 5 17 CH33­50/60C 2.0 4.0 7 22
CH35­42B 2.0 15.0 9 19 CH33­62D 1.0 3.0 5 14
CH35­42C 1.0 11.0 5 23 CH35­60D 2.0 10.0 8 31
CX35­36B 1.0 6.0 3 19 CX35­60C 2.0 0.0 8 23
CBX32MV­036 0.0 4.0 7 18 CBX32MV­060 1.0 4.0 7 16
CBX40UHV­036 0.0 4.0 7 18 CBX40UHV­060 1.0 4.0 7 16
CX34­38 0.0 9.0 7 24 CX34­49 0.0 0.0 7 12
CX34­43 1.0 0.0 8 23 CX34­62C 1.0 5.0 10 14
CX34­44/48 0.0 0.0 7 28 CX34­62D 1.0 0.0 8 13
­036 CX34­50/60C 1.0 0.0 7 28 CR33­50/60 0.0 7.0 8 20
CR33­50/60 2.0 8.0 3 11 ­060 CR33­60D 0.0 7.0 8 20
CH33­43C 0.0 12.0 8 24 CH33­49C 0.0 6.0 3 21
CH33­44/48B 0.0 12.0 8 24 CH33­50/60C 0.0 6.0 3 21
CH35­42B 3.0 0.0 12 30 CH33­62D 2.0 1.0 12 25
CX35­50/60C 1.0 15.0 7 27 CH35­60D 1.0 11.0 9 28
CBX32MV­048 0.0 7.0 5 25 CX35­60C 1.0 6.0 10 23
-048
CBX32MV­060 2.0 0.0 7 19 CX35­60D 1.0 8.0 9 27