Home

WARNING CAUTION IMPORTANT IMPORTANT

1. 640 650 G60 PE SIGNATURE C7 INDOOR O UNIT i OUI UNIT EE THERMOSTAT CAPACITOR 9 TBI gc a TB A2 UNIT A92 Is OPTIONAL 5 2 BI a LY x pu W D Wi D wala Lee KSI COMPRESSOR 2 W2 gt 7 JO POTENTIAL CONTACTOR c _ w951 740 1 Dn Y OPTIONAL d D ORANGE RUN YLW YLW OU T Y Y YI Y We 2 BLACK COMMO 1 A PURPLE Cle ga Be 2 B CAPACITOR E94 C29 QD DUAL YLW 587 Bk BK Yi CD a aoa Pe PRESSURE BI zi pe SWITC COMPRESSOR 0 m a OOD FOR USE WITH COPPER CONDUCTORS N ELECTRIC SHOCK HAZARD CAN CAUSE INJURY Ch lt 659 PRESSURE 0 OR DEATH UN UST BE GROUNDED IN
2. 11 New or Replacement Line Set 13 Brazing Connections 15 Flushing Line Set and Indoor Coil 18 Installing Indoor Metering Device 19 Leak Test Line Set and Indoor Coil 20 Evacuating Line Set and Indoor Coil 21 cie saranan an ERI 22 Servicing Units Void of Charge 23 Unio Statt UD cs od oe ses Ty ed mi bati PT Nas 23 System Refrigerant 23 System Operation 28 Maintenance 28 22 k suwaspay PH 31 Unit Wiring Diagram and Sequence of Operations 32 The XC16 Air Conditioners which will also be referred to in this instruction as the outdoor unit uses HFC 410A refrigerant This outdoor unit must be installed with a matching indoor unit and line set as outlined in the Lennox XC16 Engineering Handbook XC16 Air Conditioners are designed for use in thermal expansion valve TXV systems NOTE The XC16 outdoor unit is rated for 230V applications only A hard start kit is required for applications where the supply voltage is less than 230V A IMPORTANT This unit must matched with indoor coil as speci fied in Lennox XC16 Engineering Handbook Coils pre viously charged with HCFC 22 must be flushed Page 1 Model Number Identificatio
3. RR 208 230V 60 Hz 1 Ph 2 Model Number Over Minimum current Circuily 12 Motor HP unus Amps ELA unis LRA Protection Ampacity amps x616 056280 08 as 20 166 M Minimum Circuily 2 Model Number Over 4 mz 95 w 37 3 208 230V 60 Hz 1 Ph Compressor Condenser Fan current Protection 4 o m ws 208 230V 60 Hz 1 Ph Maximum Rated Load Motor HP Nominal Full Load Locked Rotor Amps RLA DS RPM Amps FLA Amps LRA amps Compressor Condenser Fan Maximum Model Number Over Minimum current Circuily aes REA Motor HP eun Amps ELA AIDS LEA Protection Beg 2 XC16 060 230 01 ED SEM 25 64 118 0 BENED SN 2 9 Xc1600023002 5 2587 nso 18 1 HACR type circuit breaker or fuse Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Page 3 XC16 SERIES Unit Dimensions Inches mm ES 1 LIQUID LINE CONNECTION Came C ELECTRICAL INLETS SUCTION LINE y nin Y 4 3 4 121 gt k B gt SIDE VIEW acd UNIT SUPPORT FEET Or 552 y F G
4. 1 Rotate fan to check for binding GAUGE SET CONNECTIONS FOR TESTING AND CHARGING B SUCTION LINE SERVICE PORT CONNECTION Inspect all factory and field installed wiring for loose connections After evacuation is complete open both the liquid and vapor line service valves to release the refrigerant charge contained in outdoor unit into the system Replace the stem caps and tighten to the value listed in table 1 Check voltage supply at the disconnect switch The voltage must be within the range listed on the unit s nameplate If not do not start the equipment until you have consulted with the power company and the voltage condition has been corrected Set the thermostat for a cooling demand Turn on power to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit Recheck voltage while the unit is running Power must be within range shown on the nameplate Check system for sufficient refrigerant by using the procedures listed under System Charge System Refrigerant This section outlines procedures for 1 Connecting gauge set for testing and charging 2 Checking and adjusting indoor airflow 3 Adding or removing refrigerant MANIFOLD GAUGE SET OUTDOOR UNIT REFRIGERANT TANK CHARGE IN LIQUID PHASE DIGITAL SCALE D TEMPERATURE SENSOR A VAPOR LINE SERVICE VALVE B rie ho On _ TEMPERATURE SENSOR LIQUID LINE C
5. OUTSIDE WALL LIQUID J LINE PVC N eve CAULK FIBERGLASS INSULATION NOTE Similar installation practices should be used if line set is to be installed on exterior of outside wall Figure 7 Line Set Installation Page 14 Brazing Connections A IMPORTANT Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at A WARNING paragraph 4 for brazing the liquid line to service port valve Danger of fire Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and A IM PO RTANT suction tubing Application of a brazing torch to a pressurized system may result Allow braze joint to cool before removing the wet rag in ignition of the refrigerant and oil from the service valve Temperatures above 250 F can mixture Check the high and low damage valve seals pressures before applying heat Use silver alloy brazing rods with 596 minimum silver alloy for copper to copper brazing Use 45 minimum alloy for copper to brass and copper to steel brazing 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 A WARNING A CAUTION Fire Explosion and Personal Safety Hazard
6. TO LIQUID LINE SERVICE VALVE LIQUID LINE SERVICE VALVE Close manifold gauge set valves and connect the center hose to a cylinder of HFC 410A Set for liquid phase charging Connect the manifold gauge set s low pressure side to the suction line service port Connect the manifold gauge set s high pressure side to the liquid line service port Position temperature sensor on liquid line near liquid line service port Figure 14 Gauge Set Setup and Connections Page 23 XC16 SERIES ADDING OR REMOVING REFRIGERANT This system uses HFC 410A refrigerant which operates at much higher pressures than HCFC 22 The pre installed liquid line filter drier is approved for use with HFC 410A only Do not replace it with components designed for use with HCFC 22 This unit is NOT approved for use with coils which use capillary tubes or fixed orifices as a refrigerant metering device Check airflow using the Delta T DT process using the illustration in figure 15 AIRFLOW Use the following procedure to adjust for optimal air flow across the indoor coil 1 INDOOR COIL DT 80 24 24 24 23232222 22 20 19 18 17 16 15 78 2323 23 22 22 21 21 20 19 18 17 16 15 14 76 22 22 22 212120 19 19 18 17 16 15 14 13 74 21212120 19 19 18 17 16 16 15 14 13 12 A 72 2020 19 18 17 17 16 M5 14 1312 11 10 TO 19 19 18 18 17 17 16 15 15 14 13 12 11 10 Wet bulb F 57 58 59 60 61 62 63 64 65 66 67 68 69 70 DRY BULB Temperature of air entering indoor
7. LENNOX Service Literature UNIT INFORMATION Corp 0625 L5 Revised October 8 2010 XC16 XC16 HFC 410A SERIES UNITS WARNING Improper installation adjustment alteration service or maintenance can cause personal injury loss of life or damage to property Installation and service must be performed by a licensed professional installer or equivalent or a service agency A CAUTION Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury Be aware of and use caution when working near these areas during installation or while servicing this equipment IMPORTANT The Clean Air Act of 1990 bans the intentional venting of refrigerant CFCs HCFCs and HFCs as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration may be levied for noncompliance TABLE OF CONTENTS Unit Dimensions 4 Model Number Identification 2 Typical Serial Number Identification 2 Specifications 2 EICCWiICAl Dala dessus bore dda oddest e SEXO nU 9 Unit Parts Arrangement 5 Operating Gauge Set and Service Valves 6 Recovering Refrigerant from System 8 Unit PIACEMON cod am oo pb ERR CE 9 Removing and Installing Panels
8. E and closing the manifold gauge valves F indoor unit G Perform the following e Close manifold gauge valves 1 6 TURN e Shutoff HFC 410A cylinder e Reinstall service valve cores by removing manifold hose from service valve Quickly install cores with core tool while maintaining a positive system pressure e Replace stem caps and secure finger tight then tighten an additional one sixth 1 6 of a turn as illustrated Figure 13 Evacuating System Page 21 XC16 SERIES A IMPORTANT Use thermocouple thermistor electronic vacuum gauge that is calibrated in microns Use an instrument capable of accurately measuring down to 50 microns WARNING Danger of Equipment Damage Avoid deep vacuum operation Do not use compressors to evacuate a system Extremely low vacuums can cause internal arcing and compressor failure Damage caused by deep vacuum operation will void warranty Evacuating the system of non condensables is critical for proper operation of the unit Non condensables are defined as any gas that will not condense under SIZE CIRCUIT AND INSTALL DISCONNECT SWITCH Refer to the unit nameplate for minimum circuit ampacity and maximum fuse or circuit breaker HACR per NEC Install power wiring and properly sized disconnect switch MAIN FUSE BOX BREAKER PANEL DISCONNECT SWITCH NOTE Units are approved for use only with copper conductors Ground unit at disconnect switch
9. In order to ensure peak performance your system must be properly maintained Clogged filters and blocked airflow prevent your unit from operating at its most efficient level 1 Air Filter Ask your Lennox dealer to show you where your indoor unit s filter is located It will be either at the indoor unit installed internal or external to the cabinet or behind a return air grille in the wall or ceiling Check the filter monthly and clean or replace it as needed 2 Disposable Filter Disposable filters should be replaced with a filter of the same type and size NOTE If you are unsure about the filter required for your system call your Lennox dealer for assistance 3 Reusable Filter Many indoor units are equipped with reusable foam filters Clean foam filters with a mild soap and water solution rinse thoroughly allow filter to dry completely before returning it to the unit or grille NOTE The filter and all access panels must be in place any time the unit is in operation 4 Electronic Air Cleaner Some systems are equipped with an electronic air cleaner designed to remove airborne particles from the air passing through the cleaner If your system is so equipped ask your dealer for maintenance instructions 5 Indoor Unit The indoor unit s evaporator coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the inside air Have your dealer show you the locatio
10. NOTE If necessary block outdoor coil to maintain 325 375 psig Record liquid line temperature Measure liquid line pressure and use the value to determine saturation temperature see table 4 CARDBOARD OR SAT PLASTIC SHEETS Subtract to determine subcooling SC SAT LIQ SC Compare results with table below SC Subcooling Values F 1 0 C 0 6 Models XC17 XXX 230 01 F 024 036 048 060 5 2 8 6 3 3 6 3 3 9 5 0 Temperature of air entering outdoor coil Models XC17 XXX 230 02 03 F 024 036 048 060 Any 5 2 8 6 3 3 6 3 3 9 5 0 Temperature of air entering outdoor coil Figure 19 Using HFC 410A Subcooling TXV Charge Method Page 26 Table 3 Normal Operating Pressures Liquid 10 and Suction 5 psig Use this table to perform maintenance checks it is not a procedure for charging the A IM PORT ANT system Minor variations in these pressures may be due to differences in installations Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system XC16 XXX 230 01 143 261 142 258 144 250 297 145 302 145 299 146 291 142 148 347 148 345 148 337 144 05006 16 230 02 03 First Stage Low Capacity 15467 Second Stage High Capacity Temperature of air entering outdoor coil Page 27 XC16 SERIES Ta
11. coil F Dry bulb DRY BULB 53 All temperatures are expressed in F WET BULB Determine the desired DT Measure entering air temperature using dry bulb A and wet bulb B DT is the intersecting value of A and B in the table see triangle Find temperature drop across coil Measure the coil s dry bulb entering and leaving air temperatures A and C Temperature Drop Formula Tprop A minus C Determine if fan needs adjustment If the difference between the measured Tprop and the desired DT Tprop DT is within 3 no adjustment is needed See example below Assume DT 15 and A temp 72 these C temperatures would necessitate stated actions F ACTION C Tprop DT Changing air flow affects all temperatures recheck 53 19 15 4 Increase the airflow Baia 4 s 14 15 1 within 3 range no change SC ST Nes 0 mat ine temperature drop 62 10 15 5 Decrease the airflow Adjust the fan speed See indoor unit instructions to increase decrease fan speed Figure 15 Checking Indoor Airflow over Evaporator Coil using Delta T Chart Page 24 START Determine how refrigerant is metered WHEN TO CHARGE e Warm weather best e Can charge in colder weather CHARGE METHOD Determine by e Metering device type e Outdoor ambient te
12. isolate the opening so vibration is not transmitted to the building Pay close attention to line set isolation during installation of any HVAC system When properly isolated from building structures walls ceilings floors the refrigerant lines will not create unnecessary vibration and subsequent sounds See figure 7 for recommended installation practices Also consider the following when placing and installing a high efficiency outdoor unit Liquid lines that meter the refrigerant such as RFC1 liquid lines must not be used in this application Existing line set of proper size as listed in table 2 may be reused If system was previously charged with HCFC 22 refrigerant then existing line set must be flushed see Flushing the System on page 18 Field refrigerant piping consists of liquid and vapor lines from the outdoor unit to the indoor unit coil braze connections Use Lennox L15 sweat non flare series line set or field fabricated refrigerant line sizes as listed in table 2 Table 2 Refrigerant Line Set Inches mm Field Connections Recommended Line Set Liquid Suction Liquid Suction 022 887 3 4 3 8 3 4 22 10 19 10 mm 19 mm 4 6 m 15 m 7 8 036 3 7 8 3 8 L15 65 048 10 mm 22 10 22 mm om 945 m 3 8 1 1 8 3 8 1 1 8 Field 10 mm 29 10 29mm Fabricated NOTE When installing refrigerant l
13. open de energizing HR1 once liquid line temperature reaches 70 F 6 FILTER DRIER A filter drier is factory installed as illustrated in Unit Dimensions on page 4 with each XC16 unit to ensure a clean moisture free system A replacement filter drier is available from Lennox Refer to Lennox Repair Part Program Port s1 66 1877 82 2427 2006 86 2580 101 3218 2 89 2700 104 3357 90 2741 105 3405 286 _ 09 we s MM 365 370 375 303 385 i 390 TWO STAGE COMPRESSOR The two stage scroll compressor operates much like the standard scroll compressor The two stage compressor steps between low capacity and high capacity as required to meet cooling demand The steps occur when gas is bypassed through a vent port in the first suction pocket This bypassing of gas allows the compressor to operate at low capacity if thermostat demand allows creating a more cost effective and efficient compressor Full capacity is achieved by blocking the vent port with a slider ring The slider ring vent port cover is controlled by a 24VDC internal solenoid in the open position allowing low capacity When energized the internal solenoid closes the slider ring blocking the vent port and bringing the compressor to full capacity Stepping can occur during a single thermostat demand as the motor runs continuously while the comp
14. Brazing alloys and flux contain materials which are hazardous to your health Avoid breathing vapors or fumes from brazing death operations Perform operations only in well ventilated areas Failure to follow this warning could result in damage personal injury or Never use oxygen to pressurize or purge refrigeration lines Oxygen Wear gloves and protective goggles or face shield to when exposed to a spark or open protect against burns flame can cause fire and or an ex Wash hands with soap and water after handling brazing plosion that could result in property alloys and flux damage personal injury or death Page 15 XC16 SERIES CUT AND DEBUR Cut ends of the refrigerant lines square free from nicks or dents and debur the ends The pipe must remain round Do not crimp end of the line 1 N CUT AND DEBUR lt P LINE SET SIZE MATCHES SERVICE VALVE CONNECTION SERVICE VALVE CONNECTION COPPER TUBE THAN CONNECTION v 4 REFRIGERANT LINE VALVES CONNECTOR WHEN PIPE IS SMALLER THAN CONNECTION CAP AND CORE REMOVAL Remove service cap and core from both the suction vapor and liquid line service ports SERVICE PORT SERVICE CAP PORT CORE SERVICE PORT CORE SERVICE PORT CAP SUCTION VAPOR LINE SERVICE VALVE ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION VAPOR LINE SERVICE Flow regulated nitrogen at 1 to 2 psig through the low si
15. H XC14 024 TO 060 BASE WITH ELONGATED LEGS ModelNumber Number D 024 230 01 35 27 28 16 024 230 02 39 991 30 1 2 775 35 889 XC16 036 230 01 31 787 30 1 2 775 35 889 13 7 8 352 7 3 4 197 3 1 4 83 27 1 8 689 3 5 8 92 4 1 2 114 20 5 8 524 XC16 036 230 03 45 1143 30 12 775 35 XC16 048 230 01 39 991 30 1 2 775 35 16 060 230 01 39 991 35 1 2 902 16 7 8 429 8 3 4 222 3 1 8 79 30 3 4 781 4 5 8 117 3 34 ET 26 7 8 LET Page 4 Typical Unit Parts Arrangement CONTACTOR 1POLE K1 1 GROUND LUG U 9 25 005 cS AG gt gt 9 gt BOO 2 gt 0 lt COMPRESSOR b AM 9 HARNESS Z Pa mm N LAS CRANKCASE S T THERMOSTAT S40 048 AND 060 UNITS ONLY 2 2 71 LIQUID LINE FILTER DRIER SINGLE FLOW LIQUID LINE SERVICE VALVE FIELD CONNECTION FOR LIQUID LINE SET Va SS CONTROL PANEL CAPACITOR C12 HIGH PRESSURE SWITCH MANUAL RESET S4 LOW PRESSURE SWITCH S87 SUCTION LINE SERVICE VALVE FIELD CONNECTION FOR SUCTION LINE PLUMBING SWITCHES AND SENSOR COMPONENTS Figure 1 Typical Parts Arrangements Page 5 XC16 SERIES WARNING This product and or the indoor unit it is matched with may contain fiberglass wool Di
16. coil In applications where an uncased coil is being installed in a field provided plenum install the expansion valve in a manner that will provide access for field servicing of the expansion valve Refer to below illustration for reference during installation of expansion valve unit 1 2 Turn Remove the field provided fitting that temporary reconnected the liquid line to the indoor unit s distributor assembly Install one of the provided Teflon rings around the stubbed end of the expansion valve and lightly lubricate the connector threads and expose surface of the Teflon9 ring with refrigerant oil 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 illustrated in the figure above or 20 ft Ib Place the remaining Teflon washer around the other end of the expansion valve Lightly lubricate connector threads and expose surface of the Teflon ring with refrigerantoil Attach the liquid line assembly to the expansion valve Finger tighten and use an appropriately sized wrench to turn an additional 1 2 turn clockwise as illustrated in the figure above or 20 ft Ib SENSING BULB INSTALLATION POSITION NEVER MOUNT ON BOTTOM OF LINE A Attach the vapor line sensing bulb in the proper ne eee orientation as illustrated to the right using the clamp and 4 8 Turn FITTING SEE screws provid
17. higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig NOTE The above nameplate is for illustration purposes only Go to actual nameplate on outdoor unit for charge information OUTDOOR EE 3 1617016 Figure 17 Using HFC 410A Weigh In Method Page 25 XC16 SERIES START Measure outdoor ambient temperature USE WEIGH IN METHOD Weigh in or remove refrigerant a based upon line length 64 F and BELOW APPROACH TXV If refrigerant is added or removed retest to confirm that unit is properly charged If value is greater than shown high approach add refrigerant if less than shown liquid temperature too eA close to ambient temperature low approach remove refrigerant Connect gauge set as illustrated in figure 14 Confirm proper airflow across coil using figure 15 Compare unit pressures with table 3 Normal Operating Pressures Set thermostat to call for heat must have a cooling load between 70 80 F 21 26 When heat demand is satisfied set thermostat to call for cooling Allow temperatures and pressures to stabilize Record outdoor ambient temperature AMB Record liquid line temperature LIQ Subtract to determine approach APP LIQ AMB _ zAPP O Compare results with table below APP Approach Values F 1 0 0 6 Models XC17 XXX 230 01 F 024 036 048 060 A
18. maintain a minimum of 375 psig during testing 1 Turn main power OFF to outdoor unit 2 Adjust room thermostat set point 5 F above the room temperature 3 Remove control access panel Install refrigeration gauges on unit Attach the amp meter to the common black wire wire of the compressor harness Attach thermometer to discharge line as close as possible to the compressor 4 Turn toggle switch OFF and install switch in series with Y2 wire from room thermostat 5 Cycle main power ON 6 Allow pressures and temperatures to stabilize before taking measurements may take up to 10 minutes 7 Record all of the readings for the Y1 demand 8 Close switch to energize Y2 demand Verify power is going to compressor solenoid 9 Allow pressures and temperatures to stabilize before taking any measured reading this may take up to 10 minutes 10 Record all of the readings with the Y1 and Y2 demand 11 If temperatures and pressures change in the direction noted in chart the compressor is properly modulating from low to high capacity If no amperage pressures or temperature readings change when this test is performed the compressor is not modulating between low and high capacity and replacement is necessary 12 After testing is complete return unit to original set up HOMEOWNER Cleaning of the outdoor unit s coil should be performed by a trained service technician Contact your dealer and set up a schedule pre
19. FC refrigerants during A WARN NG maintenance service repair and disposal of appliance When using a high pressure gas such as Approved methods of recovery recycling or reclaiming dry nitrogen to pressurize a refrigeration must be followed or air conditioning system use a regulator that can control the pressure A IM PORTANT down to 1 or 2 psig 6 9 to 13 8 kPa If thi it is bei tched with d li t or indoor unit coil which was previously charged with A IM PORTANT mineral oil or if it is being matched with a coil which was manufactured before January of 1999 the coil Leak detector must be capable of sensing HFC and line set must be flushed prior to installation Take refrigerant care to empty all existing traps Polyol ester POE oils are used in Lennox units charged with HFC 410A refrigerant Residual mineral oil can act as an A WARNING insulator preventing proper heat transfer It can also s clog the expansion device and reduce the system Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly performance and capacity Failure to properly flush the system per the Failure to follow this warning may result in personal injury instructions below will void the warranty or death 1 CONNECT GAUGE SET A Connect HFC 410A manifold gauge set high pressure hose to the vapor valve service port NOTE Normally the high pressure hose is connected to the liquid line port Ho
20. IELD INSTALLED EQUIPMENT R N A CLASS 11 VOLTAGE FIELD INSTALLED 2219 l G COOLING UNITS t E LENNOX CONDENSING UNITS Alte 2 16 024 250 05 D XC 16 036 230 D A XC 116 048 230 e O 0 XC 16 060 230 d YLW 8 YLW e vi 7 upersedes Form No 0606 BL e 2 2 Y2 2 BK D 5 7 535 286W 2006 Lennox Industries Inc Litho U S A Figure 20 XC16 Unit Wiring Diagram Builds SEQUENCE OF OPERATIONS First and second stage cooling operate independent of each other and can modulate back and forth according to the thermostat demand First Stage Cooling Low Capacity 1 Cooling demand imitates at Y1 at the thermostat 2 Voltage from terminal Y passes through S4 high pressure switch energizes K1 compressor contactor passes through the low pressure switch S87 and returns to common side of the 24VAC power 3 K1 closes energizing B1 compressor and B4 outdoor fan 4 Solenoid L34 is not energized so the slider ring remains open limiting compressor to low capacity Second Stage Cooling Low Capacity Compressor is operating in first stage cooling Second stage thermostat demand sends voltage to rectifier plug D4 D4 converts the AC voltage to DC voltage and energizes L34 unloader solenoid L34 closes the slider ring allowing the compressor to operate at high capacity Page 32
21. NE SET TRANSITION FROM VERTICAL TO HORIZONTAL ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE MUFFLER TYPE HANGER AUTOMOTIVE MUFFLER TYPE HANGER STRAP LIQUID LINE TO VAPOR LINE JN LIQUID LINE NON CORROSIVE METAL SLEEVE VAPOR LINE WRAPPED IN ARMAFLEX REFRIGERANT LINE SET INSTALLING HORIZONTAL RUNS 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 8 FEET 2 43 METERS s FLOOR JOIST OR ROOF RAFTER STRAPPING MATERIAL AROUND VAPOR LINE ONLY TAPE OR WIRE TIE 8 FEET 2 43 METERS NON CORROSIVE METAL SLEEVE STRAP THE VAPOR LINE TO THE JOIST OR RAFTER AT 8 FEET 2 43 METERS INTERVALS THEN STRAP THE LIQUID LINE TO THE VAPOR LINE TAPE OR WIRE TIE FLOOR JOIST OR ROOF RAFTER REFRIGERANT LINE SET INSTALLING VERTICAL RUNS NEW CONSTRUCTION SHOWN NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig OUTSIDE WALL LIQUID LINE VAPOR LINE i AE WIRE TIE 1 INSIDE WALL qa STRAP WOOD BLOCK BETWEEN STUDS I 44 WIRE TIE N WOOD BLOCK WIRE TIE MM LEEVE VAPOR LINE WRAPPED WITH ARMAFLEX
22. OW C S HIGH V N SWITCH CLEAN RECOVERY OUTDOOR UNIT CYLINDER 3 REFRIGERANT Remove existing HCFC 22 refrigerant using one of the following procedures IMPORTANT Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes and or long line sets METHOD 1 Us this method if the existing outdoor unit is not equipped with shut off valves or if the unit is not operational and you plan to use the existing HCFC 22 to flush the system Remove all HCFC 22 refrigerant from the existing system Check gauges after shutdown to confirm that the entire system is completely void of refrigerant METHOD 2 Use this method if the existing outdoor unit is equipped with manual shut off valves and you plan to use new HCFC 22 refrigerant to flush the system The following devices could prevent full system charge recovery into the outdoor unit e Outdoor unit s high or low pressure switches if applicable when tripped can cycle the compressor OFF e Compressor can stop pumping due to tripped internal pressure relief valve e Compressor has internal vacuum protection that is designed to unload the scrolls compressor stops pumping when the pressure ratio meets a certain value or when the suction pressure is as high as 20 psig Compressor suction pressures should never be allowed to go into a vacuum Prolonged operation at low suction pressu
23. STEP Figure 9 Brazing Procedures continued Page 17 XC16 SERIES Flushing Line Set and Indoor Coil TYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL REMOVAL PROCEDURE UNCASED OR PROCEDURE UNCASED COIL SHOWN COIL SHOWN TWO PIECE PATCH PLATE M LIQUID LINE 222 DISTRIBUTOR TUBES UNCASED COIL ORIFICE 2 2 LIQUID LINE ORIFICE HOUSING DISTRIBUTOR N TUBES TEFLON RING FIXED ORIFICE BRASS NUT z N ss SENSING _ LINE DISTRIBUTOR f Gp ASSEMBLY REMOVE AND DISCARD WHITE TEFLON SEAL IF PRESENT LIQUID LINE ASSEMBLY INCLUDES STRAINER LIQUID LINE ASSEMBLY WITH BRASS NUT A On fully cased coils remove the coil access and plumbing panels B Remove any shipping clamps holding the liquid line and distributor as sembly MALE EQUALIZER TS oe LINE FITTING C Using two wrenches disconnect liquid line from liquid line orifice hous LIQUID ing Take care not to twist or damage distributor tubes during this pro SENSING BULB LINE cess D Remove and discard fixed orifice valve stem assembly if present and A fully cased coils remove the coil access and plumbing panels Teflon washer as illustrated above B Remove any shipping clamps holding the liquid line and distributor E X Use a field provided fitting to temporary reconnect the liquid line to the assembly indoor unit s liquid line orifice housing C Disconnect the equalizer l
24. T WASHER NG CORNER POST Concrete slab use two plastic anchors hole drill 1 4 Wood or plastic slab no plastic anchor hole drill 1 8 DETAIL E Deck Top Mounting Stabilizing bracket 18 gauge metal 2 50 8mm width height as required bend to form right angle as exampled below S MINIMUM ONE 2 50 8MM SCH 40 PER SIDE FEMALE THREADED ADAPTER oe 2 50 8MM SCH 40 MALE THREADED Use additional 2 SCH 40 male threaded adapters which can be threaded into the female threaded adapters to make additional adjustments to the level of One bracket per side minimum For extra stability two brackets per side two inches the unit 51mm from each corner a ADAPTER SAME FASTENERS AS FOR EXTRA gie N SLAB SIDE MOUNTING STABILITY IMPORTANT To help stabilize an outdoor unit some installations may require strapping the unit to the pad using brackets and anchors commonly available in the marketplace Figure 5 Placement Slab Mounting and Stabilizing Unit Page 10 STABILIZING UNIT ON UNEVEN SURFACES A IMPORTANT Unit Stabilizer Bracket Use field provided Always use stabilizers when unit is raised above the factory height Elevated units could become unstable in gusty wind conditions Stabilizers may be used on factory height units when mounted on unstable an uneven surface With unit positioned at installation site perform the following 1 Remov
25. TEMPERATURE RATING 35 C MINIMUM Run 24VAC control wires through cutout with grommet Run 24VAC control wires through wire tie Make 24VAC control wire connections using field provided wire nuts Tighten wire tie to security 24V control wiring NOTE FOR PROPER VOLTAGES SELECT THERMOSTAT WIRE CONTROL WIRES GAUGE PER TABLE ABOVE NOTE WIRE TIE PROVIDES LOW VOLTAGE WIRE STRAIN RELIEF AND TO MAINTAIN SEPARATION OF FIELD INSTALLED LOW AND HIGH VOLTAGE CIRCUITS NOTE DO NOT BUNDLE ANY EXCESS 24VAC CONTROL WIRES INSIDE CONTROL BOX TIGHTEN WIRE TIE Page 22 If the outdoor unit is void of refrigerant clean the system using the procedure described below 1 Leak check system using procedure outlined on page 20 2 Evacuate the system using procedure outlined on page 21 Use nitrogen to break the vacuum and install a new filter drier in the system Evacuate the system again using procedure outlined on page 21 Weigh in refrigerant using procedure outlined in figure 17 Monitor the system to determine the amount of moisture remaining in the oil It may be necessary to replace the filter drier several times to achieve the required dryness level If system dryness is not verified the compressor will fail in the future Unit Start Up A IMPORTANT If unit is equipped with a crankcase heater it should be energized 24 hours before unit start up to prevent compressor damage as a result of slugging
26. a E F C ACCORDANCE WITH NATIONAL AND LOCAL CODES AMPACITY AND MAXIMUM OVER ON A92 DO NOT CUT ONBOARD W951 JUMPER A A CURRENT PROTECTION SIZE N REMOVE JUMPER FOR TWO STAGE COOL FROM R TO 0 IT IS USED FOR APPLICATIONS REFER TO COMPRESSOR IN FOR CONDENSING UNITS AL TERMINA PE z ARRANGEMENT A E CONTRO EOM e ZN FOR CONDENSING UNIT APPLICATIONS USE WHE E R TO O JUMPER REMOVE IN HEAT PUMP K APPLICATIONS AX REMOVE 05 TO YI JUMPER WHEN alee 7 HUMIDITY CONTROL IS USED hd x Tom YELLOW AX WHEN TWO STAGE THERMOSTAT 1S USED CONNECT ue SECOND STAGE HEAT BULB TO TERMINAL W2 QE TE AND REMOVE JUMPER BETWEEN R AND W2 Ss n540 S87 Ads L34 SOLENOID IS LOCATED IN COMPRESSOR Ein K P BLACK COIL IS 24 VDC DO NOT CONNECT 24VAC Pe S r TO COIL TERMINALS S 2 TT A 511 IS OPTIONAL LOW AMBIENT SWITCH 4 uz Ll E E TELEUN aa 742 CB 51MV CBX52MV SIGNATURE AX OPTIONAL HARD START KIT MAY BE REQUIRED N Om wee INDOOR 51 2 ON APPLICATIONS WHERE VOLTAGES ARE LESS A SSHRIE 5 ce 9 n THERMOSTAT 2 7 mu e H e A2 ELE ea AX es po T R AS S40 AND HRI ARE USED ON O48 AND 060 UNITS ONLY RED xq 4 DU CB29 CB30 A NE NOTE MINIMUM TRANSFORMER REQUIRED IN e Aeg vans INDOOR INDOOR UNIT 40VA ED CAPACITOR L2 eo BRED UNIT 2 INDICATES OPTIONAL COMPONENTS A2 WI m LINE VOLTAGE F
27. al side may be 6 inches 152mm LINE SET CONNECTIONS MINIMUM CLEARANCE BETWEEN 9 TWO UNITS N 48 1219 Figure 4 Installation Clearances A CAUTION x In order to avoid injury take proper precaution when lifting heavy objects See Unit Dimensions on page 3 for sizing mounting slab platforms or supports Refer to figure 4 for mandatory installation clearance requirements POSITIONING CONSIDERATIONS Consider the following when positioning the unit e Some localities are adopting sound ordinances based on the unit s sound level registered from the adjacent property not from the installation property Install the unit as far as possible from the property line e When possible do not install the unit directly outside a window Glass has a very high level of sound transmission For proper placement of unit in relation to a window see the provided illustration in figure 5 detail A PLACING UNIT ON SLAB 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 a slope tolerance as described in figure 5 detail B NOTE If necessary for stability anchor unit to slab as described in figure 5 detail D ELEVATING THE UNIT Units are outfitted with elongated support feet as illustrated in figure 5 detail C If additional elevation is necessary ra
28. ate Unit Model No Serial No Service Technician Nameplate Voltage Rated Load Ampacity Compressor Outdoor Fan Maximum Fuse or Circuit Breaker Electrical Connections Tight Indoor Filter clean Supply Voltage Unit Off Indoor Blower RPM S P Drop Over Indoor Dry Outdoor Coil Entering Air Temp Discharge Pressure Suction Pressure Refrigerant Charge Checked 4 Refrigerant Lines Leak Checked Properly Insulated Outdoor Fan Checked L Service Valves Fully Opened 1 Caps Tight 4 Thermostat Voltage With Compressor Operating Calibrated Properly Set J Level 1 Page 31 XC16 SERIES Unit Wiring Diagram and Sequence of Operations
29. ble 4 HFC 410A Temperature F Pressure Psig 80 2 2 2 100 8 45 9 71008 4 4 4 4 2590 96 2994 1032 52 1474 67 1009 83 2465 98 35071768 1941 84 2503 ij The outdoor unit and indoor blower cycle on demand from the room thermostat When the thermostat blower switch is in the ON position the indoor blower operates continuously HIGH PRESSURE SWITCH S4 XC16 units are equipped with a high pressure switch that is located in the liquid line of the compressor as illustrated in Unit Dimensions on page 4 The switch is a Single Pole Single Throw SPST manual reset switch with red cap that is normally closed and removes power from the compressor when discharge pressure rises above factory setting at 590 10 psi LOW PRESSURE SWITCH S87 XC16 units are also equipped with a low pressure switch that is located in the vapor line of the compressor The switch SPST auto reset normally closed removes power from the compressor when vapor line pressure drops below factory setting at 40 5 psi CRANKCASE THERMOSTAT S40 048 AND 060 UNITS ONLY Compressor in the XC16 048 and 060 units are equipped with a 70 watt belly band type crankcase heater HR1 prevents liquid from accumulating in the compressor HR1 is controlled by a thermostat located on the liquid line When liquid line temperature drops below 50 F the thermostat closes energizing HR1 The thermostat will
30. de refrigeration gauge set into the liquid line service port valve and out of the suction vapor line service port valve 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 C Remove core from valve in suction vapor line service port to allow nitrogen to escape ATTACH GAUGES SUCTION VAPOR SERVICE PORT MUST BE OPEN TO ALLOW EXIT POINT FOR NITROGEN SUCTION VAPOR LINE SERVICE VALVE VAPOR LINE Mi INDOOR UNIT N LIQUID LINE LIQUID LINE SERVICE VALVE USE REGULATOR FLOW NITROGEN AT 1 TO 2 PSIG OUTDOOR UNIT NITROGEN WHEN BRAZING LINE SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE Figure 8 Brazing Procedures Page 16 WRAP SERVICE VALVES To help protect service valve seals during brazing wrap water saturated cloths around service valve bodies and copper tube stubs Use additional water saturated cloths underneath the valve body to protect the base paint Flow regulated nitrogen at 1 to 2 psig through the refrigeration gauge set into the valve stem port connection on the liquid service valve and out of the suction vapor valve stem port See steps 3A 3B and 3C on manifold gauge set connections 5 FLOW NITROGEN 6 BRAZE LINE SET Wrap both service valves with water saturated cloths as illustrated here and as mentioned in step 4 bef
31. door unit coil before it enters the recovery machine A Inverted HCFC 22 cylinder with clean refrigerant to the vapor service C After all of the liquid refrigerant has been recovered switch the valve recovery machine to vapor recovery so that all of the HCFC 22 B HCFC 22 gauge set low side to the liquid line valve vapor is recovered Allow the recovery machine to pull down to 0 C HCFC 22 gauge set center port to inlet on the recovery machine with an the system empty recovery tank to the gauge set D Close the valve on the inverted HCFC 22 drum and the gauge D Connect recovery tank to recovery machines per machine instructions set valves Pump the remaining refrigerant out of the recovery machine and turn the machine off Figure 10 Installing Indoor Expansion Valve Page 18 Installing Indoor Metering Device This outdoor unit is designed for use in systems that use expansion valve metering devices at the indoor coil See the Lennox XC16 Engineering Handbook for approved expansion valve kit match ups The expansion valve unit can be installed internal or external to the indoor INDOOR EXPANSION VALVE INSTALLATION A TWO PIECE PATCH PLATE Uncased Coil Shown 2 LIQUID LINE STUB B PE ONEN ORIFICE END EXPANSION HOUSING N VALVE DISTRIBUTOR TUBES C SENSING DISTRIBUTOR ns EQUALIZER LINE LIQUID LINE ASSEMBLY WITH BRASS NUT C SEAL BONNET on gt lt
32. e two side louvered panels to expose the unit base 2 Install the brackets as illustrated in figure 5 detail D or E using conventional practices 3 Replace the panels after installation is complete ROOF MOUNTING Install the unit a minimum of 6 inches 152 mm above the roof surface to avoid ice build up around the unit Locate the unit above a load bearing wall or area of the roof that can adequately support the unit Consult local codes for rooftop applications If unit coil cannot be mounted away from prevailing winter winds a wind barrier should be constructed Size barrier at least the same height and width as outdoor unit Mount barrier 24 inches 610 mm from the sides of the unit in the direction of prevailing winds NOTICE Roof Damage This system contains both refrigerant and 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 during service and installation Failure to follow this notice could result in damage to roof surface Removing and installing Panels A IMPORTANT Do not allow panels to hang on unit by top tab Tab is for alignment and not designed to support weight of panel A IMPORTANT To help stabilize an outdoor unit some installations may require strapping the unit to the using brackets and anchors common
33. eak testing procedure NOTE The term absolute pressure means the total actual pressure within a given volume or system above the absolute zero of pressure 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 perform the following e Close manifold gauge valves e Close valve on vacuum pump e off vacuum pump Disconnect manifold gauge center port hose from vacuum pump e Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig 1034 kPa and purge the hose Open manifold gauge valves to break the vacuum in the line set and indoor unit e Close manifold gauge valves Shut off the dry nitrogen cylinder and remove the manifold gauge hose from the cylinder Open the manifold gauge valves to release the Reconnect the manifold gauge to the vacuum pump turn the pump on and continue to evacuate the line set and indoor 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 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 D dry nitrogen from the line set and indoor unit
34. ed EQUALIZER LINE NOTE Confirm proper thermal contact between vapor line INSTALLATION FOR and expansion bulb before insulating the sensing bulb once FURTHER DETAILS LIQUID LINE stalled l l l l B Connect the equalizer line from the expansion valve to sensing bulb insulation is required if the equalizer vapor port on the vapor line Finger tighten mounted external to the coil casing sensing the flare nut plus 1 8 turn 7 ft lbs as illustrated below bulb installation for bulb positioning ON LINES SMALLER THAN EQUALIZER LINE INSTALLATION 7 8 MOUNT SENSING 4 BULB AT EITHER THE 3 OR A Remove and discard either the flare seal cap or flare nut qum Sud 9 O CLOCK POSITION with copper flare seal bonnet from the equalizer line port V on the vapor line as illustrated in the figure to the right BULB EUIS B Remove and discard either the flare seal cap or flare nut J with copper flare seal bonnet from the equalizer line port on boe the vapor line as illustrated in the figure to the right gt A ag FLARE SEAL CAP ii FLARE NUT VAPOR LINE N ON 7 8 AND LARGER LINES MOUNT SENSING BULB AT COPPER FLARE EITHER THE 4 OR 8 O CLOCK MALE BRASS EQUALIZER LINE FITTING VAPOR LINE NOTE NEVER MOUNT ON BOTTOM OF LINE Figure 11 Installing Indoor Expansion Valve Page 19 XC16 SERIES A IM PORTANT Leak Test Line Set and Indoor Coil The Environmental Protection Agency EPA prohibits the intentional venting of H
35. ferably twice a year but at least once a year to inspect and service your outdoor unit The following maintenance may be performed by the homeowner A IMPORTANT Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to the outdoor unit by treated water Prolonged exposure of the unit to treated water i e sprinkler systems soakers waste water etc will corrode the surface of steel and aluminum parts and diminish performance and longevity of the unit variations between low and high capacity readings Tools Required e Refrigeration gauge set e Digital volt amp meter e Electronic temperature thermometer e On off toggle switch Procedure Outdoor Coil The outdoor unit must be properly maintained to ensure its proper operation e Please contact your dealer to schedule proper inspection and maintenance for your equipment e Make sure no obstructions restrict airflow to the outdoor unit Page 29 XC16 SERIES e Grass clippings leaves or shrubs crowding the unit can cause the unit to work harder and use more energy e Keep shrubbery trimmed away from the unit and periodically check for debris which collects around the unit Cleaning of the outdoor unit s coil should be performed by a trained service technician Contact your dealer and set up a schedule preferably twice a year but at least once a year to inspect and service your outdoor unit Routine Maintenance
36. 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 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 LIP DETAIL A DETAIL B ROTATE IN THIS DIRECTION gt THEN DOWN TO REMOVE PANEL HOLD DOOR FIRMLY TO THE HINGED ANGLE MAY BE TOO n d SIDE TO MAINTAIN EXTREME gt s FULLY ENGAGED TABS N mS po nos PREFERRED ANGLE FOR INSTALLATION ____ Figure 6 Removing and Installing Panels Page 12 New or Replacement Line Set REFRIGERANT LINE SET This section provides information on installation or replacement of existing line set If new or replacement line set is not being installed then proceed to Brazing Connections on page 15 A IMPORTANT Lennox highly recommends changing line set when converting the existing system from HCFC 22 to HFC 410A f that is not possible and the line set is the proper size as reference in table 2 use the procedure outlined under Flushing the System on page 13 If refrigerant lines are routed through a wall then seal and
37. ine from the check expansion valve equalizer line fitting on the vapor line CONNECT GAUGES AND EQUIPMENT FOR D Remove the vapor line sensing bulb FLUSHING PROCEDURE E Disconnect the liquid line from the check expansion valve at the liquid line assembly INVERTED HCFC 22 AUGE i i T CINDER COMTANS aoo heck expansion from the ine oe CLEAN HCFC 22 TO BE E A USED FOR FLUSHING process G Remove and discard check expansion valve and the two Teflon rings X Useafield provided fitting to temporary reconnect the liquid line to the indoor unit s liquid line orifice housing FLUSHING LINE SET The line set and indoor unit coil must be flushed with at least the same amount of clean refrigerant that previously charged the system Check the charge in the flushing cylinder before proceeding A Set the recovery machine for liquid recovery and start the recovery machine Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line set and indoor unit coil VAPOR LINE SERVICE VALVE NZ EXISTING INDOOR UNIT LIQUID LINE SERVICE VALVE E T c B Invertthe cylinder of clean HCFC 22 and open its valve to allow RECOVERY O liquid refrigerant to flow into the system through the vapor line DISCHARGE CYLINDE EE S valve Allow the refrigerant to pass from the cylinder and through RECOVERY MACHINE the line set and the in
38. ines longer than 50 feet see the Lennox Refrigerant Piping Design and Fabrication Guidelines CORP 9351 L9 or contact Lennox Technical Support Product Applications for assistance To obtain the correct information from Lennox be sure to communicate the following information e Model XC16 and size of unit e g 036 e Line set diameters for the unit being installed as listed in table 2 and total length of installation e Number of elbows vertical rise or drop in the piping The compressor is charged with sufficient Polyol ester oil for line set lengths up to 50 feet Recommend adding oil to system based on the amount of refrigerant charge in the system No need to add oil in system with 20 pounds of refrigerant or less For systems over 20 pounds add one ounce of every five pounds of refrigerant Recommended topping off POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATE RL32CF WARNING Polyol Ester POE oils used with HFC 410A refrigerant absorb moisture very quickly It is very important that the refrigerant system be kept closed as much as possible DO NOT remove line set caps or service valve stub caps until you are ready to make connections A IMPORTANT Mineral oils are not compatible with HFC 410A If oil must be added it must be a Polyol Ester oil Page 13 XC16 SERIES Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation REFRIGERANT LI
39. ise the unit by extending the height of the unit support feet This may be achieved by using a 2 inch 50 8mm Schedule 40 female threaded adapter The specified coupling will fit snuggly into the recessed portion of the feet Use additional 2 inch 50 8mm Schedule 40 male threaded adaptors which can be threaded into the female threaded adaptors to make additional adjustments to the level of the unit NOTE Keep the height of extenders short enough to ensure a sturdy installation If it is necessary to extend further consider a different type of field fabricated framework that is sturdy enough for greater heights Page 9 XC16 SERIES DETAIL A Outside Unit Placement Install unit away from windows DETAIL Slab Mounting at Ground Level Install unit level or if on a slope maintain slope tolerance of two 2 degrees or two inches per five feet 50 mm per 1 5 m away from building structure BUILDING STRUCTURE MOUNTING TWO 90 ELBOWS INSTALLED IN LINE SET WILL GROUND LEVEL REDUCE LINE SET VIBRATION DETAIL C Elevated Slab Mounting STABILIZING UNIT ON UNEVEN SURFACES using Feet Extenders DETAIL D Slab Side Mounting AS 10 1 2 LONG SELF DRILLING N SS SHEET METAL SCREWS STABILIZING BRACKET 18 GAUGE h METAL 2 WIDTH HEIGHT AS BASE PAN REQUIRED es N 10 1 1 4 LONG HEX HD SCREW 7 AND FLA
40. ly available in the marketplace WARNING To prevent personal injury or damage to panels unit or structure be sure to observe the following While installing or servicing this unit carefully stow all removed panels out of the way so that the panels will not cause injury to personnel nor cause damage to objects or structures nearby nor will the panels be subjected to damage e g being bent or scratched While handling or stowing the panels consider any weather conditions especially windy conditions that may cause panels to be blown around and battered Page 11 XC16 SERIES LOUVERED PANEL REMOVAL Remove the louvered panels as follows 1 Remove two screws allowing the panel to swing open slight ly 2 Hold the panel firmly throughout this procedure Rotate bot tom 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 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 illus trated 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
41. mperature OUTDOOR AMBIENT TEMPERATURE REQUIREMENTS Sufficient heat load in structure 5 5 Indoor temperature between 70 80 21 26 pa j 1 EEUU Manifold gauge set connected to unit Thermometers to measure outdoor ambient temperature to measure liquid line temperature APPROACH OR WEIGH IN to measure suction line temperature SUBCOOLING I SECOND STAGE HIGH CAPACITY Figure 16 Determining Charge Method WEIGH IN CHARGING METHOD 64 F 17 7 C and Below CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE If the system is void of refrigerant first locate and repair any leaks and then weigh in the refrigerant charge into the unit To calculate the total refrigerant charge Adjust amount for variation Amount specified on in line set length listed on nameplate line set length table below Total charge L ENN0X DALLAS TEXAS M N TSA036H4N41G Refrigerant Charge per Line Set Length HI LO 460 Liquid Line Ounces per 5 feet g per 1 5 m noma vore en x A adjust from 15 feet 4 6 m line set 3 8 9 5 mm 3 ounce per 5 85 g per 1 5 m FUSBLEICOUPE GREUTD 16 If line length is greater than 15 ft 4 6 m add this amount If line length is less than 15 ft 4 6 m subtract this amount NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become
42. n TM XXX 230 03 Refrigerant Type X R A1I0A Minor Revision Number Voltage 230 208 230V 1ph 60hz C Air c NPP Nominal Cooling Capacity 024 2 tons 036 3 tons 048 4 tons Series 060 5 tons Typical Serial Number Identification T 0 C 05716 Location Code 19 Saltillo Mexico n r V 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 Model Number i i Pone RABY eee ere Number of Blades Diameter inches XC16 024 230 02 75 602 22 Model Number i i Pound is bid Number of Blades Diameter inches XC16 036 230 02 Bibs 9 oz 22 XC16 036 230 03 815 802 22 Model Number i i is ems e i Number of Blades Diameter inches XC16 048 230 01 22 XC16 048 230 02 11 los 4 oz 22 Model Number i i manne RABY Number of Blades Diameter inches XC16 060 230 02 14 bs 2 oz 26 1 Tested according to AHRI Standard 270 2008 test conditions Refrigerant charge sufficient for 15 feet length of refrigerant lines Page 2 Electrical Data lt a 60 Hz 1 Ph Maximum Model Number Over current Minimum Circuily Rated Load Motor HP Nominal Full Load Locked Rotor Bolection Amps RLA S RPM Amps FLA Amps LRA xore 024 200 01 20 138 1025 mo 1075 14
43. n of the drain line and how to check for obstructions This would also apply to an auxiliary drain if installed Thermostat Operation See the thermostat homeowner manual for instructions on how to operate your thermostat Preservice Check If your system fails to operate check the following before calling for service e Verify room thermostat settings are correct e Verify that all electrical disconnect switches are ON e Check for any blown fuses or tripped circuit breakers e Verify unit access panels are in place e Verify air filter is clean e f service is needed locate and write down the unit model number and have it handy before calling Accessories For update to date information see any of the following publications e Lennox XC16 Engineering Handbook e Lennox Product Catalog e Lennox Price Book Page 30 Checklists Two Stage Modulation Compressors Field Operational Checklist Expected results during Y2 Unit Readings Y1 First Stage 1 Toggle switch On COMPRESSOR Voltage Same Amperage Higher OUTDOOR UNIT FAN MOTOR Amperage Same or Higher TEMPERATURE Ambient Same Outdoor Coil Discharge Air Higher Compressor Discharge Line Higher Indoor Return Air Same Indoor Coil Discharge Air Lower PRESSURES Suction Vapor Lower Liquid Higher Y2 Second Stage Start Up and Performance Checklist Job Name Date Job Location State Installer St
44. nit 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 After leak testing disconnect gauges from service ports Figure 12 Leak Test Page 20 Evacuating Line Set and Indoor Coil NOTE Remove cores from service valves if not already done 1 CONNECT GAUGE SET A Connect low side of manifold gauge set with 1 4 SAE in line tee to vapor line service valve B OUTDOOR Connect high side of manifold gauge set to liquid line service valve A Connect micron gauge available connector on the 1 4 SAE in line tee D Connect the vacuum pump with NITR BENIM gauge to the center port of the manifold gauge set The center port Kop will be used later for both the vd E FC 410A and nitrogen containers HFC 410A E A Open both manifold valves and start the vacuum pump 2 EVACUATE THE SYSTEM q HIGH H A34000 1 4 SAE TEE WITH 2 BB SWIVEL COUPLER C ss MICRON 1 TO VAPOR SERVICE VALVE TO LIQUID LINE SERVICE VALVE y 1 RECOMMEND MINIMUM 3 8 HOSE B 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 l
45. ny 8 4 4 10 5 6 8 4 4 4 2 2 Temperature of air entering outdoor coil Models XC17 XXX 230 02 03 F 024 036 048 060 Any 6 3 3 6 3 3 8 44 4 2 2 Temperature of air entering outdoor coil Figure 18 Using HFC 410A Approach TXV Charge Method START Measure outdoor ambient temperature USE WEIGH IN METHOD Weigh in or remove refrigerant based upon line length 64 F and BELOW SUBCOOLING TXV BLOCK OUTDOOR COIL sometimes necessary with lower temperatures Use cardboard or plastic sheet to restrict the airflow through the outdoor coil to achieve pressures from 325 375 psig 2240 2585 kPa Higher pressures are needed to check charge Block equal sections of air intake panels and move coverings sideways until the liquid pressure is in the above noted ranges If refrigerant is added or removed verify charge using the Approach Method If value is LESS than shown add refrigerant If value is MORE than refrigerant ABOVE or shown remove Connect gauge set as illustrated in figure 14 Confirm proper airflow across coil using figure 15 Compare unit pressures with table 3 Normal Operating Pressures Set thermostat to call for heat must have a cooling load between 70 80 F 21 26 C Measure outdoor ambient temperature When heat demand is satisfied set thermostat to call for cooling Allow temperatures and pressures to stabilize
46. or to an earth ground N S M ane CUTOUT WITH GROMMET 24V CONTROL WIRES temperatures and pressures present during operation of an air conditioning system Non condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts In the U S A wiring must conform with current local codes and the current National Electric Code NEC In Canada wiring must conform with current local codes and the current Canadian Electrical Code CEC Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size 24VAC TRANSFORMER Use the transformer provided with the furnace or air handler for low voltage control power 24VAC 40 VA minimum 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 can be affected by sunlight or drafts THERMOSTAT E 2 INSTALL THERMOSTAT NOTE 24VAC Class ll circuit connections are made in the control panel amem HIGH VOLTAGE FIELD WIRING FACTORY WIRING em ex eu eus OW VOLTAGE 24V FIELD WIRING WIRE RUN LENGTH LESS THAN 100 30 METERS 18 MORE THAN 100 30 METERS 16 AWG INSULATION
47. ore brazing to line set Water saturated cloths must remain water saturated throughout the brazing and cool down process LIQUID LINE SERVICE VALVE WHEN BRAZING LINE SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE IMPORTANT Allow braze joint to cool Apply additional water saturated cloths to help cool brazed WATER SATURATED joint Do not remove water saturated cloths until piping CLOTH has cooled Temperatures above 250 F will damage valve seals OUTRE WARNING 1 FIRE PERSONAL INJURY OR PROPERTY DAMAGE will result if you do not wrap a water SUCTION VAPOR LINE SERVICE VALVE saturated cloth around both liquid and suction line service valve bodies and copper tube stub while brazing in the line set The braze when complete must be quenched with water to absorb any residual heat WHEN BRAZING LINE SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE Do not open service valves until refrigerant lines and indoor coil have been leak tested and evacuated Refer to procedures provided in this supplement SUCTION VAPOR LINE WATER SATURATED CLOTH 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 f PREPARATION FOR NEXT
48. propriately sized wrench TO INDOOR UNIT e With torque wrench Finger tighten and torque cap per table 1 Without torque wrench Finger tighten and TO OPEN ROTATE STEM use an appropriately sized wrench to turn o BALL SHOWN E i an additional 1 6 turn clockwise VALVE TO CLOSE ROTATE STEM CLOCKWISE 90 E STEM Reinstall Stem Cap Stem cap protects the valve stem from damage and serves as the primary seal Replace the stem cap and tighten as follows SERVICE PORT 1 12 TURN SERVICE PORT e With Torque Wrench Finger tighten and Pis then torque cap per table 1 SERVICE PORT CAP Without Torque Wrench Finger tight en and use an appropriately sized TO OUTDOOR STEM CAP wrench to turn an additional 1 12 turn UNIT clockwise NOTE A label with specific torque requirements may be affixed to the stem cap If the label is present use the specified torque Figure 2 Angle and Ball Service Valves Page 7 XC16 SERIES Recovering Refrigerant from System Disconnect all power to the existing outdoor unit at the disconnect Connect a gauge set clean recovery cylinder and a recovery switch or main fuse box breaker panel machine to the service ports of the existing unit Use the instructions provided with the recovery machine to make the connections ee POWER 2 MANIFOLD GAUGE SET MAIN FUSE BOX BREAKER PANEL MAIN FUSE MANIFOLD GAUGES BOX BREAKER Rl RECOVERY MACHINE DISCONNECT L
49. res will result in overheating of the scrolls and permanent damage to the scroll tips drive bearings and internal seals Once the compressor can not pump down to a lower pressure due to one of the above system conditions shut off the vapor valve Turn OFF the main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set Perform the following task A Startthe existing HCFC 22 system in the cooling mode and close the liquid line valve B Use the compressor to pump as much of the existing HCFC 22 refrigerant into the outdoor unit until the outdoor system is full Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system NOTE It may be necessary to bypass the low pressure switches if equipped to ensure complete refrigerant evacuation C When the low side system pressures reach 0 psig close the vapor line valve D Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system Figure 3 Refrigerant Recovery Page 8 CLEARANCE ON ALL SIDES INCHES MILLIMETERS ACCESS PANEL T e NOTES 07 30 762 SN SY 7 N e EL 12 305 MINIMUM CLEARANCE ABOVE UNIT Clearance to one of the other three sides must be 36 inches 914mm Clearance to one of the remaining two sides may be 12 inches 305mm and the fin
50. ressor steps from low to full capacity DEALER Maintenance and service must be performed by a qualified installer or service agency At the beginning of each cooling season the system should be checked as follows Outdoor Unit 1 Clean and inspect the outdoor coil The coil may be flushed with a water hose Ensure the power is turned off before you clean the coil 2 Outdoor fan motor is prelubricated and sealed No further lubrication is needed 3 Visually inspect connecting lines and coils for evidence of oil leaks 4 Check wiring for loose connections 5 Check for correct voltage at the unit with the unit operating 6 Check amp draw outdoor fan motor UNIT NAMEPLATE ACTUAL NOTE If owner reports insufficient cooling the unit should be gauged and refrigerant charge checked 9 tt 8 142 5 743 5 t44 5 5 6 0 149 2 150_ JEEE o 62 3 169 8 154 3 Page 28 Outdoor Coil It may be necessary to flush the outdoor coil more frequently if it is exposed to substances which are corrosive or which block airflow across the coil e g pet urine cottonwood seeds fertilizers fluids that may contain high levels of corrosive chemicals such as salts e Outdoor Coil The outdoor coil may be flushed with a water hose e 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 req
51. rt which has a factory installed valve stem Figure 2 provides information on how to access and operating both angle and ball service valves Page 6 SERVICE VALVES ance ano Operating Angle Type Service Valve 1 Remove stem cap with an appropriately sized wrench 2 Use a service wrench with 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 TO INDOOR 556 CLOSED INSERT HEX VALVE STEM SHOWN OPEN S WRENCH HERE INSERT HEX WRENCH HERE o ZL SA STEM CAP TO OUTDOOR UNIT ANGLE TYPE SERVICE VALVE 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 SERVICE PORT CORE 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 roate 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 Operating Ball Type Service Valve Remove service port cap with an ap
52. rvice 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 Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench or stripping the valve stem recess See the Lennox Service and Application Notes C 08 1 for further details and information A IMPORTANT To prevent stripping of the various caps used the appropriately sized wrench should be used and fitted snugly over the cap before tightening Table 1 Torque Requirements Parts Recommended Torque Service valve cap 8 ft lb 11 NM Sheet metal screws Machine screws 10 28 in Ib Compressor bolts Gauge port seal cap 8 ft Ib USING MANIFOLD GAUGE SET When checking the system charge only use a manifold gauge set that features low loss anti blow back fittings Manifold gauge set used with HFC 410A refrigerant systems must be capable of handling the higher system operating pressures The gauges should be rated for use with pressures of 0 800 psig on the high side and a low side of 30 vacuum to 250 psig with dampened speed to 500 psi Gauge hoses must be rated for use at up to 800 psig of pressure with a 4000 psig burst rating OPERATING SERVICE VALVES The liquid and vapor line service valves are used for removing refrigerant flushing leak testing evacuating checking charge and charging Each valve is equipped with a service po
53. sturbing the insulation during installation maintenance or repair will expose you to fiberglass wool dust Breathing this may cause lung cancer Fiberglass wool is known to the State of California to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc 799900 Dallas TX 75379 9900 A WARNING Electric Shock Hazard Can cause injury or death Unit must be grounded in accordance with national 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 Operating Gauge Set and Service Valves These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities who have jurisdiction before installation TORQUE REQUIREMENTS When servicing or repairing heating ventilating and air conditioning components ensure the fasteners are appropriately tightened Table 1 lists torque values for fasteners IMPORTANT Only use Allen wrenches of sufficient hardness 50Rc Rockwell Harness Scale minimum Fully insert the wrench into the valve stem recess Se
54. uire frequent inspections and maintenance These inspections will determine the necessary 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 Adjust blower speed for cooling Measure the pressure drop over the coil to determine the correct blower CFM Refer to the unit information service manual for pressure drop tables and procedure Check blower drive belt for wear and proper tension Check all wiring for loose connections Check for correct voltage at unit blower operating O o Check amp draw on blower motor UNIT NAMEPLATE ACTUAL INDOOR COIL 1 Clean coil if necessary 2 Check connecting lines and coils for signs of oil leaks 3 Check condensate line and clean if necessary TWO STAGE COMPRESSOR CHECKS Use the checklist procedure on page 31 to verify part load and full load capacity operation of two stage modulation compressors A IMPORTANT This performance check is ONLY valid on systems that have clean indoor and outdoor coils proper airflow over coils and correct system refrigerant charge All components in the system must be functioning proper to correctly perform compressor modulation operational check Accurate measurements are critical to this test indoor system loading and outdoor ambient can affect NOTE Block outdoor coil to
55. wever connecting it to the vapor port better protects the manifold gauge set from high pressure damage Oo O With both manifold valves closed connect the cylinder of OUTDOOR UNIT HFC 410A refrigerant to the center port of the manifold gauge set NOTE Later in the procedure the HFC 410A container will be replaced by the nitrogen container TO VAPOR SERVICE VALVE TH Tide Dui 5 NITROGEN HFC 410A TEST FOR LEAKS After the line set has been connected to the indoor and outdoor units check the line set connections 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 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 Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set 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 u

WARNING CAUTION IMPORTANT IMPORTANT

Contents

Download Pdf Manuals

Related Search

Related Contents