XC16 Series - HvacPartsShop.com
Contents
1. Compressor Discharge Line Higher Indoor Return Air Same Indoor Coil Discharge Air Lower Pressures Suction Vapor Lower Liquid STEP 2 Confirm DC voltage output on compressor solenoid plug 11 Shut power off to outdoor unit 12 Supply 24 volts AC control voltage to the wire ends of the full wave rectifier plug Listen for a click as the sole noid is energized See figure 6 apply 24vac compressor solenoid fusite fusite terminals terminals compressor FIGURE 6 13 Unplug the full wave rectifier plug from the fusite con nection on the compressor 14 Turn the low voltage power back onto the unit Supply 24VAC to the wires of the full wave rectifier plug Set volt meter to DC volts and measure the DC voltage at the fe male connector end of the full wave rectifier plug The DC voltage reading should be 1 5 to 3 volts lower than the input voltage to the plug wire leads EX Input volt age is 24VAC output voltage is 22VDC See figure 7 rectifier apply 24vac solenoid compressor fusite fusite terminals terminals compressor FIGURE 7 Higher If the above checks verify that the solenoid plug is provid ing power to cycle into high capacity operation continue to step 3 to determine if problem is with solenoid coil in compressor STEP 3 Confirm internal unloader solenoid has prop er resistance 15 Shut all power off to unit main an2. LENNOX UNIT INFORMATION XC16 ce IM evise Service Literature XC16 SERIES UNITS The XC16 is a high efficiency residential split system con densing unit which features a two speed scroll compressor and R 410A refrigerant XC16 units are available in 2 3 4 and 5 tons XC16 units are rated for 230 volts only Applica tions where supply voltage is less requires a hard start kit The series is designed for use with an expansion valve ap proved for use with R 410A in the indoor unit This manual is divided into sections which discuss the major compo nents refrigerant system charging procedure mainte nance and operation sequence Information contained in this manual is intended for use by qualified service technicians only All specifications are sub ject to change A WARNING Improper installation adjustment alteration service or maintenance can cause property damage person al injury or loss of life Installation and service must be performed by a qualified installer or service agency A WARNING Warranty will be voided if covered equipment is re moved from original installation site Warranty will not cover damage or defect resulting from Flood wind lightning or installation and operation in a corrosive atmosphere chlorine fluorine salt TABLE OF CONTENTS A IMPORTANT Operating pressures of this R 410A unit are higher than pressures in R 22 units Always use service equipment rated for R
3. pue yoeq enpow ues pue yo Yoee Jo ju pu d pu ajeJodo jood a ejs puodas pue jsJl4 JION vis oust Sent es12169981 200007 9002 MIBZ Ses ON sey BON 082 090 919X 082 870 919X 082 9 0 919X 022 120 91 X GSTWAISNI 07314 _39VLI0A I SYD G3TIVISNI 01313 39V170A 3011 SLN3NOINOI TVNOILIO S3LVDIONI VAOY LINN YOOONI NI O3YINO34 YJNYOJSNVYL WOWININ 310N PPO Sp OPO a AINO SLINN 090 ONY 8 0 NO G3SN SUV IUH ONY OFS EY 9NIHIA AHYSS393N TIV HLIA zY L3 ONY ISA SSONTONI LIN LTOA OSZ NVHL AVLSORUSHL SS3 UV S3OVLIOA 3H3HA SNOILVOIIdd NO Lzm s G3YINOSY 3GAVAN LIN LYVLS GHYH TVNOILIO k44 SUNLYNSIS ANZ X9O2 ANIC9S2 HOLIAS INSIGNV A01 TNOILdO SI IIS y STYNINH31 1109 OL QVAV2 LI3NNOI LON 00 GA 2 SI 1109 BOSS34UAN09 NI 31V901 SI GIONSWS 81 Vv ZM ONY QH NJJALJG USANr JAONJY ONY hs TYNINH31 OL GING 1V3H 39V1S GNOI3S LO3NNOD G3SN SI LVSONUSHL 39V1S OAL NIHA 7 G3SN SI TOHIN03 ALICINNH NSHA H3dW0r 1A OL SO 3AONSY qy Nd VGH NI aAomas Nast O O1 H G3SN SI OULNOD ALIGINNH N3HA_ Y OL 3SN SNOILVOT Idd LINN ONISN3ONOD 804 V7 sa NOUS H3dm0f VIGM GHYOSNO LNO ZEV NO W YNIWH31 WALAY 04 LINN SNOLLVOT idy M04 GASH SI LT O OL ROU 7009 39V1S OAL 404 u3dM0r IANS Y zi i y 3ZIS NOI193108d LNJYYNI y udn IS6M CUVO NO Ind LON 0d Z6V NO Y H3AO ANNIXYN ONV ALTOVGAY HOLIAS 3009 1V901_ ONY IVNOILVN HLIM 39NYQUOJIV LINOYID ANMININ HO4 31V1d S3unsS3ud NI_G30NN0U9 34 ISNA LINN H1V30 X0 ONTLVY LINN Ol 4343
4. 3 Motor hp 1 10 1 6 1 4 1 3 Cfm 2320 3060 3955 4380 Rpm 1130 845 835 850 Watts 165 215 320 280 Shipping Data lbs 1 pkg 208 238 268 323 ELECTRICAL DATA Line voltage data 60hz 4 230V 1ph 4 230V 1ph 4 230V 1ph 4 230V 1ph 3 Maximum overcurrent protection amps 20 35 45 55 2 Minimum circuit ampacity 13 6 22 0 28 2 33 9 Compressor Rated load amps 10 3 16 7 21 2 25 6 Locked rotor amps 52 82 96 118 Power factor 0 98 0 99 0 99 0 99 Outdoor Fan Full load amps 0 7 1 1 1 7 1 8 Motor Locked Rotor amps 2 2 1 3 1 2 9 OPTIONAL ACCESSORIES must be ordered extra Compressor Hard Start Kit 10J42 81J69 Compressor Low Ambient Cut Off 45F08 Compressor Time Off Control 47J27 Freezestat 3 8 in tubing 93G35 5 8 in tubing 50A93 Indoor Blower Relay 40K58 Low Ambient Kit 68M04 SignatureStat Home Comfort Control 81M27 Refrigerant L15 41 20 L15 65 40 Line Sets L15 41 30 L15 65 50 L15 65 40 L15 65 30 L15 65 50 Field Fabricate Time Delay Relay 58M81 NOTE Extremes of operating range are plus 10 and minus 5 of line voltage 1 Refrigerant charge sufficient for 15 ft length of refrigerant lines Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements 2 3 HACR type breaker or fuse 4 Hard start kit is required in applications where the supply voltage is less than 230V Pa
5. a full wave rectifier that converts 24 volt AC into 24 volt DC power to power the unloader sole noid Refer to unit diagram for internal circuitry view of plug If it is suspect the unloader is not operating properly check the following A IMPORTANT This performance check is ONLY valid on systems that have clean indoor and outdoor coils proper air flow over coils and correct system refrigerant charge All components in the system must be func tioning proper to correctly perform compressor mod ulation operational check Accurate measurements are critical to this test as indoor system loading and outdoor ambient can affect variations between low and high capacity readings STEP 1 Confirm low to high capacity compressor op eration Tools required Refrigeration gauge set Digital volt amp meter Electronic temperature thermometer On off toggle switch Page 7 Procedure 1 Turn main power OFF to outdoor unit 2 Adjust room thermostat set point above heating opera tion on heat pump or below cooling operation the room temperature 5 F 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 press
6. been connected to the indoor and out door units check the line set connections and indoor unit for leaks A IMPORTANT The Clean Air Act of 1990 bans the intentional venting of CFC s and HFC s as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration my be levied for noncompliance A WARNING Fire Explosion and Personal Safety Hazard Failure to follow this warning could result in damage personal injury or death Never use oxygen to pressurize or purge refrigeration lines Oxygen when exposed to a spark or open flame can cause damage by fire and or an explosion that could result in personal injury or death A WARNING Danger of explosion Can cause equipment damage injury or death When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air con ditioning system use a regulator that can adjust the pressure from 0 to 450 psig 3103 kPa Using an Electronic Leak Detector 1 Connect a cylinder of R 410A to the center port of the manifold gauge set Connect manifold gauge to service valve port 2 With both manifold valves closed open the valve on the R 410A cylinder 3 Open the high pressure side of the manifold to allow the R 410A into the line set and indoor unit Weigh in a trace amount of R 410A A trace amount is a maximum of 2 ounces 57 g or 3 pounds 31 kPa pressure Close the valve on the R 410A cyl
7. during warm weather use one of the following procedures Charge Using the Subcooling Method Outdoor Temperature lt 65 F 18 C When the outdoor ambient temperature is below 65 F 18 C use the subcooling method to charge the unit Val ues from table 3 are used for this procedure If necessary restrict air flow through the outdoor coil to achieve pressures in the 325 375 psig 2240 2585 kPa range Higher pressures are necessary for checking the charge Block equal sections of air intake panels and move obstructions sideways until the liquid pressure is in the 325 375 psig 2240 2585 kPa range See figure 11 Blocking Outdoor Coil Outdoor coil should be blocked one side at a time with cardboard or plastic sheet until proper testing pressures are reached cardboard or plastic sheet Four sided unit shown FIGURE 11 1 With the manifold gauge hose still on the liquid service port and the unit operating stably use a digital thermom eter to record the liquid line temperature 2 At the same time record the liquid line pressure reading 3 Use a temperature pressure chart table 3 to determine the saturation temperature for the liquid line pressure reading 4 Subtract the liquid line temperature from the saturation temperature according to the chart to determine sub cooling Page 14 5 Compare the subcooling value with those in table 4 If subcooling is greater than shown recover some ref
8. proach method Page 15 NOTE Use the same digital thermometer you used to check the outdoor ambient temperature to check the liq uid line temperature 4 The difference between the ambient and liquid tempera tures should match values given in table 5 If the values don t agree with the those in table 5 add refrigerant to lower the approach temperature or recover refrigerant from the system to increase the approach temperature Be aware of the R 410A refrigerant cylinder It will be light maroon colored Refrigerant should be added through the vapor valve in the liquid state TABLE 5 XC16 Approach Values for Charging Liquid Line Temperature Outdoor Temperature Approach Temperature Model 024 036 048 060 F C 8 4 4 8 4 4 4 2 2 F 1 0 C 0 5 A IMPORTANT Table 6 is not a procedure for charging the system but may be used to perform maintenance checks Minor variations in these pressures may be due to differ ences in installations Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system 10 5 6 TABLE 6 Normal Operating Pressures In psig liquid 10 and vapor 5 PSIG Temp of 024 036 048 060 air enter ing out door coil Liq Suc Liq Suc Liq Suc Liq Suc First Stage Low Capacity 65 18 3 223 227 75 23 9 256 85 29 4 95 35 0
9. valves figures 6 and 7 and gauge ports are accessible from the outside of the unit Use the service ports for leak testing evacuating charging and checking charge Each valve is equipped with a service port which has a facto ry installed Schrader valve A service port cap protects the Schrader valve from contamination and serves as the pri mary leak seal Service valves are not rebuildable If a valve has failed you must replace it To Access Schrader Port 1 Remove service port cap with an adjustable wrench 2 Connect gauge to the service port 3 When testing is complete replace service port cap Tight en finger tight then an additional 1 6 turn To Open Service Valve 1 Remove the stem cap with an adjustable wrench 2 Using the adjustable wrench to keep the valve station ary use a service wrench with a hex head extension to back the stem out counterclockwise as far as it will go NOTE Use a 3 16 hex head extension for 3 8 line sizes or a 5 16 extension for large line sizes 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn Page 11 To Close Service Valve 1 Remove the stem cap with an adjustable wrench 2 Using the adjustable wrench to keep the valve station ary use a service wrench with a hex head extension to turn the stem clockwise to seat the valve Tighten the stem firmly NOTE Use a 3 16 hex head extension for 3 8 line sizes or
10. 105 40 6 115 46 1 15 65 18 3 75 23 9 143 85 29 4 310 95 35 0 356 105 40 6 115 46 1 152 47 These are typical pressures only Indoor indoor match up in door air quality and indoor load will cause the pressures to vary V SERVICE AND RECOVERY AWARNING Polyol ester POE oils used with R 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 connec tions A IMPORTANT USE RECOVERY MACHINE RATED FOR R 410A REFRIGERANT If the XC16 system must be opened for any kind of service such as compressor or drier replacement you must take ex tra precautions to prevent moisture from entering the sys tem The following steps will help to minimize the amount of moisture that enters the system during recovery of R 410A 1 Use a regulator equipped nitrogen cylinder to break the system vacuum Do not exceed 5 psi The dry nitrogen will fill the system purging any moisture 2 Remove the faulty component and quickly seal the sys tem using tape or some other means to prevent addi tional moisture from entering the system 3 Do not remove the tape until you are ready to install new component Quickly install the replacement compo nent 4 Evacuate the system to remove any moisture and other non condensables Any time the XC16
11. 410A recycled waste water urine fertilizers or other dam aging chemicals General asus stehen Page 1 Specifications Electrical Data Page 2 A DANGER I Application Page 3 Shock Hazard II Unit Components Page 3 Remove all power at disconnect before removing access panel III Refrigeration System Page 11 Single phase XC16 units use single pole contactors Potential IV Charging Page 12 exists for electrical shock resulting in injury or death V Service and Recovery Page 16 Line voltage exist at all components even when unit is not in operation VI Maintenance Page 16 VII Wiring and Sequence of Operation Page 17 IR Technical Page 1 2006 Lennox Industries Inc ublications SPECIFICATIONS General Model No XC16 024 XC16 036 XC16 048 XC16 060 Data Nominal Tonnage 2 3 4 5 Connections Liquid line o d in 3 8 3 8 3 8 3 8 sweat Suction line 0 d in 3 4 7 8 7 8 1 1 8 Refrigerant 1 R 410A charge furnished 7 Ibs 5 oz 8 Ibs 9 oz 11 Ibs 4 oz 14 Ibs 2 oz Outdoor Net face area sq ft Outer coil 13 22 16 33 21 00 24 93 Coil Inner coil 12 65 15 76 20 27 24 14 Tube diameter in 5 16 5 16 5 16 5 16 No of rows 2 2 2 2 Fins per inch 22 22 22 22 Outdoor Diameter in 18 22 22 26 Fan No of blades 3 4 4
12. CONTROL LUG OPTION e FIGURE 3 1 Compressor Contactor K1 The compressor is energized by a single pole contactor lo cated in the control box See figure 3 K1 is energized by the indoor thermostat terminal Y1 24V when thermostat de mand is present 2 Dual Capacitor C12 The compressor and fan in XC 16 series units use perma nent split capacitor motors The capacitor is located in side the unit control box see figure 3 A single dual ca pacitor C12 is used for both the fan motor and the com pressor see unit wiring diagram The fan side and the compressor side of the capacitor have different MFD rat ings See side of capacitor for ratings 3 Start Kit option The start kit consists of a potential relay K31 and start capac itor C7 The potential relay controls the operation of the starting circuit The relay is normally closed when contactor K1 is de energized When K1 is energized the compressor immediately begins start up K31 remains closed during compressor start up and and start capacitor C7 remains in the circuit When compressor reaches approximately 75 of its speed K31 is energized When K31 energizes the contacts open and start capacitor C7 is taken out of the cir cuit 4 Timed Off Control TOC option The time delay is electrically connected between thermostat terminal Y and the compressor contactor Between
13. I N I Y lt I D N d ay a A a d nnan LDUULUUULLU A A C AAAA TTT TN arrr a a a TY m pm MAINTAIN MINIMUM PANEL ANGLE AS CLOSE TO PARALLEL WITH THE UNIT AS POSSIBLE WHILE INSTALLING PANEL HOLD DOOR FIRMLY TO THE HINGED ANGLE MAY BE TOO ee SIDE TO MAINTAIN FIGURE 1 REM SL FULLY ENGAGED TABS Tb A CAUTION To prevent personal injury or damage to panels unit or structure be sure to observe the following While installing or servicing this unit carefully stow all removed panels out of the way so that the panels will not cause injury to personnel nor cause damage to objects or structures nearby nor will the panels be subjected to damage e g being bent or scratched PREFERRED ANGLE L Detail D While handling or stowing the panels consider any weather conditions especially windy conditions that FIGURE 2 may cause panels to be blown around and battered 2 Hold the panel firmly throughout this procedure Ro tate bottom corner of panel away from hinge corner post Remove the louvered panels as follows until lower 3 tabs clear the slots see figure 2 Detail B 1 Remove 2 screws allowing the panel to swing open 3 Move panel down until lip of upper tab clears the top slot slightly see figure 2 in corner post see figure 2 Detail A Page 3 Position and Install Panel Positio
14. II ZZZZZZZZZ SALS lt lt y N 7 2 N N NZ SSI L TIPS SEALED BY Z DISCHARGE PRESSURE ORBITING SCROLL FIGURE 3 The counterclockwise orbiting scroll draws gas into the outer crescent shaped gas pocket created by the two scrolls figure 4 1 The centrifugal action of the orbiting scroll seals off the flanks of the scrolls figure 4 2 As the orbiting motion con tinues the gas is forced toward the center of the scroll and the gas pocket becomes compressed figure 4 3 When the compressed gas reaches the center it is discharged vertical ly into a chamber and discharge port in the top of the com pressor figure1 The discharge pressure forcing down on the top scroll helps seal off the upper and lower edges tips of the scrolls figure 3 During a single orbit several pockets of gas are compressed simultaneously providing smooth con tinuous compression The scroll compressor is tolerant to the effects of liquid re turn If liquid enters the scrolls the orbiting scroll is allowed to separate from the stationary scroll The liquid is worked toward the center of the scroll and is discharged If the com pressor is replaced conventional Lennox cleanup practices must be used Due to its efficiency the scroll compressor is capable of drawing a much deeper vacuum than reciprocating com pressors Deep vacuum operation can cause internal fusite arcing resulting in damaged internal parts and will result in compress
15. Y AINO H IH ABNCNI 3SAVI NV3 GHYZVH YOOHS OI319313 Q7 suOLONONOD M33309 HLIA 3SN 404 SNINHYA 310N Y Page 17 SERVICE NOTES Page 18 SERVICE NOTES Page 19
16. a 5 16 extension for large line sizes 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn NOTE Stem cap must be replaced to help prevent valve leakage Service Valve Valve Closed yen cap service y port insert hex to outdoor coil iF wrench here service port cap Schrader valve open to line set when valve is closed front seated valve front seated Service Valve Valve Open insert hex stem cap wrench here service port to outdoor coil service port cap to indoor coil Schrader valve FIGURE 6 Vapor Line Ball Valve 5 Ton Units Only Vapor line service valves function the same way as the other valves the difference is in the construction A ball valve is illustrated in figure 7 The ball valve is equipped with a service port with a factory installed Schrader valve A service port cap protects the Schrader valve from contamination and assures a leak free seal Ball Valve Valve Open Use Adjustable Wrench To open rotate Stem Clockwise 90 To close rotate Stem Counter clockwise 90 lt stem cap to outdoor coil ball shown open service port cap Schrader valve FIGURE 7 IV CHARGING A WARNING R 410A refrigerant can be harmful if it is inhaled R 410A refrigerant must be used and recovered re sponsibly Failure to follow this warning may result in personal injury or death A Leak Testing After the line set has
17. be approved for R 410A refrigerant and POE application Foreign Matter Check It is recommended that a liquid line filter drier be replaced when the pressure drop across the filter drier is greater than 4 psig TABLE 2 10N46 Refrigerant Analysis Checkmate RT700 en ee 10N45 Acid Test Tubes Checkmate RT750A three pack A eT BUPSIESSE 10N44 Moisture Test Tubes Checkmate RT751 Tubes three pack 74N40 Easy Oil Test Tubes a RT752C Tubes three 6 12 months room temperature 2 years refrigerated 2 3 years room temperature 3 years refrigerated 74N39 Acid Test Kit Sporlan One Shot TA 1 EEE MEASURING FILTER DRIER PRESSURE DROP 1 Shut off power to unit 2 Remove high pressure switch from fitting next to filter drier A schrader core is located under the high pressure switch 3 Install high pressure gauge hose onto high pressure switch fitting 4 Turn power on to unit and turn room thermostat to call for cooling 5 Record pressure reading on gauge 6 Remove hose from high pressure fitting and install on liquid line valve 7 Read liquid line valve pressure 8 High pressure fitting pressure liquid line valve pressure filter drier Pressure drop 9 If pressure drop is greater than 4 psig replace filter drier See figure 10 10 Re install high pressure switch FIGURE 9 REPLACING FILTER DRIER 1 Recover all refrigerant from unit 2 Remove original fil
18. cycles the compressor contactor is delayed for 5 minutes 2 min utes but may last as long as 8 minutes At the end of the delay the compressor is allowed to energize When thermo stat demand is satisfied the time delay opens the circuit to the compressor contactor coil and the compressor is de en ergized Page 4 B Two Stage Scroll Compressor B1 A CAUTION In order to avoid injury take precaution when lifting heavy objects TWO STAGE MODULATED SCROLL slider ring solenoid actuator coil FIGURE 1 The scroll compressor design is simple efficient and re quires few moving parts A cutaway diagram of the scroll compressor is shown in figure 1 The scrolls are located in the top of the compressor can and the motor is located just below The oil level is immediately below the motor The scroll is a simple compression concept centered around the unique spiral shape of the scroll and its inherent proper ties Figure 2 shows the basic scroll form Two identical scrolls are mated together forming concentric spiral shapes figure 3 One scroll remains stationary while the other is allowed to orbit figure 4 Note that the orbiting scroll does not rotate or turn but merely orbits the stationary scroll SCROLL FORM FIGURE 2 Page 5 CROSS SECTION OF SCROLLS DISCHARGE STATIONARY N SCROLL SUCTION 7 N N KS SS xoyn b rSBSrFA 2 SASASSASSASY he SSSSSSSSSA SSAAAAAASA I
19. d low voltage 16 Unplug the molded plug from the compressor solenoid 2 pin fusite 17 Using a volt meter set on the 200 ohm scale solenoid rectifier plug lead fusite terminals compressor fusite terminals Replace the Compressor under these conditions Bad Solenoid a Measure the resistance at the 2 pin fusite See figure 8 The resistance should be 32 to 60 ohms depending on compressor temperature If no resistance replace com pressor b Measure the resistance from each fusite pin to ground There should not be continuity to ground If solenoid coil is grounded replace compressor Good Solenoid a Seals not shifting replace compressor b Slider ring not shifting replace compressor Page 8 C Drier A filter drier designed for all XC16 model units is factory installed in the liquid line The filter drier is designed to re move moisture and foreign matter which can lead to com pressor failure Moisture and or Acid Check Because POE oils absorb moisture the dryness of the system must be verified any time the refrigerant system is exposed to open air A compressor oil sample must be taken to determine if excessive moisture has been introduced to the oil Table 2 lists kits available from Lennox to check POE oils If oil sample taken from a system that has been exposed to open air does not test in the dry color range the filter drier MUST be replaced A IMPORTANT Replacement filter drier MUST
20. ed more than once Page 12 A IMPORTANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns Use an instrument that reads from 50 microns to at least 10 000 microns 1 Connect manifold gauge set to the service valve ports e low pressure gauge to vapor line service valve e high pressure gauge to liquid line service valve 2 Connect micron gauge 3 Connect the vacuum pump with vacuum gauge to the center port of the manifold gauge set 4 Open both manifold valves and start the vacuum pump 5 Evacuate the line set and indoor unit to an absolute pressure of 23 000 microns 29 01 inches of mercury During the early stages of evacuation it is desirable to close the manifold gauge valve at least once to deter mine if there is a rapid rise in absolute pressure A rap id rise in pressure indicates a relatively large leak If this occurs repeat the leak 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 vacu um pressure 6 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 nitrogen cylin der with pressure regulator set to 150
21. ge 2 I APPLICATION XC16 condensing units are available in 2 3 4 and 5 ton capac Removing Installing Louvered Panels IMPORTANT Do not allow panels to hang on unit by top tab Tab oe R is for alignment and not designed to support weight of panel ities All major components indoor blower and coil must be tched dina to L dati forth Panel shown slightly rotated to allow top tab to exit or enter top matched according to Lennox recommendations for the com slot for removing or installing panel pressor to be covered under warranty Refer to the Engineer h ing Handbook for approved system matchups SCREW It ll UNIT COMPONENTS noLES ST Unit components are illustrated in figure 1 w XC16 PARTS ARRANGEMENT Detail C Zin LL LLLI RLU a aT LlULLLLLLILILIL LJ JU JJ J AJ II JI Cc L b r G r L L r Cc Z L MADDA ULLLLLLDLLL JIU DULL OUTDOOR FAN DUAL CAPACITOR COMPRESSOR IHN CONTACTOR K HIGH I PRESSURE SWITCH LOW ROTATE IN THIS DIRECTION gt PRESSURE THEN DOWN TO REMOVE PANEL SWITCH FILTER DRIER y Bi mt
22. in the liquid state e Certain R 410A cylinders are identified as being equipped with a dip tube These allow liquid refrig erant to be drawn from the bottom of the cylinder without inverting the cylinder DO NOT turn this type cylinder upside down to draw refrigerant A IMPORTANT Use table 6 to perform maintenance checks Table 6 is not a procedure for charging the system Minor varia tions 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 This system is charged with R 410A refrigerant which oper ates at much higher pressures than R 22 The installed liq uid line filter drier is approved for use with R 410A Do not replace it with components designed for use with R 22 This unit is NOT approved for use with coils which use capillary tubes as a refrigerant metering device Factory Charge Units are factory charged with the amount of R 410A refrig erant indicated on the unit rating plate This charge is based on a matching indoor coil and outdoor coil with 15 ft 4 6 m line set For varying lengths of line set refer to table 2 for re frigerant charge adjustment TABLE 2 Refrigerant Charge per Line Set Lengths Liquid Line Oz per 5 ft g per 1 5 m adjust Set Diameter from 15 ft 4 6 m line set 3 8 in 9 5 mm 3 ounce per 5 ft 85 g per 1 5 m If line length is g
23. inder and the valve on the high pressure side of the manifold gauge set Disconnect the R 410A cylinder 4 Connect a cylinder of nitrogen with a pressure regulat ing valve to the center port of the manifold gauge set 5 Connect the manifold gauge set high pressure hose to the vapor valve service port Normally the high pres sure hose is connected to the liquid line port however connecting it to the vapor port better protects the man ifold gauge set from high pressure damage 6 Adjust the nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set which will pressurize line set and indoor unit 7 After a few minutes open a refrigerant port to ensure the refrigerant you added is adequate to be detected Amounts of refrigerant will vary with line lengths Check all joints for leaks Purge nitrogen and R 410A mixture Correct any leaks and recheck B Evacuating Evacuating the system of noncondensables is critical for proper operation of the unit Noncondensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system Noncondensables and water vapor combine with refrigerant to produce substances that corrode copper pip ing and compressor parts NOTE This evacuation process is adequate for a new installation with clean and dry lines If excessive mois ture is present the evacuation process may be requir
24. n the panel almost par allel with the unit figure 2 Detail D with the screw side as close to the unit as possible Then in a continuous motion Slightly rotate and guide the lip of top tab inward figure 2 Details A and C then upward into the top slot of the hinge corner post Rotate panel to vertical to fully engage all tabs Holding the panel s hinged side firmly in place close the right hand side of the panel aligning the screw holes When panel is correctly positioned and aligned insert the screws and tighten A Control Box Figure 3 XC16 units are not equipped with a 24V transformer All 24 VAC controls are powered by the indoor unit Refer to wir ing diagram Electrical openings are provided under the control box cov er Field thermostat wiring is made to color coded pigtail connections ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A CAUTION Electrostatic discharge can affect electronic com ponents Take precautions during unit installation and service to protect the unit s electronic controls Precautions will help to avoid control exposure to electrostatic discharge by putting the unit the con trol and the technician at the same electrostatic po tential Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface be fore performing any service procedure CONTROL BOX DUAL CAPACITOR C12 COMPRESSOR CONTACTOR i ae TIMED OFF GROUNDING
25. oil 1 Clean coil if necessary 2 Check connecting lines and coils for evidence of oil leaks 3 Check the condensate line and clean it if necessary C 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 3 Belt Drive Blowers Check belt for wear and proper ten sion 4 Check all wiring for loose connections 5 Check for correct voltage at unit blower operating 6 Check amp draw on blower motor Unit nameplate Actual Page 16 VII WIRING DIAGRAMS AND SEQUENCE OF OPERATION Aymedeo yBbly ye ejdo 0 Josseidwoo y Bumoile Bull pis y s sop u u pe Pousps Jepeojun pe seziBieus pue za Od 0 a elpn OV y SAUCO pq ra And yy o Be DA spuas puewap je sow Jey s puooas 4 joa Be s Is y u Bugesodo s sossasiduog y1oedeo uBiu IooS Bels puoses Ayioedeo mo o Josseidwoo Bummi uedo sulewes Bull pis ay os pezi leus ION S pe Plousjos r ue JOOpino yg pue Josseidwoo g BulziBiaue sasojo y E emod OVAPZ 94 JO pis UOWWOD o sunas pue YO MS mss sd MO 28S uB fnouu sessed jojoejuoo Jossaidwod Yy seziBioue yo MsS gunssald yy rS ynom sessed A euw WOW B BBJ oA Z yeysow Joy ul u LA Je s ljenuu puewap BulooO L Qiedeo moj p09 efejs Is puewap ye SOW 0y o upoo yo
26. or failure This type of damage can be detected and will result in denial of warranty claims The scroll com pressor can be used to pump down refrigerant as long as the pressure is not reduced below 7 psig The scroll compressors in all XC16 model units are de signed for use with R410A refrigerant and operation at high pressures Compressors are shipped from the factory with 3MA 32MMMA P O E oil See electrical section in this manual for compressor specifications NOTE During operation the head of a scroll compressor may be hot since it is in constant contact with discharge gas lt zZZz2 TWO STAGE OPERATION NOTE During operation the head of a scroll compressor may be hot since it is in constant contact with discharge gas The two stage scroll compressor operates like any standard scroll compressor with the exception the two stage com pressor modulates between first stage low capacity approximately 67 and second stage high capacity Modulation occurs when gas is bypassed through bypass ports figure 5 bypass ports open in the first suction pocket This bypassing of gas allows the compressor to operate on first stage low capacity if thermostat demand allows In door thermostat setting will determine first or second stage operation The compressor will operate on first stage until demand is satisfied or the indoor temperature reaches the thermostat set point calling for second stage Second stage high ca
27. pacity is achieved by blocking the bypass ports figure 5 bypass ports closed with a slider ring The slider ring begins in the open position and is controlled by a 24VDC internal solenoid On a Y2 call the internal sole noid closes the slider ring blocking the bypass ports and bringing the compressor to high capacity Two stage modu lation can occur during a single thermostat demand as the motor runs continuously while the compressor modulates from first stage to second stage HOW A SCROLL WORKS I MOVEMENT OF ORBIT x SUCTIONY POCKET ORBITIN SCROL SUCTION pu i a GAS CRESCENT SHAPED GAS POCKET Y STATIONARY SCROLL CENTRIFUGAL HIG PRESSURE GAS G FLANKS SEALED B FORCE SUCTION G DISCHARGE POCKET FIGURE 4 TWO STAGE MODULATION High Capacity Bypass Ports Closed a 67 Capacity FIGURE 5 Page 6 INTERNAL SOLENOID L34 The internal unloader solenoid controls the two stage op eration of the compressor by shifting a slide ring mechanism to open two by pass ports in the first compression pocket of the scrolls in the compressor The internal solenoid is acti vated by a 24 volt direct current solenoid coil The coil power requires 20VAC The internal wires from the solenoid in the compressor are routed to a 2 pin fusite connection on the side of the compressor shell The external electrical con nection is made to the compressor with a molded plug as sembly This plug contains
28. psig 1034 kPa and purge the air from the hose with nitrogen Open the manifold gauge valves to break the vacuum in the line set and indoor unit Close the manifold gauge valves A CAUTION Danger of Equipment Damage Avoid deep vacuum operation Do not use compres sors to evacuate a system Extremely low vacuums can cause internal arcing and compressor failure Damage caused by deep vacuum operation will void warranty 7 Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder Open the manifold gauge valves to release the nitrogen from the line set and in door unit Page 13 8 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 and closing the manifold gauge valves 9 When the absolute pressure requirement above has been met disconnect the manifold hose from the vacu um pump and connect it to an upright cylinder of R 410A refrigerant Open the manifold gauge valves to break the vacuum from 1 to 2 psig positive pressure in the line set and indoor unit Close manifold gauge valves and shut off the R 410A cylinder and remove the manifold gauge set C Charging NOTES e R 410A refrigerant cylinders are rose colored Re frigerant should be added through the vapor valve
29. reater than 15 ft 4 6 m add this amount If line length is less than 15 ft 4 6 m subtract this amount A IMPORTANT Mineral oils are not compatible with R 410A If oil must be added it must be a polyol ester oil The compressor is charged with sufficient polyol es ter oil for approved line set lengths Units Delivered Void of Charge If the system is void of refrigerant clean the system using the procedure described below 1 Use dry nitrogen to pressurize the system and check for leaks Repair leaks if possible 2 Evacuate the system to remove as much of the moisture as possible Use dry nitrogen to pressurize the system and check for leaks Repair leaks if possible 3 Use dry nitrogen to break the vacuum and install the pro vided filter drier in the system 4 Evacuate the system again Then weigh the appropriate amount of R 410A refrigerant listed on unit nameplate into the system 5 Monitor the system to determine the amount of moisture remaining in the oil Use test kit 10N46 to verify that the moisture content is within the kit s dry color range 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 Checking Charge The outdoor unit should be charged during warm weather However applications arise in which charging must occur in the colder months The method of charging i
30. rig erant If subcooling is less than shown add some refrig erant Be aware of the R 410A refrigerant cylinder It will be light maroon colored Refrigerant should be added through the vapor line valve in the liquid state TABLE 3 R 410A Temperature F Pressure Psig TABLE 4 XC16 Subcooling Values for Charging Saturation Temperature Liquid Line Temperature _ Subcooling Value Model 024 036 048 060 F C 5 2 8 6 3 3 6 3 3 9 5 F 1 0 C 0 5 Charge Using the Approach Method TXV Systems Outdoor Temperature gt 65 F 18 C The following procedure is intended as a general guide and is for use on expansion valve systems only For best results in door temperature should be 70 F 21 C to 80 F 26 C Monitor system pressures while charging 1 Record outdoor ambient temperature using a digital thermometer 2 Attach high pressure gauge set and operate unit for sev eral minutes to allow system pressures to stabilize 3 Compare stabilized pressures with those provided in table 6 Normal Operating Pressures Pressures high er than those listed indicate that the system is over charged Pressures lower than those listed indicate that the system is undercharged A temperature pressure chart for R 410A refrigerant is provided in table 3 for your convenience Verify adjusted charge using the ap
31. rmanently adjusted to trip open at 40 5 psi The switch automatically resets when vapor line pres sure rises above 90 5 psi F High Pressure Switch 84 XC16 units are equipped with a high pressure switch that is located in the liquid line of the compressor The switch SPST manual reset normally closed removes power from the compressor contactor control circuit when discharge pressure rises above factory setting at 590 10 psi G Crankcase Heater HR1 amp 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 pre vents liquid from accumulating in the compressor HR1 is controlled by a thermostat located on the liquid line When liq uid line temperature drops below 50 F the thermostat closes energizing HR1 The thermostat will open de energizing HR1 once liquid line temperature reaches 70 F Page 10 II REFRIGERANT SYSTEM A Plumbing Field refrigerant piping consists of liquid and suction lines from the condensing unit sweat connections to the indoor evaporator coil sweat connections Use Lennox L15 sweat series line sets as shown in table 1 TABLE 1 Liquid Suction i I L15 41 3 8 in 3 4 in 024 15 ft 50 ft co 10 mm 19 mm 4 6 m 15 m 036 3 8 in 7 8 in 048 10 mm 22 mm 4 6 er m 3 8 in 1 1 8 in Field 10 mm 29 mm Fabricated The liquid line and vapor line service
32. s determined by the unit s refrigerant metering device and the outdoor ambient temperature Measure the liquid line temperature and the outdoor ambi ent temperature as outlined below 1 Connect the manifold gauge set to the service valves e low pressure gauge to vapor valve service port e high pressure gauge to liquid valve service port 2 Close manifold gauge set valves Connect the center manifold hose to an upright cylinder of R 410A 3 Set the room thermostat to call for heat This will create the necessary load for properly charging the system in the cooling cycle 4 Record outdoor ambient temperature using a digital ther mometer 5 When the heating demand has been satisfied switch the thermostat to cooling mode with a set point of 68 F 20 C When pressures have stabilized use a digital thermometer to record the liquid line temperature 6 The outdoor temperature will determine which charging method to use Proceed with the appropriate charging procedure Charge Using Weigh in Method TXV Systems Outdoor Temp lt 65 F 18 C If the system is void of refrigerant or if the outdoor ambient temperature is cool first locate and repair any leaks and then weigh in the refrigerant charge into the unit 1 Recover the refrigerant from the unit 2 Conduct leak check evacuate as previously outlined 3 Weigh in the unit nameplate charge If weighing facilities are not available or if charging the unit
33. sealed system is opened the drier must be replaced and the system must be evacuated Any moisture not absorbed by the polyol ester oil can be re moved by evacuation Moisture that has been absorbed by the compressor oil can be removed by replacing the drier A IMPORTANT Evacuation of system only will not remove moisture from oil Drier must be replaced to eliminate mois ture from POE oil VI MAINTENANCE AWARNING Electric shock hazard Can cause inju ry or death Before attempting to per form any service or maintenance turn the electrical power to unit OFF at dis connect switch es Unit may have multiple power supplies At the beginning of each cooling season the system should be serviced In addition the system should be cleaned as follows A 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 Condenser 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 unit unit operating 6 Check amp draw condenser fan motor Unit nameplate Actual x NOTE If owner complains of insufficient cooling the unit should be gauged and refrigerant charge checked Refer to section on refrigerant charging in this instruction B Indoor C
34. ter drier 3 Install new filter drier in existing location or alternate location as shown Proper brazing procedures should be followed 4 Evacuate system See section IV partB 5 Recharge system See section IV part C FIGURE 10 Page 9 D Condenser Fan Motor B4 All units use single phase PSC fan motors which require a run capacitor In allunits the condenser fan is controlled by the compressor contactor ELECTRICAL DATA tables in this manual show specifi cations for condenser fans used in XC16 s Access to the condenser fan motor on all units is gained by removing the four screws securing the fan assembly See figure 4 The grillfan assembly can be removed from the cabinet as one piece See figure 5 The condenser fan motor is removed from the fan guard by removing the four nuts found on top of the grill See figure 5 if condenser fan motor replacement is necessary A DANGER Make sure all power is disconnected before beginning electrical service procedures Remove screws Y screws FIGURE 4 ALIGN FAN HUB FLUSH WITH END OF SHAFT FIGURE 5 E Low Pressure Switch S87 All XC16 units are equipped with an auto reset single pole single throw low pressure switch is located in the vapor line This switch shuts off the compressor by de energizing K1 when vapor line pressure drops below the factory setting The switch is closed during normal operating pressure con ditions and is pe
35. ures and temperatures to stabilize before taking any measured reading may take up to 10 min utes NOTE Block outdoor coil to maintain a minimum of 375 psig during testing 7 Record all of the readings for the Y1 demand on table 1 8 Close switch to energize Y2 demand 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 of Y2 demand on table 1 NOTE On new installations or installations that have shut down for an extended period of time if the compres sor does not cycle from low stage to high stage on the first attempt it may be necessary to recycle the compres sor back down to low stage and back up to high stage a few times in order to get the bypass seals to properly seat Compare Y1 readings with Y2 readings in table 1 Some readings should be higher lower or the same If the read ings follow what table 1 specifies the compressor is oper ating and shifting to high capacity as designed If the readings do not follow what table 1 specifies continue to step 2 to determine if problem is with external solenoid plug power TABLE 1 Cooling Operation Unit Readings Y1 1st Stage Expected Results Y2 2nd Stage Compressor Voltage Same Amperage Higher Condenser Fan motor Amperage Same or Higher Temperature Ambient Same Outdoor Coil Discharge Air Higher
Download Pdf Manuals
Related Search