Lenox Air Conditioner Elite Series User's Manual
Contents
1. Figure 4 Installation Clearances A CAUTION 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 raise 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 adapter2. REQUIRED 10 1 1 4 LONG HEX HD SCREW AND FLAT WASHER NG 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 MINIMUM ONE Stabilizing bracket 18 gauge metal 2 50 8mm width height as required bend to form right angle as exampled below PER SIDE 4 FOR EXTRA STABILITY SAME FASTENERS AS SLAB SIDE MOUNTING One bracket per side minimum For extra stability two brackets per side two inches 51mm from each corner 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 506636 01 Page 8 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 Removing and Installing Panels A IMPORTANT Do not allow panels to hang on unit by top tab Tab is for alignment designed to support weight of panel WARNING NOTICE Roof Damage This system contains both refrigerant and oil Some rubber roofing material may absorb oil and cause the rubber to
3. Litho USA Supersedes 11 10 TABLE OF CONTENTS Gerietal ce t eene ans tea pde 1 Shipping and Packing List 1 Unit Dimensions sisse esee 2 Model Number Identification 2 Unit Parts Arrangement 3 Operating Gauge Set and Service Valves 4 Recovering Refrigerant from Existing System 6 Unit Placement 7 Removing and Installing Panels 9 New or Replacement Line Set 10 Brazing lt 5 12 Flushing Line Set and Indoor Coil 15 Installing Indoor Metering Device 16 Leak Test Line Set and Indoor 17 Evacuating Line Set and Indoor Coil 18 Electrical 2 Ehe 19 Servicing Units Delivered Void of Charge 23 Unit amp 23 System Refrigerant 23 System Operation 28 Maintenance 29 Start Up and Performance Checklist 30 The XC14 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 XC14 Engineering Handbook Shipping and Packing List Check th
4. 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 7 XC14 SERIES DETAIL Outside Unit Placement Install unit away from windows DETAIL B 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 TWO 90 ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION DETAIL C Elevated Slab Mounting using Feet Extenders 2 50 8MM SCH 40 FEMALE THREADED ADAPTER 2 50 8MM SCH 40 MALE THREADED ADAPTER 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 the unit BUILDING STRUCTURE MOUNTING T GROUND LEVEL STABILIZING UNIT ON UNEVEN SURFACES DETAIL D Slab Side Mounting 10 1 2 LONG SELF DRILLING SHEET METAL SCREWS A STABILIZING BRACKET 18 GAUGE METAL 2 WIDTH HEIGHT 5
5. 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 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 require 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 C
6. INSULATION THICKNESS AND TERMINATION DESCRIPTION COMPONENT LINE VOLTAGE FIELD INSTALLED CONTROL TIMED OFF CLASS II VOLTAGE FIELD WIRING COMPRESSOR s DENOTES OPTIONAL COMPONENTS 4 MOTOR OUTDOOR FAN C12 CAPACITOR DUAL R1 EATER COMPRESSOR 1 1 CONTACTOR COMPRESSOR 4 WITCH HIGH PRESSURE 24 WITCH LOSS OF CHARGE 4 ERMOSTAT CRANKCASE WITCH LOW PRESS COMP 1 173 SWITCH THERMAL PROTECTION OAI lt 4 A 7 Figure 17 Typical Unit Wiring Diagram Page 22 Servicing Units Delivered Void of Charge 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 17 2 Evacuate the system using procedure outlined on page 18 3 Use nitrogen to break the vacuum and install a new filter drier in the system 4 Evacuate the system again using procedure outlined on page 18 5 Weigh in refrigerant using procedure outlined in figure 21 6 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 GAUGE SET CONN
7. Installing Indoor Expansion Valve Page 15 XC14 SERIES Installing Indoor Metering Device This outdoor unit is designed for use in systems that use either fixed orifice or expansion valve metering devices at the indoor coil If using a fixed orifice metering device use the the one provided with the outdoor unit The metering device is located in the installation instruction bag For installing the orifice reverse the procedure outlined in figure 10 1A INDOOR EXPANSION VALVE INSTALLATION TWO PIECE PATCH PLATE UNCASED COIL ONLY Uncased Coil Shown LIQUID LINE STUB ORIFICE END HOUSING AC EXPANSION VALVE DISTRIBUTOR TUBES __ TEFLON 7 Oane EQUALIZER LINE SENSING D LINE LIQUID LINE ASSEMBLY WITH BRASS NUT A FITTING SEE EQUALIZER LINE INSTALLATION FOR FURTHER DETAILS MALE EQUALIZER LINE LIQUID LINE B Sensing bulb insulation is required if mounted external to the coil casing sensing bulb installation for bulb positioning EQUALIZER LINE INSTALLATION A Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right FLARE SEAL F
8. Service Valves Fully Opened Caps Tight J Thermostat Voltage With Compressor Operating Calibrated Properly Set Level Page 30 506636 01
9. oe AS PREFERRED ANGLE FOR INSTALLATION 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 scratched While handling or stowing the panels consider any weather conditions especially windy conditions that may cause panels to be blown around and battered 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 ALLOW TOP TAB EXIT OR ENTER TOP SLOT FOR REMOVING OR INSTALLING PANEL L SCREW HOLES LIP gt DETAIL A L L L 4 DETAIL L L It X 0 E L DU ROTATE IN THIS DIRECTION THEN DOWN REMOVE PANEL SIDE TO MAINTAIN FULLY ENGAGED TABS gt Figure 6 Removing and Installing Panels Page 9 XC14 SERIES New or Replacement Line Set REFRIGERANT LINE SET This section provides informa
10. 208 230V 1ph 60hz Nominal Cooling Capacity 018 1 5 tons 024 2 tons 030 2 5 tons 036 3 tons 041 3 5 tons 042 3 5 tons 047 4 tons 048 4 tons 060 5 tons Unit Type C Air Conditioner Series Page 2 506636 01 Typical Unit Parts Arrangement CONTROL PANEL SINGLE POLE CONTACTOR 1POLE K1 1 GROUND LUG DUAL RUN CAPACITOR C12 THERMAL PROTECTION SWITCH S173 ONLY ON 036 AND 060 DISCHARGE LINE SN DA De 2 CYS 2 2 a 0 0 gt 2 pr 2 CrO Tad N E DIE m COMPRESSOR HARNESS y MUFFLER d 0 I THERMAL PROTECTION SWITCH S5 AAG TEZA Dds OO CRANKCASE HEATER THERMO STAT S40 041 047 048 AND 060 UNITS ONLY LIQUID LINE FILTER DRIER SINGLE FLOW HIGH PRESSURE SWITCH 54 RT Ls AB Gs OE B PF i el al 3 jw di V UP UP s UP 2 d LIQUID LINE SERVICE VALVE SUCTION LINE FIELD CONNECTION TM FIELD CONNECTION SERVICE VALVE FOR LIQUID LINE SET FOR SUCTION LINE PLUMBING AND SWITCHES COMPONENTS Figure 1 Typical Parts Arran
11. 3 When testing is completed replace service port cap and tighten as follows With torque wrench Finger tighten and 1 6 TURN torque cap per table 1 1 Without torque wrench Finger tighten and 10 use an appropriately sized wrench to turn 9 an additional 1 6 turn clockwise 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 1 12 TURN e With Torque Wrench Finger tighten and then torque cap per table 1 Without Torque Wrench Finger tight en and use an appropriately sized wrench to turn an additional 1 12 turn 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 5 XC14 SERIES Recovering Refrigerant from Existing 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 POWER 2 MANIFOLD GAUGE SET MAIN FUSE BOX BREAKER PANEL MAIN FUSE MANIFOLD GAUGES BOX BREAKER PANEL RECOVERY MACHINE DISCONNECT SWITCH CLEAN RECOVERY OUTDOOR UNIT CYLINDER 3 oo REFRIGERANT Remove existing HCFC 22 refrigerant using one of the fol
12. 4 4 G 4 wil 4 e 3 XC13 D YELLOW SENSOR OPTIONAL X2658 BLACK T BLACK BLACK BLACK Ne Nu REMOVE DS TD Y1 NOTE Refer to furnace blower coil and accessory instructions for additional wiring configurations with other JUMPER WHEN STAT optional controls DEHUMID IS USED Figure 14 24VAC Control Wiring Diagrams Field Installed DUAL RUN CAPACITOR Purge C12 suge FAN MOTOR B4 orai YELLOW ORANGE CONTACTOR K1 BLACK THERMAL PROTECTION BLUE SWITCH S5 YELLOW HIGH PRESSURE GRAY RED YELLOW SWITCH 54 GROUND LUG BLACK YELLOW 048 AND 060 ONLY GRAY RED COMPRESSOR COMPRESSOR P B1 GRAY RED CRANKCASE CRANKCASE THERMOSTAT HEATER HR1 S40 Figure 15 Typical Factory Wiring Diagram Copeland Compressor Page 20 506636 01 4 C
13. Measure outdoor ambient temperature USE WEIGH Confirm proper airflow across coil using figure 20 Compare unit pressures with table 4 Normal Operating Pressures IN METHOD Use SUPERHEAT to correctly charge unit or to verify the charge is correct Weigh in or remove refrigerant Ea 0 Setthermostat to call for heat must have a cooling based upon line length 39 F and load between 70 80 F 21 26 BELOW Connect gauge set When heat demand is satisfied set thermostat to SUPERHEAT RFC Allow temperatures and pressures to stabilize SH Superheat Values 5 F Measure the suction line pressure and use the use value to determine saturation temperature table If refrigerant 76 40 51 45 49 Record suction line temperature 50 47 VAP 55 44 Subtract to determine superheat SH 60 43 VAP SAT SH 65 41 Record the wet bulb temperature air entering 70 39 indoor coil 75 37 WB 80 35 Record outdoor ambient temperature 85 33 Compare results with table to the left 90 20 31 95 18 29 100 16 28 is 105 13 26 NOTE Do not attempt to charge system where a REMOVED retest to 110 11 25 dash appears system could be overcharged confirm that unit is 115 8 18 24 Superheat is taken at suction line service port properly charged Suction line superheat must never be less than 5 F o i j j Dry bulb
14. service valve Quickly install cores with core tool while maintaining a positive system pressure 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 18 A IMPORTANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns Use an instrument capable of accurately measuring down to 50 microns 4 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 or to an earth ground 3 UNIT LOW VOLTAGE CONNECTIONS WIRE NUTS CUTOUT WITH 4 GROMMET v 24V CONTROL WIRES temperatures and pressures present during o
15. valve stem recess See the Lennox Service and Application Notes 08 1 for further details and information 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 Ib 11 NM Sheet metal screws 16 in Ib 2 NM Machine screws 10 28 in Ib 3 NM Compressor bolts 90 in Ib 10 NM Gauge port seal 8 ft Ib 11 NM 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 port which has a factory installed valve stem Figure 2 provides information on how to access and operating both angle and ball service valves Page 4 506636 01 Operating
16. 2 140 281 138 293 140 278 144 296 142 294 142 299 140 300 137 307 142 304 141 301 140 316 142 299 145 318 143 315 142 320 139 323 138 Fixed Orifice RFC 65 18 232 124 228 125 229 128 241 131 228 131 248 135 232 1 125 240 126 244 125 70 21 248 127 244 127 243 129 258 134 245 135 266 138 249 129 260 129 263 128 75 24 267 131 261 131 261 132 277 136 263 138 285 141 268 133 281 133 281 131 80 27 286 135 284 134 284 135 298 139 284 141 305 143 286 136 301 135 303 134 85 29 90 32 307 138 303 137 305 138 321 141 306 144 327 1 145 312 140 324 138 324 136 328 141 325 140 327 140 342 1 143 327 146 349 147 332 142 346 140 347 139 100 G6 CIS 105 DICE HAT 5 a Q 457 153 447 150 449 150 480 152 453 155 471 147 476 154 460 152 473 1 150 Values shown typical pressures indoor unit match up indoor air quality equipment and indoor load will cause the pressures to vary Temperature of the air entering the outside coil System Operation UNIT COMPONENTS High Pressure Switch S4 14 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 2 The switch is a Single Pole Single Throw SPST manual reset switch with red cap that is normal
17. 20 Temp DT 1 Determine the desired DT Measure entering air temper of air 23 23 22 22 22 20 ature using dry bulb A and wet bulb B DT is the intersect entering 22 22 21 20 19 i i i indoor ing value of A and B in the table see triangle F 21 21 19 19 18 s id 20 19 19 18 47 16 2 Find temperature drop across coil Measure the coil s dry 18 17 16 15 bulb entering and leaving air temperatures A and C Tem 18 17 16 15 15 perature Drop Formula Tprop A minus 3 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 examples Assume DT 15 and A temp 72 these C temperatures would necessi tate stated actions DT F ACTION 53 19 15 4 Increase the airflow 58 14 15 1 within 3 range change 62 10 15 5 Decrease the airflow INDOOR COIL 4 Adjust the fan speed See indoor unit instructions to in crease decrease fan speed All temperatures are expressed in F Changing air flow affects all temperatures recheck tempera tures to confirm that the temperature drop and DT are within 35 Figure 20 Checking Indoor Airflow over Evaporator Coil using Delta T Chart 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
18. 36 230 XC14 041 230 XC14 042 230 3 8 10 mm 7 8 22 mm XC14 047 230 XC14 048 230 3 8 10 mm 7 8 22 mm L15 65 15 ft 50 ft 4 6 m 15 m XC14 060 230 3 8 10 mm 1 1 8 29 mm 3 8 10 mm Field Fabricated 1 1 8 29 mm NOTE Some applications may required a field provided 7 8 to 1 1 8 adapter Page 10 506636 01 Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation REFRIGERANT LINE SET TRANSITION REFRIGERANT LINE SET INSTALLING FROM VERTICAL TO HORIZONTAL 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 ANCHORED HEAVY NYLON temperature of the liquid line or when pressure drop is equal to or greater WIRE TIE OR AUTOMOTIVE AUTOMOTIVE than 20 psig MUFFLER TYPE HANGER MUFFLER TYPE HANGER OUTSIDE WALL VAPOR LINE LIQUID LINE STRAP STRAP LIQUID LINE TO WOOD BLOCK NON CORROSIVE VAPOR LINE BETWEEN STUDS METAL SLEEVE WIRE TIE NON CORROSIVE METAL SLEEVE WOOD BLOCK VAPOR LINE WRAPPED 1 IN ARMAFLEX WIRE TIE STRAP 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 VAPOR LINE WRAPPED WITH AR
19. 410A refrigerant Residual mineral oil can act as an insulator preventing proper heat transfer It can also Leak Test Line Set and Indoor Coil A WARNING When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system use regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa IMPORTANT Leak detector must be capable of sensing HFC refrigerant 4 WARNING Refrigerant can be harmful if it is inhaled Refrigerant clog the expansion device and reduce the system performance capacity Failure to properly flush the system per the instructions below will void the warranty must be used and recovered responsibly Failure to follow this warning may result in personal injury or death 1 CONNECT GAUGE SET A Connect an HFC 410A manifold gauge set high pressure LOW HIGH hose to the vapor valve service port NOTE Normally the high pressure hose is connected to MANIFOLD GAUGE SET the liquid line port However connecting it to the vapor port better protects the manifold gauge set from high pressure Q damage B With both manifold valves closed connect the cylinder of uu HFC 410A refrigerant to the center port of the manifold gauge set OUTDOOR UNIT NOTE Later in the procedure the HFC 410A container will be replaced by the nitrogen A container 1 T
20. APACITOR C12 n B4 MOTOR CAPACITOR ORANGE ORANGE CONTACTOR 1 GROUND LUG O YELLOW HIGH PRESSURE 9 GRAY RED YELLOW SWITCH HIGH PRESSURE SWITCH 54 CONTACTOR BLACK 20 BLACK YELLOW THERMAL SWITCH COMPRESSOR COMPR B1 GRAY RED GRAY RED XC13 060 01 02 03 XC14 048 060 ONLY CRANKCASE HEATER 1 CRANKCASE THERMOSTAT 840 THERMAL PROTECTION SWITCH 5 OR 173 Figure 16 Typical Factory Wiring Diagram Interlink Compressor Page 21 XC14 SERIES 506636 01 OUTDOOR DUAL CAPACITOR 4 24 VAC POWER TIMED OFF SOURCE CONTROL 20 VA MINIMUM NEC CLASS 2 Saad COMPRESSOR CONTACTOR L2 CRANKCASE L1 HEATER 208 230 60 1 L2 HIGH PRESSURE SWITCH FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE JUMPER IS USED WHEN TOC IS NOT USED TO 24 VAC S173 SWITCH USED ONLY IN UNITS EQUIPPED WITH COMPRESSORS WHICH DO NOT INCLUDE eee INTERNAL SWITCH 173 T 7 WHEN 4 IS NOT USED 173 TO 8 S NOT US NOTE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING
21. Angle Type Service Valve 1 Remove stem cap with an appropriately sized wrench 2 Use service wrench with a hex head extension 3 16 for liquid line valve sizes and 5 16 for vapor line valve sizes to back the stem out counterclockwise as far as it will go SERVICE PORT CAP SERVICE PORT CORE TO INDOOR VALVE STEM SHOWN OPEN VALVE STEM SHOWN CLOSED INSERT HEX WRENCH HERE INSERT HEX WRENCH HERE SERVICE PORT TO OUTDOOR UNIT ANGLE TYPE SERVICE VALVE BACK SEATED OPENED When service valve is OPEN the service port is open to linE set indoor and outdoor unit Operating Ball Type Service Valve 1 Remove stem cap with an appropriately sized wrench 2 Use an appropriately sized wrenched to open To open valve rotate stem counterclockwise 90 To close rotate stem clockwise 90 TO INDOOR UNIT TO OPEN ROTATE STEM COUNTERCLOCKWISE 90 BALL SHOWN CLOSED TO CLOSE ROTATE STEM CLOCKWISE 90 SERVICE PORT SERVICE PORT CORE SERVICE PORT CAP TO OUTDOOR STEM CAP UNIT D 2 SEF STEM CAP CORE ANGLE TYPE SERVICE VALVE FRONT SEATED CLOSED WHEN SERVICE VALVE IS CLOSED THE SERVICE PORT IS OPEN TO THE LINE SET AND INDOOR UNIT To Access Service Port A service port cap protects the service port core from contamination and serves as the primary leak seal 1 Remove service port cap with an appropriately sized wrench 2 Connect gauge set to service port
22. ECTIONS FOR TESTING AND CHARGING B SUCTION LINE SERVICE PORT CONNECTION CHARGE IN LIQUID PHASE a REFRIGERANT TANK DIGITAL SCALE D TEMPERATURE 1 Rotate fan to check for binding 2 Inspect all factory and field installed wiring for loose connections 3 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 4 Replace the stem caps and tighten to the value listed in table 1 5 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 6 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 7 Recheck voltage while the unit is running Power must be within range shown on the nameplate 8 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 LOW HIGH OUTDOOR UNIT A VAPOR LINE SERVICE VALVE a afa TEMPE
23. LARE NUT COPPER FLARE SEAL BONNET on iC MALE BRASS EQUALIZER LINE FITTING VAPOR LINE See the Lennox XC14 Engineering Handbook for approved expansion valve kit match ups The expansion valve unit can be installed internal or external to the indoor 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 Remove the field provided fitting that temporary 1 2 Turn 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 Teflon 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 lb 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 refrigerant oil 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
24. LENNOX 201 Lennox Industries Inc Dallas Texas USA RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation WARNING Improper installation adjustment alteration service or maintenance can cause personal injury loss of life or damage to property Installation and service must be performed by a licensed professional installer or equivalent or a service agency IMPORTANT The Clean Air Act of 1990 bans the intentional venting of refrigerant CFCs HCFCs and HFCs as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration may be levied for noncompliance A IMPORTANT This unit must be matched with an indoor coil as speci fied in Lennox XC14 Engineering Handbook Coils pre viously charged with HCFC 22 must be flushed NOTICE TO INSTALLER UNIT PLACEMENT It is critical for proper unit operation to place outdoor unit on an elevated surface as described in Unit Placement section on page 7 BRAZING LINE SET TO SERVICE VALVES It is imperative to follow the brazing technique illustrated starting on page 12 to avoid damaging the service valve s internal seals 07 11 Page 1 INSTALLATION INSTRUCTIONS Elite Series XC14 Units AIR CONDITIONER Technical Publications
25. MAFLEX 8 FEET 2 43 METERS E OUTSIDE WALL LIQUID STRAPPING MATERIAL AROUND VAPOR LINE ONLY FLOOR JOIST OR 271 S TAPE OR CAULK WIRE TIE NON CORROSIVE METAL SLEEVE FIBERGLASS INSULATION TAPE OR STRAP THE VAPOR LINE TO THE JOIST WIRE TIE OR RAFTER AT 8 FEET 2 43 METERS INTERVALS THEN STRAP THE LIQUID NOTE Similar installation practices should be used if line set is PE TSE VAPOR EINE to be installed on exterior of outside wall FLOOR JOIST OR ROOF RAFTER Figure 7 Line Set Installation Page 11 XC14 SERIES 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 Polyol Ester POE oils used with 410 refrigerant absorb moisture very quickly It is very important that the refrigerant system be kept closed A IM PORTANT as much as possible DO NOT remove line set caps or service valve stub caps until you are ready to make Allow braze joint to cool before removing the wet rag connections from the service valve Temperatures above 250 F can damage valve seals WARNIN IMPORTANT Danger of fire Bleeding the refrigerant charge from only the high side may result Use silver alloy brazing rods with 5 minimum silver 4 in pressurizati
26. O VAPOR SERVICE VALVE Ol 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 With both manifold valves closed connect the cylinder of HFC 410A refrigerant to the center port of the manifold gauge set Open the valve on the HFC 410A cylinder vapor only B Openthe 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 trace amount is a maximum of two ounces 57 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 D Adjust dry nitrogen pressure to 150 psig 1034 kPa Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor unit E After a few minutes open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector After leak testing disconnect gauges from service ports Figure 12 Leak Test Page 17 XC14 SERIES Evacuating Line Set and Indoor Coil NOTE Remove cores fro
27. RATURE SENSOR SENSOR LIQUID LINE TO LIQUID LINE SERVICE VALVE LIQUID LINE SERVICE VALVE AClose manifold gauge set valves and connect the center hose to a cylinder of HFC 410A Set for liquid phase charging BConnect the manifold gauge set s low pressure side to the suction line service port CConnect the manifold gauge set s high pressure side to the liquid line service port DPosition temperature sensor on liquid line near liquid line service port Figure 18 Gauge Set Setup and Connections Page 23 XC14 SERIES DETERMINING CHARGE METHOD 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 Outdoor ambient temperature REQUIREMENTS Sufficient heat load structure 17 7 C and Below Indoor temperature between 70 80 F 21 26 C Manifold gauge set connected to unit Thermometers to measure outdoor ambient temperature WEIGH IN to measure liquid line temperature to measure suction line temperature metering Which indoor FIXED y device 18 3 C and Above APPROACH OR SUBCOOLING Figure 19 Determining Charge Method 506636 01 Page 24 RIFICE 40 F 4 4 C and Above SUPERHEAT 39 F 3 8 C and Below WEIGH IN CHECKING AIR FLOW AT INDOOR COIL Check airflow using the Delta T DT process using the illustration in figure
28. ain 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 XC14 Engineering Handbook e Lennox Product Catalog e Lennox Price Book Start Up and Performance Checklist Job Name Job no Date Job Location City State Installer City State 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 J 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 J Refrigerant Lines Leak Checked Properly Insulated Outdoor Fan Checked L
29. ansion valve at the liquid line assembly Disconnect the expansion valve from the liquid line orifice housing Take care not to twist or damage distributor tubes during this process Remove and discard expansion valve and the two Teflon rings Use a field 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 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 Invert the cylinder of clean HCFC 22 and open its valve to allow liquid refrigerant to flow into the system through the vapor line valve Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine After all of the liquid refrigerant has been recovered switch the recovery machine to vapor recovery so that all of the HCFC 22 vapor is recovered Allow the recovery machine to pull down to 0 the system Close the valve on the inverted HCFC 22 drum and the gauge set valves Pump the remaining refrigerant out of the recovery machine and turn the machine off 3 Figure 10
30. 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 LENNOX DALLAS TE Refrigerant Charge per Line Set Length Total charge Liquid Line Ounces per 5 feet g per 1 5 m adjust from 15 feet 4 6 m line set Set Diameter 3 8 9 5 mm 3 ounce per 5 85 g per 1 5 m If line length is greater than 15 ft 4 6 m add this amount 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 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 Figure 21 Using HFC 410A Weigh In Method Page 25 XC14 SERIES Connect gauge set as illustrated in figure 18 START Measure outdoor ambient temperature Confirm proper airflow across coil using figure 20 Compare unit pressures with table 4 Normal Operating Pressures USE WEIGH IN METHOD Set thermostat to call for heat must have a cooling AE load between 70 80 21 26 Weigh in remove refrigerant Co g g When heat demand is satisfi
31. d 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 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 Page 29 XC14 SERIES 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 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 location of the dr
32. e valve stem assembly if present and Teflon washer as illustrated above Use a field provided fitting to temporary reconnect the liquid line to the indoor unit s liquid line orifice housing 2 CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE INVERTED HCFC 22 CYLINDER CONTAINS CLEAN HCFC 22 TO BE USED FOR FLUSHING GAUGE MANIFOLD A VAPOR LINE SERVICE VALVE NZ EXISTING INDOOR UNIT OUTDOOR CLOSED RECOVERY CYLINDER RECOVERY MACHINE Inverted HCFC 22 cylinder with clean refrigerant to the vapor service valve HCFC 22 gauge set low side to the liquid line valve HCFC 22 gauge set center port to inlet on the recovery machine with an empty recovery tank to the gauge set Connect recovery tank to recovery machines per machine instructions TYPICAL EXISTING EXPANSION VALVE REMOVAL PROCEDURE UNCASED COIL SHOWN STUB END LIQUID LINE ORIFICE EXPANSION VALVE DISTRIBUTOR veer x TEFLON SENSING i _ LINE EQUALIZER LIQUID LINE ASSEMBLY WITH BRASS NUT MALE EQUALIZER LINE FITTING SENSING BULB LIQUID LINE A On fully cased coils remove the coil access and plumbing panels Remove any shipping clamps holding the liquid line and distributor assembly Disconnect the equalizer line from the expansion valve equalizer line fitting on the vapor line Remove the vapor line sensing bulb Disconnect the liquid line from the exp
33. e 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 Start the existing HCFC 22 system in the cooling mode and close the liquid line valve B Usethe 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 Recovering Refrigerant Page 6 506636 01 CLEARANCE ALL SIDES INCHES MILLIMETERS ACCESS PANEL 12 305 30 762 NOTES 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 final side may be 6 inches 152mm LINE SET 36 914 CONNECTIONS MINIMUM CLEARANCE BETWEEN Aq lt 24 610 lt SJ SF 22 SFA 48 1219
34. e unit for shipping damage and listed times below are intact If damaged or if parts are missing immediately contact the last shipping carrier 1 Assembled outdoor unit 1 Refrigerant flow control RFC kit Fixed Orifice 506636 01 Unit Dimensions Inches LIQUID LINE CONNECTION i ELECTRICAL INLETS SUCTION LINE CONNECTION Y 4 1 2 4 3 4 108 121 108 B SIDE VIEW TOP VIEW UNIT SUPPORT D MN Ec 8 1 2 9 1 2 5 1 2 13 1 2 G 140 343 XC14 024 TO 060 BASE WITH XC14 018 BASE SECTION ELONGATED LEGS XC14 Dimensions in mm A D E F Model XC14 018 230 31 787 See XC14 018 base section above XC14 024 230 35 889 XC14 030 230 39 991 XC14 036 230 39 991 XC14 042 230 31 787 XC14 041 230 39 991 XC14 048 230 39 991 XC14 047 230 35 889 XC14 060 230 35 889 Model Number Identification XC14 230 03 Refrigerant Type p Minor Revision Number X R 410A Voltage 230
35. ed set thermostat to call based upon line length 64 F and for cooling BELOW Allow temperatures and pressures to stabilize Record outdoor ambient temperature APPROACH TXV Record liquid line temperature LIQ If refrigerant is added or Subtract to determine approach removed retest to confirm LIQ AMB APP that unit is properly charged Compare results with table below Approach Values F 1 0 C 0 6 F C 018 024 030 036 041 042 047 048 If value is greater than shown high 65 18 2 1 1 2 11 approach add refrigerant if less 75 24 4 22 4 22 than shown liquid temperature too emn close to ambient temperature low 85 29 4 2 2 6 3 3 approach remove refrigerant 95 35 _5 2 8 _4 2 2 _5 2 8 105 41 3 1 7 4 22 5 28 115 45 3 17 3 1 7 4 2 2 Temperature of air entering outdoor coil Connect gauge set as illustrated in figure 18 65 Confirm proper airflow across coil using figure 20 START Measure outdoor ambient temperature and Compare unit pressures with table 4 Normal ABOVE Operating Pressures Set thermostat to call for heat must have a cooling USE WEIGH IN METHOD load between 70 80 F 21 26 C Weigh in or remove refrigerant LE ABOVE or Measure outdoor ambient temperature o BELOW When heat demand is satisfied set thermostat to call 64 F and for cooling BELOW Al
36. ermostat S40 041 047 048 and 060 units only Compressor in the above reference 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 Page 28 506636 01 When liquid 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 Liquid Line Filter Drier A filter drier is factory installed as illustrated in Unit Dimensions on page 2 with each XC14 unit to ensure a clean moisture free system A replacement filter drier is available from Lennox Refer to Lennox Repair Part Program A IMPORTANT Some scroll compressor have internal vacuum protector that will unload scrolls when suction pressure goes below 20 psig A hissing sound will be heard when the compressor is running unloaded Protector will reset when low pressure in system is raised above 40 psig DO NOT REPLACE COMPRESSOR 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
37. gements Page 3 XC14 SERIES 4 Electric Shock Hazard Can cause injury or death Unit must be grounded in accordance with national and local codes Line voltage is present at all components when unit is not in operation on units with single pole contactors Disconnect all remote electric power supplies before opening access panel Unit may have multiple power supplies 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 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 Service valve stems are factory torqued from 9 ft lbs for small valves to 25 ft lbs for large valves to prevent refrigerant loss during shipping and handling Using Allen wrench rated at less than 50Rc risks rounding or breaking off the wrench or stripping the
38. gerant lines and indoor coil have been leak tested and evacuated Refer to procedures provided in this supplement SUCTION VAPOR LINE PREPARATION FOR NEXT STEP WATER SATURATED CLOTH LIQUID LINE SUCTION VAPOR LINE SERVICE VALVE WHEN BRAZING LINE SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE 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 Figure 9 Brazing Procedures continued Page 14 506636 01 Flushing Line Set and Indoor Coil TYPICAL EXISTING FIXED ORIFICE REMOVAL PROCEDURE UNCASED OR COIL SHOWN 1A 1 TWO PIECE PATCH PLATE UNCASED COIL ONLY DISTRIBUTOR TUBES LIQUID LINE ORIFICE HOUSING TEFLON RING FIXED ORIFICE BRASS NUT DISTRIBUTOR ASSEMBLY REMOVE AND DISCARD WHITE TEFLON SEAL IF PRESENT LIQUID LINE ASSEMBLY INCLUDES STRAINER On fully cased coils remove the coil access and plumbing panels Remove any shipping clamps holding the liquid line and distributor as sembly Using two wrenches disconnect liquid line from liquid line orifice hous ing Take care not to twist or damage distributor tubes during this pro cess Remove and discard fixed orific
39. heck for correct voltage at unit blower operating 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 o 3 Check condensate line and clean if necessary HOMEOWNER 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 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 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 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 shoul
40. icated refrigerant line sizes as listed in table 2 NOTE When installing refrigerant lines 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 XC14 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 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 A IMPORTANT Mineral oils are not compatible with HFC 410A If oil must be added it must be a Polyol Ester oil Table 2 Refrigerant Line Set Inches mm Model Number Field Connections Recommended Line Set Liquid Line Suction Line XC14 018 230 XC14 024 230 3 8 10 mm 3 4 19 mm XC14 030 230 Liquid Line 3 8 10 mm Suction Line L15 Line Set 3 4 19 mm L15 41 15 ft 50 ft 4 6 m 15 m XC14 0
41. low temperatures and pressures to stabilize S U B C L TXV os E block outdoor coil to maintain BLOCK OUTDOOR COIL sometimes necessary with lower gt Record liquid line temperature temperatures Use cardboard or plastic sheet to restrict the airflow LE LIQ through the outdoor coil to achieve pressures from 325 375 psig Measure liquid line pressure and use the value to 2240 2585 kPa Higher pressures are needed to check charge Block determing temperare eee table 3 equal sections of air intake panels and move coverings sideways until SAT the liquid pressure is in the above noted ranges Subtract to determine subcooling SC CARDBOARD OR PLASTIC SHEETS SAT LIQ 5 If is If value is Compare results with table below a Je or Femove MORE than verify charge using shown remove the Approach refrigerant Method F 018 024 030 036 042 based upon line length 65 18 10 5 6 10 5 6 11 6 1 13 7 2 10 5 6 75 24 6 3 3 7 3 9 8 4 4 9 5 0 i 7 3 9 If value is LESS 85 29 6 3 3 8 44 6 33 7 3 9 8 4 4 than shown add refrigerant 95 35 6 3 3 9 5 0 6 33 8 4 4 8 4 4 105 41 10 5 6 9 5 0 7 3 9 9 5 0 8 4 4 115 45 10 5 6 10 5 6 8 4 4 10 5 6 7 3 9 Temperature of air entering outdoor coil Figure 23 Using HFC 410A Subcooling TXV Charge Method Page 26 506636 01 START
42. lowing 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 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 22 refrigerant to flush the system The following devices could prevent full system charge recovery into the outdoor unit Outdoor unit s high or low pressure switches if applicable when tripped can cycle the compressor OFF Compressor can stop pumping due to tripped internal pressure relief valve 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 pressures 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 du
43. ly closed and removes power from the compressor when discharge pressure rises above factory setting at 590 10 psi Thermal Protection Switch S5 Discharge Line Mounted This unit is equipped with a discharge line mounted temperature switch that prevents compressor damage due to loss of charge The switch is located on the discharge line see figure 1 for location When the switch senses a discharge line temperature of 220 F 5 F it opens to shut off compressor operation The auto reset switch closes when the discharge line temperature drops below 180 F 9 F and the compressor is re energized This single pole single throw SPST bi metallic switch is wired in series with the 24V Y input signal to control compressor operation Thermal Protection Switch S173 Compressor Mounted Some units are equipped with a compressor mounted normally closed temperature switch that prevents compressor damage due to overheating caused by internal friction The switch is located on top of the compressor casing see figure 1 This switch senses the compressor casing temperature and opens at 239 257 F 115 C 125 C to shut off compressor operation The auto reset switch closes when the compressor casing temperature falls to 151 187 F 66 C 86 C and the compressor is re energized This single pole single throw SPST bi metallic switch is wired in series with the 24V Y input signal to control compressor operation Crankcase Th
44. m service valves if not already done A 1 CONNECT GAUGE SET Connect low side of manifold gauge set with 1 4 SAE in line tee to vapor line service valve Connect high side of manifold gauge set to liquid line service valve OUTDOOR MANIFOLD ee micron gauge available UNIT Aor TA SAE GAUGE SET SWIVEL COUPLER connector on the 1 4 SAE in line tee A Connect the vacuum pump with vacuum gauge to the center port of the manifold gauge set The center port ME MICRON line will be used later for both the j GAUGE t HFC 410A and nitrogen containers a TO VAPOR 2 506636 01 SERVICE VALVE HFC 410A J air VACUUM PUMP TO LIQUID LINE SERVICE VALVE 1 1 EVACUATE THE SYSTEM RECOMMEND A B Open both manifold valves and start the vacuum pump MINIMUM 3 8 HOSE Evacuate the line set and indoor unit to an absolute pressure of 23 000 microns 29 01 inches of mercury NOTE During the early stages of evacuation it is desirable to close the manifold gauge valve at least once A rapid rise in pressure indicates a relatively large leak If this occurs repeat the leak testing procedure NOTE The term absolute pressure means the total actual pressure within a given volume or system above the absolute zero of pressure Absolute pressure in a vacuum is eq
45. on of the low side shell and alloy for copper to copper brazing Use 4596 minimum f suction tubing Application of a brazing alloy for copper to brass and copper to steel brazing PERKE pressurized system may result in ignition of the refrigerant and oil mixture Check the high and low A WARNING pressures before applying heat Fire Explosion and Personal Safety Hazard AWARNING Failure to follow this warning could When using a high pressure gas such as result in damage personal injury or dry nitrogen to pressurize a refrigeration death or air conditioning system use a Never use oxygen to pressurize or regulator that can control the pressure purge refrigeration lines Oxygen down to 1 or 2 psig 6 9 to 13 8 kPa when exposed to a spark or open flame can cause fire and or an ex A CAUTION plosion that could result in property damage personal injury or death Brazing alloys and flux contain materials which are hazardous to your health Avoid breathing vapors or fumes from brazing operations Perform operations only in well ventilated areas Wear gloves and protective goggles or face shield to protect against burns Wash hands with soap and water after handling brazing alloys and flux Page 12 506636 01 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 CAP AND CORE REMOVAL Remove
46. or 20 ft lb SENSING BULB INSTALLATION Attach the vapor line sensing bulb in the proper orientation as illustrated to the right using the clamp and Screws provided 1 8 Turn NOTE Confirm proper thermal contact between vapor line and expansion bulb before insulating the sensing bulb once installed Connect the equalizer line from the expansion valve to the equalizer vapor port on the vapor line Finger tighten the flare nut plus 1 8 turn 7 ft lbs as illustrated below ON LINES SMALLER THAN 7 8 MOUNT SENSING BULB AT EITHER THE 3 OR 9 O CLOCK POSITION VAPOR LINE ON 7 8 AND LARGER LINES MOUNT SENSING BULB AT EITHER THE 4 OR 8 O CLOCK POSITION NEVER MOUNT ON BOTTOM OF LINE NOTE NEVER MOUNT ON BOTTOM OF LINE Figure 11 Installing Indoor Expansion Valve Page 16 506636 01 A IMPORTANT The Environmental Protection Agency EPA prohibits the intentional venting of HFC refrigerants during maintenance service repair and disposal of appliance Approved methods of recovery recycling or reclaiming must be followed A IMPORTANT If this unit is being matched with an approved line set or indoor unit coil which was previously charged with mineral oil or if it is being matched with a coil which was manufactured before January of 1999 the coil and line set must be flushed prior to installation Take care to empty all existing traps Polyol ester POE oils are used in Lennox units charged with HFC
47. peration 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 THERMOSTAT Install room thermostat ordered separately on an inside wall approximately in the center of the conditioned area and 5 feet 1 5m from the floor It should not be installed on an outside wall or where it can be affected by sunlight or drafts THERMOSTAT NOTE 24VAC Class II circuit connections are made the control panel a HIGH VOLTAGE FIELD WIRING FACTORY WIRING eu OW VOLTAGE 24V FIELD WIRING AWG INSULATION TYPE TEMPERATURE RATING 35 C MINIMUM WIRE RUN LENGTH LESS THAN 100 30 METERS 18 MORE THAN 100 30 METERS 16 Run 24VAC control wires through cutout with grommet Run 24VAC control wires through wire tie Make 24VAC control wire connec
48. service cap and core from both the suction vapor and liquid line service ports CUT AND DEBUR VEN N SERVICE PORT C e LINE SET SIZE MATCHES SERVICE VALVE CONNECTION SERVICE VALVE CONNECTION COPPER TUBE SERVICE PORT SERVICE SUCTION VAPOR LINE SERVICE VALVE LINE SET SIZE IS SMALLER NOT CRIMP SERVICE VALVE THAN CONNECTION A REFRIGERANT LINE CONNECTOR WHEN PIPE IS BMALLER THAN CONNECTION 3 ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION VAPOR LINE SERVICE VALVES Flow regulated nitrogen at 1 to 2 psig through the low side refrigeration gauge set into the liquid line service port valve and out of the suction vapor line service port valve Connect gauge set low pressure side to liquid line service valve service port USE REGULATOR TO FLOW Connect gauge set center port to bottle of EON Z N NITROGEN AF TTO ere nitrogen with regulator S 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 i INDOOR OUTDOOR UNIT E 9 UNIT c3 LIQUID LINE LIQUID LINE SERVICE WHEN BRAZING LINE SET TO VALVE SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE NITROGEN Figure 8 Brazing Proced
49. 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 damage to roof surface LOUVERED PANEL REMOVAL Remove the louvered panels as follows 1 Remove two screws allowing the panel to swing open slightly 2 Hold the panel firmly throughout this procedure Rotate bottom corner of panel away from hinged corner post until lower three tabs clear the slots as illustrated in detail B 3 Move panel down until lip of upper tab clears the top slot in corner post as illustrated in detail A LOUVERED PANEL INSTALLATION 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 Slightly rotate and guide the lip of top tab inward as illustrated in detail A and C then upward into the top slot of the hinge corner post 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 Detail C 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 EXTREME
50. temperature F of entering outdoor ambient air at the suction line service refrigerant is If value is LESS than shown then REMOVE If value is MORE ADDED retest 19 than shown then confirm that unit is retrigerant ADD refrigerant properly charged Figure 24 Using HFC 410A Superheat Fixed Orifice Charge Method Table 3 HFC 410A Temperature F Pressure Psig Page 27 XC14 SERIES Table 4 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 IMPORTANT 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 018 024 030 036 041 042 047 048 060 Liquid Liquid Liquid Liquid Suction Suction Suction Suction Expansion Valve TXV Liquid Suction Liquid Liquid Liquid Liquid Suction Suction Suction Suction 65 18 230 138 225 135 226 129 238 132 233 142 70 21 244 139 2421 137 241 131 254 135 239 142 253 140 252 140 256 138 258 135 236 138 233 139 238 136 239 133 75 24 265 140 260 138 259 134 273 138 256 143 2731141 2721141 277 139 278 136 80 27 85 29 lt 286 140 28
51. tion installation or replacement of existing line set If new or replacement line set is not being installed then proceed to Brazing Connections on page 12 A IMPORTANT Lennox highly recommends changing line set when converting the existing system from HCFC 22 to HFC 410A If 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 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 Line Set and Indoor Coil on page 15 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 fabr
52. tions using field provided wire nuts D 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 iy TIGHTEN WIRE TIE Page 19 XC14 SERIES G60V G61V G60 G61MP CUMF RTSENSE G71MPP COMFORTSENSE FURNACE 7000 STAT FURNACE 7000 STAT G40 G43 650 651 023 CUMFDRTSENSE FURNACE 3000 STAT R H iva 0 R 4 G 4 W 4 Yi OPTIONAL OUTDOOR SENSOR X2658 Ds c M l CUT W914 DS JUMPER WHEN STAT DEHUMID IS USED Y SENSUR OPTIONAL 658 l CUT W914 R TO DS JUMPER WHEN STAT DEHUMID IS USED B Ko COMFORTSENSE T a BLOWER COIL 7000 STAT BLOWER en BLOWER COMFORTSENSE COIL COMFORTSENSE BLOWER CDMFORTSENSE COIL ir ME 3000 STAT COIL 3000 STAT RED R S GREEN G BLACK We emails R
53. ual to atmospheric pressure minus vacuum pressure When the absolute pressure reaches 23 000 microns 29 01 inches of mercury perform the following Close manifold gauge valves Close valve on vacuum pump e Turn vacuum pump Disconnect manifold gauge center port hose from vacuum pump e X Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig 1034 kPa and purge the hose e Open manifold gauge valves to break the vacuum in the line set and indoor unit 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 dry nitrogen from the line set and indoor unit 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 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 410 refrigerant Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit Perform the following 1 6 TURN Close manifold gauge valves Shut off HFC 410A cylinder Reinstall service valve cores by removing manifold hose from
54. ures Page 13 XC14 SERIES 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 before 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 joint Do not remove water saturated cloths until piping has cooled Temperatures above 250 F will damage valve seals WARNING 1 FIRE PERSONAL INJURY OR PROPERTY DAMAGE may result if you do not wrap a water 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 Do not open service valves until refri
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