Lennox International Inc. Dave Lennox Signature Collection XC21 System Air Conditioner User Manual
Contents
1. WIRE RUN LENGTH AWG INSULATION TYPE LESS THAN 100 30 METERS 18 TEMPERATURE RATING MORE THAN 100 30 METERS 16 35 C MINIMUM A B ROUTE CONTROL WIRES COMMUNICATING Maximum length of wiring 18 gauge for all connections on the RSBus is 1500 feet 457 meters Wires should be color coded with a temperature rating of 95 F 35 C minimum and solid core Class II Rated Wiring All low voltage wiring must enter unit through provided field installed busing installed in electrical inlet Communicating systems using the icomfort enabled thermostat require four thermostat wires between the thermostat and the furnace air handler con trol and four wires between the outdoor unit and the furnace air handler control When a thermostat cable with more than four wires is used the extra wires must be properly connected to avoid electrical noise see illustration below Use a wire nut to bundle the four unused wires at each end of the cable Each bundle should also include an additional wire that should be connected on each end to the C terminal as shown in the figure below icomfort enabled icomfort enabled Indoor Unit Outdoor Unit icomfort enabled c Single Wire To C thermostat Terminal Single Wire ToC Foe Terminal A WY Unused Wires Unused Wires 4 ROUTE HIGH VOLTAGE AND GROUND WIRES Any excess high voltage field wiring should be tr2. BASE WITH ELONGATED LEGS STEP 1 SETTING THE UNIT Continued Unit Placement NOTICE 4 WARNING To prevent personal injury as well as damage to panels unit or structure observe the following While installing or servicing this unit carefully stow all removed panels so that the panels will not cause injury to personnel objects or nearby structures Also take care to store panels where they will not be subject to damage e g being bent or scratched While handling or stowing the panels consider any weather conditions especially wind that may cause panels to be blown around and damaged Roof Damage This system contains both refrigerant and oil Some rubber roofing material may absorb oil causing the rubber to degrade Failure to follow this notice could result in damage to roof surface IMPORTANT Page 2 Exhaust vents from dryers water heaters and furnaces should be directed away from the outdoor unit Prolonged exposure to exhaust gases and the chemicals contained within them may cause condensation to form on the steel cabinet and other metal components of the outdoor unit This will diminish unit performance and longevity PLACEMENT INSTALL UNIT AWAY FROM WINDOWS WO 90 ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION FIGURE 2 SLAB MOUNTING Install unit level or if on a slope maintain slope tol
3. j NOTE LINK NOT APPLICABLE TO TARGET ONE STAGE UNITS CUTTING LINK WILL HAVE NO AFFECT ON OPERATION OF ONE STAGE UNITS 40 DEGREE TARGET DEFAULT FIGURE 14 Page 13 XC21 SERIES STEP 5 ELECTRICAL Continued Field Control Wiring The following two illustrations provide examples of control wiring connections when using a non communicating thermostat For examples of control wiring in complete or partial communicating systems see the icomfort enabled thermostat Quick Start Guide which is provided with the thermostat Air Handler ComfortSense 7000 Thermostats Catalog Y0349 or Y2081 g 72 XC21 Two Stage Air Conditioner Control O On board link N 00 000000000 000 Low voltage thermostat wiring Flat metal jumper 000 0 3 98006 gt Thermostat T terminals are used for outdoor sensor input Use for thermostat s outdoor temperature display optional R to L connection is required for this model when using the ComfortSense 7000 catalog number Y0349 only Resistor Kit catalog number 47W97 required and ordered separately Air handler control ships from factory with metal jumpers installed across W1 W2 and W3 For one stage electric heat do not remove factory installed metal jumpers Air handler control ships from factory wi
4. putting the unit the control and the technician at the same electrostatic potential Touch hand and all tools on an unpainted unit surface before performing any service procedure to neutralize electrostatic charge ELECTROSTATIC DISCHARGE ESD Precautions and Procedures INSTALL THERMOSTAT Install room thermostat ordered separately on an inside wall in the center of the conditioned area and 5 feet 1 5m from the floor The thermostat 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 in the control box FIGURE 12 Page 11 XC21 SERIES A ROUTE CONTROL WIRES NON COMMUNICATING Install low voltage control wiring from outdoor to indoor unit and from thermostat to indoor unit All low voltage wiring must enter unit through provided field installed busing installed in electrical inlet Ta A Lol Run 24VAC control wires through hole with grommet Make 24VAC control wire connections to outdoor control A175 CONTROL NOTE Do not bundle any excess 24VAC control wires inside control box B NOTE Wire tie provides low voltage wire strain relief and maintains separation of field installed low and high voltage circuits 4 NOTE For proper voltages select control wires gauge per table below Laas es Ge Ho P mo
5. 0A cylinder and the valve on the high pressure side of the manifold gauge set Disconnect the HFC 410A cylinder Connect a cylinder of nitrogen with a pressure regulating valve to the center port of the manifold gauge set Adjust 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 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 10 Page 9 XC21 SERIES STEP 4 LEAK TEST AND EVACUATION Continued EVACUATION CONNECT GAUGE SET NOTE Remove cores from service valves if not already done 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 PUNE 1 4 SAE TEE WITH SWIVEL UGE SET Connect available micron gauge connector COUPLER on the 1 4 SAE in ine tee A Connect the vacuum pump with vacuum gauge to the center port of the manifold gauge set The center port line will be used z MICRON later for both the HFC 410A and nitrogen nice GAUGE 1 containers TO VAPOR SERVICE VALVE NOTE Position canister to deliver liquid refrigerant HF
6. C 410A J air VACUUM PUMP TO LIQUID LINE SERVICE VALVE 4 EVACUATE THE SYSTEM t RECOMMEND MINIMUM 3 8 HOSE A Open both manifold valves and start the vacuum pump B Evacuate the line set and indoor unit to an absolute pressure of 23 000 microns 29 01 inches of mercury NOTE During the early stages of evacuation it is desirable to close the manifold gauge valve at least once A rapid rise in pressure indicates a relatively large leak If this occurs repeat the leak testing procedure NOTE The term absolute pressure means the total actual pressure above zero within a given volume or system Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure C When the absolute pressure reaches 23 000 microns 29 01 inches of mercury perform the following WARNING l Close manifold gauge valves z z Close valve on vacuum pump Possible equipment damage Turn off vacuum pump Avoid deep vacuum operation Do not use Disconnect manifold gauge center port hose from vacuum pump compressors to evacuate a system Attach manifold center port hose to a nitrogen cylinder with pressure MSAA AAR Ror EAE AE L regulator set to 150 psig 1034 kPa and purge the hose arcing and compressor failure Damage Open manifold gauge valves to break the vacuum in the line set and indoor caused by deep vacuum operation will unit void warranty Close manifold gauge valves Shut off the nitrogen cyl
7. CAP AND CORE REMOVAL SERVICE PORT CORE 4 CUT AND DEBUR REDUCER LIQUID LINE SERVICE VALVE LINE SET SIZE IS SMALLER O THAN CONNECTION REFRIGERANT LINE PA SERVICE O PORT CAP SERVICE PORT CORE SUCTION VAPOR LINE SERVICE VALVE DO NOT CRIMP SERVICE VALVE CONNECTOR WHEN PIPE IS SMALLER THAN CONNECTION ATTACH THE MANIFOLD GAUGE SET FOR BRAZING 3 LIQUID AND SUCTION VAPOR LINE SERVICE VALVES A Connect gauge set low pressure side to liquid line service valve service port B Connect gauge set center port to bottle of nitrogen with regulator C With valve core removed from the suction vapor line service port nitrogen flow will have an exit point ATTACH GAUGES SUCTION VAPOR SERVICE PORT MUST BE OPEN AND SERVICE PORT CORE REMOVED TO ALLOW EXIT POINT FOR NITROGEN FLOW SUCTION VAPOR LINE SERVICE SUCTION VAPOR VALVE LINE INDOOR OUTDOOR UNIT JE En C UNIT E S NITROGEN LG IDTINE LIQUID LINE SERVICE VALVE FIGURE 7 Page 6 A CAUTION AWARNING Brazing alloys and flux contain materials which are hazardous to your health Danger of fire Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing Application of a brazing torch to a pressurized system may result in ignition
8. GE RECOVERY MACHINE 3 HCFC 22 cylinder with clean refrigerant positioned to deliver liquid refrigerant to the vapor service valve HCFC 22 gauge set low side to the liquid line valve 4 HCFC 22 gauge set center port to inlet on the recovery machine with an empty recovery tank connected to the gauge set Connect recovery tank to recovery machine per machine instructions TEFLON z RING SENSING o _ LINE ea EQUALIZER E LIQUID LINE ASSEMBLY WITH BRASS NUT MALE EQUALIZER LINE FITTING LIQUID SENSING BULB LINE On fully cased coils remove the coil access and plumbing panels Remove any shipping clamps from the liquid line and distributor assembly Disconnect the equalizer line from the check expansion valve equalizer line fitting on the vapor line Remove the vapor line sensing bulb Disconnect the liquid line from the check expansion valve at the liquid line assembly Disconnect the check expansion valve from the liquid line orifice housing Take care not to twist or damage distributor tubes during this process Remove and discard check expansion valve and the two Teflon rings Use a field provided fitting to temporarily 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 flushin
9. LENNOX gt 2012 Lennox Industries Inc Dallas Texas USA fi icomfort THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE AWARNING The State of California has determined that this product may contain or produce a chemical or chemicals in very low doses which may cause serious illness or death It may also cause cancer birth defects or reproductive harm This XC21 outdoor unit is designed for use with HFC 410A refrigerant only This unit must be installed with an ap proved indoor unit See the Lennox XC21 Product Specifi cations bulletin EHB for approved indoor component match ups These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation STEP 1 SETTING THE UNIT Clearances INSTALLATION INSTRUCTIONS Dave Lennox Signature Collection XC21 System AIR CONDITIONERS g Technical ote eee Supersedes 4 2012 Litho U S A AWARNING Improper installation adjustment alteration service or maintenance can cause property damage personal inju ry or loss of life Installation and service must be performed by a licensed professional installer or equivalent or service agency ACAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at discon nect switch NOTICE For more in depth information consult the Installa tion
10. RE 9 Page 8 STEP 4 LEAK TEST AND EVACUATION 1 2 OUTDOOR UNIT t TO VAPOR SERVICE VALVE NOTE Position canister to deliver liquid refrigerant NITROGEN HFC 410A CONNECT GAUGE SET A Connect the high pressure hose of an HFC 410A manifold gauge set to the vapor valve service port NOTE Normally the high pressure hose is connected to the liquid line port However connecting it to the vapor port better protects the manifold gauge set from high pressure damage With both manifold valves closed connect the cylinder of HFC 410A refrigerant to the center port of the manifold gauge set NOTE Later in the procedure the HFC 410A container will be replaced by the nitrogen container TEST FOR LEAKS After the line set has been connected to the indoor and outdoor units check the line set connections and indoor unit for leaks Use the following procedure to test for leaks A With both manifold valves closed connect the cylinder of HFC 410A refrigerant to the center port of B the manifold gauge set Open the valve on the HFC 410A cylinder vapor only Open the high pressure side of the manifold to allow HFC 410A into the line set and indoor unit Weigh in a trace amount of HFC 410A A trace amount is a maximum of two ounces 57 g refriger ant or three pounds 31 kPa pressure Close the valve on the HFC 41
11. and Service Procedures manual available as Corp 1007 L2 on DaveNet or through the Technical Support department at 800 453 6669 CLEARANCE ON ALL SIDES INCHES MILLIMETERS NOTES _Z mMM ol ANN inches 762mm e Clearance to o INA wT ANNA w TT UTE 5 the final side 152mm 36 914 MINIMUM CLEARANCE BETWEEN TWO UNITS MINIMUM CLEARANCE ABOVE UNIT e Clearance to access panel must be 30 ne of the other three 48 1219 sides must be 36 inches 914mm e Clearance to one of the remaining two sides may be 12 inches 305mm and may be 6 inches ACCESS PANEL LINE SET CONNECTIONS REAR VIEW OF UNIT FIGURE 1 7 2012 Page 1 506923 01 UNIT DIMENSIONS INCHES MM 39 1 2 DISCHARGE 1003 AIR Tt SUCTIOn LINE Pa INLET LIQUID LINE INLET a SIDE VIEW UNIT SUPPORT FEET 16 7 8 429 8 3 4 222 ELECTRICAL 3 1 8 gt 79 a 30 3 4 781 35 1 2 902 INLETS 1194 ACCESS VIEW 26 7 8 3 3 4 95 as 4 5 8 117
12. change in the direction noted in chart the compressor is properly modulating from low to high capacity If no amperage pressures or temperature readings change when this test is per formed the compressor is not switching between low and high capacity and replacement is necessary After testing is complete return unit to original set up XC21 Field Operational Checklist Cooling Heating Unit Readings Expected results Y1 Expected results during Y2 demand during Y2 demand toggle switch ON toggle switch ON Y2 Second First Stage Stage Compressor Voltage Amperage Condenser Fan motor Amperage Same or Higher Same or Higher Temperature Ambient Outdoor Coil Discharge Air Compressor Discharge Line Indoor Return Air Indoor Coil Discharge Air Pressures Suction Vapor Liquid Note Unit may have a low ambient control or control that locks in second stage operation below its set point It may be necessary to remove a wire from the control when performing this check On the XC21 units the System Operation Monitor controls the second stage solenoid coil in compressor Cooling Mode Operation Block outdoor coil to maintain a minimum of 375 psig during testing kk kkk Page 17 XC21 SERIES XC21 Start Up and Performance Checklist Customer Address Indoor Unit Model Outdoor Unit Model Solar Modu
13. e done at the temperature is between 15 F and 35 F and the MAIN CONTROL The Lennox ComfortSense 7000 thermostat Compressor has been OFF for 25 to 30 minutes This may be used as well as other non communicating electronic only _ Option is to help reduce the potential for ice build up on the thermostats orifice ring during system OFF cycles that are greater than 25 to 30 minutes J3 ALL UNITS 7 SEGMENT m FAN CYCLING N DISPLAY JUMPER ON ey Z al FAN ON FOR 5 MINUTES ON Set up of jumpers on PUSH replacement outdoor BUTTON control FAN COMP SHIFT D JUMPER OFF DISABLE DEFAULT de OFF SEE NOTE ABOVE FOR FURTHER DETAILS DEFROST ERMINAT ION OPEN 9DF HP ONLY J4 J1 HP ONLY DEFROST TERMINATION TEMPERATURE COMPRESSOR SHIFT DELAY 100 m DEGREE SECOND DELAY S TARGET DEFAULT 90 o DEGREE TARGET SECOND DELAY y DEFAULT WHEN JUMPER IS REMOVED OR MISSING 70 TWO STAGE HEAT neon PUMP ONLY J2 SECOND STAGE LOCK IN TEMPERATURE 50 DEGREE TARGET DEFAULT 55 DEGREE TARGET COIL AMB DIS DS TO R TWO STAGE UNIT 50 ONLY DEGREE Cut for Humiditrol Enhanced TARGET Dehumification Accessory EDA applications CUTFOR OPTION ae
14. erance of 2 degrees or 2 inches per 5 feet 50 mm per 1 5 m away from building structure BUILDING STRUCTURE 4TbiscHarce AIR MOUNTING SLAB ul GROUND LEVEL FIGURE 3 ELEVATED SLAB MOUNTING USING FEET EXTENDERS Use additional 2 SCH 40 male 2 50 8MM SCH 40 FEMALE THREADED threaded adapters which can be threaded into the female ADAPTER threaded adapters to make additional adjustments to the level of the unit 2 50 8MM N AK SCH 40 MALE IPINYA THREADED y S Pa ADAPTER RRI J KAN S S STABILIZING UNIT ON UNEVEN SURFACES 10 X 1 2 LONG SELF DRILLING SHEET METAL SCREWS STABILIZING BRACKET 18 GAUGE METAL 2 WIDTH HEIGHT AS REQUIRED 10 X 1 1 4 LONG FLAT WASHER Concrete slab use two plastic anchors hole drill 1 4 IMPORTANT Unit Stabilizer Bracket Use field provided Always use stabilizers when unit is raised above the factory height Elevated units could become unstable in gusty wind conditions Stabilizers may be used on any unit installed on unstable and uneven surfaces FIGURE 5 STEP 2 REFRIGERANT PIPING Flush ing Existing Line Set amp Indoor Coil Flush the existing line set per the following instruc tions For more information refer to the Installation and Service Procedures manual available on Dave Net CAUTION DO NOT attempt to flush and re use ex isting line sets or indoor coil when the system con
15. g 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 Position the cylinder of clean HCFC 22 for delivery of liquid refrigerant 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 the system down to 0 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 FIGURE 6 Page 5 XC21 SERIES STEP 2 REFRIGERANT PIPING Brazing Procedures Remove piping panel to access service valves Cut Remove service cap and core from both the suction ends of the refrigerant lines square free from nicks or vapor and liquid line service ports dents and debur the ends The pipe must remain amp SERVICE PORT CAP round Do not crimp end of the line j amp AM LINE SET SIZE MATCHES R SERVICE VALVE CONNECTION SERVICE VALVE CONNECTION COPPER TUBE STUB 1 PIPING PANEL REMOVAL PREPARING LINE SET
16. id line to liquid line service valve DAVENET 2 Braze suction vapor line to suction vapor service valve WHEN BRAZING LINE SET TO SERVICE VALVES POINT FLAME AWAY FROM SERVICE VALVE SUCTION VAPOR SERVICE SUCTION VAPOR LINE PORT MUST BE OPEN AND SERVICE PORT CORE RE MOVED TO ALLOW EXIT POINT FOR NITROGEN FLOW WATER SATURATED CLOTHS IMPORTANT Allow braze joint to cool Apply additional water saturated cloths to help cool brazed joints Do not remove water saturated cloths until piping has cooled Temperatures above 250 F will damage valve seals LIQUID LINE WATER SATURATED CLOTHS 7 PREPARATION FOR NEXT STEP After all connections have been brazed disconnect manifold gauge set from service ports Apply additional water saturated cloths to both services valves to cool piping Once piping is cool remove all water saturated cloths FIGURE 8 Page 7 XC21 SERIES STEP 3 INSTALLING INDOOR EXPANSION VALVE This outdoor unit is designed for use in systems that include an expansion valve metering device See the XC21 Product Specifications bulletin EHB for approved expansion valve kit match ups and application information The expansion valve can be installed internal or external to the indoor coil In applications where an uncased coil is being installed in a field pro vided plenum install the expansion valve in a manner that will provide access for future field service of the expansion valve Refer to bel
17. immed and secured away from any low voltage field wiring To facilitate a conduit a cutout is located in the bottom of the control box Connect conduit to the control box using a proper conduit fitting GROUND LUG WATERTIGHT CONTROL BOX CONDUIT FITTING 7 SU Ai a ELEGTRI AL Attach field provided INLET HIGH green ground wire to VOLTAGE provided ground lug WATERTIGHT FLEX A IBLE CONDUIT E A e NOTE Grounding wire WIRING ENTRY must be a single contin POINTS uous wire run from unit ground lug to earth TO SERVICE ground DO NOT splice DISCONNECT BOX wire DPD yy yyy ELECTRICAL INLET CONTROL WIRING LOW VOLTAGE USE BUSHING PROVIDED IN BAG ASSEMBLY HERE ACCESS VIEW FIGURE 13 Page 12 STEP 5 ELECTRICAL Continued Outdoor Control A175 Jumpers and Terminals Communication System The Lennox icomfort enabled thermostat must be The jumper settings and link are default settings and ONLY control B used in communicating applications system operation if configuration settings in the icomfort enabled thermostat are not available ee NOTE Fan cycling routine when activated will cycle the eit Communicating System fan ON for five minutes if the outdoor ambient air The unit will operate based on jumper settings and R TO DS link on i o the MAIN CONTROL All unit setting changes must b
18. inder and remove the manifold gauge hose from the cylinder Open the manifold gauge valves to release the 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 a cylinder of HFC 410A positioned to deliver liquid 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 Close manifold gauge valves Shut off HFC 410A cylinder Reinstall service valve cores by removing manifold hose from service valve Quickly install cores with core tool while maintaining a positive system pressure Replace stem caps and finger tighten them then tighten an additional one sixth 1 6 of a turn as illustrated 1 6 TURN FIGURE 11 Page 10 STEP 5 ELECTRICAL Circuit Sizing and Wire Routing 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 instructio
19. it as needed 2 Disposable filters should be replaced with a filter of the same type and size 3 The indoor 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 drain line and how to check for obstructions This would also apply to an auxiliary drain if installed Thermostat Operation See the ComfortSense 7000 or icomfort enabled ther mostat homeowner manual for instructions on how to oper ate 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 Page 19 XC21 SERIES
20. le Mfg and Model Notes START UP CHECKS Refrigerant Type Rated Load Amps Actual Amps Rated Volts Actual Volts Condenser Fan Full Load Amps Actual Amps COOLING MODE Vapor Pressure Liquid Pressure Supply Air Temperature Ambient Temperature Return Air Temperature HEATING MODE Vapor Pressure Liquid Pressure Supply Air Temperature Ambient Temperature Return Air Temperature System Refrigerant Charge Refer to manufacturer s information on unit or installation instructions for required subcooling and approach temperatures Subcooling Saturated Condensing Temperature A SUBCOOLING minus Liquid Line Temperature B Liquid Line Temperature A APPROACH minus Outdoor Air Temperature B Indoor Coil Temp Drop 18 to 22 F Return Air Temperature A COIL TEMP DROP minus Supply Air Temperature B Page 18 ACAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at discon nect switch Cleaning of the outdoor unit s coil should be performed by a licensed professional service technician or equivalent Contact your dealer and set up a schedule preferably twice a year but at least once a year to inspect and ser vice your outdoor unit The following maintenance may be performed by the homeowner IMPORTANT Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to
21. ning properly to correctly perform compressor 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 TOOLS REQUIRED e Refrigeration gauge set e Digital volt amp meter e Electronic temperature thermometer e On off toggle switch PROCEDURE 1 Turn main power OFF to outdoor unit Adjust room thermostat set point 5 F above heating operation or 5 F below cooling operation the room temperature 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 Turn toggle switch OFF Install switch in series with Y2 wire from room thermostat See note in the Field Operational Checklist on page 17 5 Cycle main power ON 6 Allow pressures and temperatures to stabilize before taking any reading may take up to 10 minutes 7 Record all of the readings for the Y1 demand 8 Close switch to energize Y2 demand Verify power is 10 11 12 Page 16 going to compressor solenoid see note in the Field Operational Checklist on page 17 Allow pressures and temperatures to stabilize before taking any reading may take up to 10 minutes Record all of the readings with the Y1 and Y2 demand If temperatures and pressures
22. ns 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 han dler for low voltage control power 24VAC 40 VA mini mum A WARNING 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 SWITCH Refer to the unit nameplate for minimum circuit ampacity and maximum fuse or circuit breaker size HACR per NEC Install power wiring and properly sized disconnect switch A swr CIRCUIT AND INSTALL DISCONNECT SERVICE DISCONNECT SWITCH NOTE Units are approved for use only with copper conductors Ground unit at disconnect switch or connect to an earth ground IMPORTANT If unit is equipped with a crankcase heater it should be energized 24 hours before unit start up to pre vent compressor damage as a result of slugging CAUTION Electrostatic discharge can affect electronic components Take care during unit installation and service to protect the unit s electronic controls Precautions will help to avoid control exposure to electrostatic discharge by
23. of the refrigerant and oil mixture Check the high and low pressures before applying heat Avoid breathing vapors or fumes from brazing operations Perform operations only in well ventilated big areas J Wear gloves and protective goggles or face shield to protect against burns Wash hands with soap and water after handling brazing alloys and flux 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 under the valve body to protect the base paint 5 FLOW NITROGEN WARNING Flow regulated nitrogen at 1 to 2 psig through the refrigeration FIRE PERSONAL INJURY OR PROPERTY DAMAGE gauge set into the valve stem port connection on the liquid service A may result if you do not wrap a water saturated cloth around valve and out of the suction vapor valve stem port See steps 3A 3B both liquid and suction line service valve bodies and copper and 3C on previous page and below for manifold gauge setup tube stub while brazing the line set The braze when complete must be quenched with water to absorb any 6 BRAZE LINE SET residual heat Cloths must remain water saturated throughout the brazing and Do not open service valves until refrigerant lines and cool down process indoor coil have been leak tested and evacuated Refer eee ie ages to Installation and Service Procedures manual found on 1 Braze liqu
24. ow illustration for reference during installation of expansion valve Install one of the provided Teflon rings around the INDOOR EXPANSION VALVE INSTALLATION stubbed end of the expansion valve and use refrigerant oil to lightly lubricate the connector threads and ex posed surface of the Teflon ring TWO PIECE PATCH PLATE Uncased Coil Shown Attach the stubbed end of the expansion valve to the UNCASED liquid line orifice housing Finger tighten then use an COIL ONLY LIQUID LINE STUB appropriately sized wrench to turn an additional 1 2 ORIFICE END HOUSING o turn clockwise as illustrated in the figure to the right or D 1 2 Turn DISTRIBUTOR TUBES __ VALVE tighten to 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 e refrigerant oil TEFLON N 6 Attach the liquid line assembly to the expansion valve SENSING Finger tighten then use an appropriately sized wrench RING Orn _ LINE to turn an additional 1 2 turn clockwise as illustrated in Si y the figure above or tighten to 20 ft lb EQUALIZER LINE LIQUID LINE ee SENSING BULB INSTALLATION 1 Attach the vapor line sensing bulb in the proper orienta tion as illustrated below using the clamp and screws MALE EQUALIZER LINE provided FITTING SEE NOTE Though it is preferred to have the sensing bulb EQUALIZER LINE in
25. s with any mechanical equipment contact with sharp sheet metal edges can result in personal injury Take care while handling this equipment REMOVAL PROCEDURE PROCEDURE UNCASED COIL SHOWN 1 A TYPICAL EXISTING FIXED ORIFICE OR 1 Broce EXISTING EXPANSION VALVE REMOVAL UNCASED COIL SHOWN STUB END TWO PIECE PATCH PLATE LIQUID LINE DISTRIBUTOR TUBES UNCASED COIL ONLY ORIFICE EXPANSION LIQUID LINE ORIFICE HOUSING WA DISTRIBUTOR vey VALVE YA TEFLON RING FIXED ORIFICE BRASS NUT DISTRIBUTOR 7 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 from 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 orifice valve stem assembly if present and Teflon washer as illustrated above Use a field provided fitting to temporarily reconnect the liquid line to the indoor unit s liquid line orifice housing CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE CYLINDER CONTAINING GAUGE CLEAN HCFC 22 TO BE MANIFOLD USED FOR FLUSHING Positioned to deliver liquid refrigerant VAPOR LINE SERVICE VALVE OUTDOOR EXISTING INDOOR 1 RECOVERY CYLINDER 2 D DISCHAR
26. stalled on a horizontal run of the vapor line installation INSTALLATION FOR on a vertical run of piping is acceptable if necessary NOTE Confirm proper thermal contact between vapor line 1 8 Turn DETAILS X Sensing bulb insulation is required if and expansion bulb before insulating the sensing bulb expansion valve is installed external to the EE sensing b lb installation for the equalizer vapor port on the vapor line Finger tighten the flare nut then tighten an additional 1 8 turn 7 ft lbs as illustrated to the right LIQUID LINE 3 Connect the equalizer line from the expansion valve to EQUALIZER LINE INSTALLATION ON LINES SMALLER THAN 1 Remove and discard either the flare seal cap or flare nut with VAPOR LINE 7 8 MOUNT SENSING copper flare seal bonnet from the equalizer line port on the vapor BULB AT EITHER THE 3 OR line as illustrated in the figure below nay Gud 9 O CLOCK POSITION Remove the field provided fitting that temporarily reconnected i gt S the liquid line to the indoor unit s distributor assembly R FLARE SEAL CAP itl FLARE NUT VAPOR LINE ON 7 8 AND LARGER LINES OR COPPER FLARE f MOUNT SENSING BULB AT SEAL BONNET EITHER THE 4 OR 8 O CLOCK 3 POSITION NEVER MOUNT lt THE SENSING BULB ON Ne is BOTTOM OF LINE MALE BRASS EQUALIZER LINE FITTING VAPOR LINE NOTE NEVER MOUNT THE SENSING BULB ON BOTTOM OF LINE FIGU
27. tSense 7000 catalog number Y0349 only Resistor Kit catalog number 47W97 required and ordered separately Cut on board link W915 clippable wire for two stage operation Cut loop jumper clippable wire DS to R on two stage units for Humiditrol applications This will slow the outdoor unit s fan speed to a specific RPM A wire must be installed between the DS terminals on the furnace and outdoor unit controls Cut on board link clippable wire DS R for Humiditrol or Harmony III applications This will slow the indoor blower motor to the lowest speed setting See furnace installation instruction or engineering handbook for lowest fan speed information FIGURE 16 Page 15 XC21 SERIES Charging The XC21 unit is factory charged with enough HFC 410A refrigerant to accommodate a 15 foot length of refrigerant piping Charge should be checked and adjusted using the tables provided on the charging procedure sticker on the unit access panel Detailed information is given in the XC21 Installation and Service Procedures manual which is available on DaveNet Start Up Checklists TWO STAGE COMPRESSOR PERFORMANCE Use this procedure to verify part and full load capacity op eration of the two stage compressor IMPORTANT This performance check is ONLY valid on systems that have clean indoor and outdoor coils proper airflow over coils and correct system refrigerant charge All components in the system must be functio
28. tains contaminants i e compressor burn out NOTE When installing refrigerant lines longer than 50 feet refer to the Refrigerant Piping Design and Fabrication Guidelines manual available on DaveNet Corp 9351 L9 or contact the Technical Support Department Product Ap plication group for assistance NOTE For new or replacement line set installation refer to Service and Application Note Corp 9112 L4 C 91 4 TABLE 1 REFRIGERANT LINE SET INCHES MM Liquid Vapor L15 Line Set Line Suction Line 3 8 10 7 8 22 L15 line set sizes are dependent on unit match up See XP21 Engineering Handbook to determine correct line set sizes 060 3 8 10 1 1 8 29 Field Fabricated NOTE Some applications may required a field provided 7 8 to 1 1 8 adapter Page 3 XC21 SERIES IMPORTANT If this unit is being matched with an approved line set or indoor unit coil that 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 installa tion Take care to empty all existing traps Polyol es ter POE oils are used in Lennox units charged with HFC 410A refrigerant Residual mineral oil can act as an insulator preventing proper heat transfer It can also clog the expansion device and reduce sys tem performance and capacity Failure to properly flush the system per this instruc
29. th metal jumpers installed across W1 W2 and W3 For two stage electric heat remove factory installed metal jumper between W1 to W2 Then connect thermostat wire between the air handler control s W2 and the thermostat s W2 terminal Cut on board link clippable wire from Y1 Y2 2 STAGE COMPR for two stage compressor and two speed fan operation Cut loop jumper clippable wire DS to R on two stage units for Humiditrol applications This will slow the outdoor unit s fan speed to a specific RPM A wire must be installed between the DS terminals on the air handler and outdoor unit controls Cut on board link clippable wire DS R for Humiditrol or Harmony III applications This will slow the indoor blower motor to the lowest speed setting See air handler installation instruction or engineering handbook for lowest fan speed information FIGURE 15 Page 14 Furnace ComfortSense 7000 Thermostats Catalog Y0349 or Y2081 XC21 Two Stage Air Conditioner Control g 72 On board link N G8 000000000 BOG Low voltage thermostat wiring 000 0 3 000 06 G0 08 806 gt Thermostat T terminals are used for outdoor sensor input Use for thermostat s outdoor temperature display optional R to L connection is required for this model when using the Comfor
30. 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 diminish performance and affect longevity of the unit Outdoor Coil The outdoor unit must be properly maintained to ensure its proper operation Please contact your dealer to schedule proper inspec tion and maintenance for your equipment Make sure no obstructions restrict airflow to the outdoor unit Grass clippings leaves or shrubs crowding the unit can cause the unit to work harder and use more energy Keep shrubbery trimmed away from the unit and periodi cally check for debris which collects around the unit Keep snow level below the louvered panels to ensure proper performance 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 NOTE The filter and all access panels must be in place any time the unit is in operation If you are unsure about the filter required for your system call your Lennox dealer for assistance 1 Ask your Lennox dealer to show you where your indoor unit s filter is located It will be either at the indoor unit installed internal or external to the cabinet or behind a return air grille in the wall or ceiling Check the filter monthly and clean or replace
31. tion and the detailed Installation and Service Proce dures manual will void the warranty A WARNING When using a high pressure gas such as nitrogen to pressurize a refrigeration or air conditioning system use a regulator that can control the pressure down to 1 or 2 psig 6 9 to 13 8 kPa 4 WARNING Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may result in personal injury or death A WARNING Fire Explosion and Personal Safety Haz ard Failure to follow this warning could re sult 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 fire and or an explosion that could result in property damage personal injury or death 4 WARNING Polyol ester POE oils used with HFC 410A refrigerant absorb moisture very quickly It is very important that the refrigerant system be kept closed as much as possible DO NOT remove line set caps or service valve stub caps until you are ready to make connections M IMPORTANT Page 4 Some scroll compressors have an internal vacuum protector that will unload scrolls when suction pres sure 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 COM PRESSOR 4 CAUTION A
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