Loading...
BLD2022-0353_Manufacturer_Specifications_and_Installation_Instructions_3.22.2022_10.33.17_AM_2752718L ENN70i ©2011 Lennox Industries Inc. Dallas, Texas, USA 11 Zz ZZ ._ `11 1 .` 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. A IMPORTANT This unit must be matched with an indoor coil as speci- fied in LennoxXC13 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. 09/11 IIII IIIIIII III IIIII IIIII IIIII IIII IIII INSTALLATION INSTRUCTIONS Elite® Series XC13 Units CONDENSING UNITS Technical 506635-01 Publications 09/11 Litho U.S.A. Supersedes 07/11 TABLE OF CONTENTS General ...................................... 1 Shipping and Packing List ...................... 1 Model Number Identification .................... 2 Unit Dimensions ............................... 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 Connections ........................... 12 Flushing Line Set and Indoor Coil ................ 15 Installing Indoor Metering Device ................ 16 Leak Test Line Set and Indoor Coil ............... 17 Evacuating Line Set and Indoor Coil ............. 18 Electrical ..................................... 19 Servicing Units Delivered Void of Charge ......... 22 Unit Start -Up .................................. 22 System Refrigerant ............................ 22 System Operation ............................. 26 Maintenance .................................. 27 Start -Up and Performance Checklist ............. 28 General The XC13 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 XC13 Engineering Handbook. Page 1 Shipping and Packing List Check the 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) 506635-01 IIIIIIII III IIIII IIIII 1111111111111111111111111111111111 IIII Model Number Identification X C 13 XXX 230 03 Refrigerant Type I I Minor Revision Number X = R-410A Voltage 230 = 208/23OV-1 ph-60hz Unit Type C = Air Conditioner — Nominal Cooling Capacity Series 018=1.5tons 024 = 2 tons 030 = 2.5 tons 036 = 3 tons 042 = 3.5 tons 048 = 4 tons 060 = 5 tons Unit Dimensions - Inches (mm) Iq LQ COI EL sU o�aQo� c�oac� o n n o o n o��coo n n n o 0 0 n n n n n n o o 0 0 0 0 n n n o 0 0 - - - - - - o n o o a o o o n n o o o o a a o o o n n o a o n n n o a o 4-1/2" 11D LINE INECTION ECTRICALINLETS CTION LINE NNECTION 4-3/4" (908) (121) SIDE VIEW B TOP VIEW Model Number A B 27 (686) 27 (686) C XC13-018-230 28 (711) XC13-024-230 XC13-030-230 31 (787) 27 (686) 28 (711) XC13-036-230 XC13-042-230 31 (787) 31 (787) 35 (889) XC13-048-230 39 (991) 31 (787) 35 (889) XC13-060-230 35 (889) 31 (787) 35 (889) UNIT SUPPORT UNIT SUPPORT FEET FEET 13-7/8 O O 0 (216) O OC. (241) (352) (216) 8-3/4 (222) 8-1/4" (210) 5-1/2" 1 13-1/2" (140) IN ON (343) XC13-018 TO -036 BASE SECTIONS (SMALL) 20-5/8 (524) (197) 4-1 /2 (114) 3-1/4 27-1/8 IN 3-5/8 (83) (689) (92) XC13-042 TO -060 BASE SECTIONS WITH ELONGATED LEGS (MEDIUM) Page 2 506635-01 11110 Typical Unit Parts Arrangement CONTROL F CONTACTOR - SINGLE POLE (K1-1) GROUNDLUG CRANKCASE HEATER THERMO- STAT (S40) (-060 UNIT ONLY) LIQUID LINE FILTER DRIER (SINGLE FLOW) LIQUID LINE SERVICE VALVE FIELD CONNECTION FOR LIQUID LINE SET DUAL RUN CAPACITOR (C12) THERMAL PROTECTION SWITCH (S173) (NOT USED ON ALL UNITS) SWITCH / COVER FIELD CONNECTION FOR SUCTION LINE THERMAL PROTECTION SWITCH (S5) (NOT USED ON ALL UNITS) PLUMBING, SWITCHES AND SENSOR COMPONENTS Figure 1. Typical Parts Arrangements Page 3 XC13 SERIES AWARNING 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. A IMPORTANT To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening. Table 1. Torque Requirements Parts Recommended Torque Service valve cap 8 ft.- lb. 11 NM Sheet metal screws 16 in.- lb. 2 NM Machine screws #10 28 in.- lb. 3 NM Compressor bolts 90 in.- lb. 10 NM Gauge port seal cap 8 ft.- lb. 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. 506635-01 11 /10 Page 4 Operating Angle Type Service Valve: 1. Remove stem cap with an appropriately sized wrench. 2. Use a service wrench with a hex -head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve sizes) to back the stem out counterclockwise as far as it ISERVICE PORT CAP P::�SERVICE PORT CORE (VALVE STEM SHOWN TO INDOORB CLOSED) INSERT HEX UNIT (VALVE STEM SHOWN OPEN) WRENCH HERE INSERT HEX WRENCH HERE SERVICE PORT STEM CAP CORE TO OUTDOOR UNIT ANGLE -TYPE SERVICE VALVE ANGLE -TYPE SERVICE VALVE (FRONT -SEATED CLOSED) (BACK -SEATED OPENED) When service valve is OPEN, the service port is WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN open to IinE set, Indoor and outdoor unit. TO THE LINE SET AND INDOOR UNIT. Operating Ball Type Service Valve: To Access Service Port: A service port cap protects the service port core from contamination and 1. Remove stem cap with an appropriately sized wrench. serves as the primary leak seal. 2. Use an appropriately sized wrenched to open. To open valve, 1. Remove service port cap with an appropriately sized wrench. rotate stem counterclockwise 90°. To close rotate stem clockwise 90°. 2. Connect gauge set to service port. 3. When testing is completed, replace service port cap and tighten as follows: TO INDOOR UNIT • With torque wrench: Finger tighten and 1/6TURN torque cap per table 1. 11 2 / • Without torque wrench: Finger tighten and 10 TO OPEN ROTATE STEM BALL (SHOWN use an appropriately sized wrench to turn 9 3 COUNTERCLOCKWISE 90°. CLOSED) an additional 1/6 turn clockwise. g 4 S VALVE % 6 TO CLOSE ROTATE STEM STEM CLOCKWISE 90°. Reinstall Stem Cap: \ Stem cap protects the valve stem from damage and serves as the SERVICE PORT primary seal. Replace the stem cap and tighten as follows: 1/12 TURN SERVICE PORT • With Torque Wrench: Finger tighten and -\/ CORE then torque cap per table 1. 11 2 1 SERVICE PORT CAP • Without Torque Wrench: Finger tight- 10 2 en and use an appropriately sized 9 3 TO OUTDOOR STEM CAP wrench to turn an additional 1/12 turn 8 4 UNIT clockwise. % 6 5 NOTE — A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque. Figure 2. Angle and Ball Service Valves Page 5 XC13 SERIES Recovering Refrigerant from Existing System ICOVERIN( REFRIGERANT FROM SYSTEM 1DISCONNECT POWER Disconnect all power to the existing outdoor unit at the disconnect switch or main fuse box/breaker panel. MAIN FUSE BOX/BREAKER PANEL MAIN FUSE 2CONNECT MANIFOLD GAUGE SET Connect a gauge set, clean recovery cylinder and a recovery machine to the service ports of the existing unit. Use the instructions provided with the recovery machine to make the connections. RECOVEI 3RECOVERING REFRIGERANT Remove existing HCFC-22 refrigerant using one of the following procedures: MANIFOLD GAUGES CLEAN RECOVERY OUTDOOR UNIT CYLINDER METHOD 1: Us this method if the existing outdoor unit is not equipped with shut-off valves, or if the unit is not operational and you plan to use the existing HCFC-22 to flush the system. Remove all HCFC-22 refrigerant from the existing system. Check gauges after shutdown to confirm that the entire system is completely void of refrigerant. METHOD 2: Use this method if the existing outdoor unit is equipped with manual shut-off valves, and you plan to use new HCFC-22 refrigerant to flush the system. The following devices could prevent full system charge recovery into the outdoor unit: • 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 due to one of the above system conditions, shut off the vapor valve. Turn OFF the main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set. Perform the following task: A Start the existing HCFC-22 system in the cooling mode and close the liquid line valve. B Use the compressor to pump as much of the existing HCFC-22 refrigerant into the outdoor unit until the outdoor system is full. Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system. NOTE — It may be necessary to bypass the low pressure switches (if equipped) to ensure complete refrigerant evacuation. C When the low side system pressures reach 0 psig, close the vapor line valve. D Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system. Page 6 506635-01 11 /10 CLEARANCE ON ALL SIDES — INCHES (MILLIMETERS) 6 (152) ACCESS PANEL NOTES: 1 • I � Clearance to one of the other three 12 (305) 30 (762) sides must be 36 inches (914mm). I • Clearance to one of the remaining 1 1 two sides may be 12 inches (305mm) and the final side may be t �--- 6 inches (152mm). LINE SET 36 (914) CONNECTIONS Figure 3. Installation Clearances New Outdoor Unit Placement 1 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 3 for mandatory installation clearance requirements. POSITIONING CONSIDERATIONS Consider the following when positioning the unit: • 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. • 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 4, detail A. MINIMUM CLEARANCE ABOVE UNIT 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 4, detail B. NOTE — If necessary for stability, anchor unit to slab as described in figure 4, detail D. ELEVATING THE UNIT Units are outfitted with elongated support feet as illustrated in figure 4, 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 adapter. The specified coupling will fit snuggly into the recessed portion of the feet. Use additional 2 inch (50.8mm) Schedule 40 male threaded adaptors which can be threaded into the female threaded adaptors to make additional adjustments to the level of the unit. NOTE — Keep the height of extenders short enough to ensure a sturdy installation. If it is necessary to extend further, consider a different type of field -fabricated framework that is sturdy enough for greater heights. Page 7 XC13 SERIES DETAIL A- Outside Unit Placement Install unit away from windows. TWO 90' ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION. DETAIL C — Elevated Slab Mounting using Feet Extenders BASE LEG DETAIL 2" (50.8MM) SCH 40 FEMALETHREADED 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. 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. GROUND LEVE Stabilizing Unit on Uneven Surfaces DETAIL D - Slab Side Mounting #10 1/2" LONG SELF -DRILLING SHEET METAL SCREWS COIL STABILIZING BRACKET (18 GAUGE 1 METAL — 2" WIDTH; HEIGHT AS BASE PAN REQUIRED) \ #10 1-1/4" LONG HEX HD SCREW AND FLAT WASHER CORNER POST Concrete slab — use two plastic anchors (hole drill 1 /4") Wood or plastic slab — no plastic anchor (hole drill 1/8") DETAIL E — Deck Top Mounting Stabilizing bracket (18 gauge metal — 2" (50.8mm) width; height as required); bend to form right angle as exampled below. MINIMUM UNt PER SIDE \ . o� o \ o 0 0 SAME FASTENERS AS FOR EXTRA SLAB SIDE MOUNTING. STABILITY q� One bracket per side (minimum). For extra stability, two brackets per side, two inches (51 mm) from each corner. Figure 4. Placement, Slab Mounting and Stabilizing Unit 506635-01 11 /10 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. 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: 1. Slightly rotate and guide the lip of top tab inward as illustrated in detail A and C; then upward into the top slot of the hinge corner post. 2. Rotate panel to vertical to fully engage all tabs. 3. Holding the panel's hinged side firmly in place, close the right-hand side of the panel, aligning the screw holes. 4. When panel is correctly positioned and aligned, insert the screws and tighten. Detail C MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT AS POSSIBLE) WHILE INSTALLING PANEL. • • • A IMPORTANT Do not allow panels to hang on unit by top tab. Tab is for alignment and not designed to support weight of panel. IMPORTANT.! DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB. TAB IS FOR ALIGNMENT AND NOT DESIGNED TO SUPPORT WEIGHT OF PANEL. PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR ENTER) TOP SLOT FOR REMOVING (OR INSTALLING) PANEL. SCREW HOLES LIP DETAIL A DETAIL B HOLD DOOR FIRMLY TO THE HINGED ANGLE MAY BE TOO _ SIDE TO MAINTAIN EXTREME \\ '� \ - _ FULLY -ENGAGED TABS PREFERRED ANGLE FOR INSTALLATION_ Figure 5. Removing and Installing Panels ROTATE IN THIS DIRECTION; �. THEN DOWN TO REMOVE PANEL Page 9 XC13 SERIES New or Replacement Line Set REFRIGERANT LINE SET This section provides information on installation or replacement of existing line set. If new or replacement line set is not being installed then proceed to Brazing Connections on page 12. 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 6 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 pagel 5). Field refrigerant piping consists of liquid and vapor lines from the outdoor unit to the indoor unit coil (braze connections). Use Lennox L15 (sweat, non -flare) series line set, or field -fabricated refrigerant line sizes as listed in table 2. 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: • Model (XC13) and size of unit (e.g. -036). • Line set diameters for the unit being installed as listed in table 2 and total length of installation. • Number of elbows vertical rise or drop in the piping. The compressor is charged with sufficient Polyol ester oil for line set lengths up to 50 feet. Recommend adding oil to system based on the amount of refrigerant charge in the system. No need to add oil in system with 20 pounds of refrigerant or less. For systems over 20 pounds - add one ounce of every five pounds of refrigerant. Recommended topping -off POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATE rM 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 Valve Field Connections Recommended Line Set Liquid Line Suction Line Liquid Line Suction Line L15 Line Sets XC 13-018-230 3/8 in. (10 mm) 3/4 in. (19 mm) 3/8 in. (10 mm) 3/4 in. (19 mm) L15-41 — 15 ft. - 50 ft. (4.6 m - 15 m) XC13-024-230 XC 13-030-230 XC 13-036-230 3/8 in. (10 mm) 7/8 in. (22 mm) 3/8 in. (10 mm) 7/8 in. (22 mm) L15-65 —15 ft. - 50 ft. (4.6 m - 15 m) XC13-042-230 XC13-048-230 XC13-060-230 3/8 in. (10 mm) 1-1/8 in. (29 mm) 3/8 in. (10 mm) 1-1/8 in. (29 mm) Field Fabricated NOTE — Some applications may required a field provided 7/8" to 1-1/8" adapter Page 10 506635-01 11 /10 Line Set Isolation — The following illustrations are examples of proper refrigerant line set isolation: REFRIGERANT LINE SET — TRANSITION FROM VERTICAL TO HORIZONTAL ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE MUFFLER -TYPE HANGER WALL STUD NON -CORROSIVE METAL SLEEVE AUTOMOTIVE MUFFLER -TYPE HANGER STRAP LIQUID LINE TO VAPOR LINE LIQUID LINE VAPOR LINE - WRAPPED IN ARMAFLEX REFRIGERANT LINE SET — INSTALLING HORIZONTAL RUNS To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties. CTD MATERIF VAPOR 8 FEET (2.43 METERS)I -- WIRE TIE (AROUND VAPOR LINE ONLY) PE OR RE TIE rERS) TAPE OR STRAP THE VAPOR LINE TO THE JOIST WIRE TIE OR RAFTER AT 8 FEET (2.43 METERS) INTERVALS THEN STRAP THE LIQUID LINE TO THE VAPOR LINE. FLOOR JOIST OR ROOF RAFTER REFRIGERANT LINE SET — INSTALLING VERTICAL RUNS (NEW CONSTRUCTION SHOWN) NOTE — Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperatureof the liquid line or when pressure drop is equal to or greater than 20 psig. OUTSIDE WALL VAPOR LINE LIQUID LINE WOOD BLOCK BETWEEN STUDS WIRE TIE INSIDE WALL STRAP NON -CORROSIVE METAL SLEEVE WIRE TIE { WOOD BLOCK WIRE TIE STRAP I SLEEVE / VAPOR LINE WRAPPED \ WITH ARMAFLEX OUTSIDE WALL LIQUID / LINE PVC \ CAULK PIPE / FIBERGLASS � INSULATION NOTE — Similar installation practices should be used if line set is to be installed on exterior of outside wall. Figure 6. Line Set Installation Page 11 XC13 SERIES 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. 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 of the refrigerant and oil mixture - Check the high and low pressures before applying heat. When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa). 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. Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve. Allow braze joint to cool before removing the wet rag from the service valve. Temperatures above 250OF can damage valve seals. Use silver alloy brazing rods with 5% minimum silver alloy for copper -to -copper brazing. Use 45% minimum alloy for copper -to -brass and copper -to -steel brazing. Fire, Explosion and Personal Safety Hazard. Failure to follow this warning could result in damage, personal injury or death. Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when exposed to a spark or open flame, can cause fire and/or an ex- plosion, that could result in property damage, personal injury or death. 1 CUT AND DEBUR CAP AND CORE REMOVAL Cut ends of the refrigerant lines square (free from nicks or dents) 2 Remove service cap and core from and debur the ends. The pipe must remain round. Do not crimp end both the suction / vapor and liquid line of the line. service ports. CUT AND DEBUR O SERVICE PORT SERVICE CAP PORT CORE LINE SET SIZE MATCHES )SERVICE VALVE CONNECTION SERVICE SERVICE VALVE PORT CONNECTION CORE SERVICE COPPER TUBE \ PORT CAP STUB O LIQUID LINE SERVICE SUCTION / VAPOR LINE REDUCER VALVE SERVICE VALVE LINE SET SIZE IS SMALLER O NOT CRIMP SERVICE VALVE / THAN CONNECTION CONNECTOR WHEN PIPE IS REFRIGERANT LINE I MALLER 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. A Connect gauge set low pressure side to liquid line service valve (service port). USE REGULATOR TO FLOW B Connect gauge set center port to bottle of LOW HIGH NITROGEN AT 1 TO 2 PSIG. nitrogen with regulator. O / C Remove core from valve in suction / vapor O line service port to allow nitrogen to escape. ATTACH —o GAUGES SUCTION / VAPOR SERVICE PORT MUST BE V OPEN TO ALLOW EXIT POINT FOR NITROGEN C SUCTION / VAPOR LINE SERVICE VAPOR LINE V/ VALVE INDOOR OUTDOOR UNIT J UNIT \ I I NITROGEN LIQUID LINE LIQUID LINE SERVICE O WHEN BRAZING LINE SET TO VALVE SERVICE VALVES, POINT FLAME AWAY FROM SERVICE VALVE. Figure 7. Brazing Procedures Page 13 XC13 SERIES 4 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. 5 FLOW NITROGEN 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, 36 and 3C on manifold gauge set connections 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. WHEN BRAZING LINE SET TO SERVICE VALVES, POINT FLAME AWAY FROM SERVICE VALVE. LIQUID LINE SERVICE VALVE L ° ° I i °r I 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. WATER SATURATED CLOTH LIQUID LINE SUCTION / VAPOR LINE SERVICE VALVE brazing in the line set! The braze, when complete, must be quenched with water to absorb any residual heat. I 2. Do not open service valves until refrigerant lines and WHEN BRAZING LINE SET TO SERVICE .� indoor coil have been leak -tested and evacuated. V OINTAWAY FROM SERVICE VALVE. Refer to procedures provided in this supplement. lc�dr_ SUCTION / VAPOR LINE WATER SATURATED CLOTH 7 PREPARATION FOR NEXT STEP After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water saturated cloths to both services valves to cool piping. Once piping is cool, remove all water saturated cloths. Refer to the unit installation instructions for the next step in preparing the unit. Figure 8. Brazing Procedures (continued) Page 14 506635-01 11 /10 Flushing Line Set and Indoor Coil TYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL 1 A REMOVAL PROCEDURE (UNCASED OR PROCEDURE (UNCASED COIL SHOWN) COIL SHOWN) 1B DISTRIBUTOR TUBES LIQUID LINE ORIFICE HOUSING /TEFLONE'RING FIXED ORIFICE BRASS NUT DISTRIBUTOR ASSEMBLY REMOVE AND DISCARD WHITE TEFLON® SEAL (IF PRESENT) LIQUID LINE ASSEMBLY (INCLUDES STRAINER) STUB END TWO PIECE PATCH PLATE LIQUID LINE CHECK (UNCASED COIL ONLY) ORIFICE EXPANSION DISTRIBUTOR HOUSING VALVE TUBES TEFLON' 0 I� RING 0 4D• � H TEFLON& \ ® RING SENSING ' \ LINE DISTRIBUTOR EQUALIZER ASSEMBLY LINE LIQUID LINE / ASSEMBLY WITH / BRASS NUT A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps holding the liquid line and distributor as- I sembly. MALE EQUALIZER / C Using two wrenches, disconnect liquid line from liquid line orifice hous- LINE FITTING VAPOR SENSING BULB LINE LIQUID ing. Take care not to twist or damage distributor tubes during this pro- LINE cess. D Remove and discard fixed orifice, valve stem assembly if present and A On fully cased coils, remove the coil access and plumbing panels. Teflon® washer as illustrated above. B Remove any shipping clamps holding the liquid line and distributor E Use a field -provided fitting to temporary reconnect the liquid line to the assembly. indoor unit's liquid line orifice housing. C Disconnect the equalizer line from the check expansion valve equalizer line fitting on the vapor line. CONNECT GAUGES AND EQUIPMENT FOR 2 D Remove the vapor line sensing bulb. FLUSHING PROCEDURE E Disconnect the liquid line from the check expansion valve at the liquid line assembly. INVERTED HCFC-22 GAUGE F Disconnect the check expansion valve from the liquid line orifice CYLINDER CONTAINS MANIFOLD CLEAN HCFC-22 TO BE housing. Take care not to twist or damage distributor tubes during this A USED FOR FLUSHING. process. G Remove and discard check expansion valve and the two Teflon® rings. LOW r 1 HIGH / H Use a field -provided fitting to temporary reconnect the liquid line to the VAPOR LINE NEW 0 indoor unit's liquid line orifice housing. SERVICE VALVE OUTDOOR \/ UNIT FLUSHING LINE SET OPENED CLOSED3 EXISTING The line set and indoor unit coil must be flushed with at least the INDOOR same amount of clean refrigerant that previously charged the UNIT B system. Check the charge in the flushing cylinder before LIQUID LINE SERVICE proceeding. VALVE A Set the recovery machine for liquid recovery and start the recovery machine. Open the gauge set valves to allow the TANK RETURN recovery machine to pull a vacuum on the existing system line \ set and indoor unit coil. o C INLET B Invert the cylinder of clean HCFC-22 and open its valve to allow RECO Y o 5 � DISCHARGE liquid refrigerant to flow into the system through the vapor line CYLINDE valve. Allow the refrigerant to pass from the cylinder and through RECOVERY MACHINE the line set and the indoor unit coil before it enters the recovery machine. A Inverted HCFC-22 cylinder with clean refrigerant to the vapor service C After all of the liquid refrigerant has been recovered, switch the valve. recovery machine to vapor recovery so that all of the HCFC-22 B HCFC-22 gauge set (low side) to the liquid line valve. vapor is recovered. Allow the recovery machine to pull down to 0 C HCFC-22 gauge set center port to inlet on the recovery machine with an the system. empty recovery tank to the gauge set. D Close the valve on the inverted HCFC-22 drum and the gauge D Connect recovery tank to recovery machines per machine instructions. set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off. Figure 9. Installing Indoor Expansion Valve Page 15 XC13 SERIES Installing Indoor Metering Device This outdoor unit is designed for use in systems that use See the Lennox XC13 Engineering Handbook for either fixed orifice or expansion valve metering devices at approved expansion valve kit match -ups. The the indoor coil. expansion valve unit can be installed internal or • If using a fixed orifice metering device, use the the one external to the indoor coil. In applications where an provided with the outdoor unit. The metering device is uncased coil is being installed in a field -provided located in the installation instruction bag. For installing plenum, install the expansion valve in a manner that the orifice, reverse the procedure outlined in figure 9, will provide access for field servicing of the expansion 1A. valve. Refer to below illustration for reference during installation of expansion valve unit. INDOOR EXPANSION VALVE INSTALLATION TWO PIECE PATCH PLATE (Uncased Coil Shown) (UNCASED COIL ONLY) LIQUID LINE STUB DISTRIBUTOR ORIFICE END EXPANSION HOUSING \ VALVE TUBES._ TEFLON® 0 I\ RING 0 o ®TEFLONO, SENSING RING LINE DISTRIBUTOR ASSEMBLY, EQUALIZER / LINE LIQUID LINE / ASSEMBLY WITH / BRASS NUT A Remove the field -provided fitting that temporary reconnected the liquid line to the indoor unit's distributor assembly. B 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. C Attach the stubbed end of the expansion valve to the liquid line orifice housing. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above, or 20 ft-lb. D 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. E Attach the liquid line assembly to the expansion valve. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or 20 ft-lb. SENSING BULB INSTALLATION 1/2 Turn 0I 11 10 9 g 4 7 5 A Attach the vapor line sensing bulb in the proper orientation as illustrated to the right using the clamp and MALE EQUALIZER LINE VAPOR screws provided. 1/8 Turn FITTING (SEE LINE EQUALIZER LINE NOTE — Confirm proper thermal contact between vapor line 1 INSTALLATION FOR and expansion bulb before insulating the sensing bulb once 10 j FURTHER DETAILS) LIQUID LINE installed. q {� B Connect the equalizer line from the expansion valve to 8 4 Sensing bulb insulation is required if the equalizer vapor port on the vapor line. Finger tighten 7 6 5 mounted external to the coil casing. sensing the flare nut plus 1/8 turn (7 ft-lbs) as illustrated below. bulb installation for bulb positioning. 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. B 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 CAP I I FLARE NUT X_ COPPER FLARE OR SEAL BONNET MALE BRASS EQUALIZER LINE FITTING VAPOR LINE ON LINES SMALLER THAN VAPOR LINE 7/8", MOUNT SENSING BULB AT EITHER THE 3 OR 9 O'CLOCK POSITION. BULB (v BULB \BULB 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. BULB ) BULB NOTE — NEVER MOUNT ON BOTTOM OF LINE. Figure 10. Installing Indoor Expansion Valve 506635-01 11 /10 Page 16 Leak Test Line Set and Indoor Coil A IMPORTANT Leak detector must be capable of sensing HFC refrigerant. 1 CONNECT GAUGE SET A Connect an HFC-410A manifold gauge set high pressure LOW hose 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 0 damage. B With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. HIGH MANIFOLD GAUGE SET OUTDOOR UNIT NOTE — Later in the procedure, the HFC-410A container will be replaced by the nitrogen B A container. TO VAPOR SERVICE VALVE NITROGEN HFC-410A ZTEST FOR LEAKS After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the following procedure to test for leaks: A With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. Open the valve on the HFC-410A cylinder (vapor only). B Open the high pressure side of the manifold to allow HFC-410A into the line set and indoor unit. Weigh in a trace amount of HFC-410A. (A trace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kPa) pressure]. Close the valve on the HFC-410A cylinder and the valve on the high pressure side of the manifold gauge set. Disconnect the HFC-410A cylinder. C Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set. D Adjust dry nitrogen pressure to 150 psig (1034 kPa). Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor unit. E After a few minutes, open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector. F After leak testing disconnect gauges from service ports. Figure 11. Leak Test Page 17 XC13 SERIES Evacuating Line Set and Indoor Coil 1 CONNECT GAUGE SET NOTE — Remove cores from service valves (if not already done). A Connect low side of manifold gauge set with 1/4 SAE in -line tee to vapor line service valve B Connect high side of manifold gauge set to liquid line service valve OUTDOOR C Connect micron gauge available UNIT connector on the 1/4 SAE in -line tee. A D Connect the vacuum pump (with vacuum gauge) to the center port of the manifold gauge set. The center port line will be used later for both the HFC-410Aand nitrogen containers. NITROGEN HFC-410A VACUUM PUMP B LOW MANIFOLD A34000 1/4 SAE TEE WITH GAUGE SET SWIVEL COUPLER 500 C MICRON GAUGE t TO VAPOR C SERVICE VALVE TO LIQUID LINE SERVICE VALVE 1 HIGH 2 EVACUATE THE SYSTEM RECOMMEND A Open both manifold valves and start the vacuum pump. MINIMUM 3/8" HOSE B Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury). NOTE— During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once. A rapid rise in pressure indicates a relatively large leak. If this occurs, repeat the leak testing procedure. NOTE — The term absolute pressure means the total actual pressure within a given volume or system, above the absolute zero of pressure. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure. C 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 • Turn off vacuum pump • Disconnect manifold gauge center port hose from vacuum pump • Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose. • Open manifold gauge valves to break the vacuum in the line set and indoor unit. • Close manifold gauge valves. D Shut off the dry nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the dry nitrogen from the line set and indoor unit. E Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and 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. F When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to an upright cylinder of HFC-410A refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit. G Perform the following: 1/6 TURN • Close manifold gauge valves. • Shut off HFC-410A cylinder. 11 1 1 2 • 10 Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core tool while maintaining a positive system pressure. 9 -j • Replace stem caps and secure finger tight, then tighten an additional one -sixth (1/6) of a turn as illustrated. 5 6 Figure 12. Evacuating System Page 18 506635-01 11 /10 t IMPORTANT I Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns. 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 1 SIZE CIRCUIT AND INSTALL DISCONNECT SWITCH Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR per NEC). Install power wiring and properly sized disconnect switch. MAIN FUSE 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 temperatures and pressures present during operation of an air conditioning system. Non-condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts. Electrical 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) 2 INSTALL THERMOSTAT Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and 5 feet (1.5m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight or drafts. THERM NOTE— 24VAC, Class 11 circuit connections are made in the control panel. HIGH VOLTAGE FIELD WIRING FACTORY WIRING - - - - - LOW VOLTAGE (24V) FIELD WIRING WIRE RUN LENGTH AWG# INSULATION TYPE LESS THAN 100' (30 METERS) 18 TEMPERATURE RATING MORE THAN 100' (30 METERS) 16 35°C MINIMUM. A Run 24VAC control wires through cutout with grommet. B Run 24VAC control wires through wire tie. C Make 24VAC control wire connections 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. TIGHTEN WIRE TIE Page 19 XC13 SERIES G60V,G61V, G60,G61MP COMFORTSENSE G71MPP COMFORTSENSE FURNACE 7000 STAT FURNACE 7000 STAT 1340,1343, G50,1351,0230 FURNACE COMFORT SENSE 3000 STAT S O O R-- R --- --- G XC13 W W XC13 O O XC13 O O v[uov Y2 © OPTIONAL Y2 © O.D. OUTDOOR SENSOR G _ _ G SENSOR OPTIONAL C1) O XX2�2665�58 DS — — — D XX226558 BLACK � C BLACK V—V J I J I CUT W914 R TO DS JUMPER WHEN STAT T J CUT W914 R TO DS JUMPER WHEN STAT T J DEHUMID. IS USED. T — DEHUMID. IS USED. T — CBX32MV BLOWER COIL COMFORTSENSE CBX26 CBX27 7000 STAT CBX32M COMFORTSENSE R BLOWER BLOWER COMFORTSENSE BLOWER _ COIL COMFORTSENSE COIL 3000 STAT R Q —3000R STAT COIL —3000R STAT RED-R R GREEN-G G G — G WHITE -WI _ W I XC13 O Q XC13 BLACK- e XC13 W -- W XC13 p v _ _ 3 — 1 YOU"YI — — 1 Y © O.D. VELLPV _ VS VELLUV YI SENSOR Y2 I G — — — G OPTIONAL — — —I X2658 BLUE-C ➢S MOVE BLACK — — BLACK — C — C BLACK C — — — NOTE - Refer to furnace, blower coil and accessory instructions for additional wiring configurations with other JUMPER VHEN13STAT— J optional controls. DEHUMID. IS USED. Figure 13. 24VAC Control Wiring Diagrams (Field Installed) OUTDOOR AN PURPLE BLACK ORANGE RED YELLOW R S C COMPRESSOR iI CRANKCASE HEATER S40 0 L1 208-230/6011 L2 , a DESCRIPTION KEY I COMPONENT A4 CONTROL -TIMED OFF B1 COMPRESSOR B4 MOTOR -OUTDOOR FAN C12 CAPACITOR -DUAL HR1 HEATER -COMPRESSOR K1,-1 CONTACTOR -COMPRESSOR S4 SWITCH -HIGH PRESSURE S24 SWITCH -LOSS OF CHARGE S40 TERMOSTAT-CRANKCASE S87 I SWITCH -LOW PRESS, COMP 1 S173 I SWITCH -THERMAL PROTECTION DUAL CAPACITOR Aq TO 24 VAC POWER F C H TIMED OFF SOURCE CONTROL 20 VA MINIMUM NEC CLASS 2 2 3 1 C Y1 BLACK I COMPRESSOR I I CONTACTOR I I L2 GROUND Ll LUG I i 208-230/ 60/ 1 K1-1 I I - GROUND L— — — — — — 1 61 BLACK C S R _ YELLOW S4 RED HIGH S173 S87 OR ORANGE PRESSURE S24 SWITCH RED BLACK 5173 0 ---�4 S40 C12 A4 \ H C F 64 S4 I I 2 — 3 S87 NOTE- FOR USE WITH COPPER CONDUCTORS I I ONLY. REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE NOTE- © TO 24 VAC IF ANY WIRE IN THIS APPLIANCE IS REPLACED,IT JUMPER IS USED WHEN TOC IS NOT USED POWER SOURCE MUST BE REPLACED WITH WIRE OF LIKE SIZE, © S173 SWITCH USED ONLY IN UNITS EQUIPPED 20 VA MINIMUM RATING, INSULATION THICKNESS, AND TERMINATION. WITH COMPRESSORS WHICH DO NOT INCLUDE NEC CLASS 2 INTERNAL SWITCH LINE VOLTAGE FIELD INSTALLED -------- CLASS II VOLTAGE FIELD WIRING ® S173 TO S87 WHEN A4 IS NOT USED DENOTES OPTIONAL COMPONENTS Figure 14. Typical Unit Wiring Diagram Page 20 506635-01 11110 PUAP E tRED L RUN CAPACITOR eL K FAN MOTOR (64) ) oAA E ORANGE AED CONTACTOR K1 0 eLacK BLUE BLUE BLUE FF ® ® THERMAL PROTECTION YELLOW SWITCH (S5 OR S173) GRAY/AED YELLOW GAaY HIGH PRESSURE SWITCH (S4) GROUND LUG BLACK rFLLOW o AED COMPRESSOR BLACK COMPRESSOR (B1) XC 3-060 s YELLOW CRANKCASE HEATER (HR1) CRANKCASE THERMOSTAT (S40) Figure 15. Typical Factory Wiring Diagram (Copland Compressor) DUAL RUN CAPACITOR (C12) CAPACITOR CONTACTOR K1 GROUND LUG BLACK 0 M XC13-111-11-02,-03 XC 14-048, -660 ONLY CRANKCASE HEATER (HR1) CRANKCASE THERMOSTAT (S4 ) FAN FAN MOTOR (64) MOTOR HIGH PRESSURE SWITCH (S4) LOW HIGH PRESSURE LLOW SWITCH e RED COMPRESSOR COMPRESSOR c BLACK (131) THERMAL PROTECTION SWITCH (S5 OR S173) Figure 16. Typical Factory Wiring Diagram (Interlink Compressor) Page 21 XC13 SERIES 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 20. 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 CONNECTIONS FOR TESTING AND CHARGING 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 B SUCTION LINE / SERVICE PORT CONNECTION Q REFRIGERANT TANK OUTDOOR UNIT CHARGEIN A LIQUID PHASE VAPOR LINE j SERVICE VALVE DIGITAL SCALE "I.".;2.5 ' D TEMPERATURE SENSOR M m `' y TEMPERATURE SENSOR LIQUID LINE ®= TO LIQUID (LIQUID LINE) SERVICE VALVE 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 17. Gauge Set Setup and Connections Page 22 506635-01 11 /10 WHEN TO CHARGE? • Warm weather best • Can charge in colder weather CHARGE METHOD? Determine by: • Metering device type • Outdoor ambient temperature REQUIREMENTS: • Sufficient heat load in structure • Indoor temperature between 70-80°F (21-26°C) • Manifold gauge set connected to unit • Thermometers: to measure outdoor ambient temperature to measure liquid line temperature to measure suction line temperature Which indoor metering device? TXV FIXED ORIFICE 64°F 65°F 400F 39°F (17.71C) and (18.3°C) and (4.4°C) and (3.8°C) and Below Above Above Below WEIGH-IN APPROACH OR SUPERHEAT WEIGH-IN SUBCOOLING Figure 18. Determining Charge Method CHECKING AIR FLOW AT INDOOR COIL Temp. DT of air 80 24 24 24 23 23 22 22 22 20 19 18 17 16 15 entering a 78 23 23 23 22 22 21 21 20 19 18 17 16 15 14 indoor 5 coil °F 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13 s' 74 21 21 21 20 19 19 18 17 16 16 15 14 13 12 G 72 20 20 19 18 17 17 16 1 15 14 13 12 11 10 70 19 19 18 18 17 17 16 15 15 14 13 12 11 10 Wet -bulb °F 57 58 59 60 61 62 63 64 65 66 67 68 69 70 TD A 30 19° 72° air flow air flow B DRY 640 DRY BULB BULB All temperatures are INDOOR WET expressed in OF o COIL • BULB • 1. Determine the desired DT—Measure entering air temperature using dry bulb (A) and wet bulb (B). DT is the intersecting value of A and B in the table (see triangle). 2. Find temperature drop across coil —Measure the coil's dry bulb entering and leaving air temperatures (A and C). Temperature Drop Formula: (TDrop) = A minus C. 3. Determine if fan needs adjustment —If the difference between the measured TDrop and the desired DT (TDrop DT) is within ±31, no adjustment is needed. See examples: Assume DT = 15 and A temp. = 721, these C temperatures would necessitate stated ac- tions: CO TDrop — DT = *FACTION 530 19 — 15 = 4 Increase the airflow 58° 14 — 15 = -1 (within ±30 range) no change 62° 10 — 15 = -5 Decrease the airflow 4. Adjust the fan speed —See indoor unit instructions to increase/ decrease fan speed. Changing air flow affects all temperatures; recheck temperatures to confirm that the temperature drop and DT are within ±30. Figure 19. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE If the system is void of refrigerant, first, locate and repair any leaks and then weigh in the refrigerant charge into the unit. To calculate the total refrigerant charge: Adjust amount. for variation Amount specified on in line set length listed on WEIGH IN nameplate line set length table below. 0 Total charge CHARGING METHOD 64°F (17.7°C) and Below Refrigerant Charge per Line Set Lenqth Liquid Line Set Diameter Ounces per 5 feet (g per 1.5 m) adjust from 15 feet (4.6 m) line set* 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. If line length is less than 15 ft. (4.6 m), subtract this amount. TE — Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the perature of the liquid line or when pressure drop is equal to or greater than 20 psig. TE — The above nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information. Figure 20. Using HFC-410A Weigh In Method Page 23 XC13 SERIES 650F and ABOVE USE WEIGH-IN METHOD � Weigh-in or remove refrigerant ABOVE or based upon line length 640F and BELOW BELOW APPROACH TXV If refrigerant is added or removed, retest to confirm that unit is properly charged. If value is greater than shown (high approach), add refrigerant; if less than shown (liquid temperature too close to ambient temperature, Iowapproach), remove refrigerant. 1. Connect gauge set as illustrated in figure 17. 2. Confirm proper airflow across coil using figure 19. 3. Compare unit pressures with table 4, Normal Operating Pressures. 4. Set thermostat to call for heat (must have a cooling load between 70-80°F (21-261C). 5. When heat demand is satisfied, set thermostat to call for cooling. 6. Allow temperatures and pressures to stabilize. 7. Record outdoor ambient temperature: AMB° = 8. Record liquid line temperature: LIQ° = 9. Subtract to determine approach (APP°): LIQ° - AMB° = APP° T::3 10. Compare results with table below. APP° (Approach) Values(F:+/-1.00 [C: +/-0.6°]) °F(°C)- -018 -024 -030 -036 -042 -048 -060 Any 4(2.2) 8(4.4) 8(4.4) 11 (6.1) 7(3.9) 8(4.4) 9(5.0) 'Temperature of air entering outdoor coil Figure 21. Using HFC-410A Approach (TXV) Charge Method 650F and ABOVE 640F and BELOW SUBCOOLING TXV BLOCK OUTDOOR COIL: [sometimes necessary with lower temperatures] Use cardboard or plastic sheet to restrict the airflow through the outdoor coil to achieve pressures from 325-375 psig (2240-2585 kPa). Higher pressures are needed to check charge. Block equal sections of air intake panels and move coverings sideways until the liquid pressure is in the above noted ranges. 1. Connect gauge set as illustrated in figure 17. 2. Confirm proper airflow across coil using figure 19. 3. Compare unit pressures with table 4, Normal Operating Pressures. 4. Set thermostat to call for heat (must have a cooling load between 70-80°F (21-26°C) 5. Measure outdoor ambient temperature 6. When heat demand is satisfied, set thermostat to call for cooling 7. Allow temperatures and pressures to stabilize. NOTE - If necessary, block outdoor coil to maintain 325 - 375 psig. 8. Record liquid line temperature: LIQ° = 9. Measure liquid line pressure and use the value to determine saturation temperature (see table 3): SAT° = CARDBOARD O 10. Subtract to determine subcooling (SC°): Once refrigerant charge is 9 9 PLASTIC SHEETS SAT° LIQ° = SC* correct, disconnect gauge set and replace service port caps. r 11. Compare results with table below. it If refrigerant is added or If value is MORE than shown, remove SC° (Subcooling) Values (F:+/-1.0° [C: +/-0.6°]) removed, verify charge '�= refrigerant. OF (°C)* -018 -024 -030 -036 -042 -048 -060 using the Approach Any 10 (5.6) 10 (5.6) 9 (5.0) 12 (6.7) 8 (4.4) 9(5.0) 7(3.9) Method. 'Temperature of air entering outdoor coil If value is LESS MORE or than shown, add LESS refrigerant. Figure 22. Using HFC-410A Subcooling (TXV) Charge Method Page 24 506635-01 11 /10 40OF START Measure outdoor ambient •- and USE WEIGH-IN METHOD ABOVE Weigh-in or remove refrigerant ABOVE or based upon line length 390F and BELOW BELOW SUPERHEAT RFC SH° (Superheat) Values (+/-5°F) If refrigerant is REMOVED, retest to confirm that unit is properly charged. 1. Confirm proper airflow across coil using figure 19. 2. Compare unit pressures with table 4, Normal Operating Pressures. 3. Use SUPERHEAT to correctly charge unit or to verify the charge is correct. 4. Set thermostat to call for heat (must have a cooling load between 70-80°F (21-26°C) 5. Connect gauge set. 6. When heat demand is satisfied, set thermostat to call for cooling. 7. Allow temperatures and pressures to stabilize. 8. Measure the suction line pressure and use the use value to determine saturation temperature (table 3): SAT° = 9. Record suction line temperature: VAP° = 10. Subtract to determine superheat (SH°): VAP° - SAT' = SH° 11. Record the wet bulb temperature (air entering indoor coil): WB= 12. Record outdoor ambient temperature. 13. Compare results with table to the left. 9 NOTE - Do not attempt to charge system where a dash appears, system could be overcharged. Superheat is taken at suction line service port. Suction line superheat must never be less than 5°F at the suction line service port. If value is LESS than If refrigerant is shown, then REMOVE If value is MORE ADDED, retest to MORE or than shown, then => confirm that unit is refrigerant. LESS ADD refrigerant. properly charged. Wet Bulb air enterinq indoor coil °F* 50 52 54156 58 60 62 64 66 68 70 72 74 76 40 15 18 20 23 26 29 32 34 38 41 43 46 48 51 45 13 16 18 21 24 27 30 33 36 39 41 44 46 49 50 11 14 16 19 22 25 28 31 34 37 39 42 44 47 55 9 12 14 17 20 23 27 30 33 36 38 40 42 44 60 7 10 12 15 18 21 24 27 30133 35 38 40 43 65 - 6 10 13 16 19 21 24 27 30 33 36 38 41 70 - 7 10 13 16 19 21 24 27 30 33 36 39 75 - 6 9 12 15 18 21 24 28 31 34 37 80 - 5 8 12 15 18 21 25 28 31 35 85 - 8 11 15 19 22 26 30 33 90 - 5 9 13 16 20 24.27 31 95 - 6 10 14 18 22 25 29 100 - - 8 12 16 21 24 28 105 - - 5 9 13 17 22 26 110 - 6 11 15 20 25 115 - - 8 14 18 24 " Dry-bulb temperature (°F) of entering outdoor ambient air. Figure 23. Using HFC-410A Superheat (Fixed Orifice) Charge Method Table 3. HFC-410A Temperature (°F) - Pressure (Psig) OF Psig OF Psig OF Psig OF Psig OF Psig OF Psig OF Psig OF Psig 32 100.8 48 137.1 63 178.5 79 231.6 94 290.8 110 365.0 125 445.9 141 545.6 33 102.9 49 139.6 64 181.6 80 235.3 95 295.1 111 370.0 126 451.8 142 552.3 34 105.0 50 142.2 65 184.3 81 239.0 96 299.4 112 375.1 127 457.6 143 559.1 35 107.1 51 144.8 66 187.7 82 242.7 97 303.8 113 380.2 128 463.5 144 565.9 36 109.2 52 147.4 67 190.9 83 246.5 98 308.2 114 385.4 129 469.5 145 572.8 37 111.4 53 150.1 68 194.1 84 250.3 99 312.7 115 390.7 130 475.6 146 579.8 38 113.6 54 152.8 69 197.3 85 254.1 100 317.2 116 396.0 131 481.6 147 586.8 39 115.8 55 155.5 70 200.6 86 258.0 101 321.8 117 401.3 132 487.8 148 593.8 40 118.0 56 158.2 71 203.9 87 262.0 102 326.4 118 406.7 133 494.0 149 601.0 41 120.3 57 161.0 72 207.2 88 266.0 103 331.0 119 412.2 134 500.2 150 608.1 42 122.6 58 163.9 73 210.6 89 270.0 104 335.7 120 417.7 135 506.5 151 615.4 43 125.0 59 166.7 74 214.0 90 274.1 105 340.5 121 423.2 136 512.9 152 622.7 44 127.3 60 169.6 75 217.4 91 278.2 106 345.3 122 428.8 137 519.3 153 630.1 45 129.7 61 172.6 76 220.9 92 282.3 107 350.1 123 434.5 138 525.8 154 637.5 46 132.2 62 175.4 77 224.4 93 286.5 108 355.0 124 440.2 139 532.4 155 645.0 47 134.6 78 228.0 109 360.0 140 539.0 Page 25 XC13 SERIES Table 4. Normal Operating Pressures (Liquid +10 and Suction +5 psig) A IMPORTANT -024 -030 -036 -042 -048 -060 XC13 -018 °F (°C) * ILiquid Line Pressure / Vapor Line Pressure ** Expansion Valve 65(18) 2331132 2441137 2481127 2631135 235/128 235/132 241/130 70(21) 2511133 2631138 2631131 2811138 249/129 254/132 260/130 75(24) 2651133 2851139 2841132 3021140 268/130 276/134 280/132 80(26) 2921135 3071140 3071134 3251142 290/132 298/134 299/134 85(29) 3141136 3291141 3301135 3491142 313/133 323/135 321/135 90(32) 3381137 3541142 3551136 3751143 337/134 350/137 344/134 95(35) 3621138 3791143 3801137 4041144 364/134 377/138 371/135 100(38) 3881140 4041144 4071138 4331145 389/135 406/140 400/137 105(41) 4151141 4381145 4341139 4621147 416/136 430/141 428/139 110(43) 4441142 4641147 4651141 4941149 445/137 4641142 458/141 115(46) 4751143 4951148 4971142 5271150 4731139 4951143 4841142 Fixed Orifice 65(18) 2331121 2461126 2451123 2611134 236/119 247/125 248/124 70(21) 2501124 2651129 2651126 2811136 250/121 266/128 266/126 75(24) 2701128 2861132 2861129 3011138 269/124 286/131 288/130 80(26) 2911131 3071135 3081132 3241140 290/127 307/133 309/133 85(29) 3131134 3301137 3311135 3461142 312/130 329/135 330/135 90(32) 3351136 3531140 3551138 3711144 334/133 353/138 354/138 95(35) 3591138 3781142 3801140 3961146 360/136 377/140 377/140 100(38) 3831140 4021143 4051142 4221148 385/139 403/142 406/142 105(41) 4091142 4281145 4311144 4481150 413/141 428/144 431/144 110(43) 4361145 4561147 4581146 4771151 438/143 455/146 457/146 115(46) 4641147 4861149 4871148 5061153 466/145 483/147 484/148 *Temperature of the air entering the outside coil. **Typical pressures; indoor unit match up, indoor air quality equipment, and indoor load causes pressure variance System Operation UNIT COMPONENTS High Pressure Switch (S4) XC13 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 normally 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 Some XC13 units are 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 XC13 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 506635-01 11110 Page 26 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 Heater Thermostat (S40) (-060 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. 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 XC13 unit to ensure a clean, moisture -free system. A replacement filter drier is available from Lennox. Refer to Lennox Repair Part Program. Maintenance DEALER Maintenance and service must be performed by a qualified installer or service agency. At the beginning of each cooling season, the system should be checked as follows: Outdoor Unit 1. Clean and inspect the outdoor coil. The coil may be flushed with a water hose. Ensure the power is turned off before you clean the coil. 2. Outdoor fan motor is prelubricated and sealed. No further lubrication is needed. 3. Visually inspect connecting lines and coils for evidence of oil leaks. 4. Check wiring for loose connections. 5. Check for correct voltage at the unit (with the unit operating). 6. Check amp -draw outdoor fan motor. UNIT NAMEPLATE: ACTUAL: NOTE - If owner reports insufficient cooling, the unit should be gauged and refrigerant charge checked. 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) • Outdoor Coil — The outdoor coil may be flushed with a water hose. • Outdoor Coil (Sea Coast) — Moist air in ocean locations can carry salt, which is corrosive to most metal. Units that are located near the ocean require frequent inspections and maintenance. These inspections 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. 3. Check blower drive belt for wear and proper tension. 4. Check all wiring for loose connections 5. Check for correct voltage at unit (blower operating). 6. Check amp -draw on blower motor. UNIT NAMEPLATE: ACTUAL: INDOOR COIL 1. Clean coil, if necessary. 2. Check connecting lines and coils for signs of oil leaks. 3. Check condensate line and clean, if necessary. 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. Outdoor Coil The outdoor unit must be properly maintained to ensure its proper operation. • Please contact your dealer to schedule proper inspection 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 periodically check for debris which collects around the unit. Cleaning of the outdoor unit's coil should be performed by a trained service technician. Contact your dealer and set up a schedule (preferably twice a year, but at least once a year) to inspect and service your outdoor unit. Routine Maintenance 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 27 XC13 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 drain line and how to check for obstructions. (This would also apply to an auxiliary drain, if installed.) Start -Up and Performance Checklist Job Name Job Location Installer Unit Model No. Serial No. Nameplate Voltage Rated Load Ampacity Compressor Maximum Fuse or Circuit Breaker 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: • Verify room thermostat settings are correct. • Verify that all electrical disconnect switches are ON. • Check for any blown fuses or tripped circuit breakers. • Verify unit access panels are in place. • Verify air filter is clean. • If 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: • Lennox XC13 Engineering Handbook • Lennox Product Catalog • Lennox Price Book Job no. City City Date State State Service Technician Outdoor Fan Electrical Connections Tight? ❑ Indoor Filter clean? ❑ Supply Voltage (Unit Off) Indoor Blower RPM S.P. Drop Over Indoor (Dry) Outdoor Coil Entering Air Temp. Discharge Pressure Suction Pressure Refrigerant Lines: - Leak Checked? ❑ Properly Insulated? ❑ Service Valves: --- Fully Opened? ❑ Caps Tight? ❑ Voltage With Compressor Operating Refrigerant Charge Checked? ❑ Outdoor Fan Checked? ❑ Thermostat Calibrated? ❑ Properly Set? ❑ Level? ❑ Page 28 506635-01 11 /10