Loading...
BLD2022-0748_Manufacturer_Specifications_and_Installation_Instructions_6.8.2022_9.01.37_AM_2919083L ENN70i ©2010 Lennox Industries Inc. Dallas, Texas, USA �Z:z�_ — �1�1"� 1 1 z 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 LennoxXC16 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. INSTALLATION INSTRUCTIONS Elite® Series XC16 Units AIR CONDITIONER Technical 506637-01 Publications 11 /10 Litho U.S.A. Supersedes 506101-01 TABLE OF CONTENTS General ...................................... 1 Shipping and Packing List ...................... 1 Unit Dimensions ............................... 2 Model Number Identification .................... 2 Unit Parts Arrangement ........................ 3 Operating Gauge Set and Service Valves ......... 4 Recovering Refrigerant from Existing System ..... 6 Unit Placement ................................ 7 Removing and Installing Panels ................. 9 New or Replacement Line Set ................... 10 Brazing 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 ......... 21 Unit Start -Up .................................. 21 System Refrigerant ............................ 22 System Operation ............................. 25 Maintenance .................................. 26 Checklist ..................................... 28 General The XC16 Air Conditioners, which will also be referred to in this instruction as the outdoor unit, uses HFC-410A refrigerant. This outdoor unit must be installed with a matching indoor unit and line set as outlined in the Lennox XC16 Engineering Handbook. XC16 Air Conditioners are designed for use in thermal expansion valve (TXV) systems. NOTE - The XC16 outdoor unit is rated for 230V applications only. A hard -start kit is required for applications where the supply voltage is less than 230V. 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. 1111111III1111111111111111111IN Page 1 111111111III1111111111111111111111111IN111111111111111IN Unit Dimensions - Inches (mm) A a a a a a a LIQ CO EL su CO / a a a a a a a a a a a a aaaaaa 0 0 0 0 0 0 aaaaaa 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 a 0 a 0 a 0 a 0 a o a n a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a aaa a a a aca a a a a a a a a a a a a a a 0 a 0 a 0 a o a a a o a 0 0 0 0 0 0 o o a a o o 0 0 0 o a o a a a a a a SIDE VIEW UNIT SUPPORT FEET UID LINE NNECTION E CTRICAL INLETS CTION LINE NNECTION 4-3/4" (121) XC14-024 TO -060 BASE WITH ELONGATED LEGS TOP VIEW Model Number A B C D E F G H J K XC16-024-230 39 (991) 30-1/2 (775) 35 (889) 13-7/8 (352) 7-3/4 (197) 3-1/4 (83) 27-1/8 (689) 3-5/8 (92) 4-1/2 (114) 20-5/8 (524) XC16-036-230 45 (1143) XC16-048-230 39 (991) XC16-060-230 1 39 (991) 35-1/2 (902) 39-3/8 (1001) 16-7/8 (429) 8-3/4 (222) 3-1/8 (79) 30-3/4 (781) 4-5/8 (117) 1 3-3/4 (95) 1 26-7/8 (683) Model Number Identification X C 16 XXX Refrigerant Type X = R-410A Unit Type C = Air Conditioner — Series 230 03 Minor Revision Number Voltage 230 = 208/23OV-1 ph-60hz Nominal Cooling Capacity 024 = 2 tons 036 = 3 tons 048 = 4 tons 060 = 5 tons Page 2 506637-01 11 /10 Typical Unit Parts Arrangement CONTROL PANEL 0 SINGLE POLE CONTACTOR (K1) O GROUND LUG ° DUAL RUN CAPACITOR (C12) a 77j- 0 COMPRESSOR i 0 COMPRESSOR HARNESS CRANKCASE THERMOSTAT (S40) -048 AND HIGH PRESSURE 060 UNITS ONLY SWITCH (MANUAL o RESET) (S4) LIQUID LINE FILTER DRIER (SINGLE FLOW) LOW PRESSURE SWITCH (S87) LIQUID LINE SERVICE SUCTION LINE VALVE SERVICE VALVE FIELD CONNECTION FIELD CONNECTION FOR SUCTION LINE FOR LIQUID LINE SET PLUMBING AND SWITCHES COMPONENTS Figure 1. Typical Parts Arrangements Page 3 XC16 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. 506637-01 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 will go. / SERVICE PORT CAP 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 Ij 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 Reinstall Stem Cap: CLOCKWISE 90°. \ 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 XC16 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 506637-01 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 t 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 XC16 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 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 iiSAME FASTENERS AS FOR EXTRA SLAB SIDE MOUNTING. STABILITY 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 506637-01 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. Removing and installing Panels A IMPORTANT Do not allow panels to hang on unit by top tab. Tab is for alignment and not designed to support weight of panel. 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 XC16 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 (XC16) 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. 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 Field Connections Recommended Line Set Liquid Line Suction Line Liquid Line Suction Line L15 Line Set XC16-024-230 3/8" (10 mm) 3/4" (19 mm) 3/8" (10 mm) 3/4" (19 mm) L15-41 — 15 ft. - 50 ft. (4.6 m - 15 m) XC 16-036-230 3/8" (10 mm) 7/8" (22 mm) 3/8" (10 mm) 7/8" (22 mm) L15-65 — 15 ft. - 50 ft. (4.6 m - 15 m) XC 16-048-230 XC16-060-230 3/8" (10 mm) 1-1/8" (29 mm) 3/8" (10 mm) 1-1/8" (29 mm) Field Fabricated NOTE — Some applications may required a field provided 7/8" to 1-1/8" adapter Page 10 506637-01 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 XC16 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 XC16 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 7 °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 valves to cool piping. Once piping is cool, remove all water saturated cloths. Refer to the unit installation instructions for the next step in I the unit. Figure 8. Brazing Procedures (continued) Page 14 506637-01 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 XC16 SERIES Installing Indoor Metering Device This outdoor unit is designed for use in systems that use coil. In applications where an uncased coil is being expansion valve metering devices at the indoor coil. installed in a field -provided plenum, install the expansion See the Lennox XC16 Engineering Handbook for valve in a manner that will provide access for field servicing approved expansion valve kit match -ups. The expansion of the expansion valve. Refer to below illustration for valve unit can be installed internal or external to the indoor reference during installation of expansion valve unit. INDOOR EXPANSION VALVE INSTALLATION A Remove the field -provided fitting that temporary 1/2 Turn TWO PIECE reconnected the liquid line to the indoor unit's distributor PATCH PLATE (Uncased Coil Shown) assembly. 11 TEFLON® (UNCASED B Install one of the provided Teflon® rings around the 10 COIL ONLY) LIQUID LINE STUB ORIFICE END EXPANSION stubbed end of the expansion valve and lightly lubricate 4 HOUSING VALVE the connector threads and expose surface of the Teflon® 8 7 5 DISTRIBUTOR \ ring with refrigerant oil. TUB _ C Attach the stubbed end of the expansion valve to the o I� RING liquid line orifice housing. Finger tighten and use an U appropriately sized wrench to turn an additional 1/2 turn 0 6 \ clockwise as illustrated in the figure above, or 20 ft-lb. -- TEFLON�, \ D Place the remaining Teflon® washer around the other SENSING RING end of the expansion valve. Lightly lubricate connector \LINE threads and expose surface of the Teflon® ring with refrigerantoil. DISTRIBUTOR EQUALIZER E Attach the liquid line assembly to the expansion valve. ASSEMBLYI LINE Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the LIQUID LINE / figure above or 20 ft-lb. / ASSEMBLY WITH SENSING BULB INSTALLATION p BRASS NUT 0 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. 9 {� 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 t Y 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 506637-01 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 XC16 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 the 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 506637-01 11 /10 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 I 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 XC16 SERIES 7 Fool START APACITOR (OPTIONAL) K31 B4 2 ® RELAYTIAL OUTDOOR FAN (OPTIONAL) (LEADED) ORANGE -RUN O 1 5 .. BLACK -COMMON ., 01 c� A K31 a HRI w C7 BI COMPRESSOR 0 ©00 L34 A C12 DUAL CAPACITOR 640,65o 060 GROUND LUG INDOOR UNIT THERMOSTAT AS INDOOR UNIT THERMOSTAT TB I TB A2 nn wo- W wl wl KI COMPRESSOR W2 CONTACTOR YLW YLW YBDLBK C /1 BK C O 0 NOTE- WARNING - FOR USE WITH COPPER CONDUCTORS 0 ELECTRIC SHOCK HAZARD,CAN CAUSE INJURY ONLY. REFER TO UNIT RATING OR DEATH UNIT MUST BE GRDUNDE❑ IN PLATE FOR MINIMUM CIRCUIT ACCORDANCE WITH NATIONAL AND LOCAL COP" AMPACITY AND MAXIMUM OVER - CURRENT PROTECTION SIZE Q REMOVE JUMPER FOR TWO STAGE COOL 0 REFER TO COMPRESSOR IN UNIT FOR ACTUAL TERMINAL 6 ON A92 CUT ONBOARD W914 JUMPER FROM DO ARRANGEMENT TO R, WHEN HUMIDITY CONTROL IS USED rj D4B4 4 < FAN MOTOR ^ YELLOW-YISSOR m (LEADED) BLUE KI i BLACK C wz w RI OF 112 CB29,CB30 2 /1 /1 DUAL RED CAPACITOR INDOOR UNIT TBI THERMOSTAT EQUIPMENT q A2 -0q GROUND 43 - 6 W2 -0 W1 YI YLW BL f BK CB3I MV,CBX32MV SIGNATURE INDOOR 51M27 UNIT THERMOSTAT BI A2 R -0R A W3 W2 D WI WI o- -© O os � 0 YLW BL BK 4 S\ Figure 13. Typical Unit Wiring Diagram SIGNATURE G61V,G60V RIM27 INDOOR UNIT A92 THERMOSTAT TBI A2 6 W914 R W9951 0❑ O WI W2 YLW YI -YI BL Y2 BK � C A ON A92 DO NOT CUT ONBOARD W951 JUMPER FROM R TO 0. IT IS USED FOR APPLICATIONS FOR CONDENSING UNITS FOR CONDENSING UNIT APPLICATIONS USE R TO 0 JUMPER. REMOVE IN HEAT PUMP APPLICATIONS. A REMOVE DO TO YI JUMPER WHEN HUMIDITY CONTROL IS USED 8 WHEN TWO STAGE THERMOSTAT IS USED, CONNECT SECOND STAGE HEAT BULB TO TERMINAL "W2 AND REMOVE JUMPER BETWEEN "R" AND ..W2" L34 SOLENOID IS LOCATED IN COMPRESSOR. COIL IS 24 VOC, DO NOT CONNECT 24VAC TO COIL TERMINALS. 0 511 I5 OPTIONAL LOW AMBIENT SWITCH A OPTIONAL HARD START KIT MAY BE REQUIRED ON APPLICATIONS WHERE VOLTAGES ARE LESS THAN 230 VOLT KIT INCLUDES K31 AND C7 WITH ALL NECESSARY WIRING. A 540 AND HRI ARE USED ON 04B AND 060 UNITS ONLY NOTE: MIINMUM TRANSFORMER REQUIRED IN INDOOR UNT-40VA INDICATES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED - CLASS II VOLTAGE FIELD INSTALLED 506637-01 11110 Page 20 PURP E E()RB L K FAFAN MOTOR (B4) DUAL RUN CAPACI-"� F MOTOR TOR (Cl 2) H C F PURPLE RED YELLOW W4 CONTACTOR oRAMCE BLACK K1 BLACK I RED O YELLOW BLACK BLUE BLACK LOW PRESSURE BLACK SWITCH (S87) IT _TT FFF reuow HIGH PRESSURE sRaviRFo YELLOW SWITCH (S4) GRAY BLACK YELLOW BLUE O R RED 75BLUE Uqa, oso oMw COMPRESSOR C BLACK BLUE 2 YELLOW GROUND COMPRES- LUG CRANKCASE CRANKCASE SOR(B1) HEATER (HR1) THERMOSTAT (S40) Figure 14. Typical Factory Wiring Diagram 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 18. 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. 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. 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. Page 21 XC16 SERIES 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. GAUGE SET CONNECTIONS FOR TESTING AND CHARGING B SUCTION LINE SERVICE PORT CONNECTION 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 f l HIGH REFRIGERANT TANK CHARGEIN A LIQUID PHASE 1 DIGITAL SCALE OUTDOOR UNIT VAPOR LINE SERVICE VALVE p TEMPERATURE SENSOR `' yL:a URELIQUID LINE TO LIQUID ID 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 15. Gauge Set Setup and Connections 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 TXV OUTDOOR AMBIENT, TEMPERATURE 65°F (18.30C) _�> � 64°F (17.70C) and ABOVE/ and BELOW . APPROACH OR WEIGH-IN SUBCOOLING (SECOND STAGE - HIGH CAPACITY) Figure 16. Determining Charge Method 506637-01 11 /10 Page 22 CHECKING AIR FLOW AT INDOOR COIL Check airflow using the Delta-T (DT) process using the illustration in figure 17. 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 n 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13 coil IF 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 Wet -bulb IF 57 58 59 60 61 62 63 64 65 66 67 68 69 70 TD A C 720 53, 190 air flow air flow B DRY 640 DRY BULB BULB All temperatures are INDOOR WET expressed in IF O COIL • BULB • 1. Determine the desired DT—Measure entering air temper- ature using dry bulb (A) and wet bulb (B). DT is the intersect- ing 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). Tem- perature 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 necessi- tate stated actions: 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 in- crease/decrease fan speed. Changing air flow affects all temperatures; recheck tempera- tures to confirm that the temperature drop and DT are within +30. Figure 17. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart WEIGH IN 6HARGING) aME ndBHOD CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE If the system is void of refrigerant, first, locate and repair any leaks and then weigh in the refrigerant charge into the unit. To calculate the total refrigerant charge: Adjust amount. for variation Amount specified on in line set length listed on nameplate line set length table below. Total charge LENNOX Refrigerant Charge per Line Set Length In■mniim "If line length is greater than 15 ft. (4.6 m), add this amount. If line length is less than 15 ft. (4.6 m), subtract this amount. NOTE — Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig. NOTE— The above nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information. Liquid Line Ounces per 5 feet (g per 1.5 m) Set Diameter adjust from 15 feet (4.6 m) line set* 3/8" (9.5 mm) 3 ounce per 5' (85 g per 1.5 m) Figure 18. Using HFC-410A Weigh In Method Page 23 XC16 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 1. Connect gauge set as illustrated in figure 15. 2. Confirm proper airflow across coil using figure 17. 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° = If refrigerant is added or 9. Subtract to determine approach (APP°): removed, retest to confirm LIQ° - AMB* = APP* that unit is properly charged. 10. Compare results with table below. APP° (Approach) Values(F:+/-1.0° [C: +/-0.6°]) Models If value is greater than shown (high OF (°C)' -024 -036 -048 -060 approach), add refrigerant; if less than shown (liquid temperature too a Any 6(3.3) 6(3.3) 8(4.4) 4(2.2 close to ambient temperature, low 'Temperature of air entering outdoor coil approach), remove refrigerant. Figure 19. Using HFC-410A Approach (TXV) Charge Method 650F and ABOVE l_____ - ._..�_.. J 640F and BELOW Q 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. PCARDBOARD ASTIC SHE �s If refrigerant is If value is added or removed, MORE than verify charge using shown, rem the Approach refrigerant. 1. Connect gauge set as illustrated in figure 15. 2. Confirm proper airflow across coil using figure 17. 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° = 10. Subtract to determine subcooling (SC°): SAT° - LIQ° = SC* T:::, 11. Compare results with table below. SC' (Subcooling) Values (F:+/-1.0° [C: +/-0.6°]) Models OF (°C)' -024 -036 -048 -060 If value is LESS MORE or Any 5(2.7) 6(3.3) 6(3.3) 9(5.0 than shown, add LESS 'Temperature of air entering outdoor coil refrigerant. Figure 20. Using HFC-410A Subcooling (TXV) Charge Method 506637-01 11 /10 Page 24 Table 3. HFC-410A Temperature (OF) - 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 ill 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 Table 4. Normal Operating Pressures (Liquid +10 and Suction +5 psig) A IMPORTANT I rt Temp.of air entering enteri -024 -036 -048 -060 outdoor coil °F (°C) Liquid Suction Liquid Suction Liquid Suction Liquid Suction First Stage (Low Capacity) 65 (18.3) 215 144 226 142 224 142 215 136 75 (23.9) 247 146 261 144 258 144 250 139 85 (29.4) 288 148 304 145 299 146 291 142 95(35.0) 332 151 352 147 345 148 337 144 105(40.6) 381 153 405 150 395 150 388 146 115 (46.1) 435 155 460 150 450 153 444 148 Second Stage (High Capacity) 65 (18.3) 225 140 228 144 235 135 220 130 75 (23.9) 258 142 262 146 269 137 256 133 85 (29.4) 301 144 306 148 313 139 299 136 95(35.0) 346 146 353 150 361 141 347 138 105 (40.6) 397 149 405 151 412 143 402 141 115(46.1) 452 151 462 154 471 146 462 143 These are typical pressures only. Indoor indoor match up, indoor air quality, and indoor load will cause the pressures to vary. System Operation Full capacity is achieved by blocking the vent port with a I'Id Th I'd t t II d b TWO -STAGE COMPRESSOR The two -stage scroll compressor operates much like the standard scroll compressor. The two -stage compressor steps between low capacity and high capacity as required to meet cooling demand. The steps occur when gas is bypassed through a vent port in the first suction pocket. This bypassing of gas allows the compressor to operate at low capacity if thermostat demand allows, creating a more cost effective and efficient compressor. s er ring. e s er ring (ven po cover) Is con ro e y a 24VDC internal solenoid in the open position allowing low capacity. When energized the internal solenoid closes the slider ring, blocking the vent port and bringing the compressor to full capacity. Stepping can occur during a single thermostat demand as the motor runs continuously while the compressor steps from low to full capacity. Page 25 XC16 SERIES UNIT COMPONENTS 4. Check wiring for loose connections. The outdoor unit and indoor blower cycle on demand from the room thermostat. When the thermostat blower switch is in the ON position, the indoor blower operates continuously. High Pressure Switch (S4) XC16 units are equipped with a high-pressure switch that is located in the liquid line of the compressor as illustrated in Unit Dimensions on page 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. Low Pressure Switch (S87) XC16 units are also equipped with a low pressure switch that is located in the vapor line of the compressor. The switch (SPST, auto -reset, normally closed) removes power from the compressor when vapor line pressure drops below factory setting at 40 + 5 psi. Crankcase Thermostat (S40) (-048 and -060 Units Only) Compressor in the XC16-048 and -060 units are equipped with a 70 watt, belly band type crankcase heater. HR1 prevents liquid from accumulating in the compressor. HR1 is controlled by a thermostat located on the liquid line. When liquid line temperature drops below 50' F the thermostat closes energizing HR1. The thermostat will 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 XC16 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. Visually inspect connecting lines and coils for evidence of oil leaks. 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. TWO -STAGE COMPRESSOR CHECKS Use the checklist procedure on page 28, to verify part -load and full -load capacity operation of two -stage modulation compressors. Tools Required • Refrigeration gauge set 506637-01 11 /10 Page 26 • Digital volt/amp meter • Electronic temperature thermometer • On -off toggle switch Procedure NOTE - Block outdoor coil to maintain a minimum of 375 psig during testing). 1. Turn main power OFF to outdoor unit. 2. Adjust room thermostat set point 5°F above the room temperature. 3. Remove control access panel. Install refrigeration gauges on unit. Attach the amp meter to the common (black wire) wire of the compressor harness. Attach thermometer to discharge line as close as possible to the compressor. 4. Turn toggle switch OFF and install switch in series with Y2 wire from room thermostat. 5. Cycle main power ON. 6. Allow pressures and temperatures to stabilize before taking measurements (may take up to 10 minutes). 7. Record all of the readings for the Y1 demand. 8. Close switch to energize Y2 demand. Verify power is going to compressor solenoid. 9. Allow pressures and temperatures to stabilize before taking any measured reading (this may take up to 10 minutes). 10. Record all of the readings with the Y1 and Y2 demand 11. If temperatures and pressures change in the direction noted in chart, the compressor is properly modulating from low to high capacity. (If no amperage, pressures or temperature readings change when this test is performed, the compressor is not modulating between low and high capacity and replacement is necessary). 12. After testing is complete, return unit to original set up HOMEOWNER Cleaning of the outdoor unit's coil should be performed by a trained service technician. Contact your dealer and set up a schedule (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 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.) 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. Page 27 XC16 SERIES Accessories 0 Lennox Product Catalog For update -to -date information, see any of the following 0 Lennox Price Book publications: • Lennox XC16 Engineering Handbook Checklists Two -Stage Modulation Compressors Field Operational Checklist Y2 - Second -Stage Unit Readings Y1 - First -Stage Expected results during Y2 demand (Toggle switch On) COMPRESSOR Voltage Same Amperage Higher OUTDOOR UNIT FAN MOTOR Amperage Same or Higher TEMPERATURE Ambient Same Outdoor Coil Discharge Air Higher Compressor Discharge Line Higher Indoor Return Air Same Indoor Coil Discharge Air Lower PRESSURES Suction (Vapor) Lower Liquid Higher Start -Up and Performance Checklist 7007 7 Job Name Job no. Date Job Location City State Installer City State Unit Model No. Serial No. Service Technician Nameplate Voltage Rated Load Ampacity Compressor Maximum Fuse or Circuit Breaker Electrical Connections Tight? ❑ Indoor Filter clean? ❑ Indoor Blower RPM S.P. Drop Over Indoor (Dry) Discharge Pressure Suction Pressure Outdoor Fan Supply Voltage (Unit Off) Outdoor Coil Entering Air Temp. Refrigerant Charge Checked? Refrigerant Lines: - Leak Checked? ❑ Properly Insulated? ❑ Outdoor Fan Checked? Service Valves: --- Fully Opened? ❑ Caps Tight? ❑ Thermostat Voltage With Compressor Operating W LW Calibrated? ❑ Properly Set? ❑ Level? ❑ Page 28 506637-01 11110