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BLD2022-1706_Manufacturer_Specifications_and_Installation_Instructions_12.14.2022_3.12.11_PM_3269800LENN17 ©2022 Lennox Industries Inc. x Dallas, Texas, USA RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE General This EL16XC1 outdoor air conditioner with all -aluminum coil is designed for use with HFC-410A refrigerant only. This unit must be installed with an approved indoor air han- dler or coil. See the Lennox EL16XC1 Product Specifica- tions bulletin (EHB) for approved indoor component match UPS. These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation. IMPORTANT: Special procedures are required for clean- ing the aluminum coil in this unit. See page 15 in this in- struction for information. NOTICE! For more in-depth information, consult the Installa- tion and Service Procedures manual, available as Corp. 1503-1_7 on LennoxPros.com or through the Technical Support department at 800-453-6669. STEP 1 -- SETTING THE UNIT -- Clearances INSTALLATION INSTRUCTIONS Elite® Series EL16XC1 Units AIR CONDITIONER 507525-02 11 /2022 A CAUTION See NOTES NOTES: Service clearance of 30 in. must be maintained on one of the sides adjacent to the control box. Clearance to one of the other three sides must be 36 in. f See Seems NOTES NOTES Clearance to one of the remaining two sides may be 12 in. and the final side may be 6 in. A clearance of 24 in. must be maintained between two units. See NOTES Control Box 48 in. clearance required on top of unit. NOTICE: Specific applications may require adjustment of the listed installation clearances to provide protection for the unit from physical damage or to avoid conditions which limit operating efficiency. (Example: Clearances may have to be increased to prevent snow or ice from falling on the top of the unit. Additional clearances may also be required to prevent air recirculation when the unit is installed under a deck or in another tight space.) FIGURE 1 507525-02 Page 1 UNIT DIMENSIONS - INCHES (MM) A Q o a a Q o LQ COI ELE SU( /COI 0 0 o o a a a Q Q o o 0 cooaoo a a a a a a 000Qoo a a a a a a a a a a a a a a a a a a 0 a 0 a o a c a c a c a 0 0 0 0 o c 0 o o 0 c 0 c 0 c 0 c 0 0 0 0 0 0 0 o o Q Q o o oo�oQoi c o c c a c oocoQo c o a c a c a c a o a c a c a a a c a a aaaaa aaaaa a aaaaa 0 a o a c a c a a a c a 4-1/2" SIDE VIEW IID LINE NECTION 'TRICALINLETS TION LINE NECTION 4-3/4" (121) TOP VIEW Model EL16XC1 Dimensions - in. (mm) A B C D I E I F G H I J EL16XC1-018-230A 31 (787) (686) (� 8 ) See EL16XC1-018 base section below. EL16XC1-024-230A 31 (787) 30-1/2 35 13-7/8 7-3/4 3-1/4 27-1/8 3-5/8 4-1/2 20-5/8 (775) (889) (352) (197) (83) (689) (92) (114) (524) EL16XC1-030-230A EL16XC1-041-230A 30-1/2 35 13-7/8 7-3/4 3-1/4 27-1/8 3-5/8 4-1/2 20-5/8 EL16XC1-042-230A 39 (991) (775) (889) (352) (197) (83) (689) (92) (114) (524) EL 16XC 1-048-230A EL16XC1-036-230B 31 (787) 30-1/2 35 13-7/8 7-3/4 3-1/4 27-1/8 3-5/8 4-1/2 20-5/8 (775) (889) (352) (197) (83) (689) (92) (114) (524) EL16XC1-036-230C 35 (889) 30-1/2 35 13-7/8 7-3/4 3-1/4 27-1/8 3-5/8 4-1/2 20-5/8 (775) (889) (352) (197) (83) (689) (92) (114) (524) EL16XC1-047-230A 35 (889) 35-1/2 (902) 39-1/2 (1003) 16-7/8 (429) 8-3/4 (222) 3-1/8 (79) 30-3/4 (781) 4-5/8 (117) 3-3/4 (95) 26-7/8 (683) EL16XC1-060-230A 45(1143) UNIT SUPPORT FEET -J (216) ���VVV 16) I I O O (1 I (241) O 8-3/4 8-1/4" (222) Tj (210) 5-1/2" i 13-1/2" (140) IN 4 (343) 01 EL16XC1-018 BASE SECTION (SMALL) UNIT SUPPORT FEET EL16XC1-024 TO -060 BASE WITH ELONGATED LEGS Page 2 EL16XC1 SERIES STEP 1 -- SETTING THE UNIT (Continued) -- Unit Placement NOTICE! Roof Damage! This system contains both refrigerantand oil. Some rubberroofing material mayabsorb oil, causing the rubberto degrade. Failureto followthis notice could result in damage to roof surface. IMPORTANT! Exhaust vents from dryers, water heaters and furnaces should be directed away from the outdoor unit. Prolonged exposure to exhaust gases and the chemicals contained within them may cause condensation to form on the steel cabinet and other metal components of the outdoor unit. This will diminish unit performance and longevity. PLACEMENT Install unit away from windows. TWO 90' ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION. FIGURE 2 SLAB MOUNTING Install unit level or, if on a slope, maintain slope tolerance of 2 degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from building structure. BUILDING STRUCTURE MOUNTING o /SLAB GROUND LEVEL FIGURE 3 ELEVATED SLAB MOUNTING USING FEET EXTENDERS Use additional 2" SCH 40 male 2" (50.8MM) SCH 40 threaded adapters which can FEMALE THREADED be threaded into the female ADAPTER threaded adapters to make additional adjustments to the level of the unit. 2" (50.8MM) s SCH 40 MALE THREADED / ADAPTER 0 LEG DETAIL FIGURE 4 BASE ACAUTION Before attempting . perform service or power to unit OFF at disconnect STABILIZING UNIT ON UNEVEN SURFACES #10 X 1 /2" LONG SELF -DRILLING SHEET METAL SCREWS COIL STABILIZING BRACKET (18 GAUGE METAL — 2" BASE PAN WIDTH; HEIGHT AS REQUIRED) #10 X 1-1/4" LONG HEX HD SCREW AND FLAT WASHER CORNER POS Concrete slab — use two plastic anchors (hole drill 1/4") 1 IMPORTANT! Unit Stabilizer Bracket Use (field -provided): Always use stabilizers when unit is raised above the factory height. (Elevated units could become unstable in gusty wind conditions.) Stabilizers may be used on any unit installed on unstable and uneven surfaces. FIGURE 5 Page 3 EL16XC1 SERIES STEP 2 -- REFRIGERANT PIPING — Flushing Existing Line Set & Indoor Coil Flush the existing line set per the following instruc- tions. For more information, refer to the Installation and Service Procedures manual available on LennoxPros.com. CAUTION - DO NOT attempt to flush and re -use existing line sets or indoor coil when the system contains contaminants (i.e., compressor burn out). IMPORTANT! If this unit is being matched with an approved line set or indoor unit coil that was previously charged with mineral oil, or if it is being matched with a coil which was manufactured before January of 1999, the coil and line set must be flushed prior to installa- tion. Take care to empty all existing traps. Polyol es- ter (POE) oils are used in Lennox units charged with HFC-410A refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the expansion device and reduce sys- tem performance and capacity. Failure to properly flush the system per this instruc- tion and the detailed Installation and Service Proce- dures manual will void the warranty. Aj AWARNING AWARNING TABLE 1 REFRIGERANT LINE SET — INCHES (MM) Valve Size Connections Recommended Line Sets Model Number Liquid Line Suction Line L15 Line Set Model Line Set Length Catalog Number EL16XC1-018-230 EL16XC1-024-230 EL16XC1-030-230 3/8" (10 mm) 3/4" (19 mm) L15-41-20 20feet (6.1 m) 89J56 L15-41-30 30feet (9.1 m) 89J57 L15-41-40 40 feet (12.2 m) 89J58 L15-41-50 50 feet (15.2 m) 89J59 EL16XC1-036-230 EL16XC1-041-230 EL16XC1-042-230 EL16XC1-047-230 EL16XC1-048-230 3/8" (10 mm) 7/8" (22 mm) L15-65-30 30 feet (9.1 m) 89J60 L15-65-40 40 feet (12.2 m) 89J61 L15-65-50 50 feet (15.2 m) 89J62 EL16XC1-060-230 3/8" (10 mm) 1-1/8" (29 mm) * Field -fabricated N/A N/A " Some applications may require a field -provided 1-1/8" to 7/8" adapter. NOTE - When installing refrigerant lines longer than 50 feet, refer to the Refrigerant Piping Design and Fabrication Guidelines manual available on LennoxPros.com (Corp. 9351-L9), or contact the Technical Support Department Product Application group for assistance. NOTE - For new or replacement line set installation, refer to Service and Application Note - Corp. 9112-L4 (C-91-4). Page 4 EL16XC1 SERIES STEP 2 -- REFRIGERANT PIPING -- Removing Existing Indoor Metering Device ATYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL REMOVAL PROCEDURE OR PROCEDURE (UNCASED COIL SHOWN) (UNCASED 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 (UNCASED COIL ONLY) ORIFICE EXPANSION DISTRIBUTOR HOUSING VALVE TUBES TEFLOr RING 1 - On fully cased coils, remove the coil access and plumbing panels. 2- Remove any shipping clamps from the liquid line and distributor as- sembly. 3 - Using two wrenches, disconnect liquid line from liquid line orifice hous- ing. Take care not to twist or damage distributor tubes during this pro- cess. 4 - Remove and discard fixed orifice, valve stem assembly (if present) and Teflon® washer as illustrated above. 5 - Use a field -provided fitting to temporarily reconnect the liquid line to the indoor unit's liquid line orifice housing. 2 CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE CYLINDER CONTAINING CLEAN HCFC-22* TO BE USED FOR FLUSHING A (Positioned to deliver liquid refrigerant) SUCTION SERVICE V / EXISTING B INDOOR / UNIT LIQUID LINE SERVICE VALVE RECOVERY CYLINDER NEW OUTDOOR UNIT GAUGE MANIFOLD HIGH .X TEFLONO \ ® RING SENSING LINE DISTRIBUTOR EQUALIZER ASSEMBLY�I LINE LIQUID LINE / ASSEMBLY WITH / BRASS NUT o I MALE EQUALIZER LINE FITTING SUCTION SENSING BULB LINE LIQUID LINE 1 - On fully cased coils, remove the coil access and plumbing panels. 2- Remove any shipping clamps from the liquid line and distributor assembly. 3 - Disconnect the equalizer line from the expansion valve equalizer line fitting on the suction line. 4 - Remove the suction line sensing bulb. 5 - Disconnect the liquid line from the expansion valve at the liquid line assembly. 6 - Disconnect the expansion valve from the liquid line orifice housing. Take care not to twist or damage distributor tubes during this process. 7 - Remove and discard expansion valve and the two Teflon® rings. 8 - Use a field -provided fitting to temporarily reconnect the liquid line to the indoor unit's liquid line orifice housing. FLUSHING LINE SET VED CLOSED 01 The line set and indoor unit coil must be flushed with at least the same amount of clean refrigerant* that previously charged the system. Check the charge in the flushing cylinder before proceeding. 1 - Set the recovery machine for liquid recovery and start the recovery machine. Open the gauge set valves to allow the recovery TANK machine to pull a vacuum on the existing system line set and indoor RETURN unit coil. D O n ��DISCHARGE 0 0 z RECOVERY MACHINE 1 - HCFC-22 cylinder with clean refrigerant* (positioned to deliver liquid refrigerant) to the suction service valve. 2- HCFC-22 gauge set (low side) to the liquid line valve. 3 - HCFC-22 gauge set center port to inlet on the recovery machine with an empty recovery tank connected to the gauge set. 4 - Connect recovery tank to recovery machine per machine instructions. 2- Position the cylinder of clean HCFC-22* for delivery of liquid refrigerant and open its valve to allow liquid refrigerant to flow into the system through the suction line valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine. 3 - After all of the liquid refrigerant has been recovered, switch the recovery machine to vapor recovery so that all of the HCFC-22 vapor is recovered. Allow the recovery machine to pull the system down to 0. 4 - Close the valve on the inverted HCFC-22 drum and the gauge set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off. *IMPORTANT - Clean refrigerant is any refrigerant in a system that has not had compressor burn out. If the system has experienced burn out, it is recommended that the existing line set and indoor coil be replaced. FIGURE 6 Page 5 EL16XC1 SERIES STEP 2 -- REFRIGERANT PIPING -- Brazing Procedures 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 �i LINE SET SIZE MATCHES SERVICE VALVE CONNECTION SERVICE VALVE CONNECTION COPPERTUBE -� STUB \ REDUCER O LINE SET SIZE IS SMALLER THAN CONNECTION REFRIGERANT LINE SERVICE PORT CAP ci -�r SERVICE PORT CORE LIQUID LINE SERVICE VALVE DO NOT CRIMP SERVICE VALVE CONNECTOR WHEN PIPE IS SMALLER THAN CONNECTION SUCTION LINE SERVICE VALVE 3 ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION 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 line service port valve. 1 - Connect gauge set low pressure side to liquid line service valve (service port). 2- Connect gauge set center port to bottle of LOW nitrogen with regulator. 3 - Remove core from valve in suction line service port to allow nitrogen to escape. ATTACH GAUGES SUCTION SERVICE PORT MUST BE OPEN TO ALLOW EXIT POINT FOR NITROGEN C SUCTION LINE SERVICE VALVE SUCTION LINE �� INDOOR UNIT = N HIGH OUTDOOR UNIT USE REGULATOR TO FLOW NITROGEN AT 1 TO 2 PSIG. \ 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 AWARNING 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. y Wear gloves and protective goggles or face shield to protect against burns. Wash hands with soap and water after handling brazing alloys and flux. Page 6 EL16XC1 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 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. Cloths must remain water -saturated throughout the brazing and cool -down process. M LIQUID LINE SERVICE VALVE WHEN BRAZING LINE SET TO SERVICE VALVES, POINT FLAME AWAY FROM SERVICE VALVE. IMPORTANT -Allow braze joint to cool. Apply additional water -saturated cloths to help cool brazed joint. Do not remove water -saturated cloths until piping has cooled. Temperatures above 250°F will damage valve seals. WATER -SATURATED CLOTH LIQUID LINE SUCTION LINE SERVICE VALVE complete, must be quenched with water to absorb any �1 residual heat. Do not open service valves until refrigerant lines and IWHEN BRAZING LINE SET TO -- indoor coil have been leak -tested and evacuated. Refer .� 'SERVICE VALVES, POINT FLAME to Installation and Service Procedures manual found on 'FROM SERVICE VALVE. DAVENET (__V SUCTION LINE 7 PREPARATION FOR NEXT STEP WATER -SATURATED CLOTH After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water -saturated cloths to both services valves to cool piping. Once piping is cool, remove all water -saturated cloths. FIGURE 7 (CONTINUED) Page 7 EL16XC1 SERIES STEP 2 — REFRIGERANT PIPING — Installing Indoor Expansion Valve This outdoor unit is designed for use in systems that use a expansion valve metering device. See the EL16XC1 Product Specifications bulletin (EHB) for approved expansion valve kit match -ups and application information. The expansion valve can be installed internal or external to the indoor coil. In applications where an uncased coil is being installed in a field -pro- vided plenum, install the expansion valve in a manner that will provide access for future field service of the expansion valve. Refer to below illustration for reference during installation of expansion valve. TWO PIECE PATCH PLATE (UNCASED COIL ONLY) DISTRIBUTOR TUBES 0 INDOOR EXPANSION VALVE INSTALLATION (Uncased Coil Shown) LIQUID LINE STUB ORIFICE END EXPANSION HOUSING \ VALVE DISTRIBUTOR ASSEMBLY,c a MALE EQUALIZER LINE FITTING (SEE EQUALIZER LINE INSTALLATION FOR FURTHER DETAILS) TEFLON®, RING J EQUALIZER / LINE TEFLOP RING SENSING LINE ,____j LIQUID LINE ASSEMBLY WITH / BRASS NUT SUCTION \ LINE LIQUID LINE Sensing bulb insulation is required if mounted external to the coil casing. sensing bulb installation for bulb positioning. For optimum performance, it is recommended to install the sensing bulb on a straight flat section of the suction line outside the cabinet for the following units: 030, 036, 041, 042, 047, 048, 059 and 060. EQUALIZER LINE INSTALLATION 3 - 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. 4- 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 tighten to 20 ft-lb. 5 - 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. 6 - 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 tighten to 20 ft-lb. SENSING BULB INSTALLATION 1 - Attach the suction line sensing bulb in the proper orientation as illustrated to the right using the clamp and screws provided. NOTE - Confirm proper thermal contact between the suction line and expansion bulb before insulating the sensing bulb once installed. 2 - Connect the equalizer line from the expansion valve to the equalizer suction port on the suction line. Finger tighten the flare nut plus 1/8 turn (7 ft-lbs) as illustrated below. 1 - Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the suction line as illustrated in the figure below. 2 - Remove the field -provided fitting that temporarily recon- nected the liquid line to the indoor unit's distributor assembly. FLARE SEAL CAP I FLARE NUT COPPER FLARE OR XSEAL BONNET MALE BRASS EQUALIZER LINE FITTING SUCTION LINE SUCTION LINE SUCTION LINE 1/2 Turn I 11 10 9 4 87 5 1/8 Turn I� 1� 10 9 8 4 7 6 5 ON LINES SMALLER THAN 7/8", MOUNT SENSING ULB AT EITHER THE 3 OR O'CLOCK POSITION. ON 7/8" AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 4 OR 8 O'CLOCK POSITION. NEVER MOUNT THE SENSING BULB ON BOTTOM OF LINE. NOTE - NEVER MOUNT THE SENSING BULB ON BOTTOM OF LINE. FIGURE 8 Page 8 EL16XCl SERIES STEP 3 -- LEAK TEST AND EVACUATION \NIFOLD GAUGE SET OUTDOOR UNIT ° B I A TO SUCTION SERVICE VALV NOTE - Position canister to deliver liquid refrigerant. NITROGEN HFC-410A 1 CONNECT GAUGE SET A - Connect the high pressure hose of an HFC-410A manifold gauge set to the suction valve service port. NOTE - Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the suction port better protects the manifold gauge set from high pressure damage. B - With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. NOTE - Later in the procedure, the HFC-410A container will be replaced by the nitrogen container. 2 TEST FOR LEAKS After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the following procedure to test for leaks: A - With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of 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) refriger- ant 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 nitrogen with a pressure regulating valve to the center port of the manifold gauge set. D - Adjust nitrogen pressure to 150 psig (1034 kPa). Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor unit. 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 9 Page 9 EL16XC1 SERIES STEP 3 -- LEAK TEST AND EVACUATION (Continued) EVACUATION 3CONNECT 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 suction line service valve B - Connect high side of manifold gauge set to OUTDOOR liquid line service valve UNIT C - Connect available micron gauge connector A on the 1/4 SAE in -line tee. 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-410A and nitrogen containers. NOTE - Position NITROGEN canister to deliver liquid refrigerant. HFC-410A VACUUM PUMP 13 4 EVACUATE THE SYSTEM 1/4 SAE TEE WITH SWIVEL COUPLER M LOW I MANIFOLD GAUGE SET GAUGE t TO SUCTION SERVICE VALVE TO LIQUID LINE SERVICE VALVE 1 t RECOMMEND MINIMUM 3/8" HOSE HIGH A - Open both manifold valves and start the vacuum pump. B - Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury). NOTE - During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once. A rapid rise in pressure indicates a relatively large leak. If this occurs, repeat the leak testing procedure. NOTE- The term absolute pressure means the total actual pressure above absolute zero within a given volume or system. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure. C - When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), WARNING! perform the following: • Close manifold gauge valves. Possible e• • damage. • Close valve on vacuum pump. Avoid deep operation. • Turn off vacuum pump. compressors • Disconnect manifold gauge center port hose from vacuum pump. Extremely low vacuum can cause inte • Attach manifold center port hose to a nitrogen cylinder with pressure arcing and compressor failure. Dam regulatorset to 150 psig (1034 kPa) and purge the hose. caused by deep vacuum operation will) • Open manifold gauge valves to break the vacuum in the line set and indoor unit. • Close manifold gauge valves. D - Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the nitrogen from the line set and 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 a cylinder of HFC-410A positioned to deliver liquid refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit. G - Perform the following: 1/6 TURN • Close manifold gauge valves. • Shut off HFC-410A cylinder. • Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core tool while maintaining a positive system pressure. • Replace stem caps and finger tighten them, then tighten an additional one -sixth (1/6) of a turn as illustrated. 60 FIGURE 10 Page 10 EL16XC1 SERIES STEP 4 -- ELECTRICAL -- Circuit Sizing and Wire Routing In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC). Refer to the furnace or air handler installation 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 han- dler for low -voltage control power (24VAC - 40 VA mini- mum) AWARNING 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. SIZE CIRCUIT AND INSTALL SERVICE 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 connect to an earth ground. Fire Hazard. Use of aluminum wire with this product may result in a fire, causing property damage, severe injury or death. Use copper wire only with this product. 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. FIGURE 11 Page 11 EL16XC1 SERIES STEP 4 -- ELECTRICAL (CONTINUED) -- Field Wiring Unit Low Voltage Wiring OWIRE NUTS CUTOUT WITH GROMMET 24V CONTROL WIRES O 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 MAINTAINS SEPARATION OF FIELD -INSTALLED LOW AND HIGH VOLTAGE CIRCUITS. NOTE -DO NOT BUNDLE ANY EXCESS 24VAC CONTROL WIRES INSIDE CONTROL BOX. O\ TIGHTEN WIRE TIE FIGURE 12 24VAC Control Wiring Diagrams (Field Installed) ML180 COMFEIRTSENSE FURNACE 3000 STAT XC14 rEEEov BLACK — — C CBX25 BLOWER COIL COMFORTSENSE 3000 STAT REC-R — R GREEN-G — G VHIiE-Vl w BLACK-V XC14 rEEEov Vl BWE-C BLACK C EL280, EL295, EL296 COMFURTSENSE FURNACE 7000 STAT R --- R M❑ O WI 1 XC14 °❑ O rEELOV V1 1 V� © OPTIONAL G G OUTDOOR SENSOR O X2658 CUT W914 R TO DS T _J JUMPER WHEN STAT T — J DEHUMID. IS USED. CBX32M BLOWER COMFORTSENSE COIL 3000 STAT AP_— R G — G W — W XC14 e 3 E_�v 1 C C NOTE - Refer to furnace, blower coil and accessory instructions for additional wiring configurations with other optional controls. CBX27 BLOWER SLP98, S1_28UH, SL280DF COMFORTSENSE FURNACE 7000 STAT R --- R ❑H O WI -- 1 XC14 °❑ Q YELLOW ILI Yl — Ve © O.D. G — SENSOR OPTIONAL ➢S — — — D XX�26�558 ➢H OB (p pt BLACK — — C — CUT W914 R TO DS T J JUMPER WHEN STAT T DEHUMID. IS USED. CBX40UHV COMFORTSENSE BLOWER COIL 7000 STAT COIL COMFORTSENSE 3000 R -- 2 STAT R �— — — R — — — I Q XC14 Q W --- RED ❑ Q R O 1 O XC14 wt — — w DRo _ L O❑ YEUM -- YI --- 1 DIED — — Y2 — — — O.D. T2 G — — — G SENSOR OPTIONAL DS — — — D DS BLACK Q �X2^658 — C — — C BLACK — — C V Y T JI T —J FIGURE 13 11 Air handler shipped with jumpers installed between W1 and W2 and W2 and W3. QR connection required for air conditioner with LSOM. Resistor kit (CAT #47W97) required when connection ComfortSense 7000 with LSOM 2. AL connection wired on units with LSOM. Page 12 EL16XCl SERIES STEP 5 -- 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. 1 - Rotate fan to check for binding. 2- Inspect all factory- and field -installed wiring for loose connections. 3 - After evacuation is complete, open the liquid line and suction line service valve stems to release the refriger- ant charge (contained in outdoor unit) into the system. 4 - Replace the stem caps and tighten to the value listed in table 2. 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 volt- age condition has been corrected. 6 - Connect manifold gauge set for testing and charging using figure 11 as a guideline. 7 - Set the thermostat for a cooling demand. Turn on pow- er to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit. 8 - Recheck voltage while the unit is running. Power must be within range shown on the unit nameplate. 9 - Check system for sufficient refrigerate using the pro- cedures outlined in under System Refrigerant. OPERATING MANIFOLD GAUGE SET AND SERVICE VALVES The liquid and suction line service valves are used for re- moving refrigerant, flushing, leak testing, evacuating, checking charge and charging. Each valve is equipped with a service port which has a fac- tory -installed valve stem. Figures 14 and 15 provide infor- mation on how to access and operate both angle- and ball - type service valves. Torque Requirements When servicing or repairing heating, ventilating, and air conditioning components, ensure the fasteners are appro- priately tightened. Table 2 lists torque values for fasteners. TABLE 2 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 1 IMPORTANT To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening. 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 sys- tems must be capable of handling the higher system oper- ating 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 BALL -TYPE SERVICE VALVE: 1 - Remove stem cap with an appropriately sized wrench. 2 - Use an appropriately sized wrenched to open. To open valve, rotate stem counterclockwise 90°. To close rotate stem clockwise 90°. TO OPEN ROTATE STEM COUNTERCLOCKWISE 90°. o BALL (SHOWN CLOSED) TO CLOSE ROTATE STEM VALVE CLOCKWISE 90°. STEM SERVICE PORT SERVICE PORT CORE SERVICE PORT CAP STEM CAP FIGURE 14 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 suction line valve sizes) to back the stem out counterclockwise as far as it will go. SERVICE PORT CAP i SERVICE PORT CORE (VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE STEM CAP ANGLE -TYPE SERVICE VALVE (BACK -SEATED OPENED) When service valve is OPEN, the service port is open to line set, indoor and outdoor unit. 1P (VALVE STEM SHOWN CLOSED) ® INSERT HEX WRENCH HERE ANGLE -TYPE SERVICE VALVE (FRONT -SEATED CLOSED) When service valve is CLOSED, the service port is open to the line set and indoor unit. NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque. FIGURE 15 Page 13 EL16XC1 SERIES TO ACCESS SERVICE PORT: A service port cap protects the service port core from contamination and serves as the primary leak seal. 1 - Remove service port cap with an appropriately sized wrench. 2 - Connect gauge set to service port. 3 - When testing is completed, replace service port cap and tighten as follows: • With torque wrench: Finger tighten and 1/6 TUF torque cap per table 2. • Without torque wrench: Finger tighten and use an appropriately sized wrench to turn an additional 1/6 turn clockwise. Reinstall Stem Cap: `Z� Stem cap protects the valve stem from damage and serves as the primary seal. Replace the stem cap and tighten as follows: 1/12 TURN • With Torque Wrench: Finger tighten and then torque cap per table 2. l �/ • Without Torque Wrench: Finger 11 12 1 tighten and use an appropriately 10 2 sized wrench to turn an addition- 9 3 al 1/12 turn clockwise. 8 4 7 6 5 FIGURE 16 Checking and Adding System Charge The EL16XCl unit is factory -charged with enough HFC-410A refrigerant to accommodate a 15-foot length of refrigerant piping. Charge should be checked and adjusted using the tables provided on the charging procedure stick- er on the unit access panel. Detailed information is given in the EL16XCl Installation and Service Procedures manual (Corpl503-L7), which is available on DaveNet. IMPORTANT! Some scroll compressors have an internal vacuum protector that will unload scrolls when suction pres- sure goes below 20 psig. A hissing sound will be heard when the compressor is running unloaded. Protector will reset when low pressure in system is raised above 40 psig. DO NOT REPLACE COMPRES- SOR. High Pressure Switch (S4) This unit is equipped with a high pressure switch which is located on the liquid line. The SPST, normally closed pres- sure switch opens when liquid line pressure rises above the factory setting of 590 ± 15 psig and automatically resets at 418 ± 15 psig. Homeowner Information ACAUTION Before attempting to perform any service or mainte- power to unit OFF at dis- connect 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. The system should be inspected and serviced before each cooling season by a licensed professional HVAC service technician (or equivalent). Homeowner Maintenance The following maintenance may be performed by the homeowner. • Contact a licensed professional HVAC technician to schedule a yearly inspection and maintenance appoint- ment for your equipment. • Check the indoor unit filter each month and replace the filter, if necessary. Have your Lennox dealer show you where your indoor unit 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. Disposable filters should be replaced with a filter of the same type and size. • Check the indoor unit drain line for obstructions monthly during the cooling season. The indoor evaporator coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the inside air. Have your dealer show you the location of the drain line and how to check for obstruc- tions. (This would also apply to an auxiliary drain, if installed.) • Check the area around the outdoor unit monthly and re- move any obstructions that may restrict airflow to the outdoor unit. This would include grass clippings, leaves, or papers that may have settled around the unit. • Trim shrubbery away from the unit and periodically check for debris which collects around the unit. • During the winter months, keep the snow level below the louvered panels. NOTE - The filter and all access panels must be in place any time the unit is in operation. If you are unsure about the filter required for your system, call your Lennox dealer for assistance. IMPORTANT! Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to the outdoor unit by treated water. Prolonged exposure of the unit to treated water (i.e., sprinkler systems, soakers, waste water, etc.) will corrode the surface of steel and aluminum parts, diminish performance and affect longevity of the unit. Thermostat Operation See the thermostat owner's 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. Page 14 EL16XCl SERIES 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. Professional Maintenance Your heating and air conditioning system should be inspec- ted and maintained twice each year (before the start of the heating and cooling seasons) by a licensed professional HVAC technician. You can expect the technician to check the following items. These checks may only be conduc- ted by a licensed professional HVAC technician. Outdoor Unit 1 - Inspect component wiring for loose, worn or damaged connections. Also check for any rubbing or pinching of wires. Confirm proper voltage plus amperage for out- door unit. 2 - Check the cleanliness of outdoor fan and blade assem- blies. Check condition of fan blades (cracks). Clean or replace them, if necessary. 3 - Inspect base pan drains for debris and clean as neces- sary. 4 - Inspect the condition of refrigerant piping and confirm that pipes are not rubbing copper -to -copper. Also, check the condition of the insulation on the refrigerant lines. Repair, correct, or replace as necessary. 5- Test capacitor. Replace as necessary. 6 - Inspect contactor contacts for pitting or burn marks. Replace as necessary. 7 - Check outdoor fan motor for worn bearings/bushings. Replace as necessary. 8 - Inspect and clean outdoor coils, if necessary and note any damage to coils or signs of leakage. NOTICE! Failure to follow instructions will cause damage to the unit. This unit is equipped with an aluminum coil. Alu- minum coils may be damaged by exposure to solu- tions with a pH below 5 or above 9. The aluminum coil should be cleaned using potable water at a mod- erate pressure (less than 50psi). If the coil cannot be cleaned using water alone, Lennox recommends use of a coil cleaner with a pH in the range of 5 to 9. The coil must be rinsed thoroughly after cleaning. In coastal areas, the coil should be cleaned with potable water several times per year to avoid corro- sive buildup (salt). Indoor Unit (Air Handler or Furnace) 1 - Inspect component wiring for loose, worn or damaged connections. Confirm proper voltage plus amperage for indoor unit. 2 - Inspect and clean or replace air filters in indoor unit. 3 - Check the cleanliness of indoor blower and clean blower, if necessary. 4 - Inspect the evaporator coil (Indoor) drain pans and condensate drains for rust, debris, obstructions, leaks or cracks. Pour water in pans to confirm proper drain- age from the pan through to the outlet of the pipe. Clean or replace as necessary. 5 - Inspect and clean evaporator (indoor) coil, if neces- sary. 6 - Inspect the condition of the refrigerant lines and con- firm that pipes are not rubbing copper -to -copper. Also, ensure that refrigerant pipes are not being affected by indoor air contamination. Check condition of insulation on the refrigerant lines. Repair, correct, or replace as necessary. 7 - Inspect the duct system for leaks or other problems. Repair or replace as necessary. 8 - Check for bearing/bushing wear on indoor blower mo- tor. Replace as necessary. 9 - Indoor unit inspections of gas- or oil -fired furnaces will also include inspection and cleaning of the burners and and a full inspection of the gas valve, heat exchanger and flue (exhaust) system. General System Test with System Operating 1 - Your technician should perform a general system test. He will turn on the air conditioner to check operating functions such as the start-up and shut-off operation. He will also check for unusual noises or odors, and measure indoor/outdoor temperatures and system pressures as needed. He will check the refrigerant charge per the charging sticker information on the out- door unit. 2 - Verify that system total static pressure and airflow set- tings are within specific operating parameters. 3 - Verify correct temperature drop across indoor coil. Page 15 EL16XC1 SERIES EL16XC1 Start -Up and Performance Checklist Customer Address Indoor Unit Model Serial Outdoor Unit Model Serial Notes: START UP CHECKS Refrigerant Type: Rated Load Amps: Actual Amps Rated Volts Actual Volts Condenser Fan Full Load Amps Actual Amps: COOLING MODE Suction Pressure: Liquid Pressure: Supply Air Temperature: Ambient Temperature:_ Return Air: Temperature: System Refrigerant Charge (Refer to manufacturer's information on unit or installation instructions for required subcooling and approach temperatures.) Subcooling: A — B = SUBCOOLING Saturated Condensing Temperature (A) minus Liquid Line Temperature (B) Approach: A — B = APPROACH Liquid Line Temperature (A) minus Outdoor Air Temperature (B) Indoor Coil Temperature Drop (18 to 22°F) A — B = COIL TEMP DROP Return Air Temperature (A) minus Supply Air Temperature (B) Page 16 EL16XC1 SERIES