E2012 Lennox Industries Inc.
Dallas, Texas, USA
THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE
WARNING
The State of California has determined that this product may contain or produce a chemical or chemicals, in very low doses, which may cause serious illness or death. It may also cause cancer, birth defects, or reproductive harm.
General
This XC21 outdoor unit is designed for use with HFC−410A refrigerant only. This unit must be installed with an approved indoor unit. See the Lennox XC21 Product Specifications 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.
INSTALLATION
INSTRUCTIONS
Dave Lennox Signature®
Collection XC21 System
AIR CONDITIONERS |
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506923−01 |
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7/2012 |
Litho U.S.A. |
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Supersedes 4/2012 |
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WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
Installation and service must be performed by a licensed professional installer (or equivalent) or service agency.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.
NOTICE !
For more in−depth information, consult the Installation and Service Procedures manual, available as
Corp.1007−L2 on DaveNet or through the Technical
Support department at 800−453−6669.
STEP 1 −− SETTING THE UNIT −− Clearances
CLEARANCE ON ALL SIDES INCHES (MILLIMETERS)
6 (152)
CONTROL
PANEL ACCESS
LOCATION 30 (762)
12 (305)
NOTES:
SClearance to access panel must be 30 inches (762mm).
SClearance to one of the other three sides must be 36 inches (914mm).
SClearance to one of the remaining two sides may be 12 inches (305mm) and the final side may be 6 inches (152mm).
MINIMUM CLEARANCE
ABOVE UNIT
48 (1219)
36 (914)
MINIMUM CLEARANCE BETWEEN TWO UNITS |
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ACCESS PANEL |
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24 |
LINE SET |
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(610) |
CONNECTIONS |
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REAR VIEW OF UNIT |
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FIGURE 1 |
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7/2012 |
Page 1 |
506923−01 |
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*2P72012* |
*P506923-01* |
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UNIT DIMENSIONS − INCHES (MM) |
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39−1/2 |
DISCHARGE |
ELECTRICAL |
35−1/2 |
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AIR |
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(1003) |
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INLETS |
(902) |
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47 |
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SUCTIOn |
(1194) |
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LINE |
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INLET |
4−1/2 |
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(114) |
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LIQUID |
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LINE |
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INLET |
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18−1/2 |
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(470) |
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8 (203) |
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SIDE VIEW |
1 (25) |
UNIT SUPPORT
FEET
26−7/8
(683)
ACCESS VIEW
16−7/8
(429)
8−3/4 |
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(222) |
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3−3/4 (95) |
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3−1/8 |
30−3/4 |
4−5/8 |
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(781) |
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(79) |
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(117) |
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BASE WITH ELONGATED LEGS
STEP 1 −− SETTING THE UNIT (Continued) −− Unit Placement
WARNING
To prevent personal injury, as well as damage to panels, unit or structure, observe the following:
While installing or servicing this unit, carefully stow all removed panels so that the panels will not cause injury to personnel, objects or nearby structures. Also, take care to store panels where they will not be subject to damage (e.g., being bent or scratched).
While handling or stowing the panels, consider any weather conditions (especially wind) that may cause panels to be blown around and damaged.
NOTICE !
Roof Damage!
This system contains both refrigerant and oil. Some rubber roofing material may absorb oil, causing the rubber to degrade. Failure to follow this notice could result in damage to roof surface.
IMPORTANT !
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.
Page 2
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 |
DISCHARGE AIR |
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STRUCTURE |
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MOUNTING
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 |
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FEMALE THREADED |
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be threaded into the female |
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ADAPTER |
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threaded |
adapters to |
make |
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additional |
adjustments |
to the |
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level of the unit. |
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2" (50.8MM) |
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SCH 40 MALE |
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THREADED |
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ADAPTER |
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BASE
LEG DETAIL
FIGURE 4
STABILIZING UNIT ON UNEVEN SURFACES
#10 X 1/2" LONG |
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SELF−DRILLING |
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SHEET METAL |
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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 POST
Concrete slab use two plastic anchors (hole drill 1/4")
!IMPORTANT !
Unit Stabilizer Bracket Use
(field−provided):
Always use stabilizers when unit is raised above the factory height.
(Elevated units could become unstable in gusty wind conditions.)
Stabilizers may be used on any unit installed on unstable and uneven surfaces.
FIGURE 5
STEP 2 −− REFRIGERANT PIPING −− Flushing Existing Line Set & Indoor Coil
Flush the existing line set per the following instructions. For more information, refer to the Installation and Service Procedures manual available on DaveNet. 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).
NOTE − When installing refrigerant lines longer than 50 feet, refer to the Refrigerant Piping Design and Fabrication
Guidelines manual available on DaveNet (Corp. 9351−L9), or contact the Technical Support Department Product Application group for assistance.
NOTE − For new or replacement line set installation, refer to Service and Application Note − Corp. 9112−L4 (C−91−4).
TABLE 1
REFRIGERANT LINE SET INCHES (MM)
Models |
Liquid |
Vapor/ |
L15 Line Set |
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Line |
Suction |
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Line |
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−024, −036 |
3/8 (10) |
7/8 (22) |
L15 line set sizes are |
and−048 |
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dependent on unit match up. |
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See XP21 Engineering |
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Handbook to determine |
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correct line set sizes. |
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−060 |
3/8 (10) |
1−1/8 (29) |
Field Fabricated |
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NOTE Some applications may required a field−provided 7/8" to 1−1/8" adapter.
Page 3
XC21 SERIES
IMPORTANT !
If this unit is being matched with an approved line set or indoor unit coil that was previously charged with mineral oil, or if it is being matched with a coil which was manufactured before January of 1999, the coil and line set must be flushed prior to installation. Take care to empty all existing traps. Polyol ester (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 system performance and capacity.
Failure to properly flush the system per this instruction and the detailed Installation and Service Procedures manual will void the warranty.
WARNING
When using a high pressure gas such as nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).
WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly.
Failure to follow this warning may result in personal injury or death.
WARNING
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 explosion, that could result in property damage, personal injury or death.
WARNING
Polyol ester (POE) oils used with HFC−410A refrigerant absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as possible. DO NOT remove line set caps or service valve stub caps until you are ready to make connections.
IMPORTANT !
Some scroll compressors have an internal vacuum protector that will unload scrolls when suction pressure goes below 20 psig. A hissing sound will be heard when the compressor is running unloaded. Protector will reset when low pressure in system is raised above 40 psig. DO NOT REPLACE COMPRESSOR.
CAUTION
As with any mechanical equipment, contact with sharp sheet metal edges can result in personal injury. Take care while handling this equipment.
Page 4
STEP 2 −− REFRIGERANT PIPING −− Removing Existing Indoor Metering Device
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TYPICAL EXISTING FIXED ORIFICE |
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TYPICAL EXISTING EXPANSION VALVE REMOVAL |
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1A |
REMOVAL PROCEDURE |
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1BPROCEDURE (UNCASED COIL SHOWN) |
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(UNCASED COIL SHOWN) |
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STUB END |
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DISTRIBUTOR TUBES |
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TWO−PIECE PATCH PLATE |
LIQUID LINE |
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(UNCASED COIL ONLY) |
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ORIFICE |
EXPANSION |
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LIQUID LINE ORIFICE HOUSING |
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DISTRIBUTOR |
HOUSING |
VALVE |
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TEFLON® RING |
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TUBES |
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TEFLON® |
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RING |
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FIXED ORIFICE |
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BRASS NUT |
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TEFLON® |
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RING |
SENSING |
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LINE |
DISTRIBUTOR ASSEMBLY
REMOVE AND DISCARD
WHITE TEFLON® SEAL
(IF PRESENT) LIQUID LINE ASSEMBLY (INCLUDES STRAINER)
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.Using two wrenches, disconnect liquid line from liquid line orifice housing. Take care not to twist or damage distributor tubes during this process.
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.
2CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE
CYLINDER CONTAINING |
GAUGE |
CLEAN HCFC−22 TO BE |
MANIFOLD |
USED FOR FLUSHING |
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A(Positionedrefrigerant) to deliver liquid
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1 |
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LOW |
HIGH |
VAPOR LINE |
NEW |
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SERVICE VALVE |
OUTDOOR |
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UNIT |
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OPENED |
CLOSED |
EXISTING |
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INDOOR |
B |
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UNIT |
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LIQUID LINE SERVICE |
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VALVE |
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RECOVERY |
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CYLINDER |
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TANK |
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RETURN |
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VAPOR LIQUID |
C |
DISCHARGE |
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D |
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INLET |
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RECOVERY MACHINE |
1.HCFC−22 cylinder with clean refrigerant (positioned to deliver liquid refrigerant) to the vapor 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.
DISTRIBUTOR EQUALIZER
ASSEMBLY LINE
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
MALE EQUALIZER |
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LINE FITTING |
VAPOR |
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LIQUID |
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SENSING BULB |
LINE |
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LINE |
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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 check expansion valve equalizer line fitting on the vapor line.
4.Remove the vapor line sensing bulb.
5.Disconnect the liquid line from the check expansion valve at the liquid line assembly.
6.Disconnect the check expansion valve from the liquid line orifice housing. Take care not to twist or damage distributor tubes during this process.
7.Remove and discard check 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.
3FLUSHING LINE SET
The line set and indoor unit coil must be flushed with at least the same amount of clean refrigerant that previously charged the system. Check the charge in the flushing cylinder before proceeding.
1.Set the recovery machine for liquid recovery and start the recovery machine. Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line set and indoor unit coil.
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 vapor line valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine.
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.
FIGURE 6
Page 5
XC21 SERIES
STEP 2 −− REFRIGERANT PIPING −− Brazing Procedures
1PIPING PANEL REMOVAL / PREPARING LINE SET
Remove piping panel to access service valves. Cut ends of the refrigerant lines square (free from nicks or dents) and debur the ends. The pipe must remain round. Do not crimp end of the line.
CUT AND DEBUR
LINE SET SIZE MATCHES
SERVICE VALVE CONNECTION
SERVICE VALVE
CONNECTION
COPPER TUBE
STUB
REDUCER
LINE SET SIZE IS SMALLER
THAN CONNECTION
REFRIGERANT LINE
DO NOT CRIMP SERVICE VALVE
CONNECTOR WHEN PIPE IS
SMALLER THAN CONNECTION
2CAP AND CORE REMOVAL
Remove service cap and core from both the suction / vapor and liquid line service ports.
SERVICE PORT CAP
SERVICE PORT
CORE
LIQUID LINE SERVICE VALVE
SERVICE PORT
CORE
SERVICE
PORT CAP
SUCTION / VAPOR LINE
SERVICE VALVE
3ATTACH THE MANIFOLD GAUGE SET FOR BRAZING
LIQUID AND SUCTION / VAPOR LINE SERVICE VALVES
A.Connect gauge set low pressure side to liquid line service valve (service port).
B.Connect gauge set center port to bottle of nitrogen with regulator.
C.With valve core removed from the suction / vapor line service port, nitrogen flow will have an exit point.
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LOW |
HIGH |
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ATTACH |
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GAUGES |
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SUCTION / VAPOR SERVICE PORT MUST BE |
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B |
OPEN AND SERVICE PORT CORE REMOVED |
C |
SUCTION / |
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TO ALLOW EXIT POINT FOR NITROGEN FLOW |
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VAPOR LINE |
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SERVICE |
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SUCTION / VAPOR |
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VALVE |
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LINE |
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INDOOR |
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OUTDOOR |
UNIT |
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UNIT |
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NITROGEN |
LIQUID LINE |
LIQUID LINE SERVICE |
A |
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VALVE |
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FIGURE 7
Page 6