Lennox XC21 User Manual

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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

 

506923−01

 

7/2012

Litho U.S.A.

Supersedes 4/2012

 

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

 

 

 

ACCESS PANEL

 

24

LINE SET

 

(610)

CONNECTIONS

 

 

REAR VIEW OF UNIT

 

FIGURE 1

 

7/2012

Page 1

506923−01

*2P72012*

*P506923-01*

 

UNIT DIMENSIONS − INCHES (MM)

 

 

39−1/2

DISCHARGE

ELECTRICAL

35−1/2

 

AIR

(1003)

 

INLETS

(902)

 

 

 

 

47

 

 

SUCTIOn

(1194)

 

 

LINE

 

 

 

INLET

4−1/2

 

 

 

 

 

 

(114)

 

 

LIQUID

 

 

 

LINE

 

 

 

INLET

 

 

 

 

18−1/2

 

 

 

(470)

 

 

 

8 (203)

 

SIDE VIEW

1 (25)

UNIT SUPPORT

FEET

26−7/8

(683)

ACCESS VIEW

16−7/8

(429)

8−3/4

 

 

(222)

 

3−3/4 (95)

 

 

3−1/8

30−3/4

4−5/8

(781)

(79)

(117)

 

 

 

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

Lennox XC21 User Manual

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

STRUCTURE

 

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

FEMALE THREADED

be threaded into the female

ADAPTER

threaded

adapters to

make

 

 

additional

adjustments

to the

 

level of the unit.

 

2" (50.8MM)

 

 

 

SCH 40 MALE

 

 

THREADED

 

 

ADAPTER

 

 

 

BASE

LEG DETAIL

FIGURE 4

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 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

 

Line

Suction

 

 

 

Line

 

 

 

 

 

−024, −036

3/8 (10)

7/8 (22)

L15 line set sizes are

and−048

 

 

dependent on unit match up.

 

 

 

See XP21 Engineering

 

 

 

Handbook to determine

 

 

 

correct line set sizes.

 

 

 

 

−060

3/8 (10)

1−1/8 (29)

Field Fabricated

 

 

 

 

NOTE Some applications may required a field−provided 7/8" to 1−1/8" adapter.

Page 3

XC21 SERIES

IMPORTANT !

If this unit is being matched with an approved line set or indoor unit coil that was previously charged with mineral oil, or if it is being matched with a coil which was manufactured before January of 1999, the coil and line set must be flushed prior to 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

 

TYPICAL EXISTING FIXED ORIFICE

 

TYPICAL EXISTING EXPANSION VALVE REMOVAL

1A

REMOVAL PROCEDURE

OR

1BPROCEDURE (UNCASED COIL SHOWN)

(UNCASED COIL SHOWN)

 

 

 

 

STUB END

 

 

DISTRIBUTOR TUBES

 

TWO−PIECE PATCH PLATE

LIQUID LINE

 

 

 

(UNCASED COIL ONLY)

 

 

 

ORIFICE

EXPANSION

 

 

 

 

 

 

 

 

LIQUID LINE ORIFICE HOUSING

 

DISTRIBUTOR

HOUSING

VALVE

 

 

 

 

 

 

TEFLON® RING

 

TUBES

 

TEFLON®

 

 

 

 

RING

 

FIXED ORIFICE

 

 

 

 

 

BRASS NUT

 

TEFLON®

 

 

 

 

 

 

 

 

RING

SENSING

 

 

 

 

 

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

 

A(Positionedrefrigerant) to deliver liquid

 

1

 

LOW

HIGH

VAPOR LINE

NEW

 

 

SERVICE VALVE

OUTDOOR

 

 

 

 

UNIT

 

 

 

 

 

OPENED

CLOSED

EXISTING

 

 

 

INDOOR

B

 

 

UNIT

 

 

 

LIQUID LINE SERVICE

 

 

 

VALVE

 

 

 

RECOVERY

 

 

 

 

CYLINDER

 

 

TANK

 

 

 

 

RETURN

 

 

VAPOR LIQUID

C

DISCHARGE

 

D

 

 

INLET

 

 

 

 

 

 

 

 

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

 

 

LINE FITTING

VAPOR

 

 

LIQUID

SENSING BULB

LINE

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 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.

 

 

LOW

HIGH

 

 

ATTACH

 

 

 

GAUGES

 

SUCTION / VAPOR SERVICE PORT MUST BE

 

 

B

OPEN AND SERVICE PORT CORE REMOVED

C

SUCTION /

TO ALLOW EXIT POINT FOR NITROGEN FLOW

 

VAPOR LINE

 

 

 

 

 

 

SERVICE

 

SUCTION / VAPOR

 

VALVE

 

LINE

 

 

 

INDOOR

 

 

OUTDOOR

UNIT

 

 

UNIT

 

 

 

NITROGEN

LIQUID LINE

LIQUID LINE SERVICE

A

VALVE

 

 

FIGURE 7

Page 6

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