Elite XC16-024-230, XC16-036-230, XC16-048-230, XC16-060-230, XC20-060-230 Installation Instructions Manual
...
INSTALLATION
E2018 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
General
This XC16 outdoor air conditioner is designed for use with
HFC-410A refrigerant only. This unit must be installed with
an approved indoor air handler or coil. See the Lennox
XC16 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.
NOTICE !
For more in-depth information, consult the Installa
tion and Service Procedures manual, available as
Corp. 0625-L5 on LennoxPROs.com or through the
Technical Support department at 800-453-6669.
INSTRUCTIONS
Elite® Series XC16 Units
AIR CONDITIONER
507161-01
7/2018
WARNING
Improper installation, adjustment, alteration, ser
vice or maintenance can cause property damage,
personal injury or loss of life.
Installation and service must be performed by a li
censed professional installer (or equivalent) or ser
vice agency.
CAUTION
Before attempting to perform any service or mainte
nance, turn the electrical power to unit OFF at dis
connect switch.
CAUTION
As with any mechanical equipment, contact with sharp
sheet metal edges can result in personal injury. Take
care while handling this equipment and wear gloves and
protective clothing.
STEP 1 -- SETTING THE UNIT -- Clearances
NOTES:
See NOTES
See
NOTES
See NOTES
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.)
See
NOTES
Control
Box
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.
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.
48 in. clearance required on top of unit.
FIGURE 1
Page 1
UNIT DIMENSIONS - INCHES (MM)
A
LIQUID LINE
CONNECTION
ELECTRICAL INLETS
SUCTION LINE
CONNECTION
C
4-3/4”
(121)
B
TOP VIEW
K
J
G
H
SIDE VIEW
UNIT SUPPORT
FEET
4-1/2”
(108)
D
E
F
XC16-024 TO -060 BASE WITH
ELONGATED LEGS
Model Number A B C D E F G H J K
XC16-024-230 45 (1143)
XC16-036-230 31 (787)
XC16-048-230 39 (991)
XC16-060-230 45 (1143) 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) 3-3/4 (95) 26-7/8 (683)
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)
Page 2
STEP 1 -- SETTING THE UNIT (Continued)
-- Unit Placement
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.
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.
ELEVATED SLAB MOUNTING USING FEET
EXTENDERS
Use additional 2” SCH 40 male
threaded adapters which can
be threaded into the female
threaded adapters to make
additional adjustments to the
2” (50.8MM) SCH 40
MALE THREADED
ADAPTER
FEMALE THREADED
LEG DETAIL
2” (50.8MM) SCH 40
ADAPTER
level of the unit.
FIGURE 4
BASE
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
STABILIZING UNIT ON UNEVEN SURFACES
#10 X 1/2” LONG
SELF-DRILLING
SHEET METAL
SCREWS
STABILIZING BRACKET
(18-GAUGE METAL — 2”
WIDTH; HEIGHT AS
REQUIRED)
#10 X 1-1/4” LONG
HEX HD SCREW AND
FLAT WASHER
PLASTIC ANCHORS
(DRILL 1/4” HOLE)
CONCRETE SLAB
!
IMPORTANT !
CORNER POST
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
COIL
BASE PAN
GROUND LEVEL
FIGURE 3
MOUNTING
SLAB
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 3
XC16 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 Dave
Net. CAUTION - DO NOT attempt to flush and re-use ex
isting line sets or indoor coil when the system con
tains 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 Ap
plication group for assistance.
NOTE - For new or replacement line set installation, refer
to Service and Application Note - Corp. 9112-L4 (C-91-4).
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.
IMPORTANT !
If this unit is being matched with an approved line set or in
door 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
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.
TABLE 1
REFRIGERANT LINE SET — INCHES (MM)
Field
Model
-024
-036
-048
-060
NOTE - Some applications may require a field-provided 7/8” to 1-1/8” adapter.
Connections
Liquid
Line
3/8”
(10 mm)
3/8”
(10mm)
3/8”
(10mm)
Suction
Line
3/4”
(19 mm)
7/8”
(22mm)
1-1/8”
(29 mm)
WEIGH-IN
CHARGING METHOD FOR LONG LINE SETS
64ºF (17.7ºC) and Below
Amount specified
on nameplate
Adjust amount for variation in
line set length and liquid line
diameter using table below.
+
Recommended Line Set
Liquid
(10 mm)
(10 mm)
(10 mm)
Line
3/8”
3/8”
3/8”
Suction
Line
3/4”
(19 mm)
7/8”
(22 mm)
1-1/8”
(29 mm)
L15 Line Set
L15-41: 15 ft.–50 ft.
(4.6 m–15 m)
L15-65: 15 ft.– 50 ft.
(4.6 m–15 m)
Field-Fabricated
Total charge
=
WARNING
Fire, Explosion and Personal Safety Haz
ard. Failure to follow this warning could
result in damage, personal injury or
death.
Never use oxygen to pressurize or purge
refrigeration lines. Oxygen, when ex
posed to a spark or open flame, can cause
fire and/or an explosion, that could result
in property damage, personal injury or
death.
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 COMPRESSOR.
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
Set Diameter
5/16”
3/8”
1/2”
HFC-410A
(ounces per foot)
0.40
0.60
1.00
Charging Formula for Liquid Line Charge Adjustments
[(Line set oz./ft. x total length) (factory charge for line set)] = charge adjustment
Example: Units are factorycharged for 15 feet (4.6 meters) of 3/8" line set.
Factory charge for 3/8" is 0.60 oz/ft x 15 = 9.0 ounces.
FIGURE 6
Page 4
STEP 2 -- REFRIGERANT PIPING -- Removing Existing Indoor Metering Device
TYPICAL EXISTING FIXED ORIFICE
1A
DISTRIBUTOR
ASSEMBLY
A. On fully cased coils, remove the coil access and plumbing panels.
B. Remove any shipping clamps from the liquid line and distributor as
sembly.
C. 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.
D. Remove and discard fixed orifice, valve stem assembly (if present)
and Teflon® washer as illustrated above.
E. Use a field-provided fitting to temporarily reconnect the liquid line to the
indoor unit's liquid line orifice housing.
(UNCASED COIL SHOWN)
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
TEFLON® RING
FIXED ORIFICE
REMOVE AND DISCARD
WHITE TEFLON
(IF PRESENT)
®
SEAL
LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
REMOVAL PROCEDURE
OR
BRASS NUT
1B
TWO-PIECE PATCH PLATE
(UNCASED COIL ONLY)
CONNECT GAUGES AND EQUIPMENT FOR
FLUSHING PROCEDURE
2
VAPOR LINE
SERVICE VALVE
EXISTING
INDOOR
UNIT
LIQUID LINE SERVICE
VALV E
RECOVERY
CYLINDER
D
A. HCFC-22 cylinder with clean refrigerant (positioned to deliver liquid
refrigerant) to the vapor service valve.
B. HCFC-22 gauge set (low side) to the liquid line valve.
C. HCFC-22 gauge set center port to inlet on the recovery machine with an
empty recovery tank connected to the gauge set.
D. Connect recovery tank to recovery machine per machine instructions.
CYLINDER CONTAINING
CLEAN HCFC-22 TO BE USED
FOR FLUSHING
(Positioned to deliver liquid
refrigerant)
A
1
B
VAPOR
LIQUID
NEW
OUTDOOR
UNIT
C
GAUGE
MANIFOLD
LOW HIGH
OPENED
TANK
RETURN
INLET
DISCHARGE
RECOVERY MACHINE
CLOSED
TYPICAL EXISTING EXPANSION VALVE REMOVAL
PROCEDURE (UNCASED COIL SHOWN)
ORIFICE
HOUSING
EQUALIZER
LINE
STUB END
TEFLON
RING
VAPOR
EXPANSION
VALV E
®
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
LINE
TEFLON
RING
®
SENSING
LINE
LIQUID
LINE
LIQUID LINE
DISTRIBUTOR
TUBES
DISTRIBUTOR
ASSEMBLY
MALE EQUALIZER
LINE FITTING
SENSING BULB
A. On fully cased coils, remove the coil access and plumbing panels.
B. Remove any shipping clamps from the liquid line and distributor
assembly.
C. Disconnect the equalizer line from the expansion valve equalizer
line fitting on the vapor line.
D. Remove the vapor line sensing bulb.
E. Disconnect the liquid line from the expansion valve at the liquid line
assembly.
F. Disconnect the expansion valve from the liquid line orifice housing.
Take care not to twist or damage distributor tubes during this
process.
G. Remove and discard expansion valve and the two Teflon® rings.
H. Use a field-provided fitting to temporarily reconnect the liquid line to
the indoor unit's liquid line orifice housing.
FLUSHING LINE SET
The line set and indoor unit coil must be flushed with at least the same
3
amount of clean refrigerant that previously charged the system. Check
the charge in the flushing cylinder before proceeding.
A. 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
B
unit coil.
B. 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.
C. 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.
D. 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 7
Page 5
XC16 SERIES
STEP 2 -- REFRIGERANT PIPING -- Brazing Procedures
CUT AND DEBUR
Cut ends of the refrigerant lines square (free from nicks or dents)
1
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
COPPER TUBE
REDUCER
CONNECTION
STUB
LINE SET SIZE IS SMALLER
THAN CONNECTION
REFRIGERANT LINE
DO NOT CRIMP SERVICE VALVE
CONNECTOR WHEN PIPE IS
SMALLER THAN CONNECTION
CAP AND CORE REMOVAL
Remove service cap and core from
2
both the suction / vapor and liquid line
service ports.
SERVICE PORT
CAP
SERVICE
PORT
CORE
LIQUID LINE SERVICE
VALV E
SUCTION / VAPOR LINE
SERVICE VALVE
ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE
VALVES
3
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).
B. Connect gauge set center port to bottle of
nitrogen with regulator.
C. Remove core from valve in suction / vapor
line service port to allow nitrogen to escape.
ATTACH
GAUGES
HIGHLOW
USE REGULATOR TO FLOW
NITROGEN AT 1 TO 2 PSIG.
SERVICE
PORT
CORE
SERVICE
PORT CAP
SUCTION / VAPOR SERVICE PORT MUST BE
OPEN TO ALLOW EXIT POINT FOR NITROGEN
VAPOR LINE
INDOOR
UNIT
LIQUID LINE
C
LIQUID LINE SERVICE
SUCTION /
VAPOR LINE
VALV E
CAUTION
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.
SERVICE
VALV E
A
FIGURE 8
B
OUTDOOR
UNIT
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
WARNING
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.
NITROGEN
Page 6
STEP 2 -- REFRIGERANT PIPING -- Brazing Procedures (Continued)
WRAP SERVICE VALVES
To help protect service valve seals during brazing, wrap water-saturated cloths around service valve bodies and copper tube stubs. Use
4
additional water-saturated cloths underneath the valve body to protect the base paint.
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
5
out of the suction / vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set connections.
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
6
remain water-saturated throughout the brazing and cool-down process.
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 250ºF will damage valve seals.
WARNING
FIRE, PERSONAL INJURY, OR PROPERTY DAMAGE
may result if you do not wrap a water-saturated cloth around
both liquid and suction line service valve bodies and copper
tube stub while brazing the line set! The braze, when
complete, must be quenched with water to absorb any
residual heat.
Do not open service valves until refrigerant lines and
indoor coil have been leak-tested and evacuated. Refer
to Installation and Service Procedures manual found on
DAVENET.
SUCTION / VAPOR LINE
WATER-SATURATED
CLOTH
LIQUID LINE
SUCTION / VAPOR LINE
SERVICE VALVE
WATER-SATURATED
CLOTH
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
PREPARATION FOR NEXT STEP
Disconnect manifold gauge set from service ports after all connections have been brazed. Apply additional water-saturated cloths to both
7
service valves to cool piping. Once piping is cool, remove all water-saturated cloths.
FIGURE 9
Page 7
XC16 SERIES
STEP 3 -- INSTALLING INDOOR EXPANSION VALVE
This outdoor unit is designed for use in systems that include an expansion valve metering device. See the XC16 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 provides access for future field service of the expansion valve.
Refer to following illustration for reference during installation of expansion valve.
INDOOR EXPANSION VALVE INSTALLATION
TWO PIECE
PATCH PLATE
(UNCASED
COIL ONLY)
DISTRIBUTOR
TUBES
DISTRIBUTOR
ASSEMBLY
MALE EQUALIZER LINE
FITTING (SEE
EQUALIZER LINE
INSTALLATION FOR
FURTHER DETAILS)
(Uncased Coil Shown)
LIQUID LINE
ORIFICE
HOUSING
STUB
END
TEFLON
RING
EQUALIZER
LINE
VAPOR
EXPANSION
VALV E
®
ASSEMBLY WITH
LINE
TEFLON
RING
LIQUID LINE
BRASS NUT
LIQUID LINE
Sensing bulb insulation is required if
mounted external to the coil casing. See
Sensing Bulb Installation for correct 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 below.
B. Remove the field-provided fitting that temporarily recon
nected the liquid line to the indoor unit's distributor as
sembly.
®
SENSING
LINE
C. 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.
D. 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.
E. 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.
F. 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
A. Attach the vapor line sensing bulb in the proper
orientation (illustrated below) using the clamp and
screws provided.
NOTE - Confirm proper thermal contact between vapor
line and expansion valve sensing bulb before insulating
the sensing bulb once installed.
B. Connect the equalizer line from the expansion valve to
the equalizer vapor port on the vapor line. Finger tighten
the flare nut plus 1/8 turn (7 ft-lbs) as illustrated below left.
9 O'CLOCK TO
3 O'CLOCK
ON LINES SMALLER THAN
BULB
12
BULB
7/8”, MOUNT SENSING
BULB BETWEEN THE 9 AND
3 O'CLOCK POSITIONS.
®
1/2 Turn
11
10
9
8
7
1/8 Turn
11
10
9
8
7
12
1
2
3
4
5
6
12
1
2
3
4
5
6
FLARE SEAL CAP
OR
FLARE NUT
COPPER FLARE
SEAL BONNET
MALE BRASS EQUALIZER
LINE FITTING
VAPOR LINE
FIGURE 10
Page 8
VAPOR LINE
VAPOR LINE
12
BULB
NOTE - NEVER MOUNT THE SENSING BULB ON
BOTTOM OF LINE.
BULB
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.
STEP 4 -- LEAK TEST AND EVACUATION
HIGHLOW
MANIFOLD GAUGE SET
OUTDOOR UNIT
1
2
B
TO VAPOR
SERVICE VALVE
NOTE - Position
canister to deliver
liquid refrigerant.
NITROGEN
CONNECT GAUGE SET
A. Connect the high-pressure hose of an HFC-410A manifold gauge set 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 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.
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.
HFC-410A
A
FIGURE 11
Page 9
XC16 SERIES
STEP 4 -- LEAK TEST AND EVACUATION (Continued)
EVACUATION
CONNECT GAUGE SET
NOTE - Remove cores from service valves (if not already done).
3
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
C. Connect available micron gauge connector
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 is used later
for both the HFC-410A and nitrogen
containers.
NITROGEN
NOTE - Position
canister to deliver
liquid refrigerant.
HFC-410A
VACUUM PUMP
OUTDOOR
UNIT
A
B
1/4 SAE TEE WITH SWIVEL
COUPLER
500
C
MICRON
GAUGE
D
EVACUATE THE SYSTEM
4
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).
MANIFOLD
GAUGE SET
TO VAPOR
SERVICE VALVE
TO LIQUID LINE
SERVICE VALVE
MINIMUM 3/8” HOSE
LOW
RECOMMEND
HIGH
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),
perform the following:
S Close manifold gauge valves.
S Close valve on vacuum pump.
S Turn off vacuum pump.
S Disconnect manifold gauge center port hose from vacuum pump.
S Attach manifold center port hose to a nitrogen cylinder with pressure
regulator set to 150 psig (1034 kPa) and purge the hose.
S Open manifold gauge valves to break the vacuum in the line set and indoor
unit.
S 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:
S Close manifold gauge valves.
S Shut off HFC-410A cylinder.
S Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core
tool while maintaining a positive system pressure.
S Replace stem caps and finger tighten them, then tighten an additional one-sixth (1/6) of a turn as illustrated.
Possible equipment damage.
Avoid deep vacuum operation. Do not use
compressors to evacuate a system.
Extremely low vacuum can cause internal
arcing and compressor failure. Damage
caused by deep vacuum operation will
void warranty.
WARNING !
11
10
9
8
1/6 TURN
12
7
6
1
2
3
4
5
FIGURE 12
Page 10
STEP 5 -- ELECTRICAL -- Circuit Sizing and Wire Routing
In the U.S.A., wiring must conform with current local codes and the cur
rent 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 addition
al 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).
If unit is equipped with a crankcase heater, it should be en
ergized 24 hours before unit start-up to prevent compres
sor damage as a result of slugging.
IMPORTANT !
CAUTION
WARNING
Electric Shock Hazard. Can cause injury or
death. Unit must be grounded in
accordance with national and local codes.
Line voltage is present at all components
when unit is not in operation on units with
single‐pole contactors. Disconnect all
remote electric power supplies before
opening access panel. Unit may have
multiple power supplies.
SIZE CIRCUIT AND INSTALL DISCONNECT SWITCH
Refer to the unit nameplate for minimum circuit ampacity, and
1
maximum fuse or circuit breaker (HACR per NEC). Install power wiring
and properly sized disconnect switch.
MAIN FUSE BOX/
BREAKER PANEL
DISCONNECT
SWITCH
Electrostatic discharge can affect
electronic components. Take care during
unit installation and service to protect the
ELECTROSTATIC
DISCHARGE
(ESD)
Precautions and
Procedures
INSTALL THERMOSTAT
Install room thermostat (ordered separately) on an inside wall
2
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.
THERMOSTAT
unit's electronic controls. Precautions
will help to avoid control exposure to
electrostatic discharge by putting the
unit, the control and the technician at the
same electrostatic potential. Touch hand
and all tools on an unpainted unit surface
before performing any service procedure
to neutralize electrostatic charge.
5 FEET
(1.5M)
NOTE - Units are approved for use only with copper conductors.
Ground unit at disconnect switch or connect to an earth ground.
UNIT LOW VOLTAGE CONNECTIONS
3
WIRE NUTS
C
BLACK
YELLOW
D
A
CUTOUT WITH
GROMMET
24V CONTROL
B
BLUE
WIRES
NOTE - 24VAC, Class II circuit connections are made in the control
panel.
FIGURE 13
TIGHTEN
WIRE TIE
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.
FIGURE 14
Page 11
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 35ºC 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.
XC16 SERIES
FIGURE 15
Page 12
Charging
The XC16 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 sticker on the unit access
panel. Detailed information is given in the XC16 Installation and Service Procedures manual, which is available on DaveNet.
Field Operation Checklist for Two-Stage Modulation Compressors
Unit Readings Y1 - First‐Stage
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
Use the checklist procedure above to verify part‐load and
full‐load capacity operation of two‐stage modulation com
pressors.
TOOLS REQUIRED
S Refrigeration gauge set
S Digital volt/amp meter
S Electronic temperature thermometer
S On‐off toggle switch
Expected results during Y2
demand (Toggle switch On)
This performance check is ONLY valid on systems
that have clean indoor and outdoor coils, proper
airflow over coils, and correct system refrigerant
charge. All components in the system must be
functioning properly to correctly perform
compressor operational check.
Accurate measurements are critical to this test as
indoor system loading and outdoor ambient can
affect variations between low and high-capacity
readings.
Y2 - Second‐Stage
IMPORTANT
Page 13
XC16 SERIES
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
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:
Saturated Condensing Temperature (A)
minus Liquid Line Temperature (B)
Approach:
Liquid Line Temperature (A)
minus Outdoor Air Temperature (B)
Indoor Coil Temperature Drop (18 to 22°F)
Return Air Temperature (A)
minus Supply Air Temperature (B)
HIGH-PRESSURE SWITCH (S4)
This unit is equipped with a high-pressure switch which is located on the liquid line. The SPST, normally closed pressure
switch opens when liquid line pressure rises above the factory setting of 590 + 15 psig and automatically resets at 418 + 15
psig.
A — B = SUBCOOLING
A — B = APPROACH
A — B = COIL TEMP DROP
Actual Volts
Page 14
Homeowner Information
CAUTION
Before attempting to perform any service or mainte
nance, turn the electrical power to unit OFF at dis
connect switch.
Cleaning of the outdoor unit's coil should be performed by
a licensed professional service technician (or equivalent).
Contact your dealer and set up a schedule (preferably
twice a year, but at least once a year) to inspect and ser
vice your outdoor unit. The following maintenance may be
performed by the homeowner.
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.
Outdoor Coil
The outdoor unit must be properly maintained to ensure its
proper operation.
S Please contact your dealer to schedule proper inspec
tion and maintenance for your equipment.
S Make sure no obstructions restrict airflow to the out
door unit.
S Grass clippings, leaves, or shrubs crowding the unit
can cause the unit to work harder and use more energy.
S Keep shrubbery trimmed away from the unit and peri
odically check for debris which collects around the unit.
S Keep snow level below the louvered panels to ensure
proper performance.
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.
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.
A. 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.
B. Disposable filters should be replaced with a filter of the
same type and size.
C. 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
obstructions. (This would also apply to an auxiliary
drain, if installed.)
Thermostat Operation
See the ComfortSense® 7000 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:
S Verify room thermostat settings are correct.
S Verify that all electrical disconnect switches are ON.
S Check for any blown fuses or tripped circuit breakers.
S Verify unit access panels are in place.
S Verify air filter is clean.
S If service is needed, locate and write down the unit
model number and have it handy before calling.
Page 15
XC16 SERIES
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