Lennox Collection XC21 System Installation Instructions Manual
INSTALLATION
E2011 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
NOTICE TO INSTALLER
It is critical for proper unit operation to place outdoor unit on an
elevated surface as described in Unit Placement section on page 7.
BRAZING LINE SET TO SERVICE VALVES
It is imperative to follow the brazing technique illustrated starting on
page 12 to avoid damaging the service valve’s internal seals.
UNIT PLACEMENT
NOTICE
A thermostat is not included and must be ordered
separately.
D The Lennox icomfort Touch® thermostat must be used
in communicating applications.
D In non−communicating applications, the Lennox
ComfortSense® 7000 thermostat may be used, as well
as other non−communicating thermostats.
In all cases, setup is critical to ensure proper system
operation.
Field wiring examples for non−communicating
applications begin on page 23.
See the icomfort Toucht thermostat Quick Start Guide
for communicating and partial communicating field
wiring connections.
INSTRUCTIONS
Dave Lennox Signature
Collection XC21 System
AIR CONDITIONER
506587−01
06/11
Supersedes 10/10
TABLE OF CONTENTS
General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Number Identification 2. . . . . . . . . . . . . . . . . . . .
Unit Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . .
Using Manifold Gauge Set 4. . . . . . . . . . . . . . . . . . . . . .
Operating Service Valves 4. . . . . . . . . . . . . . . . . . . . . . .
Recovering Refrigerant from Existing System 6. . . . .
Unit Placement 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and Installing Panels 9. . . . . . . . . . . . . . . . .
New or Replacement Line Set 10. . . . . . . . . . . . . . . . . . .
Brazing Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Line Set and Indoor Coil 15. . . . . . . . . . . . . . . .
Installing Indoor Expansion Valve 16. . . . . . . . . . . . . . . .
Leak Test Line Set and Indoor Coil 17. . . . . . . . . . . . . . .
Evacuating Line Set and Indoor Coil 17. . . . . . . . . . . . .
Electrical 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioner Control (A175) Jumpers and
Terminals 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Control Wiring 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Unit Delivered Void of Charge 25. . . . . . . . . .
Unit Start−Up 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Refrigerant 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and Temperature Pressures 29. . . . . . . . . . .
System Operations 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Status, Fault and Lockout LED Codes 37. . . . .
Field Configuration and Testing 42. . . . . . . . . . . . . . . . . .
Maintenance (Dealer and Homeowner) 49. . . . . . . . . . .
SunSource® Home Energy System 50. . . . . . . . . . . . . .
Checklists 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
This outdoor unit 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 XC21
Engineering Handbook for approved indoor component
matchups.
®
Litho U.S.A.
06/11 506587−01
*2P0611* *P506587-01*
Page 1
Unit Dimensions − Inches (mm) and Parts Arrangement
39−1/2
(1003)
DISCHARGE
AIR
SIDE VIEW
UNIT SUPPORT
FEET
SUCTIOn
LINE
INLET
LIQUID
LINE
INLET
ELECTRICAL
INLETS
47
(1194)
18−1/2
(470)
4−1/2
(114)
8 (203)
1 (25)
35−1/2
(902)
ACCESS VIEW
16−7/8
(429)
8−3/4
(222)
3−1/8
(79)
Model Number Identification
Refrigerant Type
X = R−410A
Unit Type
C = Air Conditioner
Series
30−3/4
(781)
BASE WITH ELONGATED LEGS
X
C 21
XXX
230
Nominal Cooling Capacity
024 = 2 tons
036 = 3 tons
048 = 4 tons
060 = 5 tons
05
26−7/8
(683)
3−3/4 (95)
4−5/8
(117)
Minor Revision Number
Voltage
230 = 208/230V−1ph−60hz
506587−01
Page 2
Typical Unit Parts Arrangement
WIRE TIE
OUTDOOR AMBIENT
TEMPERATURE
SENSOR (RT13)
SECOND GROUND LUG FOR SOURCESOURCE
HIGH VOLTAGE FIELD
CONNECTIONS
GROUND LUG
AIR CONDITIONER
CONTROL (A175)
®
CONTACTOR−1
POLE (K1)
FAN MOTOR (A177) CONTROL
CAPACITOR (C12)
HIGH DISCHARGE LINE
TEMPERATURE SENSOR (RT28)
COMPRESSOR HARNESS
FIELD CONNECTION FOR
SUCTION LINE SERVICE
FIELD CONNECTION FOR
SUCTION LINE
VALVE PORT
LIQUID LINE SERVICE
VALVE PORT
LIQUID LINE
LIQUID LINE FILTER
DRIER (SINGLE FLOW)
LOW PRESSURE SWITCH
(S87)
HIGH PRESSURE SWITCH (S4)
CRANKCASE THERMOSTAT (S40)
Figure 1. Plumbing, Switches and Sensor Components
Page 3
XC21 SERIES
WARNING
Improper installation, adjustment, alteration, service or
maintenance can cause personal injury, loss of life, or
damage to property.
Installation and service must be performed by a licensed
professional installer (or equivalent) or a service agency.
1 Bushing (for low voltage wiring)
2 Isolation grommets for liquid and suction lines
Using Manifold Gauge Set
When checking the system charge, only use a manifold
gauge set that features low−loss anti−blow back fittings.
IMPORTANT
CAUTION
Physical contact with metal edges and corners while
applying excessive force or rapid motion can result in
personal injury. Be aware of, and use caution when
working near these areas during installation or while
servicing this equipment.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting of
refrigerant (CFCs, HCFCs AND HFCs) as of July 1,
1992. Approved methods of recovery, recycling or
reclaiming must be followed. Fines and/or incarceration
may be levied for noncompliance.
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.
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted
snugly over the cap before tightening.
Manifold gauge set used with HFC−410A refrigerant
systems must be capable of handling higher system
operating pressures. The gauges should be rated for use
with pressures of 0 − 800 psig on the high side and a low
side of 30" vacuum to 250 psig with dampened speed to
500 psi. Gauge hoses must be rated for use at or up to 800
psig of pressure with a 4000 psig burst rating.
Table 1. Torque Requirements
Parts Recommended Torque
Service valve cap 8 ft.− lb. 11 NM
Sheet metal screws 16 in.− lb. 2 NM
Machine screws #10 28 in.− lb. 3 NM
Compressor bolts 90 in.− lb. 10 NM
Gauge port seal cap 8 ft.− lb. 11 NM
Operating Service Valves
The liquid and vapor line service valves are used for
removing refrigerant, flushing, leak testing, evacuating,
verifying charge and charging.
Each valve is equipped with a service port which has a
factory−installed valve stem. Figure 2 provides information
on how to access and operating both angle and ball service
valves.
IMPORTANT
This model is designed for use in check expansion valve
systems only. An indoor expansion valve approved for
use with HFC−410A refrigerant must be ordered
separately, and installed prior to operating the system.
Shipping and Packing List
Check unit for shipping damage. Consult last carrier
immediately if damage is found.
1 Assembled outdoor unit.
1 Bag assembly which includes the following:
506587−01
IMPORTANT
Only use Allen wrenches of sufficient hardness (50Rc −
Rockwell Harness Scale minimum). Fully insert the
wrench into the valve stem recess.
Service valve stems are factory−torqued (from 9 ft−lbs for
small valves, to 25 ft−lbs for large valves) to prevent
refrigerant loss during shipping and handling. Using an
Allen wrench rated at less than 50Rc risks rounding or
breaking off the wrench, or stripping the valve stem
recess.
See the Lennox Service and Application Notes #C−08−1
for further details and information.
Page 4
SERVICE VALVES
ANGLE AND BALL
Operating Angle Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. Use a service wrench with a hex−head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve sizes) to back
the stem out counterclockwise as far as it will go.
SERVICE PORT CAP
SERVICE PORT CORE
(VALVE STEM SHOWN
CLOSED) INSERT HEX
WRENCH HERE
TO INDOOR
UNIT
(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE
STEM CAP
TO OUTDOOR UNIT
ANGLE−TYPE SERVICE VALVE
(BACK−SEATED OPENED)
When service valve is OPEN, the service port is
open to linE set, indoor and outdoor unit.
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 INDOOR UNIT
TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°.
TO CLOSE ROTATE STEM
CLOCKWISE 90°.
SERVICE PORT
SERVICE PORT
SERVICE PORT
CORE
CAP
TO OUTDOOR
UNIT
BALL (SHOWN
CLOSED)
VALV E
STEM
STEM CAP
ANGLE−TYPE SERVICE VALVE
(FRONT−SEATED CLOSED)
WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN
TO
THE LINE SET AND INDOOR UNIT.
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:
11
1/6 TURN
12
1
2
3
4
5
7
6
1/12 TURN
S With torque wrench: Finger tighten and
torque cap per table 1.
S Without torque wrench: Finger tighten and
use an appropriately sized wrench to turn
an additional 1/6 turn clockwise.
Reinstall Stem Cap:
Stem cap protects the valve stem from damage and serves as the
primary seal. Replace the stem cap and tighten as follows:
10
9
8
S With Torque Wrench: Finger tighten and then
torque cap per table 1.
S Without Torque Wrench: Finger tighten and use
an appropriately sized wrench to turn an additional 1/12 turn clockwise.
9
10
8
11
12
1
2
4
5
7
6
3
NOTE A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
Figure 2. Angle and Ball Service Valves
Page 5
XC21 SERIES
Recovering Refrigerant from Existing System
DISCOnNECT POWER
Disconnect all power to the existing outdoor unit at the disconnect
1
switch or main fuse box/breaker panel.
SERVICE DISCONNECT
SWITCH
COnNECT MANIFOLD GAUGE SET
Connect a gauge set, clean recovery cylinder and a recovery
2
machine to the service ports of the existing unit. Use the
instruction provided with the recovery machine to make the
connections.
MANIFOLD GAUGES
RECOVERY MACHINE
LOW
HIGH
RECOVERING REFRIGERANT
Remove existing HCFC−22 refrigerant using one of the following methods
3
below:
IMPORTANT Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes, and/or
long line sets.
CLEAN RECOVERY
CYLINDER
OUTDOOR UNIT
METHOD 1:
Us this method if the existing outdoor unit is not equipped with shut−off valves, or if the unit is not operational and you plan to use the existing
HCFC−22 to flush the system.
Remove all HCFC−22 refrigerant from the existing system. Check gauges after shutdown to confirm that the entire system is completely void of
refrigerant.
METHOD 2:
Use this method if the existing outdoor unit is equipped with manual shut−off valves, and you plan to use new HCFC−22 refrigerant to flush the
system.
The following devices could prevent full system charge recovery into the outdoor unit:
S Outdoor unit’s high or low−pressure switches (if applicable) when tripped can cycle the compressor OFF.
S Compressor can stop pumping due to tripped internal pressure relief valve.
S Compressor has internal vacuum protection that is designed to unload the scrolls (compressor stops pumping) when the pressure ratio meets
a certain value or when the suction pressure is as high as 20 psig. (Compressor suction pressures should never be allowed to go into a vacuum.
Prolonged operation at low suction pressures will result in overheating of the scrolls and permanent damage to the scroll tips, drive bearings and
internal seals.)
Once the compressor can not pump down to a lower pressure due to one of the above system conditions, shut off the vapor valve. Turn OFF the
main power to unit and use a recovery machine to recover any refrigerant left in the indoor coil and line set.
Perform the following task:
A Start the existing HCFC−22 system in the cooling mode and close the liquid line valve.
B Use the compressor to pump as much of the existing HCFC−22 refrigerant into the outdoor unit until the outdoor system is full (high pressure
switch will trip and shut the compressor off). Turn the outdoor unit main power OFF and use a recovery machine to remove the remaining refrigerant from the system.
NOTE It may be necessary to bypass the low pressure switch (if equipped) to ensure complete refrigerant evacuation.
C When the low side system pressures reach 0 psig, close the vapor line valve.
D Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system.
Figure 3. Old Refrigerant Recovery Procedure
Page 6
506587−01
CLEARANCE ON ALL SIDES INCHES (MILLIMETERS)
MINIMUM CLEARANCE
ABOVE UNIT
12 (305)
6 (152)
36 (914)
ACCESS PANEL
CONTROL PANEL
ACCESS
LOCATION
30 (762)
LINE SET
CONNECTIONS
MINIMUM CLEARANCE BETWEEN
TWO UNITS
24 (610)
Figure 4. Installation Clearances
NOTES:
S CLEARANCE TO ONE OF THE
OTHER THREE SIDES MUST BE 36
INCHES (914MM).
S CLEARANCE TO ONE OF THE
REMAINING TWO SIDES MAY BE 12
INCHES (305MM) AND THE FINAL
SIDE MAY BE 6 INCHES (152MM).
ACCESS PANEL
LINE SET
CONNECTIONS
48 (1219)
REAR VIEW OF UNIT
Unit Placement
CAUTION
In order to avoid injury, take proper precaution when
lifting heavy objects.
See Unit Dimensions on page 3 for sizing mounting slab,
platforms or supports. Refer to figure 4 for mandatory
installation clearance requirements.
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
S Some localities are adopting sound ordinances based
on the unit’s sound level registered from the adjacent
property, not from the installation property. Install the
unit as far as possible from the property line.
S When possible, do not install the unit directly outside
a window. Glass has a very high level of sound
transmission. For proper placement of unit in relation
to a window see the provided illustration in figure 5,
detail A.
PLACING UNIT ON SLAB
When installing unit at grade level, the top of the slab
should be high enough above grade so that water from
higher ground will not collect around the unit. The slab
should have a slope tolerance as described in figure 5,
detail B.
NOTE If necessary for stability, anchor unit to slab as
described in figure 5, detail D.
ELEVATING THE UNIT
Units are outfitted with elongated support feet as illustrated
in figure 5, detail C.
If additional elevation is necessary, raise the unit by
extending the height of the unit support feet. This may be
achieved by using a 2 inch (50.8mm) Schedule 40 female
threaded adapter.
The specified coupling will fit snuggly into the recessed
portion of the feet. Use additional 2 inch (50.8mm)
Schedule 40 male threaded adaptors which can be
threaded into the female threaded adaptors to make
additional adjustments to the level of the unit.
NOTE Keep the height of extenders short enough to
ensure a sturdy installation. If it is necessary to extend
further, consider a different type of field−fabricated
framework that is sturdy enough for greater heights.
STABILIZING UNIT ON UNEVEN SURFACES
With unit positioned at installation site, perform the
following:
1. Remove two side louvered panels to expose the unit
base.
2. Install the brackets as illustrated in figure 5, detail D
using conventional practices.
3. Replace the panels after installation is complete.
Page 7
XC21 SERIES
DETAIL A
Outside Unit Placement
INSTALL UNIT AWAY FROM WINDOWS
DETAIL B
Install unit level or, if on a slope, maintain slope tolerance of two (2)
degrees (or two inches per five feet [50 mm per 1.5 m]) away from
building structure.
Slab Mounting at Ground Level
BUILDING
STRUCTURE
MOUNTING
SLAB
TWO 90° ELBOWS INSTALLED IN LINE SET WILL
REDUCE LINE SET VIBRATION.
DETAIL C
Elevated Slab Mounting
using Feet Extenders
LEG DETAIL
2" (50.8MM) SCH 40
FEMALE THREADED
ADAPTER
BASE
GROUND LEVEL
STABILIZING UNIT ON UNEVEN SURFACES
DETAIL D
#10 1/2" LONG SELF−DRILLING
SHEET METAL SCREWS
STABILIZING BRACKET (18 GAUGE
METAL 2" WIDTH; HEIGHT AS
#10 1−1/4" LONG HEX HD SCREW
Concrete slab use two plastic anchors (hole
drill 1/4")
Wood or plastic slab no plastic anchor (hole
drill 1/8")
DETAIL E
Stabilizing bracket (18 gauge metal 2" (50.8mm) width; height as required); bend to form
right angle as exampled below.
Slab Side Mounting
REQUIRED)
AND FLAT WASHER
Deck Top Mounting
MINIMUM ONE
PER SIDE
COIL
BASE PAN
CORNER POST
2" (50.8MM) SCH 40
MALE THREADED
ADAPTER
Use additional 2" SCH 40 male threaded adapters
which can be threaded into the female threaded
adapters to make additional adjustments to the level of
the unit.
IMPORTANT To help stabilize an outdoor unit, some installations may require strapping the unit to the pad using brackets and anchors
commonly available in the marketplace.
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 factory height units when mounted on unstable an uneven surface.
Figure 5. Placement and Slab Mounting
506587−01
SAME FASTENERS AS
SLAB SIDE MOUNTING.
One bracket per side (minimum). For extra stability, two brackets per side, two inches
(51mm) from each corner.
FOR EXTRA
STABILITY
Page 8
ROOF MOUNTING
Install the unit a minimum of six inches (152 mm) above the
roof surface to avoid ice build−up around the unit. Locate
the unit above a load bearing wall or area of the roof that
Removing and Installing Panels
See figure 6 for information on removing and installing unit
panels.
can adequately support the unit. Consult local codes for
rooftop applications.
To prevent personal injury, or damage to panels, unit or
NOTICE
Roof Damage!
This system contains both refrigerant and oil. Some
rubber roofing material may absorbed oil and cause the
rubber to swell when it comes into contact with oil. The
rubber will then bubble and could cause leaks. Protect
the roof surface to avoid exposure to refrigerant and oil
during service and installation. Failure to follow this
notice could result in damage to roof surface.
Panel shown slightly rotated to allow top tab to exit (or enter) top slot for removing (or
installing) panel.
structure, be sure to observe the following:
While installing or servicing this unit, carefully stow all
removed panels out of the way, so that the panels will not
cause injury to personnel, nor cause damage to objects
or structures nearby, nor will the panels be subjected to
damage (e.g., being bent or scratched).
While handling or stowing the panels, consider any
weather conditions, especially windy conditions, that
may cause panels to be blown around and battered.
LOUVERED PANEL REMOVAL
Remove the louvered panels as follows:
1. Remove two screws, allowing the panel to swing open slightly.
2. Hold the panel firmly throughout this procedure Rotate bottom corner of panel
away from hinged corner post until lower three tabs clear the slots as illustrated
in detail B.
3. Move panel down until lip of upper tab clears the top slot in corner post as
illustrated in detail A.
LOUVERED PANEL INSTALLATION
Position the panel almost parallel with the unit as illustrated in detail D with the screw
side as close to the unit as possible. Then, in a continuous motion:
1. Slightly rotate and guide the lip of top tab inward as illustrated in detail A and C;
then upward into the top slot of the hinge corner post.
2. Rotate panel to vertical to fully engage all tabs.
3. Holding the panel’s hinged side firmly in place, close the right−hand side of the
panel, aligning the screw holes.
4. When panel is correctly positioned and aligned, insert the screws and tighten.
Detail A
LIP
WARNING
REMOVE 4 SCREWS TO
REMOVE PANEL FOR
ACCESSING COMPRESSOR
AND CONTROLS.
Position panel with holes
aligned; install screws and
tighten.
Detail C
Maintain minimum panel angle (as close to parallel with the unit as possible) while
installing panel.
IMPORTANT Do not allow panels to hang on unit
by top tab. Tab is for alignment and not designed to
support weight of panel.
Detail D
ANGLE MAY BE
TOO EXTREME
PREFERRED
ANGLE FOR
INSTALLATION
HOLD DOOR FIRMLY ALONG
THE HINGED SIDE TO MAINTAIN
FULLY−ENGAGED TABS
Figure 6. Removing and Installing Panels
Page 9
SCREW
HOLES
Detail B
ROTATE IN THIS DIRECTION; THEN
DOWN TO REMOVE PANEL
XC21 SERIES
New or Replacement Line Set
REFRIGERANT LINE SET
This section provides information on installation or
replacement of existing line set. If new or replacement line
set is not being installed then proceed to Brazing
Connections on page 12.
IMPORTANT
Lennox highly recommends changing line set when
converting the existing system from HCFC−22 to
HFC−410A. If that is not possible and the line set is the
proper size as reference in table 2, use the procedure
outlined under Flushing the System on page 13.
If refrigerant lines are routed through a wall, then seal and
isolate the opening so vibration is not transmitted to the
building. Pay close attention to line set isolation during
installation of any HVAC system. When properly isolated
from building structures (walls, ceilings. floors), the
refrigerant lines will not create unnecessary vibration and
subsequent sounds. See figure 7 for recommended
installation practices. Also, consider the following when
placing and installing a high−efficiency outdoor unit.
Liquid lines that meter the refrigerant, such as RFC1 liquid
lines, must not be used in this application. Existing line set
of proper size as listed in table 2 may be reused. If system
was previously charged with HCFC−22 refrigerant, then
existing line set must be flushed (see Flushing the System
on page 15).
Field refrigerant piping consists of liquid and vapor lines
from the outdoor unit to the indoor unit coil (braze
connections). Use Lennox L15 (sweat, non−flare) series
line set, or field−fabricated refrigerant line sizes as listed in
table 2.
IMPORTANT
Mineral oils are not compatible with HFC−410A. If oil
must be added, it must be a Polyol Ester oil.
Table 2. Refrigerant Connections and Line Set
Requirements
Models Liquid
Line
−024, −036
and−048
−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.
3/8 (10) 7/8 (22) L15 line set sizes are
Vapor/
Suction
Line
L15 Line Set
dependent on unit match up.
See XC21 Engineering
Handbook to determine
correct line set sizes.
NOTE When installing refrigerant lines longer than 50
feet, see the Lennox Refrigerant Piping Design and
Fabrication Guidelines, CORP. 9351−L9, or contact
Lennox Technical Support Product Applications for
assistance.
To obtain the correct information from Lennox, be sure to
communicate the following information:
S Model (XC21) and size of unit (e.g. −036).
S Line set diameters for the unit being installed as listed
in table 2 and total length of installation.
S Number of elbows vertical rise or drop in the piping.
The compressor is charged with sufficient Polyol ester oil
for line set lengths up to 50 feet. Recommend adding oil to
system based on the amount of refrigerant charge in the
system. No need to add oil in system with 20 pounds of
refrigerant or less. For systems over 20 pounds − add one
ounce of every five pounds of refrigerant.
Recommended topping−off POE oils are Mobil EAL
ARCTIC 22 CC or ICI EMKARATEt RL32CF.
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.
506587−01
Page 10
Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation:
REFRIGERANT LINE SET TRANSITION
FROM VERTICAL TO HORIZONTAL
ANCHORED HEAVY NYLON
WIRE TIE OR AUTOMOTIVE
MUFFLER-TYPE HANGER
WALL
STUD
NON−CORROSIVE
METAL SLEEVE
AUTOMOTIVE
MUFFLER-TYPE HANGER
STRAP LIQUID LINE TO
VAPOR LINE
LIQUID LINE
VAPOR LINE − WRAPPED
IN ARMAFLEX
REFRIGERANT LINE SET INSTALLING
HORIZONTAL RUNS
To hang line set from joist or rafter, use either metal strapping material
or anchored heavy nylon wire ties.
WIRE TIE (AROUND
VAPOR LINE ONLY)
8 FEET (2.43 METERS)
STRAPPING
MATERIAL (AROUND
VAPOR LINE ONLY)
TAPE OR
WIRE TIE
FLOOR JOIST OR
ROOF RAFTER
8 FEET (2.43 METERS)
NON−CORROSIVE
METAL SLEEVE
STRAP THE VAPOR LINE TO THE JOIST
OR RAFTER AT 8 FEET (2.43 METERS)
INTERVALS THEN STRAP THE LIQUID
LINE TO THE VAPOR LINE.
TAPE OR
WIRE TIE
REFRIGERANT LINE SET INSTALLING
VERTICAL RUNS (NEW CONSTRUCTION SHOWN)
NOTE Insulate liquid line when it is routed through areas where the
surrounding ambient temperature could become higher than the
temperature of the liquid line or when pressure drop is equal to or greater
than 20 psig.
OUTSIDE WALL
WOOD BLOCK
BETWEEN STUDS
VAPOR LINE WRAPPED
WITH ARMAFLEX
OUTSIDE
WALL
PVC
PIPE
FIBERGLASS
INSULATION
VAPOR LINE
SLEEVE
CAULK
LIQUID
LINE
NOTE Similar installation practices should be used if line set is
to be installed on exterior of outside wall.
LIQUID LINE
WIRE TIE
INSIDE WALL
STRAP
NON−CORROSIVE
METAL SLEEVE
WIRE TIE
WOOD BLOCK
WIRE TIE
STRAP
FLOOR JOIST OR
ROOF RAFTER
Figure 7. Line Set Installation
Page 11
XC21 SERIES
Brazing Connections
Use the procedures outline in figures 8 and 9 for brazing
line set connections to service valves.
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.
IMPORTANT
Connect gauge set low pressure side to vapor line
service valve and repeat procedure starting at
paragraph 4 for brazing the liquid line to service port
valve.
IMPORTANT
Allow braze joint to cool before removing the wet rag
from the service valve. Temperatures above 250ºF can
damage valve seals.
WARNING
When using a high pressure gas such as
dry nitrogen to pressurize a refrigeration
or air conditioning system, use a
regulator that can control the pressure
down to 1 or 2 psig (6.9 to 13.8 kPa).
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.
IMPORTANT
Use silver alloy brazing rods with 5% minimum silver
alloy for copper−to−copper brazing. Use 45% minimum
alloy for copper−to−brass and copper−to−steel brazing.
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.
506587−01
Page 12
PIPING PANEL REMOVAL AND PREPARING LINE
SET
1
Remove piping panel for easier access to 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
COPPER TUBE
REDUCER
STUB
CONNECTION
LINE SET SIZE IS SMALLER
THAN CONNECTION
CAP AND CORE REMOVAL
Remove service cap and core from both the suction / vapor and
2
liquid line service ports.
SERVICE PORT CAP
SERVICE PORT
CORE
LIQUID LINE SERVICE VALVE
REFRIGERANT LINE
DO NOT CRIMP SERVICE VALVE
CONNECTOR WHEN PIPE IS
SMALLER THAN CONNECTION
ATTACH THE MANIFOLD GAUGE SET FOR BRAZING
LIQUID AND SUCTION / VAPOR LINE SERVICE VALVES
3
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.
ATTACH
GAUGES
SUCTION / VAPOR SERVICE PORT MUST BE
OPEN AND SERVICE PORT CORE REMOVED
TO ALLOW EXIT POINT FOR NITROGEN FLOW
SUCTION / VAPOR
LINE
INDOOR
UNIT
C
SUCTION /
VAPOR LINE
SERVICE
VALV E
SUCTION / VAPOR LINE
SERVICE VALVE
HIGHLOW
B
OUTDOOR
UNIT
SERVICE PORT
CORE
SERVICE
PORT CAP
LIQUID LINE
LIQUID LINE SERVICE
VALV E
A
Figure 8. Brazing Procedures
Page 13
NITROGEN
XC21 SERIES
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
5
gauge set into the valve stem port connection on the liquid service
valve and out of the suction / vapor valve stem port. See steps 3A, 3B
and 3C on previous page and below for manifold gauge setup.
BRAZE LINE SET
Water saturated cloths must remain water saturated throughout
6
the brazing and cool−down process.
A Braze liquid line to liquid line service valve.
B Braze suction / vapor line to suction / vapor service
valve.
1. FIRE, PERSONAL INJURY, OR PROPERTY
DAMAGE will 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 in the line set! The braze, when complete,
must be quenched with water to absorb any residual
heat.
2. Do not open service valves until refrigerant lines and
indoor coil have been leak−tested and evacuated.
Refer to procedures provided in this supplement.
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME AWAY
FROM SERVICE VALVE.
WARNING
6B
SUCTION / VAPOR LINE
WATER SATURATED CLOTHS
IMPORTANT Allow braze joint to cool. Apply
additional water saturated cloths to help cool
brazed joints. Do not remove water saturated
cloths until piping has cooled. Temperatures
above 250ºF will damage valve seals.
SUCTION / VAPOR SERVICE PORT
MUST BE OPEN AND SERVICE PORT
CORE REMOVED TO ALLOW EXIT
POINT FOR NITROGEN FLOW
6A
LIQUID LINE
WATER SATURATED
PREPARATION FOR NEXT STEP
After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water saturated cloths to both services
7
valves to cool piping. Once piping is cool, remove all water saturated cloths. Refer to the unit installation instructions for the next step in preparing
the unit.
CLOTHS
Figure 9. Brazing Procedures (Continued)
506587−01
Page 14
Flushing Line Set and Indoor Coil
TYPICAL EXISTING FIXED ORIFICE
1A
DISTRIBUTOR
ASSEMBLY
A On fully cased coils, remove the coil access and plumbing panels.
B Remove any shipping clamps holding 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 process.
D Remove and discard fixed orifice, valve stem assembly if present and
Teflon® washer as illustrated above.
E Use a field−provided fitting to temporary reconnect the liquid line to the
indoor unit’s liquid line orifice housing.
COIL SHOWN)
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
REMOVE AND DISCARD
WHITE TEFLON
(IF PRESENT)
TEFLON® RING
FIXED ORIFICE
®
SEAL
LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
REMOVAL PROCEDURE (UNCASED
OR
BRASS NUT
1B
TWO PIECE PATCH PLATE
(UNCASED COIL ONLY)
CONNECT GAUGES AND EQUIPMENT FOR
FLUSHING PROCEDURE
2
INVERTED HCFC−22
CYLINDER CONTAINS
CLEAN HCFC−22 TO BE
USED FOR FLUSHING.
A
1
VAPOR LINE
SERVICE VALVE
EXISTING
INDOOR
UNIT
LIQUID LINE SERVICE
VALV E
VAPOR
LIQUID
D
RECOVERY
CYLINDER
A Inverted HCFC−22 cylinder with clean 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 to the gauge set.
D Connect recovery tank to recovery machines per machine instructions.
OUTDOOR
B
NEW
UNIT
OPENED
C
RECOVERY MACHINE
GAUGE
MANIFOLD
LOW HIGH
CLOSED
TANK
RETURN
INLET
DISCHARGE
TYPICAL EXISTING EXPANSION VALVE REMOVAL
PROCEDURE (UNCASED COIL SHOWN)
ORIFICE
HOUSING
EQUALIZER
LINE
STUB END
TEFLOn
RING
VAPOR
CHECK
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 holding the liquid line and distributor
assembly.
C Disconnect the equalizer line from the check expansion valve
equalizer line fitting on the vapor line.
D Remove the vapor line sensing bulb.
E Disconnect the liquid line from the check expansion valve at the liquid
line assembly.
F Disconnect the check expansion valve from the liquid line orifice
housing. Take care not to twist or damage distributor tubes during this
process.
G Remove and discard check expansion valve and the two Teflon® rings.
H Use a field−provided fitting to temporary 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
3
same 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
B
set and indoor unit coil.
B Invert the cylinder of clean HCFC−22 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 down to 0
the system.
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 10. Flushing Line Set and Indoor Coil
Page 15
XC21 SERIES
Installing Indoor 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
CHECK
EXPANSION
VALV E
®
LIQUID LINE
ASSEMBLY WITH
LINE
TEFLON
RING
SENSING
BRASS NUT
LIQUID LINE
Sensing bulb insulation is required if
mounted external to the coil casing. sensing
bulb installation for bulb positioning.
EQUALIZER LINE INSTALLATIOn
A Remove and discard either the flare seal cap or flare nut
with copper flare seal bonnet from the equalizer line port
on the vapor line as illustrated in the figure to the right.
B Remove and discard either the flare seal cap or flare nut
with copper flare seal bonnet from the equalizer line port on
the vapor line as illustrated in the figure to the right.
®
LINE
A Remove the field−provided fitting that temporary
reconnected the liquid line to the indoor unit’s distributor
assembly.
B Install one of the provided Teflon® rings around the
stubbed end of the check expansion valve and lightly
lubricate the connector threads and expose surface of
the Teflon
®
ring with refrigerant oil.
C Attach the stubbed end of the check 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 20 ft−lb.
®
D Place the remaining Teflon
washer around the other
end of the check expansion valve. Lightly lubricate
connector threads and expose surface of the Teflon
ring with refrigerant oil.
E Attach the liquid line assembly to the check 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 20 ft−lb.
SENSING BULB INSTALLATIOn
A Attach the vapor line sensing bulb in the proper
orientation as illustrated to the right using the clamp and
screws provided.
NOTE Confirm proper thermal contact between vapor line
and check expansion bulb before insulating the sensing bulb
once installed.
B Connect the equalizer line from the check 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.
VAPOR LINE
BULB
12
ON LINES SMALLER THAN
7/8", MOUNT SENSING
BULB AT EITHER THE 3 OR
9 O’CLOCK POSITION.
BULB
®
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
506587−01
OR
FLARE NUT
COPPER FLARE
SEAL BONNET
MALE BRASS EQUALIZER
LINE FITTING
VAPOR LINE
VAPOR LINE
12
BULB
NOTE NEVER MOUNT ON BOTTOM OF LINE.
Figure 11. Installing Indoor Expansion Valve
Page 16
ON 7/8" AND LARGER LINES,
MOUNT SENSING BULB AT
EITHER THE 4 OR 8 O’CLOCK
POSITION. NEVER MOUNT ON
BOTTOM OF LINE.
BULB
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