Lennox EL16XC1-030-230, EL16XC1-024-230, EL16XC1-042-230, EL16XC1-060-230, EL16XC1-047-230 Installation Instructions Manual

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Page 1

INSTALLATION

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

General

This EL16XC1 outdoor air conditioner with all-aluminum coil is designed for use with HFC-410A refrigerant only.

This unit must be installed with an approved indoor air han dler or coil. See the Lennox EL16XC1 Product Specifica tions bulletin (EHB) for approved indoor component match ups.

These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.

IMPORTANT: Special procedures are required for clean ing the aluminum coil in this unit. See page 15 in this in struction for information.

INSTRUCTIONS

Elite® Series EL16XC1 Units

AIR CONDITIONER 507525-01

08/2016

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal inju ry or loss of life.

Installation and service must be performed by a licensed professional installer (or equivalent) or service agency.

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 pro tective clothing.

NOTICE !

For more in-depth information, consult the Installa tion and Service Procedures manual, available as Corp. 1503-L7 on LennoxPROs.com or through the Technical Support department at 800-453-6669.

STEP 1 -- SETTING THE UNIT -- Clearances

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

NOTES:

Service clearance of 30 in. must be maintained on one of the sides adjacent to the control box.

Clearance to one of the other three sides must be 36 in.

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

Page 2

UNIT DIMENSIONS - INCHES (MM)

LIQUID LINE CONNECTION

ELECTRICAL INLETS

SUCTION LINE CONNECTION

SIDE VIEW

Model

EL16XC1-018-230

EL16XC1-024-230

EL16XC1-030-230 EL16XC1-041-230 EL16XC1-042-230 EL16XC1-048-230

EL16XC1-036-230

EL16XC1-047-230 35 (889) EL16XC1-060-230 45 (1143)

UNIT SUPPORT

FEET

8-1/2”

(216)

A B C D E F G H I J

31 (787)

39 (991)

31 (787)

(686)

30-1/2

(775)

30-1/2

(775)

30-1/2

(775)

35-1/2

(902)

(711)

(889)

39-1/2 (1003)

4-1/2”

(108)

4-3/4”

(121)

EL16XC1 Dimensions - in. (mm)

See EL16XC1-018 base section below.

9-1/2”

(241)

13-7/8

(352)

13-7/8

(352)

13-7/8

(352)

16-7/8

(429)

UNIT SUPPORT

FEET

7-3/4 (197)

8-3/4 (222)

3-1/4

(83)

3-1/4

(83)

3-1/4

(83)

3-1/8

(79)

27-1/8

(689)

27-1/8

(689)

27-1/8

(689)

30-3/4

(781)

TOP VIEW

3-5/8

(92)

3-5/8

(92)

3-5/8

(92)

4-5/8 (117)

4-1/2 (114)

3-3/4

(95)

20-5/8

(524)

20-5/8

(524)

20-5/8

(524)

26-7/8

(683)

8-3/4 (222)

5-1/2”

(140)

13-1/2”

(343)

EL16XC1-018 BASE SECTION (SMALL)

8-1/4”

(210)

Page 2

EL16XC1-024 TO -060 BASE WITH

ELONGATED LEGS

EL16XC1 SERIES

Page 3

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.

IMPORTANT !

Exhaust vents from dryers, water heaters and furnaces should be directed away from the outdoor unit. Prolonged exposure to exhaust gases and the chemicals contained within them may cause condensation to form on the steel cabinet and other metal components of the outdoor unit. This will diminish unit performance and longevity.

PLACEMENT

Install unit away from windows.

ELEVATED SLAB MOUNTING USING FEET

EXTENDERS

2” (50.8MM) SCH 40

FEMALE THREADED

ADAPTER

2” (50.8MM) SCH 40 MALE THREADED ADAPTER

LEG DETAIL

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.

BASE

FIGURE 4

CAUTION

TWO 90° ELBOWS INSTALLED IN LINE SET

WILL REDUCE LINE SET VIBRATION.

FIGURE 2

SLAB MOUNTING

Install unit level or, if on a slope, maintain slope tolerance of 2 degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from building structure.

BUILDING

STRUCTURE

MOUNTING SLAB

GROUND LEVEL

Before attempting to perform any service or mainte nance, turn the electrical power to unit OFF at disconnect switch.

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

Concrete slab — use two plastic anchors (hole drill 1/4”)

IMPORTANT !

CORNER POST

COIL

BASE PAN

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 3

FIGURE 5

Page 3

EL16XC1 SERIES

Page 4

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.

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 DaveNet.

CAUTION - DO NOT attempt to flush and re-use exist

ing line sets or indoor coil when the system contains contaminants (i.e., compressor burn out).

IMPORTANT !

If this unit is being matched with an approved line set or indoor unit coil that was previously charged with mineral oil, or if it is being matched with a coil which was manufactured before January of 1999, the coil and line set must be flushed prior to installa tion. Take care to empty all existing traps. Polyol es ter (POE) oils are used in Lennox units charged with HFC-410A refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the expansion device and reduce sys tem performance and capacity.

Failure to properly flush the system per this instruc tion and the detailed Installation and Service Proce dures manual will void the warranty.

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 Haz ard. Failure to follow this warning could re sult 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.

TABLE 1

REFRIGERANT LINE SET — INCHES (MM)

Valve Size Connections Recommended Line Sets

Model Number (-xx*)

EL16XC1-018-230AXX EL16XC1-024-230AXX EL16XC1-030-230AXX

EL16XC1-036-230AXX

EL16XC1-041-230-XX

EL16XC1-042-230AXX

EL16XC1-047-230-XX EL16XC1-048-230-XX

EL16XC1-060-230-XX 3/8” (10 mm) 1-1/8” (29 mm) ** Field-fabricated N/A N/A

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).

Liquid Line Suction Line

3/8” (10 mm) 3/4” (19 mm)

3/8” (10 mm) 7/8” (22 mm)

* Applicable to all minor revision numbers unless otherwise specified.

** Some applications may require a field-provided 1-1/8” to 7/8” adapter.

L15 Line Set

Model

L15-41-20 20 feet (6.1 m) 89J56

L15-41-30 30 feet (9.1 m) 89J57

L15-41-40 40 feet (12.2 m) 89J58

L15-41-50 50 feet (15.2 m) 89J59

L15-65-30 30 feet (9.1 m) 89J60

L15-65-40 40 feet (12.2 m) 89J61

L15-65-50 50 feet (15.2 m) 89J62

Line Set Length Catalog Number

Page 4

EL16XC1 SERIES

Page 5

STEP 2 -- REFRIGERANT PIPING -- Removing Existing Indoor Metering Device

TYPICAL EXISTING FIXED ORIFICE

DISTRIBUTOR

ASSEMBLY

1 - On fully cased coils, remove the coil access and plumbing panels. 2 - Remove any shipping clamps from the liquid line and distributor as

sembly.

3 - Using two wrenches, disconnect liquid line from liquid line orifice hous

ing. Take care not to twist or damage distributor tubes during this pro cess.

4 - Remove and discard fixed orifice, valve stem assembly (if present)

and Teflon® washer as illustrated above.

5 - Use a field-provided fitting to temporarily reconnect the liquid line to the

indoor unit's liquid line orifice housing.

(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

BRASS NUT

TWO-PIECE PATCH PLATE

(UNCASED COIL ONLY)

CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE

SUCTION LINE

SERVICE VALVE

EXISTING

INDOOR

UNIT

LIQUID LINE SERVICE

VALV E

RECOVERY

CYLINDER

LIQUID

1 - HCFC-22 cylinder with clean refrigerant* (positioned to deliver liquid

refrigerant) to the suction service valve.

2 - HCFC-22 gauge set (low side) to the liquid line valve. 3 - HCFC-22 gauge set center port to inlet on the recovery machine with an

empty recovery tank connected to the gauge set.

4 - Connect recovery tank to recovery machine per machine instructions.

CYLINDER CONTAINING CLEAN HCFC-22* TO BE USED FOR FLUSHING (Positioned to deliver liquid

refrigerant)

SUCTION

NEW

OUTDOOR

UNIT

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

SUCTION

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

1 - On fully cased coils, remove the coil access and plumbing panels. 2 - Remove any shipping clamps from the liquid line and distributor

assembly.

3 - Disconnect the equalizer line from the expansion valve equalizer

line fitting on the suction line.

4 - Remove the suction line sensing bulb. 5 - Disconnect the liquid line from the expansion valve at the liquid line

assembly.

6 - Disconnect the expansion valve from the liquid line orifice housing.

Take care not to twist or damage distributor tubes during this process.

7 - Remove and discard expansion valve and the two Teflon® rings. 8 - Use a field-provided fitting to temporarily reconnect the liquid line to

the indoor unit's liquid line orifice housing.

FLUSHING LINE SET

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

3 - After all of the liquid refrigerant has been recovered, switch the

4 - Close the valve on the inverted HCFC-22 drum and the gauge set

refrigerant and open its valve to allow liquid refrigerant to flow into the system through the suction line valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine.

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.

valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off.

*IMPORTANT - Clean refrigerant is any refrigerant in a system that has not had compressor burn out. If the system has experienced burn out, it is recommended that the existing line set and indoor coil be replaced.

FIGURE 6

Page 5

EL16XC1 SERIES

Page 6

STEP 2 -- REFRIGERANT PIPING -- Brazing Procedures

CUT AND DEBUR

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

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

both the suction / vapor and liquid line service ports.

SERVICE PORT

CAP

SERVICE

PORT

CORE

LIQUID LINE SERVICE

VALV E

SUCTION LINE SERVICE

ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION LINE SERVICE VALVES

Flow regulated nitrogen (at 1 to 2 psig) through the low-side refrigeration gauge set into the liquid line service port valve, and out of the suction line service port valve.

1 - Connect gauge set low pressure side to

liquid line service valve (service port).

2 - Connect gauge set center port to bottle of

nitrogen with regulator.

3 - Remove core from valve in suction line

service port to allow nitrogen to escape.

ATTACH

GAUGES

HIGHLOW

USE REGULATOR TO FLOW

NITROGEN AT 1 TO 2 PSIG.

VALV E

SERVICE

PORT

CORE

SERVICE PORT CAP

SUCTION SERVICE PORT MUST BE OPEN TO

ALLOW EXIT POINT FOR NITROGEN

SUCTION LINE

INDOOR

UNIT

LIQUID LINE

LIQUID LINE SERVICE

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.

SUCTION

LINE

SERVICE

VALV E

FIGURE 7

OUTDOOR

UNIT

WHEN BRAZING LINE SET TO

SERVICE VALVES, POINT FLAME

AWAY FROM SERVICE VALVE.

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

WARNING

Page 6

EL16XC1 SERIES

Page 7

WRAP SERVICE VALVES

To help protect service valve seals during brazing, wrap water-saturated cloths around service valve bodies and copper tube stubs. Use

additional water-saturated cloths underneath the valve body to protect the base paint.

FLOW NITROGEN

Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and

out of the suction valve stem port. See steps 3A, 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

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.

LIQUID LINE

WATER-SATURATED CLOTH

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 LINE

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 valves to cool piping. Once piping is cool, remove all water-saturated cloths.

SUCTION LINE SERVICE

VALV E

WATER-SATURATED CLOTH

WHEN BRAZING LINE SET TO

SERVICE VALVES, POINT FLAME

AWAY FROM SERVICE VALVE.

FIGURE 7 (CONTINUED)

Page 7

EL16XC1 SERIES

Page 8

STEP 2 — REFRIGERANT PIPING — Installing Indoor Expansion Valve

This outdoor unit is designed for use in systems that use a expansion valve metering device. See the EL16XC1 Product Specifications bulletin (EHB) for approved expansion valve kit match-ups and application information. The expansion valve

can be installed internal or external to the indoor coil. In applications where an uncased coil is being installed in a field-pro vided plenum, install the expansion valve in a manner that will provide access for future field service of the expansion valve. Refer to below illustration for reference during installation of expansion valve.

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

SUCTION

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

1 - Remove and discard either the flare seal cap or flare nut with

copper flare seal bonnet from the equalizer line port on the suction line as illustrated in the figure below.

2 - Remove the field-provided fitting that temporarily recon

nected the liquid line to the indoor unit's distributor assembly.

LINE

3 - Install one of the provided Teflon® rings around the

stubbed end of the expansion valve and lightly lubricate the connector threads and expose surface of the Teflon ring with refrigerant oil.

4 - Attach the stubbed end of the expansion valve to the

liquid line orifice housing. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above, or tighten to 20 ft-lb.

5 - Place the remaining Teflon® washer around the other

end of the expansion valve. Lightly lubricate connector threads and expose surface of the Teflon® ring with refrigerant oil.

6 - Attach the liquid line assembly to the expansion valve.

Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or tighten to 20 ft-lb.

SENSING BULB INSTALLATION

1 - Attach the suction line sensing bulb in the proper

orientation as illustrated to the right using the clamp and screws provided.

NOTE - Confirm proper thermal contact between the suction line and expansion bulb before insulating the sensing bulb once installed.

2 - Connect the equalizer line from the expansion valve to

the equalizer suction port on the suction line. Finger tighten the flare nut plus 1/8 turn (7 ft-lbs) as illustrated below.

SUCTION LINE

BULB

ON LINES SMALLER THAN 7/8”, MOUNT SENSING BULB AT EITHER THE 3 OR 9 O'CLOCK POSITION.

BULB

1/2 Turn

1/8 Turn

FLARE SEAL CAP

FLARE NUT

COPPER FLARE SEAL BONNET

MALE BRASS EQUALIZER LINE FITTING

SUCTION LINE

FIGURE 8

Page 8

SUCTION LINE

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.

EL16XC1 SERIES

Page 9

STEP 3 -- LEAK TEST AND EVACUATION

HIGHLOW

MANIFOLD GAUGE SET

OUTDOOR UNIT

TO SUCTION

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 suction valve service

port.

NOTE - Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the suction port better protects the manifold gauge set from high pressure damage.

B - With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of

the manifold gauge set.

NOTE - Later in the procedure, the HFC-410A container will be replaced by the nitrogen container.

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

FIGURE 9

Page 9

EL16XC1 SERIES

Page 10

STEP 3 -- LEAK TEST AND EVACUATION (Continued)

CONNECT GAUGE SET

NOTE - Remove cores from service valves (if not already done).

A - Connect low side of manifold gauge set with

1/4 SAE in-line tee to suction line service valve

B - Connect high side of manifold gauge set to

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 will be used later for both the HFC-410A and nitrogen containers.

NITROGEN

NOTE - Position canister to deliver liquid refrigerant.

HFC-410A

VACUUM PUMP

OUTDOOR

UNIT

EVACUATION

1/4 SAE TEE WITH SWIVEL COUPLER

500

MICRON

GAUGE

GAUGE SET

TO SUCTION

SERVICE VALVE

TO LIQUID LINE SERVICE VALVE

LOW

MANIFOLD

EVACUATE THE SYSTEM

A - Open both manifold valves and start the vacuum pump. B - Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury).

NOTE - During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once. A rapid rise in pressure indicates a relatively large leak. If this occurs, repeat the leak testing procedure.

NOTE - The term absolute pressure means the total actual pressure above absolute zero within a given volume or system. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure.

C - When the absolute pressure reaches 23,000 microns (29.01 inches of mercury),

perform the following:

● Close manifold gauge valves.

● Close valve on vacuum pump.

● Turn off vacuum pump.

● Disconnect manifold gauge center port hose from vacuum pump.

● Attach manifold center port hose to a nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose.

● Open manifold gauge valves to break the vacuum in the line set and indoor unit.

● Close manifold gauge valves.

D - Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the nitrogen

from the line set and indoor unit.

E - Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and indoor unit until the absolute

pressure does not rise above 500 microns (29.9 inches of mercury) within a 20-minute period after shutting off the vacuum pump and closing the manifold gauge valves.

F - When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to a

cylinder of HFC-410A positioned to deliver liquid refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit.

G - Perform the following:

● Close manifold gauge valves.

● Shut off HFC-410A cylinder.

● Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core tool while maintaining a positive system pressure.

● Replace stem caps and finger tighten them, then tighten an additional one-sixth (1/6) of a turn as illustrated.

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 !

RECOMMEND

MINIMUM 3/8” HOSE

1/6 TURN

HIGH

FIGURE 10

Page 10

EL16XC1 SERIES

Page 11

STEP 4 -- ELECTRICAL -- Circuit Sizing and Wire Routing

In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC).

Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit

Fire Hazard. Use of aluminum wire with this product may result in a fire, causing property damage, severe injury or death. Use copper wire only with this product.

nameplate for minimum circuit ampacity and maximum overcurrent protection size.

24VAC TRANSFORMER

Use the transformer provided with the furnace or air han dler for low‐voltage control power (24VAC - 40 VA mini mum)

Failure to use properly sized wiring and circuit breaker may result in property damage. Size wiring and circuit breaker(s) per Product Specifications bulletin (EHB) and unit rating plate.

WARNING

Electric Shock Hazard. Can cause injury or death. Unit must be properly 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.

IMPORTANT !

If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start-up to prevent compressor damage as a result of slugging.

ELECTROSTATIC

DISCHARGE

(ESD)

Precautions and

Procedures

WARNING

CAUTION

Electrostatic discharge can affect electroniccomponents.Takecareduring unit installation and service to protect the 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 beforeperforminganyserviceprocedure to neutralize electrostatic charge.

SIZE CIRCUIT AND INSTALL SERVICE

DISCONNECT SWITCH

Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR per NEC). Install power wiring and properly sized disconnect switch.

NOTE - Units are approved for use only with copper conductors. Ground unit at disconnect switch or connect to an earth ground.

MAIN FUSE

BOX/BREAKER

PANEL

DISCONNECT

SWITCH

FIGURE 11

Install room thermostat (ordered separately) on an inside wall

INSTALL THERMOSTAT

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

5 FEET

(1.5M)

NOTE - 24VAC, Class II circuit connections are made in the control panel.

Page 11

EL16XC1 SERIES

Page 12

STEP 4 -- ELECTRICAL (CONTINUED) -- Field Wiring

Unit Low Voltage Wiring

WIRE NUTS

BLACK

CUTOUT WITH

GROMMET

24V CONTROL WIRES

24VAC Control Wiring Diagrams (Field Installed)

ML180

YELLOW

TIGHTEN WIRE TIE

FIGURE 12

EL280, EL295, EL296

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.

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.

SLP98, SL28UH, SL280DF

XC14 XC14XC14

CBX25

XC14

NOTE - Refer to furnace, blower coil and accessory instructions for additional wiring configurations with other optional controls.

XC14

CBX40UHV

XC14

RED

BROWN

BLUE

Air handler shipped with jumpers installed between W1 and W2

and W2 and W3.

R connection required for air conditioner with LSOM. Resistor kit

(CAT #47W97) required when connection ComfortSense 7000 with LSOM 2.

L connection wired on units with LSOM.

FIGURE 13

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EL16XC1 SERIES

Page 13

STEP 5 -- UNIT START-UP

IMPORTANT

If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start-up to prevent compressor damage as a result of slugging.

1 - Rotate fan to check for binding. 2 - Inspect all factory- and field-installed wiring for loose

connections.

3 - After evacuation is complete, open the liquid line and

suction line service valve stems to release the refriger ant charge (contained in outdoor unit) into the system.

4 - Replace the stem caps and tighten to the value listed

in table 2.

5 - Check voltage supply at the disconnect switch. The

voltage must be within the range listed on the unit's nameplate. If not, do not start the equipment until you have consulted with the power company and the volt age condition has been corrected.

6 - Connect manifold gauge set for testing and charging

using figure 11 as a guideline.

7 - Set the thermostat for a cooling demand. Turn on pow

er to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit.

8 - Recheck voltage while the unit is running. Power must

be within range shown on the unit nameplate.

9 - Check system for sufficient refrigerate using the pro

cedures outlined in under System Refrigerant.

OPERATING MANIFOLD GAUGE SET AND SERVICE VALVES

The liquid and suction line service valves are used for re moving refrigerant, flushing, leak testing, evacuating, checking charge and charging.

Each valve is equipped with a service port which has a fac tory-installed valve stem. Figures 14 and 15 provide infor mation on how to access and operate both angle- and balltype service valves.

Torque Requirements

When servicing or repairing heating, ventilating, and air conditioning components, ensure the fasteners are appro priately tightened. Table 2 lists torque values for fasteners.

TABLE 2

TORQUE REQUIREMENTS

Parts Recommended Torque

Service valve cap 8 ft.- lb. 11 NM

Sheet metal screws 16 in.- lb. 2 NM

Machine screws #10 28 in.- lb. 3 NM

Compressor bolts 90 in.- lb. 10 NM

Gauge port seal cap 8 ft.- lb. 11 NM

Using Manifold Gauge Set

When checking the system charge, only use a manifold gauge set that features low loss anti-blow back fittings.

Manifold gauge set used with HFC-410A refrigerant sys tems must be capable of handling the higher system oper ating pressures. The gauges should be rated for use with pressures of 0 - 800 psig on the high side and a low side of 30” vacuum to 250 psig with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psig of pressure with a 4000 psig burst rating.

OPERATING BALL-TYPE SERVICE VALVE:

1 - Remove stem cap with an appropriately sized wrench.

2 - Use an appropriately sized wrenched to open. To open valve,

rotate stem counterclockwise 90°. To close rotate stem clockwise 90°.

TO OPEN ROTATE STEM COUNTERCLOCKWISE 90°.

TO CLOSE ROTATE STEM CLOCKWISE 90°.

SERVICE PORT

CORE

CAP

BALL (SHOWN CLOSED)

VALV E STEM

STEM CAP

FIGURE 14

OPERATING ANGLE-TYPE SERVICE VALVE:

1 - Remove stem cap with an appropriately sized wrench.

2 - Use a service wrench with a hex-head extension (3/16” for liquid

line valve sizes and 5/16” for suction line valve sizes) to back the stem out counterclockwise as far as it will go.

SERVICE PORT CAP

SERVICE PORT CORE

(VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE

STEM CAP

ANGLE-TYPE SERVICE VALVE

(BACK-SEATED OPENED)

When service valve is OPEN, the service port is

open to line set, indoor and outdoor unit.

(VALVE STEM SHOWN CLOSED) INSERT HEX WRENCH HERE

ANGLE-TYPE SERVICE VALVE

(FRONT-SEATED CLOSED)

IMPORTANT

To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening.

When service valve is CLOSED, the service port is

open to the line set and indoor unit.

NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.

FIGURE 15

Page 13

EL16XC1 SERIES

Page 14

TO ACCESS SERVICE PORT:

A service port cap protects the service port core from contamination and serves as the primary leak seal.

1 - Remove service port cap with an appropriately sized wrench.

2 - Connect gauge set to service port.

3 - When testing is completed, replace service port cap and tighten

as follows:

● With torque wrench: Finger tighten and

torque cap per table 2.

● Without torque wrench: Finger tighten and

use an appropriately sized wrench to turn an additional 1/6 turn clockwise.

Reinstall Stem Cap:

Stem cap protects the valve stem from damage and serves as the primary seal. Replace the stem cap and tighten as follows:

● With Torque Wrench: Finger tighten

and then torque cap per table 2.

● Without Torque Wrench: Finger

tighten and use an appropriately sized wrench to turn an addition al 1/12 turn clockwise.

1/12 TURN

1/6 TURN

FIGURE 16

Checking and Adding System Charge

The EL16XC1 unit is factory-charged with enough HFC-410A refrigerant to accommodate a 15-foot length of refrigerant piping. Charge should be checked and adjusted using the tables provided on the charging procedure stick er on the unit access panel. Detailed information is given in the EL16XC1 Installation and Service Procedures manual (Corp1503-L7), which is available on DaveNet.

IMPORTANT !

Some scroll compressors have an internal vacuum protector that will unload scrolls when suction pres sure goes below 20 psig. A hissing sound will be heard when the compressor is running unloaded. Protector will reset when low pressure in system is raised above 40 psig. DO NOT REPLACE COMPRES SOR.

High Pressure Switch (S4)

This unit is equipped with a high pressure switch which is located on the liquid line. The SPST, normally closed pres sure switch opens when liquid line pressure rises above the factory setting of 590 + 15 psig and automatically resets at 418 + 15 psig.

Homeowner Information

CAUTION

Before attempting to perform any service or mainte nance, turn the electrical power to unit OFF at dis connect switch.

WARNING

This product contains a chemical known to the State of California to cause cancer, birth defects, or other repro ductive harm.

In order to ensure peak performance, your system must be properly maintained. Clogged filters and blocked airflow prevent your unit from operating at its most efficient level. The system should be inspected and serviced before each cooling season by a licensed professional HVAC service technician (or equivalent).

Homeowner Maintenance

The following maintenance may be performed by the homeowner.

● Contact a licensed professional HVAC technician to

schedule a yearly inspection and maintenance appoint ment for your equipment.

● Check the indoor unit filter each month and replace the

filter, if necessary. Have your Lennox dealer show you where your indoor unit filter is located. It will be either at the indoor unit (installed internal or external to the cabinet) or behind a return air grille in the wall or ceiling. Check the filter monthly and clean or replace it as needed. Disposable filters should be replaced with a filter of the same type and size.

● Check the indoor unit drain line for obstructions monthly

during the cooling season. The indoor evaporator coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the inside air. Have your dealer show you the location of the drain line and how to check for obstruc tions. (This would also apply to an auxiliary drain, if installed.)

● Check the area around the outdoor unit monthly and re

move any obstructions that may restrict airflow to the outdoor unit. This would include grass clippings, leaves, or papers that may have settled around the unit.

● Trim shrubbery away from the unit and periodically check

for debris which collects around the unit.

● During the winter months, keep the snow level below the

louvered panels.

NOTE - The filter and all access panels must be in place any time the unit is in operation. If you are unsure about the filter required for your system, call your Lennox dealer for assistance.

IMPORTANT !

Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to the outdoor unit by treated water. Prolonged exposure of the unit to treated water (i.e., sprinkler systems, soakers, waste water, etc.) will corrode the surface of steel and aluminum parts, diminish performance and affect longevity of the unit.

Page 14

EL16XC1 SERIES

Page 15

Thermostat Operation

See the thermostat owner's manual for instructions on how to operate your thermostat.

Preservice Check

If your system fails to operate, check the following before calling for service:

● Verify room thermostat settings are correct.

● Verify that all electrical disconnect switches are ON.

● Check for any blown fuses or tripped circuit breakers.

● Verify unit access panels are in place.

● Verify air filter is clean.

● If service is needed, locate and write down the unit

model number and have it handy before calling.

Professional Maintenance

Your heating and air conditioning system should be inspec ted and maintained twice each year (before the start of the heating and cooling seasons) by a licensed professional HVAC technician. You can expect the technician to check the following items. These checks may only be conduc

ted by a licensed professional HVAC technician.

Outdoor Unit

1 - Inspect component wiring for loose, worn or damaged

connections. Also check for any rubbing or pinching of wires. Confirm proper voltage plus amperage for out door unit.

NOTICE !

Failure to follow instructions will cause damage to the unit. This unit is equipped with an aluminum coil. Alu minum coils may be damaged by exposure to solu tions with a pH below 5 or above 9. The aluminum coil should be cleaned using potable water at a mod erate pressure (less than 50psi). If the coil cannot be cleaned using water alone, Lennox recommends use of a coil cleaner with a pH in the range of 5 to 9. The coil must be rinsed thoroughly after cleaning. In coastal areas, the coil should be cleaned with potable water several times per year to avoid corro sive buildup (salt).

Indoor Unit (Air Handler or Furnace)

1 - Inspect component wiring for loose, worn or damaged

connections. Confirm proper voltage plus amperage for indoor unit.

2 - Inspect and clean or replace air filters in indoor unit.

3 - Check the cleanliness of indoor blower and clean

blower, if necessary.

4 - Inspect the evaporator coil (Indoor) drain pans and

condensate drains for rust, debris, obstructions, leaks or cracks. Pour water in pans to confirm proper drain age from the pan through to the outlet of the pipe. Clean or replace as necessary.

5 - Inspect and clean evaporator (indoor) coil, if neces

sary.

2 - Check the cleanliness of outdoor fan and blade assem

blies. Check condition of fan blades (cracks). Clean or replace them, if necessary.

3 - Inspect base pan drains for debris and clean as neces

sary.

4 - Inspect the condition of refrigerant piping and confirm

that pipes are not rubbing copper-to-copper. Also, check the condition of the insulation on the refrigerant lines. Repair, correct, or replace as necessary.

5 - Test capacitor. Replace as necessary.

6 - Inspect contactor contacts for pitting or burn marks.

Replace as necessary.

7 - Check outdoor fan motor for worn bearings/bushings.

Replace as necessary.

8 - Inspect and clean outdoor coils, if necessary and note

any damage to coils or signs of leakage.

6 - Inspect the condition of the refrigerant lines and con

firm that pipes are not rubbing copper-to-copper. Also, ensure that refrigerant pipes are not being affected by indoor air contamination. Check condition of insulation on the refrigerant lines. Repair, correct, or replace as necessary.

7 - Inspect the duct system for leaks or other problems.

Repair or replace as necessary.

8 - Check for bearing/bushing wear on indoor blower mo

tor. Replace as necessary.

9 - Indoor unit inspections of gas- or oil-fired furnaces will

also include inspection and cleaning of the burners and and a full inspection of the gas valve, heat exchanger and flue (exhaust) system.

General System Test with System Operating

1 - Your technician should perform a general system test.

He will turn on the air conditioner to check operating functions such as the startup and shutoff operation. He will also check for unusual noises or odors, and measure indoor/outdoor temperatures and system pressures as needed. He will check the refrigerant charge per the charging sticker information on the out door unit.

2 - Verify that system total static pressure and airflow set

tings are within specific operating parameters.

3 - Verify correct temperature drop across indoor coil.

Page 15

EL16XC1 SERIES

Page 16

EL16XC1 Start-Up and Performance Checklist

Customer Address

Indoor Unit Model Serial

Outdoor Unit Model Serial

Notes:

START UP CHECKS

Refrigerant Type:

Rated Load Amps: Actual Amps Rated Volts

Actual Volts

Condenser Fan Full Load Amps Actual Amps:

COOLING MODE

Suction Pressure: Liquid Pressure:

Supply Air Temperature: Ambient Temperature: Return Air: Temperature:

System Refrigerant Charge (Refer to manufacturer's information on unit or installation instructions for required subcooling and approach temperatures.)

Subcooling:

A — B = SUBCOOLING

Saturated Condensing Temperature (A)

minus Liquid Line Temperature (B)

Approach:

A — B = APPROACH

Liquid Line Temperature (A)

minus Outdoor Air Temperature (B)

Indoor Coil Temperature Drop (18 to 22°F)

A — B = COIL TEMP DROP

Return Air Temperature (A)

minus Supply Air Temperature (B)

Page 16

EL16XC1 SERIES