Lennox XC17, 506510-01 User Manual

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INSTALLATION

E2010 Lennox Industries Inc.

Dallas, Texas, USA

NOTICE

A thermostat is not included and must be ordered separately.

The Lennox ComfortSense® 7000 thermostat may be used, as well as other thermostats.

In all cases, setup is critical to ensure proper system operation.

Field wiring is illustrated in diagrams, which begin on Page 19.

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.

General

This single−stage 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 XC17 Engineering Handbook for approved indoor component matchups.

IMPORTANT

This model is designed for use in 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.

INSTRUCTIONS

Dave Lennox Signature Collection XC17 Units

AIR CONDITIONER

506510−01 04/10 Supersedes 506498−01

RETAIN THESE INSTRUCTIONS FOR FUTURE

REFERENCE

TABLE OF CONTENTS

General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .

Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Number Identification 2. . . . . . . . . . . . . . . . . . . .

Unit Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . . . .

Operating Gauge Set and Service Valves 4. . . . . . . . .

Recovering Refrigerant from Existing System 6. . . . .

New Outdoor Unit Placement 7. . . . . . . . . . . . . . . . . . .

Removing and Installing Panels 10. . . . . . . . . . . . . . . . .

New or Replacement Line Set 11. . . . . . . . . . . . . . . . . . .

Flushing the System 14. . . . . . . . . . . . . . . . . . . . . . . . . . .

Leak Testing the System 16. . . . . . . . . . . . . . . . . . . . . . .

Evacuating the System 16. . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Control Jumpers and Terminals 22. . . . . . . . . . . . .

Field Control Wiring 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Unit Delivered Void of Charge 26. . . . . . . . . .

Unit Start−Up 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Refrigerant 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating and Temperature Pressures 30. . . . . . . . . . .

System Operations 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Control LED Alert Codes 35. . . . . . . . . . . . . . . . . .

Maintenance (Dealer and Homeowner) 42. . . . . . . . . . .

Start−Up and Performance Checklist 48. . . . . . . . . . . . .

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:

1  Bushing (for low voltage wiring) 2  Isolation grommets for liquid and suction lines

Litho U.S.A.

04/10 506510−01

Page 1

*2P0410* *P506510-01*

Unit Dimensions − Inches (mm) and Parts Arrangement

39.40" (1003)

DISCHARGE AIR

SIDE VIEW

UNIT SUPPORT

FEET

ELECTRICAL INLETS

SUCTION LINE INLET

LIQUID LINE INLET

[−024] 41 (1040)

[−030 THROUGH

−060] 47 (1194)

18.60" (470)

8.00" (203)

1 (25)

35.50" (902)

ACCESS VIEW

Model Number Identification

Refrigerant Type

X = R−410A

Unit Type

C = Air Conditioner

Series

16−7/8

(429)

8−3/4 (222)

3−1/8

(79)

BASE WITH ELONGATED LEGS

C 17 036− −

X 2−

26−7/8

3−3/4 (95)

30−3/4

(781)

4−5/8 (117)

230

Voltage

230 = 208/230V−1ph−60hz

Nominal Cooling Capacity

024 = 2 tons 030 = 2.5 tons 036 = 3 tons 042 = 3.5 tons 048 = 4 tons 060 = 5 tons

(683)

Minor Revision Number

506510−01

Page 2

Typical Unit Parts Arrangement

CONTACTOR−1POLE (K1−1)

WIRE TIE

HIGH VOLTAGE FIELD

SLEEVE

OUTDOOR AMBIENT

TEMPERATURE

SENSOR

CONNECTIONS

GROUND LUG

MAIN CONTROL

FAN MOTOR SURGE

PROTECTION

FAN MOTOR CONTROL 

PULSE−WIDTH MODULATION (PWM)

CAPACITOR (C12)

CONTROL BOX

HIGH PRESSURE SWITCH

FIELD CONNECTION

FOR SUCTION LINE

SUCTION LINE SERVICE

LIQUID LINE SERVICE

FOR LIQUID LINE SET

VALVE PORT

VALV E

VALVE PORT

VALV E

FIELD CONNECTION

MUFFLER

HIGH DISCHARGE

LINE TEMPERATURE

SENSOR

COMPRESSOR

HARNESS

VIBRATION ISOLATOR SLEEVE LOCATIONS (DO NOT REMOVE)

SR1 SOUND DOME

LIQUID LINE FILTER

DRIER (SINGLE FLOW)

LOW PRESSURE SWITCH

HIGH PRESSURE SWITCH

PLUMBING, SWITCHES AND SENSOR COMPONENTS

Figure 1. Typical Parts Arrangements

Page 3

THERMOSTAT

XC17 SERIES

CAUTION

IMPORTANT

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.

IMPORTANT

This unit must be matched with an indoor coil as specified in Lennox’ Engineering Handbook. Coils previously charged with HCFC−22 must be flushed.

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.

Operating Gauge Set and Service Valves

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

TORQUE REQUIREMENTS

When servicing or repairing heating, ventilating, and air conditioning components, ensure the fasteners are appropriately tightened. Table 1 lists torque values for fasteners.

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.

IMPORTANT

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

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

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 systems must be capable of handling the 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 up to 800 psig of pressure with a 4000 psig burst rating.

OPERATING SERVICE VALVES

The liquid and vapor line service valves are used for removing refrigerant, flushing, leak testing, evacuating, checking 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.

506510−01

Page 4

SERVICE VALVES

VARIOUS TYPES

OPEN TO BOTH INDOOR AND

OUTDOOR UNITS

SERVICE PORT CAP

SERVICE PORT

TO INDOOR

CORE

UNIT

SERVICE PORT

(VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE

STEM CAP

SERVICE PORT CAP

SERVICE PORT

CORE

VALVE STEM

FRONT-SEATED

TO INDOOR

UNIT

TO OUTDOOR

UNIT

(FRONT−SEATED

STEM CAP

ANGLE−TYPE

SERVICE VALVE

CLOSED)

SERVICE PORT

(VALVE STEM SHOWN CLOSED) INSERT HEX WRENCH HERE

CLOSED TO BOTH

INDOOR AND OUTDOOR

UNITS

TO INDOOR UNIT

TO OUTDOOR UNIT

WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN TO THE LINE SET AND INDOOR UNIT.

WHEN SERVICE VALVE IS OPEN, THE SERVICE PORT IS OPEN TO LINE SET, INDOOR AND OUTDOOR UNIT.

ANGLE−TYPE SERVICE VALVE

(BACK−SEATED OPENED)

TO OPEN ROTATE STEM COUNTERCLOCKWISE 90°.

TO CLOSE ROTATE STEM CLOCKWISE 90°.

SERVICE PORT

SERVICE PORT CORE

SERVICE PORT CAP

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:

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.

TO OUTDOOR UNIT

1/6 TURN

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.

BALL (SHOWN CLOSED)

BALL−TYPE SERVICE

VAL VE

VALVE STEM

STEM CAP

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°.

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:

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.

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

1/6 TURN

Figure 2. Angle and Ball Service Valves

Page 5

XC17 SERIES

Recovering Refrigerant from Existing System

RECOVERING

REFRIGERANT FROM SYSTEM

DISCONNECT POWER

Disconnect all power to the existing outdoor unit at the disconnect

switch or main fuse box/breaker panel.

MAIN FUSE BOX/BREAKER PANEL

SERVICE

DISCONNECT

SWITCH

RECOVERING REFRIGERANT

Remove existing HCFC−22 refrigerant using one of the following procedures:

IMPORTANT  Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes,

and/or long line sets.

CONNECT MANIFOLD GAUGE SET

Connect a gauge set, clean recovery cylinder and a recovery

machine to the service ports of the existing unit. Use the instructions provided with the recovery machine to make the connections.

MANIFOLD GAUGES

RECOVERY MACHINE

LOW

CLEAN RECOVERY CYLINDER

OUTDOOR UNIT

HIGH

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. 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 switches (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.

506510−01

Page 6

CLEARANCE ON ALL SIDES  INCHES (MILLIMETERS)

MINIMUM CLEARANCE

ABOVE UNIT

6 (152)

12 (305)

36 (914)

ACCESS PANEL

CONTROL PANEL

ACCESS

LOCATION

30 (762)

LINE SET CONNECTIONS

MINIMUM CLEARANCE BETWEEN

TWO UNITS

24 (610)

New Outdoor Unit Placement

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

Figure 3. Installation Clearances

property, not from the installation property. Install the unit as far as possible from the property line.

48 (1219)

REAR VIEW OF UNIT

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 3 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

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 4, 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 4, Detail B.

NOTE  If necessary for stability, anchor unit to slab as described in Figure 4, Detail D.

Page 7

XC17 SERIES

ELEVATING THE UNIT

Units are outfitted with elongated support feet as illustrated in Figure 4, 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

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.

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 4, Detail D using conventional practices.

3. Replace the panels after installation is complete.

ROOF MOUNTING

Install the unit a minimum of 6 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 can adequately support the unit. Consult local codes for rooftop applications.

If unit coil cannot be mounted away from prevailing winter winds, a wind barrier should be constructed. Size barrier at least the same height and width as outdoor unit. Mount barrier 24 inches (610 mm) from the sides of the unit in the direction of prevailing winds.

NOTICE

Roof Damage! This system contains both refrigerant and oil. Some

rubber roofing material may absorb 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.

506510−01

Page 8

DETAIL A

INSTALL UNIT AWAY FROM WINDOWS

DETAIL B

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

TWO 90° ELBOWS INSTALLED IN LINE SET WILL

REDUCE LINE SET VIBRATION.

Outside Unit Placement

DETAIL C

BASE

GROUND LEVEL

Slab Mounting at Ground Level

DETAIL D

Slab Side Mounting

#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")

REQUIRED)

AND FLAT WASHER

MOUNTING SLAB

COIL

BASE PAN

CORNER POST

LEG DETAIL

2" (50.8MM) SCH 40

FEMALE THREADED

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.

ADAPTER

2" (50.8MM) SCH 40

MALE THREADED

ADAPTER

Elevated Slab Mounting using Feet

Extenders

Figure 4. Placement, Slab Mounting and Stabilizing Unit

MINIMUM ONE

Deck Top Mounting

STABILIZING BRACKET (18 GAUGE METAL  2" (50.8MM) WIDTH; HEIGHT AS REQUIRED); BEND TO FORM RIGHT ANGLE

SAME FASTENERS AS SLAB SIDE MOUNTING.

ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY, TWO BRACKETS PER SIDE, 2" (50.8MM) FROM EACH CORNER.

PER SIDE

FOR EXTRA

STABILITY

Stabilizing Unit on Uneven Surfaces

IMPORTANT  To help stabilize an outdoor unit, some installations may require strap-

ping the unit to the pad using brackets and anchors commonly available in the marketplace.

Page 9

XC17 SERIES

Removing and Installing Panels

ACCESS PANEL REMOVAL

Removal and reinstallation of the access

PANELS

ACCESS AND LOUVERED

WARNING

To prevent personal injury, or damage to panels, unit or 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.

panel is as illustrated.

Detail A

REMOVE 4 SCREWS TO REMOVE PANEL FOR ACCESSING COMPRESSOR AND CONTROLS.

POSITION PANEL WITH HOLES ALIGNED; INSTALL SCREWS AND TIGHTEN.

IMPORTANT  Do not allow panels to hang on unit by top tab. Tab is for alignment and not designed to support weight of panel.

PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR ENTER) TOP SLOT FOR REMOVING (OR INSTALLING) PANEL.

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 C

MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT AS POSSIBLE) WHILE INSTALLING PANEL.

Detail D

ANGLE MAY BE TOO EXTREME

LIP

SCREW

HOLES

Detail B

ROTATE IN THIS DIRECTION; THEN

DOWN TO REMOVE PANEL

HOLD DOOR FIRMLY ALONG THE HINGED SIDE TO MAINTAIN FULLY−ENGAGED TABS

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.

Page 10

506510−01

PREFERRED ANGLE FOR INSTALLATION

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 13.

IMPORTANT

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.

IMPORTANT

Mineral oils are not compatible with HFC−410A. If oil

must be added, it must be a Polyol ester oil.

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 5 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 14).

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.

Table 2. Refrigerant Line Set  Inches (mm)

Field

Connections

Model

Size

−024

−030

−036

−042

−048

−060

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

Liquid

Line

3/8 (10)

Vapor

Line

3/4 (19)

7/8 (22)

1−1/8.

(29)

Recommended Line Set

Liquid

Line

3/8

(10)

3/8

(10)

3/8

(10)

3/8

(10)

Vapor

Line

3/4 (19)

7/8 (22)

1−1/8

(29)

L15

Line Sets

Feet (Meters)

L15−41

15 − 50’ (5 − 15)

L15−65

15 − 50’ (5 − 15)

Field Fabricated

The compressor is charged with sufficient Polyol ester oil for line set lengths up to 50 feet. If line set lengths longer than 50 feet will be required, all one (1) ounce of oil for every additional 10 feet of line set. Do not add any more than seven (7) ounces of oil.

Recommended topping−off POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATEt RL32CF.

To obtain the correct information from Lennox, be sure to communicate the following information:

S Model (XC17) 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.

WARNING

Danger of fire. Bleeding the refrigerant charge from only the high side may result in the low side shell and suction tubing being pressurized. Application of a brazing torch while pressurized may result in ignition of the refrigerant and oil mixture − check the high and low pressures before unbrazing.

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.

Page 11

XC17 SERIES

LINE SET

INSTALLATION

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

AUTOMOTIVE

MUFFLER-TYPE HANGER

IMPORTANT  Refrigerant lines must not contact structure.

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.

IMPORTANT  Refrigerant lines must not contact wall

OUTSIDE WALL

VAPOR LINE

LIQUID LINE

WALL STUD

STRAP LIQUID LINE TO VAPOR LINE

LIQUID LINE

NON−CORROSIVE

METAL SLEEVE

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

WIRE TIE

INSIDE WALL

CAULK

LIQUID LINE

STRAP

NON−CORROSIVE METAL SLEEVE

WIRE TIE

WOOD BLOCK

WIRE TIE

STRAP

WOOD BLOCK

BETWEEN STUDS

SLEEVE

VAPOR LINE WRAPPED

WITH ARMAFLEX

OUTSIDE

WALL

PVC

PIPE

FIBERGLASS

INSULATION

NOTE  Similar installation practices should be used if line set is to be installed on exterior of outside wall.

FLOOR JOIST OR

506510−01

ROOF RAFTER

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.

Figure 5. Line Set Installation

Page 12

BRAZING

CONNECTIONS

CUT AND DEBUR

Cut ends of the refrigerant lines square

(free from nicks or dents) and debur the ends. The pipe must remain round and do not pinch end of the line.

ATTACHED GAUGES

A Connect gauge set low pressure side to liquid line service

valve.

B Connect gauge set center port to bottle of nitrogen with

regulator.

SERVICE PORT MUST BE OPEN TO ALLOW EXIT

INDOOR

UNIT

NOTE − Use silver alloy brazing rods with five or six percent minimum silver alloy for copper−to−copper brazing, 45 percent alloy for copper−to−brass and copper−to−steel brazing.

CAP AND CORE REMOVAL

Remove service cap and core

from both the vapor and liquid line service ports.

HIGHLOW

ATTACH

POINT FOR NITROGEN

vapor LINE

GAUGES

VAPOR LINE

SERVICE

VALV E

OUTDOOR

UNIT

USE REGULATOR TO FLOW

NITROGEN AT 1 TO 2 PSIG.

WRAP SERVICE VALVE

To protect components during

brazing, wrap a wet cloth around the liquid line service valve body and copper tube stub and use another wet cloth underneath the valve body to protect the base paint.

BRAZE LINE SET

Braze the liquid line to the liquid line

service valve. Turn off nitrogen flow.

POINT FLAME AWAY FROM

SERVICE VALVE

LIQUID LINE

LIQUID LINE SERVICE

NOTE  The fixed orifice or check expansion valve metering device at the indoor unit will allow low pressure nitrogen to flow through the system.

VALV E

FLOW NITROGEN

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

INSTALL SERVICE PORT CAPS ONLY

After all connections have been brazed, disconnect manifold gauge

set from service ports, cool down piping with wet rag and remove all wrappings. Do not reinstall cores until after evacuation procedure. Reinstall service port caps if desired to close off refrigerant ports.

LOW

NITROGEN

HIGH

USE REGULATOR TO

FLOW NITROGEN AT 1

TO 2 PSIG.

NITROGEN

WARNING  Allow braze joint to cool before removing the wet rag from the service valve. (TEMPERATURES ABOVE 250ºF CAN DAMAGE VALVE SEALS

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.

Page 13

SERVICE PORT

SERVICE PORT CORE

SERVICE PORT CAP

XC17 SERIES

Flushing the System

FLUSHING

LINE SET AND INDOOR COIL (1 OF 2)

TYPICAL FIXED ORIFICE REMOVAL PROCEDURE

(Uncased Coil Shown)

DISTRIBUTOR TUBES

LIQUID LINE ORIFICE HOUSING

TEFLON RING

FIXED ORIFICE

TWO PIECE PATCH PLATE

(UNCASED COIL ONLY)

DISTRIBUTOR

TUBES

TYPICAL CHECK EXPANSION VALVE

REMOVAL PROCEDURE

(Uncased Coil Shown)

ORIFICE

HOUSING

STUB END

TEFLON RING

CHECK

EXPANSION

VALV E

TEFLON

RING

LIQUID LINE

SENSING

LINE

BRASS NUT

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

assembly.

C Using two wrenches, disconnect liquid line from liquid line orifice

housing. 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.

REMOVE AND DISCARD

WHITE TEFLON SEAL (IF

PRESENT)

LIQUID LINE ASSEMBLY

(INCLUDES STRAINER)

CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE

VAPOR LINE

SERVICE VALVE

EXISTING

INDOOR unit

INVERTED HCFC−22 CYLINDER CONTAINS CLEAN HCFC−22 TO BE USED FOR FLUSHING.

NEW

OUTDOOR

UNIT

LOW

OPENED

GAUGE

MANIFOLD

CLOSED

HIGH

LIQUID LINE SERVICE

RECOVERY

CYLINDER

A Inverted HCFC−22 cylinder with clean refrigerant to the vapor service

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

D Connect recovery tank to recovery machines per machine

VALV E

VAPOR

LIQUID

valve.

an empty recovery tank to the gauge set.

instructions.

TANK RETURN

INLET

DISCHARGE

RECOVERY MACHINE

A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps holding the liquid line and distributor as-

C Disconnect the equalizer line from the check expansion valve equaliz-

D Remove the vapor line sensing bulb. E Disconnect the liquid line from the check expansion valve at the liquid

F Disconnect the check expansion valve from the liquid line orifice hous-

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

DISTRIBUTOR

ASSEMBLY

MALE EQUALIZER

LINE FITTING

SENSING BULB

sembly.

er line fitting on the vapor line.

line assembly.

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

indoor unit’s liquid line orifice housing.

CAUTION  This procedure should not be performed on systems which contain contaminants (Example compressor burn out.

EQUALIZER LINE

ASSEMBLY WITH

VAPOR

LINE

LIQUID LINE

BRASS NUT

LIQUID

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.

A Set the recovery machine for liquid recovery and start the recov-

ery 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.

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.

LINE

506510−01

Page 14

FLUSHING LINE SET AND INDOOR COIL (2 OF 2)

TYPICAL CHECK EXPANSION VALVE INSTALLATION PROCEDURE

This outdoor unit is designed for use in systems that use check expansion valve metering device. See the Lennox XC17 Engineering Handbook

for approved check expansion valve kit match−ups and application information.

The check expansion valve unit can be installed internal or

TWO PIECE

PATCH PLATE

(UNCASED

COIL ONLY)

DISTRIBUTOR

TUBES

DISTRIBUTOR

ASSEMBLY

MALE EQUALIZER LINE

FITTING (SEE

EQUALIZER LINE

INSTALLATION FOR

FURTHER DETAILS)

SENSING BULB INSULATION IS REQUIRED IF MOUNTED EXTERNAL TO THE COIL CASING. SENSING BULB INSTALLATION FOR BULB POSITIONING.

(Uncased Coil Shown)

LIQUID LINE

ORIFICE

HOUSING

STUB

END

TEFLON RING

EQUALIZER LINE

CHECK

EXPANSION

VALV E

LIQUID LINE

ASSEMBLY WITH

BRASS NUT

VAPOR

LINE

external to the indoor coil. In applications where an uncased coil is being installed in a field−provided plenum, install the check expansion valve in a manner that will provide access for field servicing of the check expansion valve. Refer to below illustration for reference during installation of check expansion valve unit.

TEFLON

RING

A Remove the field−provided fitting that temporary reconnected the liquid

line to the indoor unit’s distributor assembly.

SENSING

LINE

LIQUID LINE

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.

VAPOR LINE

BULB

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

BULB

1/2 TURN

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.

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.

1/8 TURN

VAPOR LINE

FLARE SEAL CAP

ON 7/8" AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 4 OR 8 O’CLOCK

BULB

NOTE  NEVER MOUNT ON BOTTOM OF LINE.

POSITION. NEVER MOUNT ON BOTTOM OF LINE.

BULB

FLARE NUT

COPPER FLARE SEAL BONNET

MALE BRASS EQUALIZER LINE FITTING

VAPOR LINE

Page 15

XC17 SERIES

INSTALLING ISOLATION GROMMETS

Locate the isolation grommets (provided). Slide grommets onto vapor and liquid lines. Insert grommets into piping panel to isolate refrigerant lines from sheet metal edges.

Leak Testing the System

SUCTION LINE

LIQUID LINE

TWO ISOLATION GROMMETS ARE PROVIDE FOR THE LIQUID AND SUCTION LINE PIPE PANEL PASS THROUGH.

REAR VIEW OF UNIT EXTERIOR

Figure 6. Isolation Grommets

PIPING PANEL

IMPORTANT

The Environmental Protection Agency (EPA) prohibits the intentional venting of HFC refrigerants during maintenance, service, repair and disposal of appliance. Approved methods of recovery, recycling or reclaiming must be followed.

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).

IMPORTANT

Leak detector must be capable of sensing HFC refrigerant.

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 indoor unit coil which 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 the system performance and capacity. Failure to properly flush the system per the instructions below will void the warranty.

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 damage by fire and/or an explosion, that could result in personal injury or death.

506510−01

Page 16

LEAK TEST

LINE SET AND INDOOR COIL

CONNECT GAUGE SET

A Connect an HFC−410A manifold gauge set high

pressure hose to the vapor valve service port.

B With both manifold valves closed, connect the

cylinder of HFC−410A refrigerant to the center port of the manifold gauge set.

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.

HIGHLOW

MANIFOLD GAUGE SET

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

TO VAPOR

SERVICE VALVE

NITROGEN

HFC−410A

TEST FOR LEAKS

After the line set has been connected to the indoor unit and air conditioner, 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) refrigerant 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 dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set.

D Adjust dry 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.

OUTDOOR UNIT

VAPOR SERVICE VALVE

LIQUID LINE SERVICE VALVE

Page 17

XC17 SERIES

Evacuating the System

EVACUATING

LINE SET AND INDOOR COIL

CONNECT GAUGE SET

NOTE  Remove cores from service valves (if not al-

ready done).

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 micron gauge available

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.

LIQUID LINE

SERVICE VALVE

HFC−410A

VACUUM PUMP

OUTDOOR

VAPOR

SERVICE

VALV E

UNIT

A34000 1/4 SAE TEE WITH SWIVEL COUPLER

500

MICRON

GAUGE

LOW

TO VAPOR

SERVICE VALVE

TO LIQUID LINE SERVICE VALVE

MANIFOLD

GAUGE SET

HIGH

NITROGEN

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 ter m absolute pressure means the total actual pressure within a given volume or system, above the absolute zero of pressure. 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), close the manifold gauge valves, turn off the vacuum

pump and disconnect the manifold gauge center port hose from vacuum pump. Attach the manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose. Open the manifold gauge valves to break the vacuum in the line set and indoor unit. Close the manifold gauge valves.

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

dry 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 an

upright cylinder of HFC−410A 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:

RECOMMEND

MINIMUM 3/8" HOSE

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 the stem caps and secure finger tight, then tighten an additional one−sixth (1/6) of a turn as

illustrated.

1/6 TURN

506510−01

Page 18

IMPORTANT

Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns.

WARNING

Danger of Equipment Damage. Avoid deep vacuum operation. Do not use compressors to evacuate a system. Extremely low vacuums can cause internal arcing and compressor failure. Damage caused by deep vacuum operation will void warranty.

Evacuating the system of non−condensables is critical for proper operation of the unit. Non−condensables are defined as any gas that will not condense under

temperatures and pressures present during operation of an air conditioning system. Non−condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts.

Electrical

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 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)

SIZE CIRCUIT AND INSTALL 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.

SERVICE

DISCONNECT

SWITCH

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

MAIN FUSE BOX/

BREAKER PANEL

WARNING

Electric Shock Hazard. Can cause injury or death. Unit must be grounded in accordance with national and local codes.

INSTALL THERMOSTAT

Install room thermostat (ordered separately) on an inside wall

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.

CAUTION

ELECTROSTATIC DISCHARGE

(ESD)

Precautions and Procedures

Electrostatic discharge can affect electronic components. Take precautions during 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. Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface before performing any service procedure

Page 19

XC17 SERIES

ROUTE CONTROL WIRES

Install low voltage control wiring from outdoor to indoor unit and from

thermostat to indoor unit as illustrated. See Figures 10 and 10 for typical configurations.

A Run 24VAC control wires through hole with grommet.

B Make 24VAC control wire connections to Main Control.

NOTE  Do not bundle any excess 24VAC control wires inside control panel.

NOTE  Wire tie provides low voltage wire strain relief and to maintain separation of field installed low and high voltage circuits.

NOTE  For proper voltages, select thermostat wire (control wires) gauge per table below.

WIRE RUN LENGTH AWG# INSULATION TYPE

LESS THAN 100’ (30 METERS) 18 TEMPERATURE RATING

MORE THAN 100’ (30 METERS) 16 35ºC MINIMUM.

MAIN CONTROL

CONTROL PANEL

HOLE

ROUTE HIGH VOLTAGE AND GROUND WIRES

Any excess high voltage field wiring should be trimmed and secured away from any low voltage field wiring. To facilitate a conduit, a cutout is

located in the bottom of the control panel. Connect conduit to the control panel using a proper conduit fitting.

PIPING PANEL

HIGH VOLTAGE

CONDUIT HOLE

WATERTIGHT

CONDUIT

FITTING

WATERTIGHT

FLEXIBLE CONDUIT

TO SERVICE

DISCONNECT BOX

CONTROL PANEL

GROUND LUG

CONTACTOR

ELECTRICAL INLET (CONTROL WIRING  LOW VOLTAGE). USE BUSHING PROVIDED IN BAG ASSEMBLY HERE.

ELECTRICAL INLET

(HIGH VOLTAGE)

WIRING ENTRY POINTS

ACCESS VIEW

506510−01

Page 20

Figure 7. Typical XC17 Wiring

Page 21

XC17 SERIES

Main Control Jumpers and Terminals

MAIN CONTROL  AIR CONDITIONER  ONE STAGE

TABLE 3 PROVIDES ADDITIONAL INFORMATION CONCERNING JUMPERS, LOOP, AND CONNECTIONS FOR THE MAIN CONTROL.

DS11 and DS14

LED ALERT CODES

E12

E16

DS13 and DS15

LED ALERT CODES

TEST PINS

E33

506510−01

CUT FOR HUMIDITROL  ENHANCED DEHUMIDIFICATION ACCESSORY (EDA) APPLICATIONS.

Figure 8. Control Jumpers, Loop and Terminals

Page 22

Table 3. Main Control Jumpers and Terminals

Board ID Label Description

E12 PSC Fan 240 VAC output connection for outdoor fan.

E16 PSC Fan 240 VAC input connection for outdoor fan.

W 24VAC output for defrost auxiliary heat output.

L Thermostat service light connection.

Y2 24VAC thermostat input/output for second stage operation of the unit.

E18

E21 and E22 LO−PS S4 connection for low−pressure switch (2.4 milliamps @ 18VAC)

E31 and E32 Y1 OUT 24VAC common output, switched for enabling compressor contactor.

E24 and E25 HS−PS S87 connection for high−pressure switch.

E26 FAN 1

E27 FAN 2

E28 FAN C ECM common connection for ECM fan.

E30

E33 Field Test

W1 Short DS To R Cut for Humiditrol  Enhanced Dehumidification Accessory (EDA) applications.

* Factory default setting

Y1 24VAC thermostat input for first stage operation of the unit.

O 24VAC thermostat input for reversing valve operation

DS Humiditrol Input

C 24VAC system common

24VAC system power input

First Stage and second stage basic and precision dehumidification ECM fan motor 24VDC output connection 1.

Second stage basic and precision dehumidification ECM fan motor 24VDC output connection

Six position square pin header E30 provides connections for the temperature sensors.

DIS 5  Discharge line temperature sensor supply.

DIS (YELLOW) Pins 5 and 6

DIS 6  Discharge line temperature sensor return.

Range is −35ºF to 310ºF. Sensor is clipped on a 1/2" copper tube.

AMB (BLACK) Pins 3 and 4

AMB 3  Outdoor ambient temperature sensor supply. AMB 4  Outdoor ambient temperature return.

Range is −40ºF to +140ºF

COIL 1  Outdoor coil temperature sensor supply.

COIL (BROWN) Pins 5 and 6

COIL 2  Outdoor coil temperature sensor return

This model does not utilize a coil sensor. The cable harness assembly for the sensors incorporates a built−in 10K resistor between pins 5 and 6.

This jumper allows service personnel to defeat the timed off control, and field programming of unit capacity feature. Placing a jumper across both pins on E33 will terminate the anti−short delay. It will also clear lockout alarms

Page 23

XC17 SERIES

Field Control Wiring

One−Stage

Air Conditioner Control

Air Handler Control

ComfortSense[ 7000 Thermostats

Catalog # Y0349 or Y2081

On−board link

Low voltage thermostat

wiring

Flat metal jumper

Outdoor sensor for outdoor temperature display (Optional).

R connection required for outdoor unit with Control LSOM function. Resistor Kit (Cat# 47W97) is required when

using the ComfortSense 7000 (Y0349) with Control LSOM feature. Resistor kit not required when using ComfortSense 7000 (Y2081).

Air Handler Control comes from factory with metal jumpers across W1, W2 and W3. For one−stage electric heat, do not remove

metal jumpers.

Air Handler Control comes from factory with metal jumpers across W1, W2 and W3. For two−stage electric heat, remove metal

jumper between W1 to W2 and connect thermostat wire between Air Handler Control W2 to thermostat W2.

Cut for Humiditrol  Enhanced Dehumidification Accessory (EDA) applications.

Figure 9. ComfortSense® 7000 Series Thermostat 

Air Hander/One−Stage Air Conditioner

Page 24

506510−01

One−Stage

Air Conditioner Control

Furnace Control

ComfortSense[ 7000 Thermostats

Catalog # Y0349 or Y2081

On−board link

Low voltage thermostat wiring

Cut on−board link (W914) (clippable wire) from DS to R for dehumidification (Optional).

Outdoor sensor for outdoor temperature display (Optional).

R connection required for outdoor unit with Control LSOM function. Resistor Kit (Cat# 47W97) is required when using the ComfortSense 7000 (Y0349) with Control LSOM feature. Resistor kit not required when using

ComfortSense 7000 (Y2081).

Cut for Humiditrol  Enhanced Dehumidification Accessory (EDA) applications.

Figure 10. ComfortSense® 7000 Series Thermostat 

Furnace/One−Stage Air Conditioner

Page 25

XC17 SERIES

Servicing Units Delivered Void of Charge

If the outdoor unit is void of refrigerant, clean the system using the procedure described below.

1. Leak check system using procedure outlined on Page

16.

2. Evacuate the system using procedure outlined on Page 18.

3. Use nitrogen to break the vacuum and install a new filter drier in the system.

4. Evacuate the system again using procedure outlined on Page 18.

5. Weigh in refrigerant using procedure outlined in Figure

14.

6. Monitor the system to determine the amount of moisture remaining in the oil. It may be necessary to replace the filter drier several times to achieve the required dryness level. If system dryness is not

verified, the compressor will fail in the future.

Unit Start−Up

1. Rotate fan to check for binding.

2. Inspect all factory− and field−installed wiring for loose connections.

3. After evacuation is complete, open both the liquid and vapor line service valves to release the refrigerant charge contained in outdoor unit into the system.

4. Replace the stem caps and tighten to the value listed in Table 1.

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 voltage condition has been corrected.

6. Set the thermostat for a cooling demand. Turn on power to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit.

7. Recheck voltage while the unit is running. Power must be within range shown on the nameplate.

8. Check system for sufficient refrigerant by using the procedures listed under System Charge.

System Refrigerant

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.

GAUGE SET

This section outlines procedures for:

1. Connecting gauge set for testing and charging;

2. Checking and adjusting indoor airflow;

3. Adding or removing refrigerant.

MANIFOLD GAUGE SET

LOW

HIGH

CONNECTIONS FOR TESTING AND CHARGING

SUCTION LINE

SERVICE PORT CONNECTION

REFRIGERANT TANK

CHARGE IN

LIQUID PHASE

DIGITAL SCALE

TEMPERATURE

SENSOR

A Close manifold gauge set valves and connect the center hose to a cylinder of HFC−410A. Set for liquid phase charging.

B Connect the manifold gauge set’s low pressure side to the suction line service port.

C Connect the manifold gauge set’s high pressure side to the liquid line service port.

D Position temperature sensor on liquid line near liquid line service port.

TO LIQUID

LINE SERVICE

VALV E

TEMPERATURE SENSOR

(LIQUID LINE)

OUTDOOR UNIT

VAPOR LINE

SERVICE VALVE

LIQUID LINE

SERVICE VALVE

506510−01

Figure 11. Gauge Set Setup and Connections

Page 26

ADDING OR REMOVING REFRIGERANT

This system uses HFC−410A refrigerant which operates at much higher pressures than HCFC−22. The pre−installed liquid line filter drier is approved for use with HFC−410A only. Do not replace it with components designed for use with HCFC−22. This unit is NOT approved for use with coils which use capillary tubes or fixed orifices as a refrigerant metering device.

Check airflow using the Delta−T (

DT) process using the illustration in Figure 12.

AIRFLOW

INDOOR COIL

Temperature of air entering indoor coil ºF

Wet−bulb ºF

80 24 24 24 23 23 22 22 22 20 19 18 17 16 15 78 23 23 23 22 22 21 21 20 19 18 17 16 15 14 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13

Dry−bulb

74 21 21 21 20 19 19 18 17 16 16 15 14 13 12 72 20 20 19 18 17 17 16 15 15 14 13 12 11 10 70 19 19 18 18 17 17 16 15 15 14 13 12 11 10

57 58 59 60 61 62 63 64 65 66 67 68 69 70

DRY

BULB

53º

19º

Drop

air flow

64º

All temperatures are expressed in ºF

INDOOR COIL

WET BULB

Use the following procedure to adjust for optimal air flow across the indoor coil:

1. Determine the desired DT  Measure entering air temperature using dry bulb (A) and wet bulb (B). DT is the intersecting value of A and B in the table (see triangle).

2. Find temperature drop across coil  Measure the coil’s dry bulb entering and leaving air temperatures (A and C). Temperature Drop Formula: (T

3. Determine if fan needs adjustment  If the difference between the measured T

DT (T

–DT) is within +3º, no adjustment is needed. See example below:

Drop

) = A minus C.

Drop

and the desired

Drop

Assume DT = 15 and A temp. = 72º, these C temperatures would necessitate stated actions:

72º

DRY BULB

Cº T

53º 19 – 15 = 4 Increase the airflow 58º 14 – 15 = −1 (within +3º range) no change 62º 10 – 15 = −5 Decrease the airflow

– DT = ºF ACTION

Drop

Changing air flow affects all temperatures; recheck temperatures to confirm that the temperature drop and DT are within +3º.

4. Adjust the fan speed  See indoor unit instructions to increase/decrease fan speed.

Figure 12. Checking Indoor Airflow over Evaporator Coil using Delta−T Chart

Page 27

XC17 SERIES

Use WEIGH IN to initially charge a system when the outdoor unit is void of charge. To verify charge and add or

remove refrigerant use either

APPROACH or SUBCOOLING methods.

START: Determine the correct charge method:

WHEN TO CHARGE?

S Warm weather best

TXV

S Can charge in colder weather

CHARGE METHOD? Determine by:

S Outdoor ambient temperature

65ºF

(18.3ºC) and

Above

64ºF

(17.7ºC) and

Below

REQUIREMENTS:

S Sufficient heat load in structure S Indoor temperature between 70-80ºF (21−26ºC) S Manifold gauge set connected to unit S Thermometers:

− to measure outdoor ambient temperature

APPROACH OR

SUBCOOLING

WEIGH-IN

− to measure liquid line temperature

− to measure suction line temperature

Figure 13. Determining Charge Method

WEIGH IN

CHARGING METHOD

CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE

64ºF (17.7ºC) and Below

If the system is void of refrigerant, first, locate and repair any leaks and then weigh in the refrigerant charge into the unit. To calculate the total refrigerant charge:

Adjust amount. for variation

Amount specified on

nameplate

NOTE  The above nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information.

in line set length listed on

line set length table below.

Total charge

Refrigerant Charge per Line Set Length

Liquid Line

Set Diameter

3/8" (9.5 mm)

*If line length is greater than 15 ft. (4.6 m), add this amount. If line length is less than 15 ft. (4.6 m), subtract this amount.

Ounces per 5 feet (g per 1.5 m)

adjust from 15 feet (4.6 m) line set*

3 ounce per 5’ (85 g per 1.5 m)

506510−01

Figure 14. Using HFC−410A Weigh In Method

Page 28

1. Confirm proper airflow across coil using Figure 12.

APPROACH

TEST AND CHARGE METHOD

65ºF (18.3ºC) and Above

If refrigerant added or removed, retest to confirm that unit is properly charged

If value is greater than shown (high approach), add refrigerant; if less than shown (liquid temp too close to ambient temp, low approach), remove refrigerant.

APPº (Approach) Values(F:+/−1.0° [C: +/−0.6°])*

Models

ºF (ºC)* −024 −030 −036 −042 −048 −060. . . . . .

Any 10 (5.6) 10 (5.6) 6 (3.3) 10 (5.6) 8 (4.4) 8 (4.4). . . *Temperature of air entering outdoor coil

* These approach values are also listed on the unit charging sticker 580005−01 located on the access panel.

Figure 15. Using Approach Test and Charge Method

2. Compare unit pressures with Table 4, Normal Operating Pressures.

3. Use APPROACH to correctly charge unit or to verify the charge is correct.

4. Set thermostat to call for heat (must have a cooling load between 70-80ºF (21−26ºC).

5. Connect gauge set.

6. When heat demand is satisfied, set thermostat to call for cooling.

7. Allow temperatures and pressures to stabilize.

8. Record outdoor ambient temperature:

AMBº =_________

9. Record line temperature:

LIQº = __________

10. Subtract to determine approach (APPº):

LIQº_____ − AMBº _____ = APPº_____

11. Compare results with table to the left.

SUBCOOLING

TEST AND CHARGE METHOD

65ºF (18.3ºC) and Above

BLOCK OUTDOOR COIL: [sometimes necessary with lower temperatures] Use cardboard or plastic sheet to restrict the airflow through the outdoor coil to achieve pressures from 325−375 psig (2240−2585 kPa). Higher pressures are needed to check charge. Block equal

CARDBOARD OR

PLASTIC SHEET

If refrigerant added or removed, verify charge using the approach method

If value is greater than shown, remove refrigerant; if less than shown, add refrigerant

SCº (Subcooling) Values (F:+/−1.0° [C: +/−0.6°])

ºF (ºC)* −024 −030 −036 −042 −048 −060. . . . . .

Any 4 (2.2) 4 (2.2) 7 (3.9) 5 (2.8) 6 (3.3) 6 (3.3). . . *Temperature of air entering outdoor coil

* These subcooling values are also listed on the unit charging sticker 580005−01 located on the access panel.

sections of air intake panels and move coverings sideways until the liquid pressure is in the above noted ranges.

Models

1. Confirm proper airflow across coil using Figure 12.

2. Compare unit pressures with Table 4, Normal Operating Pressures.

3. Use SUBCOOLING to correctly charge unit or to verify the charge is correct.

4. Set thermostat to call for heat (must have a cooling load between 70-80ºF (21−26ºC)

5. Connect gauge set

6. Measure outdoor ambient temperature

7. When heat demand is satisfied, set thermostat to call for cooling

8. Allow temperatures and pressures to stabilize.

NOTE − If necessary, block outdoor coil to maintain 325 − 375 psig.

9. Record liquid line temperature:

LIQº = ______

10. Measure liquid line pressure and use the value to determine saturation temperature (see Table 5):

SATº = ______

11. Subtract to determine subcooling (SCº):

SATº_____ − LIQº _____ = SCº _____

12. Compare results with table to the left.

Figure 16. Using Subcooling Test and Charge Method

Page 29

XC17 SERIES

Operating and Temperature Pressures

Minor variations in these pressures may be expected due to differences in installations. Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system.

Table 4. Normal Operating Pressures (Liquid +10 and Suction +5 psig)*

Use this table to perform maintenance checks; it is not a procedure for charging the

IMPORTANT

Model −024 −030 −036 −042 −048 −060

°F (°C)** Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction

65 (18.3) 234 139 236 134 226 134 232 137 232 132 236 131

70 (21.1) 249 140 251 135 245 135 249 139 249 133 254 132

75 (23.9) 268 141 271 138 266 137 270 140 268 134 273 133

80 (26.7) 289 142 291 139 287 138 291 141 288 135 294 135

85 (29.4) 310 142 312 140 310 139 314 142 311 136 317 136

90 (32.2) 334 144 335 142 333 140 338 143 333 137 340 137

95 (35.0) 358 145 358 142 358 141 363 144 357 138 364 139

100 (37.8) 383 146 383 143 383 143 389 145 380 139 389 140

105 (40.6) 408 147 409 144 410 144 419 147 406 140 416 142

110 (43.3) 436 148 436 145 437 145 447 148 433 142 444 143

115 (46.1) 465 150 467 147 464 146 480 149 462 143 475 145

* Typical pressures only, expressed in psig (liquid +/− 10 and vapor+/− 5 psig); indoor match up, indoor air quality, and indoor load will cause the pressures

to vary. These operating pressures are also listed on the unit charging sticker (580005−01) located on the access panel.

** Temperature of air entering outdoor coil.

system. Minor variations in these pressures may be due to differences in installations. Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system.

Table 5. HFC−410A Temperature (° Fahrenheit)  Pressure (Psig)

°F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig

32 100.8 48 137.1 63 178.5 79 231.6 94 290.8 110 365.0

33 102.9 49 139.6 64 181.6 80 235.3 95 295.1 111 370.0 126 451.8 142 552.3

34 105.0 50 142.2 65 184.3 81 239.0 96 299.4 112 375.1 127 457.6 143 559.1

35 107.1 51 144.8 66 187.7 82 242.7 97 303.8 113 380.2 128 463.5 144 565.9

36 109.2 52 147.4 67 190.9 83 246.5 98 308.2 114 385.4 129 469.5 145 572.8

37 111.4 53 150.1 68 194.1 84 250.3 99 312.7 115 390.7 130 475.6 146 579.8

38 113.6 54 152.8 69 197.3 85 254.1 100 317.2 11 6 396.0 131 481.6 147 586.8

39 115.8 55 155.5 70 200.6 86 258.0 101 321.8 11 7 401.3 132 487.8 148 593.8

40 118.0 56 158.2 71 203.9 87 262.0 102 326.4 11 8 406.7 133 494.0 149 601.0

41 120.3 57 161.0 72 207.2 88 266.0 103 331.0 11 9 412.2 134 500.2 150 608.1

42 122.6 58 163.9 73 210.6 89 270.0 104 335.7 120 417.7 135 506.5 151 615.4

43 125.0 59 166.7 74 214.0 90 274.1 105 340.5 121 423.2 136 512.9 152 622.7

44 127.3 60 169.6 75 217.4 91 278.2 106 345.3 122 428.8 137 519.3 153 630.1

45 129.7 61 172.6 76 220.9 92 282.3 107 350.1 123 434.5 138 525.8 154 637.5

46 132.2 62 175.4 77 224.4 93 286.5 108 355.0 124 440.2 139 532.4 155 645.0

47 134.6 78 228.0 109 360.0 140 539.0

125 445.9

141 545.6

506510−01

Page 30

System Operation

IMPORTANT

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

The Main Control provides the following system functions:

S Compressor anti−short−cycle delay. S High and low pressure switches S Am bient and Discharge Line Temperatures Monitoring

and Protection.

S Five strikes lockout safety feature for High/Low

Pressure Switches and High Discharge Line Temperature. See Figures 19, 20 and 21 feature function.

COMPRESSOR ANTI−SHORT CYCLE DELAY

The Main Control protects the compressor from:

S Short cycling (five minutes) when there is initial power

S Interruption in power to the unit S High or low pressure switch or discharge line sensor

trips

S Delay after Y1 demand is removed.

The anti−short timer in the outdoor control is 5 minutes. To override timer when active or inactive − place jumper on the field test pins between 1 and 2 seconds.

Resetting Anti−Short Cycle Delay

The FIELD TEST pins (E33) on the Main Control can be jumpered between 1 to 2 seconds to bypass delay.

HIGH AND LOW PRESSURE SWITCHES

The unit’s reset pressure switches LO PS (S4) and HI PS (S87) are factory−wired into the Main Control on the LO−PS and HI−PS terminals, there locations are illustrated on Page 3. Sequence of operations for both pressure switches are provided in Figures 19 and 20.

HIGH DISCHARGE LINE TEMPERATURE SENSOR

(RT28)

The high discharge line temperature sensor location is illustrated on Page 3. This sensor’s sequence of operations is provided in Figure 21.

High Discharge Line Sensor Open/Shorted Event

Condition

Discharge sensor open / short fault is ignored during initial 90−seconds of compressor run time. After that, if discharge temperature sensor is detected open or short, the control will de−energize all the outputs and anti−short cycle timer is started. Discharge sensor faulty alert LED code will be displayed.

OUTDOOR AMBIENT TEMPERATURE (RT13)

If the outdoor ambient temperature sensor detected a open, or out of range −40ºF to +140ºF (−40ºC to 60ºC) then LED alert codes are displayed, however cooling operation will continue. See Table 9 for LED alert codes for the ambient sensor. Location of outdoor ambient temperature sensor is illustrated on Page 3.

COIL TEMPERATURE SENSOR

This model does not use a coil temperature sensor. The cable assembly attached to the Main Control’s E30 connection has a 10K resister installed between pins 5 and 6 as illustrated in Figure 17. No alerts or alarms would be generated if resistor is damage.

Ambient Air

Temperature Sensor

High Discharge Line

Temperature Sensor

Figure 17. 10k Resistor Location

TESTING AMBIENT AND HIGH DISCHARGE LINE TEMPERATURE SENSORS

Sensors connect through a field-replaceable harness assembly that plugs directly into the Main Control. Through these sensors, the Main Control can monitor outdoor ambient and discharge line temperature fault conditions. As the detected temperature changes, the resistance across the sensor changes. Figures 6 and 7 lists how the resistance varies as the temperature changes for both type of sensors. Sensor resistance values can be checked by ohming across pins shown in Table 8.

When a sensor indicates a resistance value that is not within the range as listed in Table 8, then the following condition may be present:

10K resistor

S Sensor detects an out−of−range outdoor ambient air

temperature condition and will display LED alert code on the Main Control.

S The sensor is operating normally when the ambient air

temperature at the sensor is below or above the Main Control’s expected ohm values. The Main Control will indicate the sensor as faulty, however under this scenario, the sensor is not actually faulty.

S Once the outdoor ambient air temperature has

returned to within the sensor’s normal operating range, the LED alert code will automatically stop.

Page 31

XC17 SERIES

TEST PINS FUNCTION

Placing the JUMPER ON the field test pins (E33) (see Page 22 for location of TEST pins) allows the technician to

S Clear compressor anti−short cycle delay. S Clear five−strike fault lockouts  High / Low pressure switches and High Discharge Temperature Sensor.

Y1 Active

Place a JUMPER ON1 the TEST pins for longer than one second2. Then remove jumper and place in JUMPER OFF position.

FACTORY DEFAULT

JUMPER SETTING

Clears any short cycle lockout and five strike fault lockout function, if applicable. No other functions will be executed and unit will continue in the mode it was operating.

JUMPER

OFF

JUMPER

NOTES: 1  Placing a JUMPER ON the TEST pins will not bring the unit out of inactive mode. The only way manually

activate the outdoor unit from an inactive mode is to cycle the 24VAC power to the outdoor unit’s Main Control. 2  If the jumper remains on the TEST pins for longer than five seconds, the Main Control will ignore the

JUMPER ON TEST pins and revert to normal operation.

Figure 18. Clearing Anti−Short Cycle Delay and Five−Strike Fault Lockouts

506510−01

Page 32

Table 6. Ambient Sensor Temperature / Resistance Range

Degrees

Fahrenheit

136.3 2680 56.8 16657 21.6 44154 −11.3 123152

133.1 2859 56.0 16973 21.0 44851 −11.9 125787

130.1 3040 55.3 17293 20.5 45560 −12.6 128508

127.3 3223 54.6 17616 20.0 46281 −13.2 131320

124.7 3407 53.9 17942 19.4 47014 −13.9 134227

122.1 3592 53.2 18273 18.9 47759 −14.5 137234

119.7 3779 52.5 18607 18.4 48517 −15.2 140347

117.5 3968 51.9 18945 17.8 49289 −15.9 143571

115.3 4159 51.2 19287 17.3 50074 −16.5 146913

113.2 4351 50.5 19633 16.8 50873 −17.2 150378

111.2 4544 49.9 19982 16.3 51686 −17.9 153974

109.3 4740 49.2 20336 15.7 52514 −18.6 157708

107.4 4937 48.5 20695 15.2 53356 −19.3 161588

105.6 5136 47.9 21057 14.7 54215 −20.1 165624

103.9 5336 47.3 21424 14.1 55089 −20.8 169824

102.3 5539 46.6 21795 13.6 55979 −21.5 174200

100.6 5743 46.0 22171 13.1 56887 −22.3 178762

99.1 5949 45.4 22551 12.5 57811 −23.0 183522

97.6 6157 44.7 22936 12.0 58754 −23.8 188493

96.1 6367 44.1 23326 11.5 59715 −24.6 193691

94.7 6578 43.5 23720 11.0 60694 −25.4 199130

93.3 6792 42.9 24120 10.4 61693 −26.2 204829

92.0 7007 42.3 24525 9.9 62712 −27.0 210805

90.6 7225 41.7 24934 9.3 63752 −27.8 217080

89.4 7444 41.1 25349 8.8 64812 −28.7 223677

88.1 7666 40.5 25769 8.3 65895 −29.5 230621

86.9 7890 39.9 26195 7.7 67000 −30.4 237941

85.7 8115 39.3 26626 7.2 68128 −31.3 245667

84.5 8343 38.7 27063 6.7 69281 −32.2 253834

83.4 8573 38.1 27505 6.1 70458 −33.2 262482

82.3 8806 37.5 27954 5.6 71661 −34.1 271655

81.2 9040 37.0 28408 5.0 72890 −35.1 281400

80.1 9277 36.4 28868 4.5 74147 −36.1 291774

79.0 9516 35.8 29335 3.9 75431 −37.1 302840

78.0 9757 35.2 29808 3.4 76745 −38.2 314669

77.0 10001 34.7 30288 2.8 78090 −39.2 327343

76.0 10247 34.1 30774 2.3 79465

75.0 10496 33.5 31267 1.7 80873

74.1 10747 33.0 31766 1.2 82314

73.1 11000 32.4 32273 0.6 83790

72.2 11256 31.9 32787 0.0 85302

71.3 11515 31.3 33309 −0.5 86852

70.4 11776 30.7 33837 −1.1 88440

69.5 12040 30.2 34374 −1.7 90068

68.6 12306 29.6 34918 −2.2 91738

67.7 12575 29.1 35471 −2.8 93452

66.9 12847 28.6 36031 −3.4 95211

66.0 13122 28.0 36600 −4.0 97016

65.2 13400 27.5 37177 −4.6 98870

64.4 13681 26.9 37764 −5.2 100775

63.6 13964 26.4 38359 −5.7 102733

62.8 14251 25.8 38963 −6.3 104746

62.0 14540 25.3 39577 −6.9 106817

61.2 14833 24.8 40200 −7.5 108948

60.5 15129 24.2 40833 −8.2 1111 41

59.7 15428 23.7 41476 −8.8 113400

59.0 15730 23.2 42130 −9.4 115727

58.2 16036 22.6 42794 −10.0 118126

57.5 16345 22.1 43468 −10.6 120600

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

Page 33

XC17 SERIES

Table 7. High Discharge Sensor Temperature / Resistance Range

Degrees

Fahrenheit

303.1 183 186.1 1052 136.8 2656 94.5 6613

298.1 195 185.0 1072 136.0 2698 93.6 6739

293.4 207 183.9 1093 135.2 2740 92.8 6869

289.0 220 182.8 1114 134.5 2783 92.0 7002

284.8 232 181.8 1135 133.7 2827 91.2 7139

280.9 245 180.7 1157 132.9 2872 90.3 7281

277.1 258 179.6 1179 132.2 2917 89.5 7426

273.6 270 178.6 1201 131.4 2963 88.6 7575

270.2 283 177.6 1223 130.6 3010 87.8 7729

267.0 297 176.6 1245 129.9 3057 86.9 7888

263.9 310 175.5 1268 129.1 3105 86.0 8051

260.9 323 174.6 1291 128.4 3154 85.2 8220

258.1 336 173.6 1315 127.6 3204 84.3 8394

255.3 350 172.6 1338 126.8 3255 83.4 8574

252.7 364 171.6 1362 126.1 3307 82.5 8759

250.1 378 170.6 1386 125.3 3359 81.6 8951

247.7 391 169.7 1411 124.6 3413 80.7 9149

245.3 405 168.7 1435 123.8 3467 79.8 9354

243.0 420 167.8 1460 123.1 3523 78.8 9566

240.8 434 166.9 1486 122.3 3579 77.9 9786

238.6 448 165.9 1511 121.6 3637 76.9 10013

236.5 463 165.0 1537 120.8 3695 76.0 10250

234.4 478 164.1 1563 120.1 3755 75.0 10495

232.4 492 163.2 1590 119.3 3816 74.1 10749

230.5 507 162.3 1617 118.5 3877 73.1 11014

228.6 523 161.4 1644 117.8 3940 72.1 11289

226.7 538 160.5 1672 117.0 4005 71.1 11575

224.9 553 159.7 1699 116.3 4070 70.0 11873

223.2 569 158.8 1728 115.5 4137 69.0 12184

221.5 584 157.9 1756 114.8 4205 68.0 12509

219.8 600 157.1 1785 114.0 4274 66.9 12848

218.1 616 156.2 1815 113.2 4345 65.8 13202

216.5 632 155.3 1845 112.5 4418 64.7 13573

214.9 649 154.5 1875 111.7 4491 63.6 13961

213.4 665 153.6 1905 111.0 4567 62.5 14368

211.9 682 152.8 1936 110.2 4644 61.3 14796

210.4 698 152.0 1968 109.4 4722 60.2 15246

208.9 715 151.1 1999 108.7 4802 59.0 15719

207.5 732 150.3 2032 107.9 4884 57.8 16218

206.0 750 149.5 2064 107.1 4968 56.6 16744

204.6 767 148.7 2098 106.4 5054 55.3 17301

203.3 785 147.9 2131 105.6 5141 54.0 17891

201.9 803 147.1 2165 104.8 5231 52.7 18516

200.6 821 146.2 2200 104.0 5323 51.4 19180

199.3 839 145.4 2235 103.3 5416 50.0 19887

198.0 857 144.6 2270 102.5 5512 48.6 20641

196.8 876 143.8 2306 101.7 5610 47.2 21448

195.5 894 143.0 2343 100.9 5711 45.7 22311

194.3 913 142.3 2380 100.1 5814

193.1 932 141.5 2418 99.3 5920

191.9 952 140.7 2456 98.5 6028

190.7 971 139.9 2495 97.7 6139

189.5 991 139.1 2534 96.9 6253

188.4 1011 138.3 2574 96.1 6370

187.2 1031 137.6 2615 95.3 6489

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

Degrees

Fahrenheit

Resistance

506510−01

Page 34

Table 8. Sensor Temperature / Resistance Range

Temperature

Sensor

Outdoor (Ambient)

Discharge −35ºF to 310ºF

Note: Sensor resistance decreases as sensed temperature increases (see Figures 6 and 7).

Range °F (°C)

−40ºF to 140ºF (−40ºC to 60ºC)

(−37ºC to 154ºC)

Resistance values range (ohms)

280,000 to 3750 3 and 4

41,000 to 103 1 and 2

Pins/Wire Color

(Black)

(Yellow)

Main Control LED Alert Codes

Main Control LED alert codes (simply referred to as LED alert codes) are located on the Main Control and marked with the following identification.

DS11 AND DS14 LED SYSTEM AND ALERT CODES

DS11 (Green) and DS14 (Red) LEDs indicate diagnostics conditions that are listed in Table 9.

These LEDs display fault conditions in system cooling capacity, dehumidification mode, anti−short cycle lockout, high and low pressures, discharge line temperature, outdoor temperature, and discharge sensor failures.

DS15 AND DS13 LED COMPRESSOR ALERT CODES

DS15 (Yellow) and DS13 (Red) LEDs indicate diagnostics conditions that are listed in Table 9.

These LEDs display the most common fault conditions in the system. When an abnormal condition is detected, this function communicates the specific condition through LEDs. The diagnostic function is capable of detecting both mechanical and electrical system abnormal conditions.

RESETTING LED ALERT CODES

LED alert codes can be reset either manually or automatically:

1. Manual Reset

Manual reset can be achieve by one of the following methods:

S Disconnect R wire from the Main Control’s R

terminal.

S Turning main power OFF and then ON at the unit’s

disconnect switch.

After power up, existing code will display for 60 seconds and then clear.

2. Automatic Reset

After an alert is detected, the Main Control continues to monitor the unit’s system and compressor operations. When/if conditions return to normal, the alert code is turned off automatically.

IMPORTANT

LED alert codes do not provide safety protection. The is a monitoring function only and cannot control or shut down other devices.

Table 9. System LED Alert Codes

Outdoor Main Control

Alternating FAST Flash

LEDs

DS11

Green

OFF OFF Power problem

Simultaneous SLOW

Alternating SLOW

Simultaneous FAST

DS14 Red

Flash

Condition Possible Cause(s) Solution

Normal operation

5−minute

anti−short cycle

delay

Ambient Sensor

Problem

Coil Sensor

Problem

SYSTEM STATUS

No power (24V) to control terminals R and C or control failure.

Unit operating normally or in standby mode.

Initial power up, safety trip, end of room thermostat demand.

Sensor being detected open or shorted or out of temperature range. control will revert to time/temperature defrost operation. (System will still heat or cool).

This model does not utilize a coil sensor, however this alert indicates either an open or shorted circuit. See if 10K resistor is not damage or missing. Resistor is located in the sensor harness assembly, brown lead.

Check control transformer power (24V).

If power is available to control and LED(s) do not light, replace control.

Indicates that control has internal component failure. Cycle 24 volt power to control. If code does not clear, replace control.

None required (Jumper FIELD TEST pins to override)

ON ON

Main Control

Board Failure

Indicates that control has internal component failure. Cycle 24 volt power to control. If code does not clear, replace control.

Page 35

XC17 SERIES

Outdoor Main Control

LEDs

DS11

Green

DS14 Red

1 Fast

OFF

Flash then

Pause

Heating Low

Capacity

SolutionPossible Cause(s)Condition

OFF

1 Fast

Flash then

Pause

2 Fast

Flash then

Pause

2 Fast

Flash then

Pause

OFF

OFF ON

SLOW

Flash

ON OFF

2 Fast

Flash then

Pause

2 Fast

Flash then

Pause

OFF

SLOW

Flash

OFF

Heating High

Capacity

Defrost

Cooling Low

Capacity

Cooling High

Capacity

Dehumidification

Mode

Low Pressure

Fault

Low Pressure

Switch Lockout

High Pressure

Fault

High Pressure

Discharge Sensor

Lockout

These are codes that show status of operation whether in low stage or high stage, heating or cooling, defrost or in the EDA mode.

ALERT STATUS

Restricted air flow over indoor or outdoor coil.

Improper refrigerant charge in system.

Improper metering device installed or incorrect operation of metering device.

Incorrect or improper sensor location or con-

Remove any blockages or restrictions from coils and/or fans. Check indoor and outdoor fan motor for proper current draws.

Check system charge using approach and subcooling temperatures.

Check system operating pressures and compare to unit charging charts.

Make sure all pressure switches and sensors have secure connections to system to prevent refrigerant leaks or errors in pressure and temperature measurements.

nection to system.

SLOW

Flash

FAST Flash

OFF Fast Flash

Fast simultaneous

flashing of DS11, DS13,

DS14 and DS15

Discharge Line

Temperature Fault

Discharge Line

Temperature

Lockout

Discharge Sensor

Fault

This code detects high discharge temperatures. If the discharge line temperature exceeds a temperature of 279ºF (137ºC) during compressor operation, the control will de−energize the compressor contactor output (and the defrost output if active). The compressor will remain off until the discharge temperature has dropped below 225ºF (107ºC). See Figure 21 for further details concerning lockouts and reset procedures.

The control detects open or short sensor or out of temperature sensor range. This fault is detected by allowing the unit to run for 90 seconds before checking sensor resistance. If the sensor resistance is not within range after 90 seconds, the control will raise the alarm.

OEM Mode Factory Test Mode.

506510−01

Page 36

Outdoor Main Control LEDs

DS15 Yellow

DS13

Red

OFF ON

1 Flashes then

OFF Long run time.

Pause

2 Flashes then

OFF

Pause

3 Flashes then

OFF Short Cycling

Pause

4 Flashes then

OFF Locked Rotor

Pause.

Condition

Compressor

Internal

Overload Trip

System

Pressure Trip

Table 10. Compressor LED Alert Codes

Possible Cause(s)

Thermostat demand signal Y1 is present, but compressor not running

Compressor is running extremely long run cycles.

Indicates the compressor protector is open or missing supply power to the compressor.

Compressor is running less than three minutes.

Compressor has a locked out due to run capacitor short, bearings are seized, excessive liquid refrigerant.

Solution

Compressor protector is open.

S Check for high head pressure S Check compressor supply voltage

Outdoor unit power disconnect is open.

Compressor circuit breaker or fuse(s) is open.

Broken wire or connector is not making contact.

Low or high pressure switch open if present in the system.

Compressor contactor has failed to close.

Low refrigerant charge.

Evaporator blower is not running.

S Check blower relay coil and contacts S Check blower motor capacitor S Check blower motor for failure or blockage S Check evaporator blower wiring and connectors S Check indoor blower control S Check thermostat wiring for open circuit

Evaporator coil is frozen.

S Check for low suction pressure S Check for excessively low thermostat setting S Check evaporator airflow (coil blockages or return

air filter)

S Check ductwork or registers for blockage.

Faulty metering device.

S Check TXV bulb installation (size, location and

contact)

S Check if TXV/fixed orifice is stuck closed or de-

fective

Condenser coil is dirty

Liquid line restriction (filter drier blocked if present)

Thermostat is malfunctioning

S Check thermostat sub−base or wiring for short cir-

cuit

S Check thermostat installation (location and level)

High head pressure.

S Check high pressure switch if present in system S Check if system is overcharged with refrigerant S Check for non−condensable in system

Condenser coil poor air circulation (dirty, blocked, damaged).

Condenser fan is not running.

S Check fan capacitor S Check fan wiring and connectors S Check fan motor for failure or blockage

Return air duct has substantial leakage.

Thermostat demand signal is intermittent.

Time delay relay or Main Control is defective.

If high pressure switch is present, see Flash Code 2 information.

Run capacitor has failed.

Low line voltage (contact utility if voltage at disconnect is low).

S Check wiring connections

Excessive liquid refrigerant in the compressor.

Compressor bearings are seized.

Clearing Status

Clears the error after current is sensed in the run and start winding for two seconds, service removed or power reset.

Clears the error after 30 consecutive normal run cycles, or after power reset.

Clears after four consecutive normal compressor run cycles, or after power reset.

Clears after power reset or four normal compressor cycles.

Page 37

XC17 SERIES

Outdoor Main

Control LEDs

DS15 Yellow

5 Flashes then Pause

6 Flashes then Pause

7 Flashes then Pause

Condition

DS13

Condition

Red

OFF Open Circuit

OFF

Open Start

Circuit

Open Run

Circuit

Possible

Possible Cause(s)

Cause(s)

Compressor has an open circuit due to power disconnection, fuse is open or other similar conditions.

Current not sensed by Start transformer.

Current not sensed by run transformer.

Solution

Outdoor unit power disconnect is open.

Unit circuit breaker or fuse(s) is open.

Unit contactor has failed to close.

S Check compressor contactor wiring and con-

nectors

S Check for compressor contactor failure (burned,

pitted or open)

S Check wiring and connectors between supply and

compressor

S Check for low pilot voltage at compressor con-

tactor coil

High pressure switch is open and requires manual reset.

Open circuit in compressor supply wiring or connections.

Unusually long compressor protector reset time due to extreme ambient temperature.

Compressor windings are damaged.

S Check compressor motor winding resistance

Run capacitor has failed.

Open circuit in compressor start wiring or connections.

S Check wiring and connectors between supply and

the compressor S terminal

Compressor start winding is damaged.

S Check compressor motor winding resistance

Open circuit in compressor start wiring or connections.

S Check wiring and connectors between supply and

the compressor R terminal

Compressor start winding is damaged.

S Check compressor motor winding resistance

Clearing Status

Clears after one normal compressor run cycle or power reset.

Clears when amperage is detected in RUN and START sensors, or after power reset.

8 Flashes then

OFF

Pause

9 Flashes then

OFF

Pause

Fast simultaneous

flashing of DS11,

DS13, DS14 and

DS15

Welded

Contactor

Secondary

Low Voltage

Compressor always runs

24VAC is below 18VAC.

OEM Mode Factory Test Mode.

Compressor contactor failed to open.

Thermostat demand signal not connected to module.

Control circuit transformer is overloaded.

Low line voltage (contact utility if voltage at disconnect is low).

S Check wiring connections

Clears after one normal compressor run cycle or after power reset.

Clears after voltage is higher than 20VAC for two seconds, or after power reset.

506510−01

Page 38

Figure 19. High Pressure Switch Operation

Page 39

XC17 SERIES

506510−01

Figure 20. Low Pressure Switch Operation

Page 40

Figure 21. High Discharge Temperature Sensor Operation

Page 41

XC17 SERIES

Maintenance

WARNING

Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.

VERIFYING LED STATUS CODES

During start up, the fan motor control LED will display any error conditions. If error conditions exist then no other codes will display. If no error conditions are present, then the stage status and and RPM indicator are displayed. Fan motor speeds

are not adjustable for a single stage outdoor unit (see table 11).

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.

DEALER

Verifying Fan Motor Operation

FAN MOTOR CONTROL AND START UP

This motor control is used in controlling motors which employ a Pulse Width Modulation (PWM) controller. A PWM signal will run the fan motor at a revolutions per minute (RPM) that corresponds to a specific PWM signal.

VERIFYING JUMPER SETTINGS (J2)

The unit is shipped from the factory with the default motor RPM setting required for the specific model size. Use table 11 for one−stage to verify that the jumpers are set correctly for the specific size unit.

Table 11. One Stage  Motor Control RPM Jumper Settings, LED RPM Indicator and P2 DC Voltage Outputs

CFM Profile Pin Select

Model LED Code*

4 3 2 1 RPM (J2) DC Volt

VERIFYING CORRECT DC OUTPUT VOLTAGE (J2)

The following three methods can be used to determine whether the fan motor is operating at the correct RPMs based on unit size.

1. Use the information provided in tables 11 to verify that all four jumper terminals are set correctly for the specific size unit.

2. Verify LED RPM indicator is displaying the correct flash sequence for the applicable size unit (see Table

11).

3. Test DC voltage output on the Motor Control’s J2 terminals (see Figure 23) while under full load and verify the voltage read to the voltage listed in Table 11 for the applicable size unit.

4. If no voltage is detected at the J2 terminals, verify there is a Y1 demand at the thermostat and 24V present at the Fan Control’s EXT PWR/R terminal during that Y1 demand (see Figure 24).

5. If 24V is present at the Fan Control EXT PWR/R terminal during a Y1 thermostat demand, and no voltage is present at the J2 terminals, then Fan Control should be replaced.

ECM1/Y1

(One Stage and EDA Operation)

XP/XC17−048, −060 9 OFF OFF OFF ON 675 21.6

XP/XC17−036, −042 8 OFF OFF ON ON 600 19.2

XP/XC17−030 6 OFF ON ON OFF 450 14.3

XP/XC17−024 5 OFF ON ON ON 400 12.7

* LED Code indicates Fan Control LED flash sequence. For example, LED Code 9 indicates 9 slow flashes and pause.

Page 42

506510−01

LED CODES AND SEQUENCE OF OPERATIONS

During start up, the LED will first display any error conditions (see table 12) if present. If no errors are detected then the LED code indicating one or two stage operation will display then a long pause. The RPM indicator is displayed next. After the RPM indicator is displayed there is a short pause and the sequence repeats if a thermostat demand is still present. See Figure 22 for LED sequence of operations. See table 13 for description of flash and pause durations.

Table 12. Error/Fault LED Codes

Unit Status Motor Control LED Possible Cause

Mismatched RPM Fast Flash with no pause

Internal feedback, PWM does not match target.

CRC Failure Constant ON. Microcontroller CRC failure.

Table 13. Fan Motor Board Unit LED Codes

Unit Status Unit Status Motor Control LED

One Stage Operation Low Stage  ECM1/Y1 ONLY One slow flash, then short pause.

RPM Indicator

NOTE  There is a long pause between stage operation and RPM indicator. See Tables 1 and 2 for LED RPM indicator.

Flash Flash = Three flashes per second.

Slow Flash = One flash per second.

Short Pause = Two seconds of OFF time.

Long Pause = Five seconds of OFF time.

RPM Indicator

Appropriate number of flashes (See Tables 11 and 2).

YES

DEMAND

BEGINS

MISMATCHED

RPM

CRC FAILURE

SINGLE STAGE

OR EDA

OPERATION

DEMAND

ENDED

FAN MOTOR PWM CONTROL (ONE STAGE AND

SINGLE FAN SPEED)

DEFAULT FAN

MOTOR SPEED

ECM1/Y1

ONLY OR

ECM2/Y2

ONLY

MOTOR SPEED

USED

DEFAULT FAN

USED

FAN MOTOR

RPM SET PER

JUMPER

SETTINGS

LED CONTINUOUS FAST

FLASH

LED CONSTANT ON

REPLACE FAN MOTOR

CONTROL BOARD

REPLACE FAN MOTOR

CONTROL BOARD

STAGE LED INDICATOR: ONE SLOW FLASH AND ONE SHORT PAUSE FOR SINGLE STAGE OR EDA OPERATION

LED RPM INDICATOR: EXAMPLE: (2−TON UNIT) – 5 SLOW FLASHES AND ONE

LONG PAUSE

Figure 22. Single Stage LED Sequence of Operation

Page 43

XC17 SERIES

FAN MOTOR CONTROL 

PULSE−WIDTH MODULATION (PWM)

CFM Profile Pin Select

MAIN CONTROL

CONTROL PANEL

VERIFY DC VOLTAGE OUTPUT USING FAN PWM OUT AND COM TERMINALS. SEE TABLE 11 FOR OPTIMAL DC VOLTAGE BASED ON CFM PROFILE USED.

COM

PARK

JUMPER

OFF

JUMPER

LED

GREEN

FAN PWM OUT

RED

YELLOW BLACK

YELLOW

BLACK

BLUE

YELLOW

BLACK

PWM FAN CONTROL

SEE TABLE 11 FOR CFM PROFILE SELECTION OPTIONS.

Figure 23. Fan Control, Wiring, Jumper Settings, Testing and LED Location

GREEN

RED RED

BLACK

BROWN

506510−01

Page 44

FAN MOTOR CONTROL 

PULSE−WIDTH MODULATION (PWM)

MAIN CONTROL

GREEN

RED

YELLOW BLACK

CONTROL PANEL

BLACK WIRE

TO MAIN CONTROL

YELLOW WIRE

YELLOW

BLACK

COM

EXT PWR/R

GREEN

RED

BLACK

BROWN

BLUE

YELLOW

BLACK

YELLOW

PWM FAN CONTROL

SEE TABLE 11 FOR CFM PROFILE SELECTION OPTIONS.

Figure 24. Testing for External Power to Fan Control

Page 45

XC17 SERIES

FAN MOTOR TEST PROCEDURE

A simple test can be used to test the fan motor operation. A fully charged 9V battery will be required for this procedure.

FAN MOTOR TEST

This is a test that will verify that the motor does operate.

1. Verify main (240 volt) power if OFF to unit.

2. Remove both wires (brown and black) from the J2 terminal on the fan motor control.

3. Room thermostat should be in OFF position (Unit in idle mode − no heating or cooling demands)

4. Turn main power (240 volt) ON to unit.

5. Connect 9 Volt batter to outdoor fan motor plugs as noted in picture below..

6. Outdoor fan motor should run at a reduced fan speed.

7. If Outdoor fan motor does not run, then replace fan motor assembly.

REMOVE BOTH LEADS

FROM J2 TERMINALS

BLACK LEAD

BROWN LEAD

COM

PARK

FAN PWM OUT

FAN MOTOR CONTROL

BLACK LEAD

CONNECT FAN MOTOR BLACK

COMMON WIRE TO 9V BATTERY

NEGATIVE TERMINAL

NEGATIVE TERMINAL POSITIVE TERMINAL

BLACK LEAD

BROWN LEAD

CONNECT FAN MOTOR WIRE TO 9V BATTERY POSITIVE TERMINAL

506510−01

FULLY CHARGED 9V BATTERY

Figure 25. Fan Motor Test

Page 46

FAN MOTOR SURGE PROTECTION

Surge Protector (Metal Oxide Varistor − MOV) − A part

designed to protect electrical devices from voltage spikes that are 3 to 4 times the normal circuit voltage (See Figure 26 for illustration of component).

An MOV works as follows: It is essentially a batch of metallic−oxide grains separated by insulating layers. Repeated voltage surges break down the insulating layers, lowering the overall resistance and eventually causing the device to draw too much current and trip whatever over−current protection is inherent in the system)

MOV Check: They are supposed to be located beyond the line fuse (though possibly not always). In this case, where the line fuse blows or circuit breaker trips but there is no visible damage to the MOV(s), the simplest test may be to just temporarily remove the MOV(s) and see if the problem goes away.

See Figure 1 for location of the Surge Protections device which is located in the unit control box area.

NOTE  It may be necessary to flush the outdoor coil more frequently if it is exposed to substances which are corrosive or which block airflow across the coil (e.g., pet urine, cottonwood seeds, fertilizers, fluids that may contain high levels of corrosive chemicals such as salts)

Sea Coast  Moist air in ocean locations can carry salt, which is corrosive to most metal. Units that are located near the ocean require frequent inspections and maintenance. These inspections will determine the necessary need to wash the unit including the outdoor coil. Consult your installing contractor for proper intervals/procedures for your geographic area or service contract.

Indoor Unit

1. Clean or change filters.

2. Lennox blower motors are prelubricated and permanently sealed. No more lubrication is needed.

3. Adjust blower speed for cooling. Measure the pressure drop over the coil to determine the correct blower CFM. Refer to the unit information service manual for pressure drop tables and procedure.

4. Belt Drive Blowers − Check belt for wear and proper tension.

5. Check all wiring for loose connections.

6. Check for correct voltage at unit. (blower operating)

7. Check amperage draw on blower motor.

Motor Nameplate:_________ Actual:__________.

Indoor Coil

1. Clean coil if necessary.

2. Check connecting lines, joints and coil for evidence of oil leaks.

3. Check condensate line and clean if necessary.

Figure 26. Fan Motor Surge Protection Device

Outdoor Unit

Maintenance and service must be performed by a qualified installer or service agency. At the beginning of each cooling season, the system should be checked as follows:

1. Outdoor unit fan motor is pre−lubricated and sealed. No further lubrication is needed.

2. Visually inspect all connecting lines, joints and coils for evidence of oil leaks.

3. Check all wiring for loose connections.

4. Check for correct voltage at unit (unit operating).

5. Check amperage draw on outdoor fan motor.

Motor Nameplate:_________ Actual:__________.

6. Inspect drain holes in coil compartment base and clean if necessary.

NOTE - If insufficient cooling occurs, the unit should be gauged and refrigerant charge should be checked.

Outdoor Coil

Clean and inspect outdoor coil (may be flushed with a water hose). Ensure power is off before cleaning.

HOMEOWNER

Cleaning of the outdoor unit’s coil should be performed by a trained service technician. Contact your dealer and set up a schedule (preferably twice a year, but at least once a year) to inspect and service your outdoor unit. The following maintenance may be performed by the homeowner.

CAUTION

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 and diminish performance and longevity of the unit.

Page 47

XC17 SERIES

Outdoor Coil

The outdoor unit must be properly maintained to ensure its proper operation.

S Please contact your dealer to schedule proper

inspection and maintenance for your equipment.

S Make sure no obstructions restrict airflow to the

outdoor 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

periodically check for debris which collects around the unit.

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.

1. Air Filter  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.

2. Disposable Filter  Disposable filters should be

replaced with a filter of the same type and size.

NOTE  If you are unsure about the filter required for your system, call your Lennox dealer for assistance.

3. Reusable Filter  Many indoor units are equipped

with reusable foam filters. Clean foam filters with a mild soap and water solution; rinse thoroughly; allow filter to dry completely before returning it to the unit or grille.

NOTE  The filter and all access panels must be in place any time the unit is in operation.

4. Electronic Air Cleaner  Some systems are

equipped with an electronic air cleaner, designed to remove airborne particles from the air passing through the cleaner. If your system is so equipped, ask your dealer for maintenance instructions.

5. Indoor Unit  The indoor unit’s 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.

Accessories

For update−to−date information, see any of the following publications:

S Lennox XC17 Engineering Handbook S Lennox Product Catalog S Lennox Price Book

WARNING

This product and/or the indoor unit it is matched with may contain fiberglass wool.

Disturbing the insulation during installation, maintenance, or repair will expose you to fiberglass wool dust. Breathing this may cause lung cancer. (Fiberglass wool is known to the State of California to cause cancer.)

Fiberglass wool may also cause respiratory, skin, and eye irritation.

To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor.

Lennox Industries Inc. P.O. Box 799900 Dallas, TX 75379−9900

XC17 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

Page 48

506510−01

XC17 Start−Up and Performance Checklist

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) A  B = COIL TEMP DROP

Return Air Temperature (A)

minus Supply Air Temperature (B)

A  B = SUBCOOLING

A  B = APPROACH

Page 49

XC17 SERIES

Lennox XC17, 506510-01 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual