Lennox XP16-024-230-01, XP16-024-230-05, XP16-024-230-03, XP16-036-230-01, XP16-024-230-04 Unit Information

Corp. 0626−L5

Service Literature

Revised October 21, 2010

XP16 (HFC−410A) SERIES UNITS

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.

CAUTION

Physical contact with metal edges and corners while
applying excessive force or rapid motion can result in
personal injury. Be aware of, and use caution when
working near these areas during installation or while
servicing this equipment.

XP16

TABLE OF CONTENTS

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

Typical Serial Number Identification 2. . . . . . . . . . . . . .

Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Data 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Dimensions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Parts Arrangement 5. . . . . . . . . . . . . . . . . . . . . . . .

Operating Gauge Set and Service Valves 7. . . . . . . . .

Recovering Refrigerant from System 9. . . . . . . . . . . . .

Unit Placement 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and Installing Panels 12. . . . . . . . . . . . . . . . .

New or Replacement Line Set 14. . . . . . . . . . . . . . . . . .

Brazing Connections 16. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Line Set and Indoor Coil 19. . . . . . . . . . . . . . .

Installing Indoor Metering Device 20. . . . . . . . . . . . . . . .

Leak Test Line Set and Indoor Coil 21. . . . . . . . . . . . . .

Evacuating Line Set and Indoor Coil 22. . . . . . . . . . . . .

Electrical 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Units Void of Charge 24. . . . . . . . . . . . . . . . . .

Unit Start−Up 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Refrigerant 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defrost System 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Wiring Diagram and Sequence of

Operations 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checklists 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The XP16 is a high efficiency residential split−system
two−stage heat pump unit, which features a scroll
compressor and HFC−410A refrigerant. XP16 units are
available in 2, 3, 4 and 5 tons. tons. XP16 units are rated for
230 volts only. Applications where supply voltage is less
requires a hard start kit. The series is designed for use with
an indoor unit with an expansion valve approved for
HFC−410A.

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.

Page 1

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.

2006 Lennox Industries Inc.

Model Number Identification

Refrigerant Type

X = HFC−410A

Unit Type

P = Heat Pump

− −

P 16 036

X 5

Nominal Cooling Capacity

230

−

Minor Revision Number

Voltage

230 = 208/230V−1ph−60hz

024 = 2 tons

Series

036 = 3 tons
048 = 4 tons
060 = 5 tons

Typical Serial Number Identification

Location Code

19 = Saltillo, Mexico

58 = Marshalltown, IA

Year Code

08 = 2008
09 = 2009
10 = 2010

19 09 C

05716

5 (or 6) Digit Unique Number

Month Code

A = January
B = February
C = March

Specifications

Unit Outdoor Fan

Model Number

XP16−024−230−01 74 9 lbs. 9 oz. 3 18

XP16−024−230−03 74 7 lbs. 13 oz. 3 18

XP16−024−230−04 74 7 lbs. 13 oz. 3 18

XP16−024−230−05 74 8 lbs. 13 oz. 3 18

Sound Rating Number

(dB)

1

Factory Refrigerant

Charge

2

Number of Blades Diameter − inches.

Unit Outdoor Fan

Model Number

XP16−036−230−01 76 12 lbs. 8 oz. 4 22

XP16−036−230−02 76 12 lbs. 8 oz. 4 22

XP16−036−230−03 76 10 lbs. 4 oz. 4 22

XP16−036−230−04 76 10 lbs. 4 oz. 4 22

XP16−036−230−05 76 10 lbs. 9 oz. 4 22

Model Number

XP16−048−230−01 76 15 lbs. 7 oz. 4 22

XP16−048−230−02 76 15 lbs. 7 oz. 4 22

XP16−048−230−03 76 15 lbs. 7 oz. 4 22

XP16−048−230−04 76 15 lbs. 7 oz. 4 22

XP16−048−230−05 76 11 lbs. 12 oz. 3 26

Model Number

XP16−060−230−01 78 13 lbs. 8 oz. 3 26

XP16−060−230−02 78 13 lbs. 8 oz. 3 26

XP16−060−230−03 78 11 lbs. 7 oz. 3 26

XP16−060−230−04 78 11 lbs. 7 oz. 3 26

XP16−060−230−05 78 12 lbs. 15 oz. 3 26

1

Tested according to AHRI Standard 270−2008 test conditions.

2

Refrigerant charge sufficient for 15 feet length of refrigerant lines.

Sound Rating Number

Sound Rating Number

Sound Rating Number

(dB)

(dB)

(dB)

1

1

1

Factory Refrigerant

Unit Outdoor Fan

Factory Refrigerant

Unit Outdoor Fan

Factory Refrigerant

Charge

Charge

Charge

2

2

2

Number of Blades Diameter − inches.

Number of Blades Diameter − inches.

Number of Blades Diameter − inches.

Page 2

XP16

Electrical Data

208/230V−60 Hz−1 Ph

Unit Compressor Condenser Fan

Model Number

Over−

current

Protection

(amps)

1

Minimum

Circuity

Ampacity

Rated Load

Amps (RLA)

2

Maximum

XP16−024−230−01 20 14.0 10.25 52.0 1/10 PSC 1075 0.7 1.4

XP16−024−230−03 20 14.0 10.25 52.0 1/10 PSC 1075 0.7 1.4

XP16−024−230−04 20 14.0 10.25 52.0 1/10 PSC 1075 0.7 1.4

XP16−024−230−05 20 14.0 10.25 52.0 1/10 PSC 1075 0.7 1.4

Unit Compressor Condenser Fan

Model Number

Over−

current

Protection

(amps)

1

Minimum

Circuity

Ampacity

Rated Load

Amps (RLA)

2

Maximum

XP16−036−230−01 35 22.0 16.67 82.0 1/6 PSC 825 1.1 2.1

XP16−036−230−02 35 22.0 16.67 82.0 1/6 PSC 825 1.1 2.1

XP16−036−230−03 35 22.0 16.67 82.0 1/6 PSC 825 1.1 2.1

XP16−036−230−04 35 22.0 16.67 82.0 1/6 PSC 825 1.1 1.87

XP16−036−230−05 35 22.5 16.67 82.0 1/4 PSC 825 1.7 3.1

Locked

Rotor
Amps

(LRA)

Motor

HP

208/230V−60 Hz−1 Ph

Locked

Rotor
Amps
(LRA)

Motor

HP

Motor

Type

Motor Type

Nominal

RPM

Nominal

RPM

Full Load

Amps (FLA)

Full Load

Amps (FLA)

Locked Rotor

Amps (LRA)

Locked Rotor

Amps (LRA)

208/230V−60 Hz−1 Ph

Unit Compressor Condenser Fan

Model Number

Maximum

Over−

current

Protection

(amps)

1

Minimum

Circuity

Ampacity

Rated Load

Amps (RLA)

2

Locked

Rotor
Amps
(LRA)

Motor

HP

Motor Type

Nominal

RPM

Full Load

Amps (FLA)

Locked Rotor

Amps (LRA)

XP16−048−230−01 45 28.2 21.15 96.0 1/4 PSC 825 1.7 3.1

XP16−048−230−02 45 28.2 21.15 96.0 1/4 PSC 825 1.7 3.1

XP16−048−230−03 45 28.2 21.15 96.0 1/4 PSC 825 1.7 3.1

XP16−048−230−04 45 28.2 21.15 96.0 1/4 PSC 825 1.7 3.1

XP16−048−230−05 45 28.2 21.15 96.0 1/3 PSC 825 1.8 2.9

208/230V−60 Hz−1 Ph

Unit Compressor Condenser Fan

Model Number

Maximum

Over−

current

Protection

(amps)

1

Minimum

Circuity

Ampacity

Rated Load

Amps (RLA)

2

Locked

Rotor
Amps
(LRA)

Motor

HP

Motor Type

Nominal

3

RPM

Full Load

Amps (FLA)

Locked Rotor

Amps (LRA)

XP16−060−230−01 55 33.9 25.64 118.0 1/3 PSC 825 1.8 2.9

XP16−060−230−02 60 33.9 25.87 118.0 1/3 PSC 825 1.8 2.9

XP16−060−230−03 60 33.9 25.87 118.0 1/3 PSC 825 1.8 2.9

XP16−060−230−04 60 33.9 25.87 118.0 1/3 PSC 825 1.8 2.9

700

XP16−060−230−05 60 35.1 25.87 118.0 1/3 VS

1

HACR type circuit breaker or fuse.

2

Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.

3

PSC = permanent split capacitor motor (single speed); VS = variable speed.

(1st Stage)

820

(2nd Stage)

2.8 N/A

XP16

Page 3

Unit Dimensions − Inches (mm)

A

LIQUID LINE
CONNECTION

ELECTRICAL INLETS

SUCTION LINE
CONNECTION

C

9−1/2
(241)

8−1/4
(210)

4−3/4"

(121)

UNIT SUPPORT FEET

B

TOP VIEW

D

E

F

G

XP16−036 to −060 BASE WITH LEGS

K

J

H

UNIT SUPPORT

FEET

8−1/2
(216)

8−3/4
(222)

SIDE VIEW

5−1/2
(140)

13−1/2

(343)

XP16−024 BASE SECTION

4−1/2"

(108)

Model Number A B C D E F G H J K

XP16−024−01,

−02, −03, −04

31 (889) 27 (686) 28 (711) − − − − − − −

XP16−024−05 35 (889) 27 (686) 28 (711) − − − − − − −

XP16−036−01,

−02, −03, −04

35 (889) 30−1/2 (775) 35 (889) 13−7/8 (352) 7−3/4 (197) 3−1/4 (83) 27−1/8 (689) 3−5/8 (92) 4−1/2 (114) 20−5/8 (524)

XP16−036−05 39 (991) 30−1/2 (775) 35 (889) 13−7/8 (352) 7−3/4 (197) 3−1/4 (83) 27−1/8 (689) 3−5/8 (92) 4−1/2 (114) 20−5/8 (524)

XP16−048−01,

−02, −03, −04

XP16−048−05 35 (889) 35−1/2 (902)

XP16−060−01,

−02, −03, −04

XP16−060−05 45 (1143 35−1/2 (902)

45 (1143) 30−1/2 (775) 35 (889)) 16−7/8 (429) 8−3/4 (222) 3−1/8 (79) 30−3/4 (781) 4−5/8 (117) 3−3/4 (95) 26−7/8 (683)

39 (991) 35−1/2 (902)

39−1/2
(1003)

39−1/2
(1003)

39−1/2
(1003)

16−7/8 (429) 8−3/4 (222) 3−1/8 (79) 30−3/4 (781) 4−5/8 (117) 3−3/4 (95) 26−7/8 (683)

16−7/8 (429) 8−3/4 (222) 3−1/8 (79) 30−3/4 (781) 4−5/8 (117) 3−3/4 (95) 26−7/8 (683)

16−7/8 (429) 8−3/4 (222) 3−1/8 (79) 30−3/4 (781) 4−5/8 (117) 3−3/4 (95) 26−7/8 (683)

Page 4

XP16

Typical Unit Parts Arrangement

CAPACITOR (LOCATION OF
CAPACITOR VARIES.)

DEFROST CONTROL (A108)

GROUND

LUG

CONTACTOR

(K−1)

AMBIENT
TEMPERATURE
SENSOR (RT13)

DISCHARGE LINE SENSOR (RT28)

REVERSING VALVE

REVERSING VALVE SOLENOID

TRUE SUCTION PORT

HIGH PRESSURE SWITCH (S4)

COMPRESSOR

CHECK

EXPANSION VALVE

FOR COIL SENSOR (RT21) LOCATION

SEE FIGURE 2.

XP16

LOW PRESSURE SWITCH (S87)

EXPANSION VALVE SENSING BULB

LIQUID VALVE AND GAUGE PORT / LIQUID LINE CONNECTIONS

Figure 1. Typical Parts Arrangements

Page 5

CRANKCASE HEATER THERMOSTAT (S40)

VAPOR VALVE AND GAUGE

PORT / SUCTION LINE

CONNECTIONS

LIQUID LINE BI−FLOW FILTER DRIER

XP16−024

COIL SENSOR −THIRD
HAIRPIN DOWN FROM
THE TOP ON INSIDE
ROW.

XP16−036

COIL SENSOR − NINTH
HAIRPIN UP FROM THE
BOTTOM ON INSIDE
ROW.

XP16−048

COIL SENSOR − EIGHT HAIRPIN
UP FROM THE BOTTOM ON
INSIDE ROW.

XP16−060

COIL SENSOR −
SIXTH HAIRPIN UP
FROM THE BOTTOM

ON INSIDE ROW.

XP16−024

COIL SENSOR
7 tubes up from
bottom (7−1/2")

XP16−036

COIL SENSOR
17 tubes up
from bottom
(17−1/2")

XP16−060

COIL SENSOR
12 tubes up from
bottom (11−1/2")

XP16−048

COIL SENSOR
13 tubes up from
bottom (12−1/2")

(XP16−XXX−230−05)

(XP16−XXX−230−01 through 04)

CLIP COIL TEMPERATURE SENSOR FROM THE DEFROST BOARD ON THE RETURN BEND SHOWN.

Figure 2. Coil Sensor (RT21) Locations

Page 6

XP16

WARNING

IMPORTANT

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

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.

IMPORTANT

Only use Allen wrenches of sufficient hardness (50Rc −
Rockwell Harness Scale minimum). Fully insert the
wrench into the valve stem recess.

Service valve stems are factory−torqued (from 9 ft−lbs for
small valves, to 25 ft−lbs for large valves) to prevent
refrigerant loss during shipping and handling. Using an
Allen wrench rated at less than 50Rc risks rounding or
breaking off the wrench, or stripping the valve stem
recess.

See the Lennox Service and Application Notes #C−08−1 for
further details and information.

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 3 provides information
on how to access and operating both angle and ball service
valves.

XP16

Page 7

SERVICE VALVES

ANGLE AND BALL

Operating Angle Type Service Valve:

1. Remove stem cap with an appropriately sized wrench.

2. Use a service wrench with a hex−head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve sizes) to back

the stem out counterclockwise as far as it will go.

SERVICE PORT CAP

SERVICE PORT CORE

(VALVE STEM SHOWN

TO INDOOR

UNIT

(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE

CLOSED) INSERT HEX
WRENCH HERE

SERVICE PORT

CORE

TO OUTDOOR UNIT

ANGLE−TYPE SERVICE VALVE

(BACK−SEATED OPENED)

When service valve is OPEN, the service port is
open to linE set, indoor and outdoor unit.

Operating Ball Type Service Valve:

1. Remove stem cap with an appropriately sized wrench.

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

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

TO INDOOR UNIT

TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°.

TO CLOSE ROTATE STEM
CLOCKWISE 90°.

SERVICE PORT

SERVICE PORT

SERVICE PORT

CORE

CAP

TO OUTDOOR

UNIT

BALL (SHOWN
CLOSED)

VALV E
STEM

STEM CAP

STEM CAP

ANGLE−TYPE SERVICE VALVE

(FRONT−SEATED CLOSED)

WHEN SERVICE VALV E IS CLOSED, THE SERVICE PORT IS
OPEN

TO THE LINE SET AND INDOOR UNIT.

To Access Service Port:

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

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

2. Connect gauge set to service port.

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

follows:

D With torque wrench: Finger tighten and

torque cap per table 1.

D Without torque wrench: Finger tighten and

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

Reinstall Stem Cap:

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

D With Torque Wrench: Finger tighten and

then torque cap per table 1.

D Without Torque Wrench: Finger

tighten and use an appropriately
sized wrench to turn an additional
1/12 turn clockwise.

9

10

9

10

8

12

11

8

7

6

12

11

7

6

1/6 TURN

1

2

3

4

5

1/12 TURN

1

2

3

4

5

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

Figure 3. Angle and Ball Service Valves

Page 8

XP16

Recovering Refrigerant from System

DISCONNECT POWER

Disconnect all power to the existing outdoor unit at the disconnect

1

switch or main fuse box/breaker panel.

MAIN FUSE BOX/BREAKER PANEL

MAIN FUSE

BOX/BREAKER

PANEL

DISCONNECT

SWITCH

RECOVERING REFRIGERANT

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

3

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

umes, and/or long line sets.

CONNECT MANIFOLD GAUGE SET

Connect a gauge set, clean recovery cylinder and a recovery

2

machine to the service ports of the existing unit. Use the
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

D Outdoor unit’s high or low−pressure switches (if applicable) when tripped can cycle the compressor OFF.
D Compressor can stop pumping due to tripped internal pressure relief valve.
D 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
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.

:

to go into a vacuum.

Figure 4. Refrigerant Recovery

XP16

Page 9

CLEARANCE ON ALL SIDES  INCHES (MILLIMETERS)

12 (305)

6 (152)

36 (914)

ACCESS PANEL

CONTROL PANEL

ACCESS

LOCATION

30 (762)

LINE SET
CONNECTIONS

MINIMUM CLEARANCE BETWEEN

TWO UNITS

24 (610)

Figure 5. Installation Clearances

NOTES:

D Clearance to one of the other three

sides must be 36 inches (914mm).

D Clearance to one of the remaining

two sides may be 12 inches
(305mm) and the final side may be
6 inches (152mm).

MINIMUM CLEARANCE

ABOVE UNIT

48 (1219)

Unit Placement

CAUTION

In order to avoid injury, take proper precaution when lifting
heavy objects.

See Unit Dimensions on page 3 for sizing mounting slab,
platforms or supports. Refer to figure 5 for mandatory
installation clearance requirements.

POSITIONING CONSIDERATIONS

Consider the following when positioning the unit:

D Some localities are adopting sound ordinances based

on the unit’s sound level registered from the adjacent
property, not from the installation property. Install the
unit as far as possible from the property line.

D 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 6, 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 6, detail B.

NOTE  If necessary for stability, anchor unit to slab as
described in figure 6, detail D.

ELEVATING THE UNIT

Units are outfitted with elongated support feet as illustrated
in figure 6, 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.

Page 10

XP16

DETAIL A

Install unit away from windows.

 Outside Unit Placement

DETAIL B

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

 Slab Mounting at Ground Level

BUILDING

STRUCTURE

MOUNTING
SLAB

TWO 90° ELBOWS INSTALLED IN LINE SET WILL

REDUCE LINE SET VIBRATION.

DETAIL C

 Elevated Slab Mounting

using Feet Extenders

LEG DETAIL

2" (50.8MM) SCH 40

FEMALE THREADED

ADAPTER

BASE

GROUND LEVEL

STABILIZING UNIT ON UNEVEN SURFACES

DETAIL D

#10 1/2" LONG SELF−DRILLING

SHEET METAL SCREWS

STABILIZING BRACKET (18 GAUGE

METAL  2" WIDTH; HEIGHT AS

#10 1−1/4" LONG HEX HD SCREW

Concrete slab  use two plastic anchors (hole
drill 1/4")

Wood or plastic slab  no plastic anchor (hole
drill 1/8")

DETAIL E

Stabilizing bracket (18 gauge metal  2" (50.8mm) width; height as required); bend to form
right angle as exampled below.

 Slab Side Mounting

REQUIRED)

AND FLAT WASHER

 Deck Top Mounting

MINIMUM ONE

PER SIDE

COIL

BASE PAN

CORNER POST

2" (50.8MM) SCH 40

MALE THREADED

ADAPTER

Use additional 2" SCH 40 male threaded adapters
which can be threaded into the female threaded
adapters to make additional adjustments to the level
of the unit.

IMPORTANT  To help stabilize an outdoor unit, some installations may require strapping the unit to the pad using brackets and anchors
commonly available in the marketplace.

One bracket per side (minimum). For extra stability, two brackets per side, two inches
(51mm) from each corner.

SAME FASTENERS AS
SLAB SIDE MOUNTING.

FOR EXTRA

STABILITY

Figure 6. Placement, Slab Mounting and Stabilizing Unit

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Page 11

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

2. Install the brackets as illustrated in figure 6, detail D or

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.

:

base.

E using conventional practices.

Removing and Installing Panels

IMPORTANT

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

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.

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.

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.

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XP16

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 bot-

tom 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.

IMPORTANT
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.

! DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB. TAB IS FOR

SCREW

LIP

DETAIL A

DETAIL B

ANGLE MAY BE TOO
EXTREME

HOLES

ROTATE IN THIS DIRECTION;

THEN DOWN TO REMOVE

HOLD DOOR FIRMLY TO THE HINGED

PANEL

SIDE TO MAINTAIN

FULLY−ENGAGED TABS

PREFERRED ANGLE
FOR INSTALLATION

Figure 7. Removing and Installing Panels

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Page 13

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 16.

IMPORTANT

Lennox highly recommends changing line set when
converting the existing system from HCFC−22 to
HFC−410A. If that is not possible and the line set is the
proper size as reference in table 2, use the procedure
outlined under Flushing the System on page 13.

If refrigerant lines are routed through a wall, then seal and
isolate the opening so vibration is not transmitted to the
building. Pay close attention to line set isolation during
installation of any HVAC system. When properly isolated
from building structures (walls, ceilings. floors), the
refrigerant lines will not create unnecessary vibration and
subsequent sounds. See figure 8 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

19).

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)

Model

−018

−024

−030

−036

−042

−048

−060

Valve Field
Connections

Liquid
Line

3/8 in.
(10 mm)

3/8 in.
(10 mm)

3/8 in.
(10 mm)

Vapor
Line

3/4 in
(19 mm)

7/8 in
(22 mm)

1−1/8 in.
(29 mm)

Recommended Line Set

Liqui
d
Line

3/8 in.
(10
mm)

3/8 in.
(10
mm)

3/8 in.
(10
mm)

Vapor
Line

3/4 in
(19 mm)

7/8 in
(22 mm)

1−1/8 in.
(29 mm)

L15
Line Sets

L15−41
15 ft. − 50 ft.
(4.6 m − 15
m)

L15−65
15 ft. − 50 ft.
(4.6 m − 15
m)

Field
Fabricated

NOTE  When installing refrigerant lines longer than 50
feet, see the Lennox Refrigerant Piping Design and
Fabrication Guidelines, CORP. 9351−L9, or contact Lennox
Technical Support Product Applications for assistance.

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

D Model (XP16) and size of unit (e.g. −036).

D Line set diameters for the unit being installed as listed

in table 2 and total length of installation.

D Number of elbows vertical rise or drop in the piping.

The compressor is charged with sufficient Polyol ester oil for
line set lengths up to 50 feet. Recommend adding oil to
system based on the amount of refrigerant charge in the
system. No need to add oil in system with 20 pounds of
refrigerant or less. For systems over 20 pounds − add one
ounce of every five pounds of refrigerant.

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

WARNING

Polyol Ester (POE) oils used with HFC−410A
refrigerant absorb moisture very quickly. It is very
important that the refrigerant system be kept closed as
much as possible. DO NOT remove line set caps or
service valve stub caps until you are ready to make
connections.

IMPORTANT

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

be added, it must be a Polyol Ester oil.

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Line Set Isolation  The following illustrations are examples of proper refrigerant line set isolation:

REFRIGERANT LINE SET  TRANSITION

FROM VERTICAL TO HORIZONTAL

ANCHORED HEAVY NYLON
WIRE TIE OR AUTOMOTIVE

MUFFLER-TYPE HANGER

WALL
STUD

NON−CORROSIVE

METAL SLEEVE

AUTOMOTIVE

MUFFLER-TYPE HANGER

STRAP LIQUID LINE TO
VAPOR LINE

LIQUID LINE

VAPOR LINE − WRAPPED
IN ARMAFLEX

REFRIGERANT LINE SET  INSTALLING

HORIZONTAL RUNS

To hang line set from joist or rafter, use either metal strapping materi­al or anchored heavy nylon wire ties.

WIRE TIE (AROUND
VAPOR LINE ONLY)

8 FEET (2.43 METERS)

STRAPPING

MATERIAL (AROUND

VAPOR LINE ONLY)

TAPE OR
WIRE TIE

FLOOR JOIST OR

ROOF RAFTER

8 FEET (2.43 METERS)

NON−CORROSIVE
METAL SLEEVE

STRAP THE VAPOR LINE TO THE
JOIST OR RAFTER AT 8 FEET (2.43
METERS) INTERVALS THEN STRAP
THE LIQUID LINE TO THE VAPOR LINE.

TAPE OR
WIRE TIE

REFRIGERANT LINE SET  INSTALLING

VERTICAL RUNS (NEW CONSTRUCTION SHOWN)

NOTE  Insulate liquid line when it is routed through areas where the
surrounding ambient temperature could become higher than the
temperature of the liquid line or when pressure drop is equal to or
greater than 20 psig.

OUTSIDE WALL

WOOD BLOCK

BETWEEN STUDS

VAPOR LINE WRAPPED

WITH ARMAFLEX

OUTSIDE

WALL

PVC

PIPE

FIBERGLASS

INSULATION

VAPOR LINE

SLEEVE

CAULK

LIQUID
LINE

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

LIQUID LINE

WIRE TIE

INSIDE WALL

STRAP

NON−CORROSIVE
METAL SLEEVE

WIRE TIE

WOOD BLOCK

WIRE TIE

STRAP

FLOOR JOIST OR

XP16

ROOF RAFTER

Figure 8. Line Set Installation

Page 15

Brazing Connections

Use the procedures outline in figures 9 and 10 for brazing
line set connections to service valves.

WARNING

Danger of fire. Bleeding the refrigerant
charge from only the high side may result
in pressurization of the low side shell and
suction tubing. Application of a brazing
torch to a pressurized system may result in
ignition of the refrigerant and oil mixture −
Check the high and low pressures before
applying heat.

IMPORTANT

Connect gauge set low pressure side to vapor line
service valve and repeat procedure starting at paragraph
4 for brazing the liquid line to service port valve.

IMPORTANT

Allow braze joint to cool before removing the wet rag from
the service valve. Temperatures above 250ºF can
damage valve seals.

IMPORTANT

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.

Use silver alloy brazing rods with 5% minimum silver alloy
for copper−to−copper brazing. Use 45% minimum alloy for
copper−to−brass and copper−to−steel brazing.

WARNING

Fire, Explosion and Personal Safety
Hazard.

Failure to follow this warning could re­sult in damage, personal injury or
death.

Never use oxygen to pressurize or
purge refrigeration lines. Oxygen,
when exposed to a spark or open
flame, can cause fire and/or an ex­plosion, that could result in property
damage, personal injury or death.

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