Lennox XP19, Signature XP19-024, Signature XP19-036, Signature XP19-048, Signature XP19-060 Installation Instructions Manual
INSTALLATION
E2009 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
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.
INSTRUCTIONS
Dave Lennox Signature
Collection XP19 Series
Units
HEAT PUMPS
505,331M
06/09
Supersedes 05/09
Table of Contents
Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XP19 Heat Pumps 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Recovering Refrigerant from Existing System 4. . . . .
Removing Existing Outdoor Unit 5. . . . . . . . . . . . . . . . .
Positioning New Outdoor Unit 5. . . . . . . . . . . . . . . . . . .
Removing Panels 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New or Replacement Line Set 8. . . . . . . . . . . . . . . . . . .
Brazing Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Indoor Unit Metering Device 10. . . . . . . . . . .
Flushing the System 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing New Indoor Unit Metering Device 12. . . . . . . .
Testing for Leaks 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuating the System 14. . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Unit Delivered Void of Charge 15. . . . . . . . . .
Electrical Connections 16. . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up and Charging Procedures 16. . . . . . . . . . . . . . .
System Operations 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lennox System Operation Monitor (LSOM) 21. . . . . . .
Defrost System 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two−Stage Compressor Check−out 30. . . . . . . . . . . . . . .
Homeowner Information 30. . . . . . . . . . . . . . . . . . . . . . . .
Field Operational Checklist 32. . . . . . . . . . . . . . . . . . . . .
Start−up and Performance Checklist 32. . . . . . . . . . . . . .
Shipping and Packing List1
®
Litho U.S.A.
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.
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.
06/09 505,331M
*2P0609* *P505331M*
Check the unit for shipping damage and listed times below
are intact. If damaged, or if parts are missing, immediately
contact the last shipping carrier.
1 Assembled outdoor unit.
1 Bag assembly which contains the followings:
1 Bushing (for low voltage wiring
2 Isolation grommets for liquid and suction lines
ISOLATION GROMMETS (2)
Figure 1. Bag Assembly (Parts)
Page 1
BUSHING (1)
Unit Dimensions −− Inches (mm)2
UNIT SUPPORT
FEET
16−7/8
(429)
8−3/4
(222)
3−1/8
(79)
39−1/2
(1003)
DISCHARGE AIR
SIDE VIEW
30−3/4
(781)
SUCTION LINE
INLET
LIQUID LINE
INLET
26−7/8
(683)
3−3/4 (95)
4−5/8
(117)
ELECTRICAL
INLETS
37 (940) [−024, −036]
47 (1194) [−048, −060]
18−1/2
(470)
CONTACTOR
DEFROST
CONTROL
SYSTEM
OPERATION
MONITOR
VAPOR VALVE
AND GAUGE
PORT
DISCHARGE
LINE
REVERSING
VALV E
VAPOR LINE
FILTER DRIER
4−1/2
(114)
8 (203)
1 (25)
35−1/2
(902)
ACCESS VIEW
OUTDOOR FAN
RUN
CAPACITOR
TWO−STAGE
COMPRESSOR
COMPRESSOR
TERMINAL
PLUG
LOW
PRESSURE
SWITCH
HIGH
PRESSURE
SWITCH
BASE
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
505331M 06/09
XP19 PARTS ARRANGEMENT
XP19 Heat Pumps3
The XP19 Heat Pumps, which will also be referred to in this
instruction as the outdoor unit, uses HFC−410A
refrigerant. This outdoor unit must be installed with a
matching indoor unit and line set as outlined in the Lennox
XP19 Engineering Handbook.
This outdoor unit is designed for use in systems that use
check thermal expansion valve (CTXV) refrigerant
metering devices.
General Information4
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
When servicing or repairing HVAC components, ensure
the fasteners are appropriately tightened. Table 1 shows
torque values for fasteners.
Page 2
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 SETS
When checking the system charge, only use a manifold
gauge set that features low loss anti−blow back fittings.
See Figure 3 for a typical manifold gauge connection
setup.
Manifold gauge sets 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 on the high side and a low side of
30" vacuum to 250 psi with dampened speed to 500 psi.
Gauge hoses must be rated for use at up to 800 psi of
pressure with a 4000 psi 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.
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.
1/12 TURN
12
1
2
3
4
7
5
6
9
10
8
11
1/6 TURN
12
1
2
3
4
7
5
6
11
10
9
8
Figure 2. Cap Tightening Distances
IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and
fitted snugly over the cap before tightening.
To Access Angle−Type 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 to the service port.
3. When testing is completed, replace service port cap and
tighten as follows:
D With Torque Wrench: Finger tighten and then
tighten per Table 1.
D Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in Figure 2.
To Open and Close Angle−Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak−free seal.
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.
CHECK
EXPANSION VALVE
LOW
PRESSURE
GAUGE MANIFOLD
PRESSURE
TO
HFC−410
A DRUM
HIGH
LIQUID
LINE
VALV E
Figure 3. Typical Manifold Gauge Connection Setup
BI−FLOW
FILTER /
DRIER
MUFFLER
LIQUID
SERVICE
PORT
DISTRIBUTOR
OUTDOOR
COIL
COMPRESSOR
Page 3
HEAT PUMP
REVERSING VALVE
VAPOR
SERVICE
PORT
NOTE − Arrows indicate direction
of refrigerant flow.
VAPOR
LINE
VALV E
CHECK EXPANSION VALVE
INDOOR
COIL
XP19 SERIES
3. Replace the stem cap and tighten as follows:
D With Torque Wrench: Tighten finger tight and then
tighten per Table 1.
D Without Torque Wrench: Finger tighten and use an
appropriately sized wrenched to turn an additional
1/12 turn clockwise as illustrated in Figure 2.
SERVICE PORT
CORE
VALVE STEM
FRONT-SEATED
TO INDOOR
UNIT
TO OUTDOOR UNIT
SERVICE PORT
CAP
SERVICE PORT
(VALVE STEM SHOWN
CLOSED) INSERT HEX
WRENCH HERE
STEM CAP
CLOSED TO BOTH INDOOR
AND OUTDOOR UNITS
Figure 4. Angle−Type Service Valve
(Font−Seated Closed)
NOTE A label with specific torque requirements may be
affixed to the stem cap. If the label is present, use the
specified torque.
NOTE To prevent stripping of the cap, the wrench
should be appropriately sized and fit snugly over the cap
before tightening the cap.
SERVICE PORT CAP
SERVICE PORT
CORE
OPEN TO BOTH
INDOOR AND
OUTDOOR UNITS
TO INDOOR
UNIT
TO OUTDOOR UNIT
STEM CAP
SERVICE PORT
(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE
Figure 5. Angle−Type Service Valve
(Back−Seated Opened)
To Access Ball−Type 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 to the service port.
3. When testing is completed, replace service port cap and
tighten as follows:
D With Torque Wrench: Finger tighten and then
tighten per Table 1.
D Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in Figure 2.
OPEN TO LINE SET WHEN VALVE IS CLOSED,
TO BOTH LINE SET AND UNIT WHEN VALVE IS
OPEN.
TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°.
TO CLOSE ROTATE STEM
CLOCKWISE 90°.
SERVICE PORT
SERVICE PORT
CORE
SERVICE PORT CAP
TO OUTDOOR UNIT
TO INDOOR UNIT
BALL (SHOWN
CLOSED)
STEM CAP
VALV E
STEM
Figure 6. Ball−Type Service Valve
To Open and Close Ball−Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak−free seal.
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°.
3. Replace the stem cap and tighten as follows:
D With Torque Wrench: Finger tighten and then
tighten per Table 1.
D Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in Figure 2.
NOTE A label with specific torque requirements may be
affixed to the stem cap. If the label is present, use the
specified torque.
Recovering Refrigerant from Existing
System5
Remove existing HCFC−22 refrigerant using one of the
following procedures:
METHOD 1:
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.
NOTE Use recovery machine instructions for specific
setup requirements.
1. Disconnect all power to the existing outdoor unit.
2. Connect to the existing unit a gauge set, clean
recovery cylinder and a recovery machine. Use the
instructions provided with the recovery machine on
how to setup the connections.
505331M 06/09
Page 4
3. Remove all HCFC−22 refrigerant from the existing
system. Check gauges after shutdown to confirm that
the entire system is completely void of refrigerant.
RECOVERY MACHINE
CLEAN RECOVERY
CYLINDER
MANIFOLD GAUGES
OUTDOOR UNIT
Figure 7. Typical Refrigerant Recovery
(Method 1)
NOTE Use recovery machine instructions for specific
setup requirements.
METHOD 2:
Use this method if the existing outdoor unit is equipped
with manual shut−off valves, and plan on using new
HCFC−22 refrigerant to flush the system.
IMPORTANT: Some system configurations may contain
higher than normal refrigerant charge due to either large
internal coil volumes, and/or long line sets. The following
conditions may cause the compressor to stop functioning:
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 cycled 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 suction 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:
1. Start the existing HCFC−22 system in the cooling
mode and close the liquid line valve.
2. Pump as much of the existing HCFC−22 refrigerant
with the compressor back into the outdoor unit until
you have reached the limitations of the outdoor
system. Turn the outdoor unit main power OFF and
use a recovery machine to remove the remaining
refrigerant in the system.
NOTE It may be necessary to bypass the low pressure
switches if equipped to ensure complete refrigerant
evacuation.
3. When the low side system pressures reach 0 psig,
close the suction line valve.
4. Check gauges after shutdown to confirm that the
valves are not allowing refrigerant to flow back into the
low side of the system.
Removing Existing Outdoor Unit6
Perform the following task at the existing outdoor unit:
S Disconnect line set at the service valves.
S Disconnect electrical service at the disconnect switch.
S Remove old outdoor unit.
Positioning New Outdoor Unit7
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 8 for mandatory
installation clearance requirements.
CONTROL PANEL
ACCESS LOCATION
SEE NOTES BELOW THIS FIGURE FOR FURTHER DETAILS.
Figure 8. Installation Clearances
NOTES:
S Service clearance of 30 in. (762 mm) must be
maintained on one of the sides adjacent to the control
box.
S Clearance to one of the other three sides must be 36
in. (914 mm)
S Clearance to one of the remaining two sides may be
12 in. (305 mm) and the final side may be 6 in. (152
.
mm)
S 48 in. (1219 mm) clearance required on top of unit.
S A clearance of 24 in. (610 mm) must be maintained
between two units.
.
Page 5
XP19 SERIES
POSITIONING CONSIDERATIONS
INSTALL UNIT AWAY
FROM WINDOWS
TWO 90° ELBOWS INSTALLED
IN LINE SET WILL REDUCE
LINE SET VIBRATION.
Figure 9. Outside Unit Placement
Consider the following when positioning the unit:
S Some localities are adopting sound ordinances based
on the unit’s sound level registered from the adjacent
property, not from the installation property. Install the
unit as far as possible from the property line.
S When possible, do not install the unit directly outside
a window. Glass has a very high level of sound
transmission. For proper placement of unit in relation
to a window see the provided illustration in Figure 9.
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 10.
NOTE If necessary for stability, anchor unit to slab as
described in Stabilizing Unit on Uneven Surfaces on page
7.
ELEVATING THE UNIT
This unit is outfitted with elongated support feet as
illustrated in Figure 11 which uses a similar method for
elevating the unit.
BASE
LEG DETAIL
2" (50.8MM) SCH 40
FEMALE THREADED
ADAPTER
Figure 11. Elevated Slab Mounting using Feet
Extenders
If additional elevation is necessary, raise the unit by
extending the length of the unit support feet. This may be
achieved by using a 2" SCH 40 female threaded adapter.
The specified coupling will fit snuggly into the recessed
portion of the feet. Use additional 2" SCH 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.
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.
STRUCTURE
GROUND
LEVEL
Figure 10. Slab Mounting at Ground Level
505331M 06/09
BUILDING
MOUNTING
SLAB
Removing and Installing Panels8
CAUTION
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.
Page 6
WARNING
Unit must be grounded in accordance
with national and local codes.
Electric Shock Hazard. Can cause
injury or death.
Line voltage is present at all
components when unit is not in
operation on units with single-pole
contactors. Disconnect all remote
electric power supplies before
opening access panel. Unit may have
multiple power supplies.
IMPORTANT! 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.
SCREW
HOLES
LIP
ACCESS PANEL
Removal and reinstallation of the access panel is
illustrated in Figure 12.
REMOVE 4 SCREWS TO REMOVE PANEL FOR
ACCESSING COMPRESSOR AND CONTROLS.
INSTALL BY POSITIONING PANEL WITH HOLES
ALIGNED; INSTALL SCREWS AND TIGHTEN.
Figure 12. Access Panel
LOUVERED PANELS
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 Figure 13, detail B.
3. Move panel down until lip of upper tab clears the top
slot in corner post as illustrated in Figure 13, detail A.
Position and Install PanelPosition the panel almost
parallel with the unit as illustrated in Figure 14, detail D with
the screw side as close to the unit as possible. Then, in a
continuous motion:
S Slightly rotate and guide the lip of top tab inward as
illustrated in Figure 13, details A and C; then upward
into the top slot of the hinge corner post.
S Rotate panel to vertical to fully engage all tabs.
S Holding the panel’s hinged side firmly in place, close
the right−hand side of the panel, aligning the screw
holes.
When panel is correctly positioned and aligned, insert the
screws and tighten.
Detail A
Detail B
Detail C
ROTATE IN THIS DIRECTION;
THEN DOWN TO REMOVE PANEL
Figure 13. Removing/Installing Louvered Panels
(Detail A, B and C)
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT
AS POSSIBLE) WHILE INSTALLING PANEL.
ANGLE MAY BE TOO
EXTREME
PREFERRED ANGLE
FOR INSTALLATION
HOLD DOOR FIRMLY ALONG
THE HINGED SIDE TO MAINTAIN
FULLY−ENGAGED TABS
Detail D
Figure 14. Removing/Installing Louvered Panels
(Detail D)
STABILIZING UNIT ON UNEVEN SURFACES
With unit positioned at installation site, remove two side
louvered panels to expose the unit base pan. Install the
brackets as illustrated in Figure 15 using conventional
practices; replace the panels after installation is complete.
Page 7
XP19 SERIES
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.
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.
Slab Side Mounting
REFRIGERANT LINE SET
Field refrigerant piping consists of liquid and suction lines
from the outdoor unit (braze connections) to the indoor unit
coil (flare or sweat connections). Use Lennox L15 (sweat,
non−flare) series line set, or use field−fabricated refrigerant
lines as listed in Table 2.
Table 2. Refrigerant Line Set
Field Connections Recommended Line Set
Model
−024
−036
−048
−060
Liquid
Line
3/8".
(10 mm)
3/8".
(10 mm)
Suction
Line
7/8"
(22 mm)
1−1/8".
(29 mm)
Liquid
Line
3/8"
(10 mm)
3/8"
(10 mm)
Suction
Line
7/8"
(22 mm)
1−1/8"
(29 mm)
L15 Line Set
L15−65
15 ft. − 50 ft.
(4.6 m − 15 m)
Field
Fabricated
#10 1/2" LONG SELF−
DRILLING SHEET
METAL SCREWS
STABILIZING
BRACKET (18 GAUGE
METAL − 2" WIDTH;
HEIGHT AS REQ’D)
#10 1−1/4" LONG
HEX HD SCREW
AND FLATWASHER
CONCRETE SLAB − USE PLASTIC
PLASTIC ANCHOR (HOLE DRILL
1/4")PLASTIC SLAB − NO PLASTIC
ANCHOR (HOLE DRILL 1/8")
COIL
BASE PAN
CORNER POST
Deck Top
Mounting
STABILIZING BRACKET
(18 GAUGE METAL − 2"
WIDTH; HEIGHT AS
REQ’D); BEND TO FORM
RIGHT ANGLE
FOR EXTRA
ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY,
2 BRACKETS PER SIDE, 2" FROM EACH CORNER.
STABILITY
MINIMUM 1
PER SIDE
Figure 15. Installing Stabilizer Brackets
New or Replacement Line Set9
This section provides information on installation or
replacement of existing line set. If line set are not being
installed then proceed to Brazing Connections on page 12.
If refrigerant lines are routed through a wall, 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. Also, consider the following when
placing and installing a high−efficiency air conditioner.
NOTE When installing refrigerant lines longer than 50
feet, see the Lennox Refrigerant Piping Design and
Fabrication Guidelines, or contact Lennox Technical
Support Product Applications for assistance. To obtain the
correct information from Lennox, be sure to communicate
the following points:
S Model (XP19) and size of unit (e.g. −060).
S Line set diameters for the unit being installed as listed
in Table 2 and total length of installation.
S Number of elbows and if there is a rise or drop of the
piping.
MATCHING WITH NEW OR EXISTING INDOOR COIL
AND LINE SET
The RFC1−metering line consisted of a small bore copper
line that ran from condenser to evaporator coil. Refrigerant
was metered into the evaporator by utilizing
temperature/pressure evaporation effects on refrigerant in
the small RFC line. The length and bore of the RFC line
corresponded to the size of cooling unit.
If the XP19 is being used with either a new or existing
indoor coil which is equipped with a liquid line which served
as a metering device (RFCI), the liquid line must be
replaced prior to the installation of the XP19 unit. Typically
a liquid line used to meter flow is 1/4" in diameter and
copper.
INSTALLING LINE SET
Line Set Isolation This reference illustrates
procedures, which ensure proper refrigerant line set
isolation:
S Installation of line set on horizontal runs is
illustrated in Figure 16.
S Installation of line set on vertical runs is illustrated in
Figure 17.
S Installation of a transition from horizontal to
vertical is illustrated in Figure 18.
505331M 06/09
Page 8
TO HANG LINE SET FROM JOIST OR
RAFTER, USE EITHER METAL STRAPPING
MATERIAL OR ANCHORED HEAVY NYLON
WIRE TIES.
STRAPPING MATERIAL
(AROUND SUCTION
LINE ONLY)
FLOOR JOIST OR
ROOF RAFTER
TAPE OR
WIRE TIE
8 FEET
FLOOR JOIST OR
ROOF RAFTER
METAL
SLEEVE
WIRE TIE
(AROUND
SUCTION LINE
ONLY)
TAPE OR
8 FEET
STRAP THE SUCTION LINE TO
THE JOIST OR RAFTER AT 8 FEET
INTERVALS THEN STRAP THE
LIQUID LINE TO THE SUCTION
LINE.
WIRE TIE
AUTOMOTIVE
STRAP LIQUID LINE
TO SUCTION LINE
LIQUID LINE
SUCTION LINE − WRAPPED
IN ARMAFLEX
ANCHORED HEAVY NYLON
WIRE TIE OR AUTOMOTIVE
MUFFLER-TYPE HANGER
WALL
STUD
METAL SLEEVE
MUFFLER-TYPE HANGER
Figure 18. Refrigerant Line Set: Transition from
Vertical to Horizontal
Figure 16. Refrigerant Line Set: Installing
Horizontal Runs
IMPORTANT - REFRIGERANT LINES
OUTSIDE WALL
WOOD BLOCK
BETWEEN STUDS
NOTE − SIMILAR INSTALLATION
PRACTICES SHOULD BE USED
IF LINE SET IS TO BE INSTALLED
ON EXTERIOR OF OUTSIDE
WALL.
SUCTION LINE
WRAPPED WITH
ARMAFLEX
OUTSIDE
PVC
PIPE
MUST NOT CONTACT WALL.
LIQUID LINE
WALL
CAULK
FIBERGLASS
INSULATION
SUCTION LINE
SLEEVE
IMPORTANT! REFRIGERANT
LINES MUST NOT CONTACT
STRUCTURE.
LIQUID LINE
WIRE TIE
INSIDE WALL
STRAP
SLEEVE
WIRE TIE
WOOD BLOCK
WIRE TIE
STRAP
Brazing Connections10
Use the following procedure to braze the line set to the new
air conditioner unit. Figure 19 is provided as a general
guide for preparing to braze the line set to the air
conditioner unit.
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.
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).
Figure 17. Refrigerant Line Set: Installing Vertical
Runs (New Construction Shown)
1. Cut ends of the refrigerant lines square (free from
nicks or dents). Debur the ends. The pipe must remain
round, do not pinch end of the line.
Page 9
XP19 SERIES
1
2
3
CUT AND DEBUR
7
INSTALL CORE ONLY FOR
BOTH SERVICE PORTS after they
have coolED.
INDOOR UNIT
6
BRAZE LINE SET
REMOVE CAP AND CORE FROM
BOTH LIQUID AND SUCTION
SERVICE PORTS
SERVICE PORT MUST BE
OPEN TO ALLOW EXIT
POINT FOR NITROGEN
SUCTION LINE
LIQUID LINE
Figure 19. Brazing Connections
2. Remove service cap and core from both the suction
and liquid line service ports.
3. Connect gauge low pressure side to liquid line service
valve.
4. 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.
Also, shield the light maroon R−410A sticker.
5. 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 suction service
valve.
ATTACH
GAUGES
SERVICE
5
VALVE
SERVICE
VALVE
outdoor
UNIT
FLOW NITROGEN
NITROGEN
4
WRAP
SERVICE
VALV E
Removing Indoor Unit Metering Device11
Remove the existing HCFC−22 refrigerant flow control
orifice or thermal expansion valve from the indoor coil. The
existing indoor unit HCFC−22 metering device is not
approved for use with HFC−410A refrigerant and may
prevent proper flushing.
REPLACEMENT PARTS
If replacement parts are necessary for the indoor unit,
order kit 69J46. The kit includes:
LIQUID LINE ORIFICE HOUSINGS (10)
TEFLON RINGS (20)
BRASS NUTS (10)
PISTON
RETAINER
STRAINER
NOTE The RFCIV or TXV metering device at the indoor
unit will allow low pressure nitrogen to flow through the
system.)
6. Braze the liquid line to the liquid line service valve.
Turn off nitrogen flow. Repeat procedure starting at
paragraph 4 for brazing the suction line to the suction
service valve.
7. After all connections have been brazed, disconnect
manifold gauge set the from service ports, cool down
piping with wet rag and remove all wrappings. Do not
reinstall cores until after evacuation procedures.
Reinstall service caps if desired to close off refrigerant
ports.
505331M 06/09
Page 10
COPPER
TUBE
LIQUID LINE ASSEMBLIES
(INCLUDES STRAINER) (10)
LIQUID LINE
ASSEMBLY
Figure 20. 69J46 Kit Components
TYPICAL FIXED ORIFICE REMOVAL PROCEDURE
1. On fully cased coils, remove the coil access and
plumbing panels.
2. Remove any shipping clamps holding the liquid line
and distributor assembly.
3. Using two wrenches, disconnect liquid line from liquid
line orifice housing. Take care not to twist or damage
distributor tubes during this process.
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