INSTALLATION
2010 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
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.
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.
INSTRUCTIONS
Elite® Series XC16 Units
AIR CONDITIONER
506637−01
11/10
Supersedes 506101−01
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. . . . .
Unit Placement 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and Installing Panels 9. . . . . . . . . . . . . . . . .
New or Replacement Line Set 10. . . . . . . . . . . . . . . . . . .
Brazing Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Line Set and Indoor Coil 15. . . . . . . . . . . . . . . .
Installing Indoor Metering Device 16. . . . . . . . . . . . . . . .
Leak Test Line Set and Indoor Coil 17. . . . . . . . . . . . . . .
Evacuating Line Set and Indoor Coil 18. . . . . . . . . . . . .
Electrical 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Units Delivered Void of Charge 21. . . . . . . . .
Unit Start−Up 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Refrigerant 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
Litho U.S.A.
This unit must be matched with an indoor coil as specified in Lennox XC16 Engineering Handbook. Coils pre-
viously charged with HCFC−22 must be flushed.
IMPORTANT
NOTICE TO INSTALLER
UNIT PLACEMENT
It is critical for proper unit operation to place outdoor unit on an
elevated surface as described in Unit Placement section on page 7.
BRAZING LINE SET TO SERVICE VALVES
It is imperative to follow the brazing technique illustrated starting on
page 12 to avoid damaging the service valve’s internal seals.
11/10 506637−01
The XC16 Air Conditioners, 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
XC16 Engineering Handbook. XC16 Air Conditioners are
designed for use in thermal expansion valve (TXV)
systems.
NOTE − The XC16 outdoor unit is rated for 230V
applications only. A hard-start kit is required for
applications where the supply voltage is less than 230V.
Shipping and Packing List
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.
Page 1
*2P1110* *P506637-01*
Unit Dimensions − Inches (mm)
A
LIQUID LINE
CONNECTION
ELECTRICAL INLETS
SUCTION LINE
CONNECTION
C
4−3/4"
(121)
B
TOP VIEW
K
J
G
H
SIDE VIEW
UNIT SUPPORT
FEET
4−1/2"
(108)
D
E
F
XC14−024 TO −060 BASE WITH
ELONGATED LEGS
Model Number A B C D E F G H J K
XC16−024−230 39 (991)
XC16−036−230 45 (1143)
XC16−048−230 39 (991)
XC16−060−230 39 (991) 35−1/2 (902) 39−3/8 (1001) 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)
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)
Model Number Identification
Refrigerant Type
X = R−410A
Unit Type
C = Air Conditioner
Series
506637−01 11/10
X
C 16
XXX
230
Nominal Cooling Capacity
024 = 2 tons
036 = 3 tons
048 = 4 tons
060 = 5 tons
03
Page 2
Minor Revision Number
Voltage 230 = 208/230V−1ph−60hz
Typical Unit Parts Arrangement
SINGLE POLE CONTACTOR (K1)
CONTROL PANEL
GROUND LUG
COMPRESSOR
HARNESS
COMPRESSOR
DUAL RUN CAPACITOR
(C12)
CRANKCASE
THERMOSTAT
(S40) −048 AND
−060 UNITS ONLY
LIQUID LINE FILTER
DRIER (SINGLE FLOW)
LIQUID LINE SERVICE
VALV E
FIELD CONNECTION
FOR LIQUID LINE SET
PLUMBING AND SWITCHES COMPONENTS
Figure 1. Typical Parts Arrangements
Page 3
HIGH PRESSURE
SWITCH (MANUAL
RESET) (S4)
LOW PRESSURE
SWITCH (S87)
SUCTION LINE
SERVICE VALVE
FIELD CONNECTION
FOR SUCTION LINE
XC16 SERIES
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.
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.
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.
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.
506637−01 11/10
Page 4
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,
rotate stem counterclockwise 90°. To close rotate stem
clockwise 90°.
TO INDOOR UNIT
TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°.
TO CLOSE ROTATE STEM
CLOCKWISE 90°.
SERVICE PORT
SERVICE PORT
SERVICE PORT
CORE
CAP
TO OUTDOOR
UNIT
BALL (SHOWN
CLOSED)
VALV E
STEM
STEM CAP
STEM CAP
ANGLE−TYPE SERVICE VALVE
(FRONT−SEATED CLOSED)
WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN
TO
THE LINE SET AND INDOOR UNIT.
To Access Service Port:
A service port cap protects the service port core from contamination and
serves as the primary leak seal.
1. Remove service port cap with an appropriately sized wrench.
2. Connect gauge set to service port.
3. When testing is completed, replace service port cap and tighten as
follows:
With torque wrench: Finger tighten and
torque cap per table 1.
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:
9
10
8
11
12
7
6
With Torque Wrench: Finger tighten and
then torque cap per table 1.
Without Torque Wrench: Finger tight-
en and use an appropriately sized
wrench to turn an additional 1/12 turn
clockwise.
9
10
8
11
12
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 2. Angle and Ball Service Valves
Page 5
XC16 SERIES
Recovering Refrigerant from Existing System
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 volumes,
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:
Outdoor unit’s high or low−pressure switches (if applicable) when tripped can cycle the compressor OFF.
Compressor can stop pumping due to tripped internal pressure relief valve.
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.
506637−01 11/10
Page 6
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 3. Installation Clearances
NOTES:
Clearance to one of the other three
sides must be 36 inches (914mm).
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)
New Outdoor 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 3 for mandatory
installation clearance requirements.
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
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.
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.
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.
Page 7
XC16 SERIES
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 4. Placement, Slab Mounting and Stabilizing Unit
Page 8
506637−01 11/10
ROOF MOUNTING
Removing and Installing Panels
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.
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.
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.
IMPORTANT
Do not allow panels to hang on unit by top tab. Tab is for
alignment and not designed to support weight of panel.
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.
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
LIP
DETAIL A
DETAIL B
HOLES
Detail 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
Figure 5. Removing and Installing Panels
HOLD DOOR FIRMLY TO THE HINGED
SIDE TO MAINTAIN
FULLY−ENGAGED TABS
Page 9
ROTATE IN THIS DIRECTION;
THEN DOWN TO REMOVE
PANEL
XC16 SERIES
New or Replacement Line Set
REFRIGERANT LINE SET
This section provides information on installation or
replacement of existing line set. If new or replacement line
set is not being installed then proceed to Brazing
Connections on page 12.
IMPORTANT
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.
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.
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 6 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 Line Set
and Indoor Coil on page15).
Table 2. Refrigerant Line Set Inches (mm)
Model
XC16−024−230 3/8" (10 mm) 3/4" (19 mm) 3/8" (10 mm) 3/4" (19 mm) L15−41 15 ft. − 50 ft. (4.6 m − 15 m)
XC16−036−230
XC16−048−230
XC16−060−230 3/8" (10 mm) 1−1/8" (29 mm) 3/8" (10 mm) 1−1/8" (29 mm) Field Fabricated
NOTE Some applications may required a field provided 7/8" to 1−1/8" adapter
3/8" (10 mm) 7/8" (22 mm) 3/8" (10 mm) 7/8" (22 mm) L15−65 15 ft. − 50 ft. (4.6 m − 15 m)
Field Connections Recommended Line Set
Liquid Line Suction Line Liquid Line Suction Line L15 Line Set
To obtain the correct information from Lennox, be sure to
communicate the following information:
Model (XC16) and size of unit (e.g. −036).
Line set diameters for the unit being installed as listed
in table 2 and total length of installation.
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 EMKARATE RL32CF.
IMPORTANT
Mineral oils are not compatible with HFC−410A. If oil
must be added, it must be a Polyol Ester oil.
506637−01 11/10
Page 10
Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation:
REFRIGERANT LINE SET TRANSITION
FROM VERTICAL TO HORIZONTAL
ANCHORED HEAVY NYLON
WIRE TIE OR AUTOMOTIVE
MUFFLER-TYPE HANGER
WALL
STUD
NON−CORROSIVE
METAL SLEEVE
AUTOMOTIVE
MUFFLER-TYPE HANGER
STRAP LIQUID LINE TO
VAPOR LINE
LIQUID LINE
VAPOR LINE − WRAPPED
IN ARMAFLEX
REFRIGERANT LINE SET INSTALLING
HORIZONTAL RUNS
To hang line set from joist or rafter, use either metal strapping material
or anchored heavy nylon wire ties.
WIRE TIE (AROUND
VAPOR LINE ONLY)
8 FEET (2.43 METERS)
STRAPPING
MATERIAL (AROUND
VAPOR LINE ONLY)
TAPE OR
WIRE TIE
FLOOR JOIST OR
ROOF RAFTER
8 FEET (2.43 METERS)
NON−CORROSIVE
METAL SLEEVE
STRAP THE VAPOR LINE TO THE JOIST
OR RAFTER AT 8 FEET (2.43 METERS)
INTERVALS THEN STRAP THE LIQUID
LINE TO THE VAPOR LINE.
TAPE OR
WIRE TIE
REFRIGERANT LINE SET INSTALLING
VERTICAL RUNS (NEW CONSTRUCTION SHOWN)
NOTE Insulate liquid line when it is routed through areas where the
surrounding ambient temperature could become higher than the
temperature of the liquid line or when pressure drop is equal to or greater
than 20 psig.
OUTSIDE WALL
WOOD BLOCK
BETWEEN STUDS
VAPOR LINE WRAPPED
WITH ARMAFLEX
OUTSIDE
WALL
PVC
PIPE
FIBERGLASS
INSULATION
VAPOR LINE
SLEEVE
CAULK
LIQUID
LINE
NOTE Similar installation practices should be used if line set is
to be installed on exterior of outside wall.
LIQUID LINE
WIRE TIE
INSIDE WALL
STRAP
NON−CORROSIVE
METAL SLEEVE
WIRE TIE
WOOD BLOCK
WIRE TIE
STRAP
FLOOR JOIST OR
ROOF RAFTER
Figure 6. Line Set Installation
Page 11
XC16 SERIES
Brazing Connections
Use the procedures outline in figures 7 and 8 for brazing
line set connections to service valves.
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 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.
WARNING
When using a high pressure gas such as
dry nitrogen to pressurize a refrigeration
or air conditioning system, use a
regulator that can control the pressure
down to 1 or 2 psig (6.9 to 13.8 kPa).
CAUTION
Brazing alloys and flux contain materials which are
hazardous to your health.
Avoid breathing vapors or fumes from brazing
operations. Perform operations only in well−ventilated
areas.
Wear gloves and protective goggles or face shield to
protect against burns.
Wash hands with soap and water after handling brazing
alloys and flux.
IMPORTANT
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
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.
506637−01 11/10
Page 12
CUT AND DEBUR
Cut ends of the refrigerant lines square (free from nicks or dents)
1
and debur the ends. The pipe must remain round. Do not crimp end
of the line.
CUT AND DEBUR
LINE SET SIZE MATCHES
SERVICE VALVE CONNECTION
SERVICE VALVE
COPPER TUBE
REDUCER
CONNECTION
STUB
CAP AND CORE REMOVAL
Remove service cap and core from
2
both the suction / vapor and liquid line
service ports.
SERVICE PORT
CAP
SERVICE
PORT
CORE
LIQUID LINE SERVICE
VALV E
SERVICE
PORT
CORE
SERVICE
PORT CAP
SUCTION / VAPOR LINE
SERVICE VALVE
LINE SET SIZE IS SMALLER
THAN CONNECTION
REFRIGERANT LINE
DO NOT CRIMP SERVICE VALVE
CONNECTOR WHEN PIPE IS
SMALLER THAN CONNECTION
ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE
VALVES
3
Flow regulated nitrogen (at 1 to 2 psig) through the low−side refrigeration gauge set into the liquid line service port valve, and out of the suction /
vapor line service port valve.
A Connect gauge set low pressure side to
liquid line service valve (service port).
B Connect gauge set center port to bottle of
nitrogen with regulator.
C Remove core from valve in suction / vapor
line service port to allow nitrogen to escape.
SUCTION / VAPOR SERVICE PORT MUST BE
OPEN TO ALLOW EXIT POINT FOR NITROGEN
VAPOR LINE
INDOOR
UNIT
LIQUID LINE
ATTACH
GAUGES
C
LIQUID LINE SERVICE
SUCTION /
VAPOR LINE
SERVICE
VALV E
VALV E
HIGHLOW
B
OUTDOOR
UNIT
WHEN BRAZING LINE SET TO
A
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
USE REGULATOR TO FLOW
NITROGEN AT 1 TO 2 PSIG.
NITROGEN
Figure 7. Brazing Procedures
Page 13
XC16 SERIES
WRAP SERVICE VALVES
To help protect service valve seals during brazing, wrap water saturated cloths around service valve bodies and copper tube stubs. Use
4
additional water saturated cloths underneath the valve body to protect the base paint.
FLOW NITROGEN
Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and
5
out of the suction / vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set connections
BRAZE LINE SET
Wrap both service valves with water saturated cloths as illustrated here and as mentioned in step 4, before brazing to line set. Water
6
saturated cloths must remain water saturated throughout the brazing and cool−down process.
LIQUID LINE SERVICE VALVE
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
IMPORTANT Allow braze joint to cool. Apply
additional water saturated cloths to help cool brazed
joint. Do not remove water saturated cloths until piping
has cooled. Temperatures above 250ºF will damage
valve seals.
LIQUID LINE
WATER SATURATED
CLOTH
WARNING
1. FIRE, PERSONAL INJURY, OR PROPERTY
DAMAGE may result if you do not wrap a water
saturated cloth around both liquid and suction line
service valve bodies and copper tube stub while
brazing in the line set! The braze, when complete,
must be quenched with water to absorb any residual
heat.
2. Do not open service valves until refrigerant lines and
indoor coil have been leak−tested and evacuated.
Refer to procedures provided in this supplement.
SUCTION / VAPOR LINE
PREPARATION FOR NEXT STEP
After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water saturated cloths to both services
7
valves to cool piping. Once piping is cool, remove all water saturated cloths. Refer to the unit installation instructions for the next step in preparing
the unit.
SUCTION / VAPOR LINE
SERVICE VALVE
WATER SATURATED
CLOTH
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
506637−01 11/10
Figure 8. Brazing Procedures (continued)
Page 14
Flushing Line Set and Indoor Coil
TYPICAL EXISTING FIXED ORIFICE
1A
DISTRIBUTOR
ASSEMBLY
A On fully cased coils, remove the coil access and plumbing panels.
B Remove any shipping clamps holding the liquid line and distributor as-
sembly.
C Using two wrenches, disconnect liquid line from liquid line orifice hous-
ing. Take care not to twist or damage distributor tubes during this process.
D Remove and discard fixed orifice, valve stem assembly if present and
Teflon® washer as illustrated above.
E Use a field−provided fitting to temporary reconnect the liquid line to the
indoor unit’s liquid line orifice housing.
COIL SHOWN)
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
REMOVE AND DISCARD
WHITE TEFLON
(IF PRESENT)
TEFLON® RING
FIXED ORIFICE
®
SEAL
LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
REMOVAL PROCEDURE (UNCASED
OR
BRASS NUT
1B
TWO PIECE PATCH PLATE
(UNCASED COIL ONLY)
CONNECT GAUGES AND EQUIPMENT FOR
FLUSHING PROCEDURE
2
INVERTED HCFC−22
CYLINDER CONTAINS
CLEAN HCFC−22 TO BE
USED FOR FLUSHING.
A
1
VAPOR LINE
SERVICE VALVE
EXISTING
INDOOR
UNIT
LIQUID LINE SERVICE
VALV E
VAPOR
LIQUID
D
RECOVERY
CYLINDER
A Inverted HCFC−22 cylinder with clean refrigerant to the vapor service
valve.
B HCFC−22 gauge set (low side) to the liquid line valve.
C HCFC−22 gauge set center port to inlet on the recovery machine with an
empty recovery tank to the gauge set.
D Connect recovery tank to recovery machines per machine instructions.
OUTDOOR
B
NEW
UNIT
OPENED
C
RECOVERY MACHINE
GAUGE
MANIFOLD
LOW HIGH
CLOSED
TANK
RETURN
INLET
DISCHARGE
TYPICAL EXISTING EXPANSION VALVE REMOVAL
PROCEDURE (UNCASED COIL SHOWN)
ORIFICE
HOUSING
EQUALIZER
LINE
STUB END
TEFLON
RING
VAPOR
CHECK
EXPANSION
VALV E
®
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
LINE
TEFLON
RING
®
SENSING
LINE
LIQUID
LINE
LIQUID LINE
DISTRIBUTOR
TUBES
DISTRIBUTOR
ASSEMBLY
MALE EQUALIZER
LINE FITTING
SENSING BULB
A On fully cased coils, remove the coil access and plumbing panels.
B Remove any shipping clamps holding the liquid line and distributor
assembly.
C Disconnect the equalizer line from the check expansion valve
equalizer line fitting on the vapor line.
D Remove the vapor line sensing bulb.
E Disconnect the liquid line from the check expansion valve at the liquid
line assembly.
F Disconnect the check expansion valve from the liquid line orifice
housing. Take care not to twist or damage distributor tubes during this
process.
G Remove and discard check expansion valve and the two Teflon® rings.
H Use a field−provided fitting to temporary reconnect the liquid line to the
indoor unit’s liquid line orifice housing.
FLUSHING LINE SET
The line set and indoor unit coil must be flushed with at least the
3
same amount of clean refrigerant that previously charged the
system. Check the charge in the flushing cylinder before
proceeding.
A Set the recovery machine for liquid recovery and start the
recovery machine. Open the gauge set valves to allow the
recovery machine to pull a vacuum on the existing system line
B
set and indoor unit coil.
B Invert the cylinder of clean HCFC−22 and open its valve to allow
liquid refrigerant to flow into the system through the vapor line
valve. Allow the refrigerant to pass from the cylinder and through
the line set and the indoor unit coil before it enters the recovery
machine.
C After all of the liquid refrigerant has been recovered, switch the
recovery machine to vapor recovery so that all of the HCFC−22
vapor is recovered. Allow the recovery machine to pull down to 0
the system.
D Close the valve on the inverted HCFC−22 drum and the gauge
set valves. Pump the remaining refrigerant out of the recovery
machine and turn the machine off.
Figure 9. Installing Indoor Expansion Valve
Page 15
XC16 SERIES
Installing Indoor Metering Device
This outdoor unit is designed for use in systems that use
expansion valve metering devices at the indoor coil.
See the Lennox XC16 Engineering Handbook for
approved expansion valve kit match−ups. The expansion
valve unit can be installed internal or external to the indoor
INDOOR EXPANSION VALVE INSTALLATION
TWO PIECE
PATCH PLATE
(UNCASED
COIL ONLY)
DISTRIBUTOR
TUBES
DISTRIBUTOR
ASSEMBLY
MALE EQUALIZER LINE
FITTING (SEE
EQUALIZER LINE
INSTALLATION FOR
FURTHER DETAILS)
Sensing bulb insulation is required if
mounted external to the coil casing. sensing
bulb installation for bulb positioning.
EQUALIZER LINE INSTALLATION
A Remove and discard either the flare seal cap or flare nut
with copper flare seal bonnet from the equalizer line port
on the vapor line as illustrated in the figure to the right.
B Remove and discard either the flare seal cap or flare nut
with copper flare seal bonnet from the equalizer line port on
the vapor line as illustrated in the figure to the right.
(Uncased Coil Shown)
LIQUID LINE
ORIFICE
HOUSING
STUB
END
TEFLON
RING
EQUALIZER
LINE
VAPOR
EXPANSION
VALV E
®
ASSEMBLY WITH
LINE
TEFLON
LIQUID LINE
BRASS NUT
®
RING
SENSING
LINE
LIQUID LINE
coil. In applications where an uncased coil is being
installed in a field−provided plenum, install the expansion
valve in a manner that will provide access for field servicing
of the expansion valve. Refer to below illustration for
reference during installation of expansion valve unit.
A Remove the field−provided fitting that temporary
reconnected the liquid line to the indoor unit’s distributor
assembly.
®
B Install one of the provided Teflon
stubbed end of the expansion valve and lightly lubricate
the connector threads and expose surface of the Teflon
rings around the
®
ring with refrigerant oil.
C Attach the stubbed end of the expansion valve to the
liquid line orifice housing. Finger tighten and use an
appropriately sized wrench to turn an additional 1/2 turn
clockwise as illustrated in the figure above, or 20 ft−lb.
®
D Place the remaining Teflon
washer around the other
end of the expansion valve. Lightly lubricate connector
threads and expose surface of the Teflon® ring with
refrigerant oil.
E Attach the liquid line assembly to the expansion valve.
Finger tighten and use an appropriately sized wrench to
turn an additional 1/2 turn clockwise as illustrated in the
figure above or 20 ft−lb.
SENSING BULB INSTALLATION
A Attach the vapor line sensing bulb in the proper
orientation as illustrated to the right using the clamp and
screws provided.
NOTE Confirm proper thermal contact between vapor line
and expansion bulb before insulating the sensing bulb once
installed.
B Connect the equalizer line from the expansion valve to
the equalizer vapor port on the vapor line. Finger tighten
the flare nut plus 1/8 turn (7 ft−lbs) as illustrated below.
VAPOR LINE
BULB
12
ON LINES SMALLER THAN
7/8", MOUNT SENSING
BULB AT EITHER THE 3 OR
9 O’CLOCK POSITION.
BULB
1/2 Turn
11
10
9
8
7
1/8 Turn
11
10
9
8
7
12
1
2
3
4
5
6
12
1
2
3
4
5
6
FLARE SEAL CAP
506637−01 11/10
OR
FLARE NUT
COPPER FLARE
SEAL BONNET
MALE BRASS EQUALIZER
LINE FITTING
VAPOR LINE
VAPOR LINE
12
BULB
NOTE NEVER MOUNT ON BOTTOM OF LINE.
Figure 10. Installing Indoor Expansion Valve
Page 16
ON 7/8" AND LARGER LINES,
MOUNT SENSING BULB AT
EITHER THE 4 OR 8 O’CLOCK
POSITION. NEVER MOUNT ON
BOTTOM OF LINE.
BULB
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.
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.
CONNECT GAUGE SET
A Connect an HFC−410A manifold gauge set high pressure
1
hose to the vapor valve service port.
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.
B With both manifold valves closed, connect the cylinder of
HFC−410A refrigerant to the center port of the manifold gauge
set.
NOTE Later in the procedure,
the HFC−410A container will be
replaced by the nitrogen
container.
Leak Test Line Set and Indoor Coil
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.
HIGHLOW
MANIFOLD GAUGE SET
OUTDOOR UNIT
B
A
TO VAPOR
SERVICE VALVE
NITROGEN
HFC−410A
TEST FOR LEAKS
After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the
2
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.
Figure 11. Leak Test
Page 17
XC16 SERIES
Evacuating Line Set and Indoor Coil
CONNECT GAUGE SET
NOTE Remove cores from service valves (if not already done).
1
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.
NITROGEN
HFC−410A
VACUUM PUMP
OUTDOOR
UNIT
A
B
A34000 1/4 SAE TEE WITH
SWIVEL COUPLER
500
C
MICRON
GAUGE
MANIFOLD
GAUGE SET
TO VAPOR
SERVICE VALVE
TO LIQUID LINE
SERVICE VALVE
LOW
D
EVACUATE THE SYSTEM
A Open both manifold valves and start the vacuum pump.
2
B Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury).
NOTE During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once. A rapid rise in pressure
indicates a relatively large leak. If this occurs, repeat the leak testing procedure.
NOTE The term absolute pressure means the total actual pressure 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), perform the following:
Close manifold gauge valves
Close valve on vacuum pump
Turn off vacuum pump
Disconnect the manifold gauge center port hose from vacuum pump
Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose.
Open manifold gauge valves to break the vacuum in the line set and indoor unit.
Close manifold gauge valves.
D Shut off the 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:
Close manifold gauge valves.
Shut off HFC−410A cylinder.
Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core
tool while maintaining a positive system pressure.
Replace stem caps and secure finger tight, then tighten an additional one−sixth (1/6) of a turn as illustrated.
RECOMMEND
MINIMUM 3/8" HOSE
10
9
8
1/6 TURN
12
11
7
HIGH
1
2
3
4
5
6
506637−01 11/10
Figure 12. Evacuating System
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
1
Refer to the unit nameplate for minimum circuit ampacity, and
maximum fuse or circuit breaker (HACR per NEC). Install power
wiring and properly sized disconnect switch.
NOTE Units are approved for use only with copper conductors.
Ground unit at disconnect switch or to an earth ground.
MAIN FUSE
BOX/BREAKER
PANEL
DISCONNECT
SWITCH
UNIT LOW VOLTAGE CONNECTIONS
3
C
WIRE NUTS
INSTALL THERMOSTAT
Install room thermostat (ordered separately) on an inside wall
2
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.
HIGH VOLTAGE FIELD WIRING
FACTORY WIRING
LOW VOLTAGE (24V) FIELD WIRING
WIRE RUN LENGTH AWG# INSULATION TYPE
LESS THAN 100’ (30 METERS) 18 TEMPERATURE RATING
MORE THAN 100’ (30 METERS) 16 35ºC MINIMUM.
CUTOUT WITH
GROMMET
A
24V CONTROL WIRES
BLUE
BLACK
B
YELLOW
D
TIGHTEN WIRE TIE
Page 19
A Run 24VAC control wires through cutout with grommet.
B Run 24VAC control wires through wire tie.
C Make 24VAC control wire connections using field provided wire
nuts.
D Tighten wire tie to security 24V control wiring.
NOTE − FOR PROPER VOLTAGES, SELECT THERMOSTAT WIRE (CONTROL WIRES)
GAUGE PER TABLE ABOVE.
NOTE − WIRE TIE PROVIDES LOW VOLTAGE WIRE STRAIN RELIEF AND TO MAINTAIN
SEPARATION OF FIELD INSTALLED LOW AND HIGH VOLTAGE CIRCUITS.
NOTE − DO NOT BUNDLE ANY EXCESS 24VAC CONTROL WIRES INSIDE CONTROL
BOX.
XC16 SERIES
Figure 13. Typical Unit Wiring Diagram
ƒ ⁄
506637−01 11/10
Page 20
DUAL RUN CAPACITOR (C12)
FAN MOTOR (B4)
CONTACTOR
GROUND
LUG
K1
CRANKCASE
HEATER (HR1)
CRANKCASE
THERMOSTAT
(S40)
Figure 14. Typical Factory Wiring Diagram
LOW PRESSURE
SWITCH (S87)
HIGH PRESSURE
SWITCH (S4)
COMPRESSOR (B1)
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
17.
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
18.
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
IMPORTANT
If unit is equipped with a crankcase heater, it should be
energized 24 hours before unit start−up to prevent
compressor damage as a result of slugging.
1. Rotate fan to check for binding.
2. Inspect all factory− and field−installed wiring for loose
connections.
3. After evacuation is complete, open 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.
Page 21
XC16 SERIES
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.
GAUGE SET
CONNECTIONS FOR TESTING AND CHARGING
SUCTION LINE
B
SERVICE PORT
CONNECTION
System Refrigerant
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
REFRIGERANT TANK
CHARGE IN
LIQUID PHASE
DIGITAL SCALE
TEMPERATURE
D
SENSOR
AClose manifold gauge set valves and connect the center hose to a cylinder of HFC−410A. Set for liquid phase charging.
BConnect the manifold gauge set’s low pressure side to the suction line service port.
CConnect the manifold gauge set’s high pressure side to the liquid line service port.
DPosition temperature sensor on liquid line near liquid line service port.
A
TO LIQUID
LINE SERVICE
VALV E
C
TEMPERATURE SENSOR
(LIQUID LINE)
Figure 15. Gauge Set Setup and Connections
START: Determine how refrigerant is metered
WHEN TO CHARGE?
Warm weather best
Can charge in colder weather
TXV
CHARGE METHOD? Determine by:
Metering device type
Outdoor ambient temperature
REQUIREMENTS:
Sufficient heat load in structure
Indoor temperature between 70-80ºF (21−26ºC)
Manifold gauge set connected to unit
65ºF (18.3ºC)
and ABOVE
OUTDOOR AMBIENT
TEMPERATURE
Thermometers:
− to measure outdoor ambient temperature
− to measure liquid line temperature
− to measure suction line temperature
APPROACH OR
SUBCOOLING
(SECOND STAGE − HIGH
CAPACITY)
OUTDOOR UNIT
SERVICE VALVE
64ºF (17.7ºC)
and BELOW
WEIGH-IN
VAPOR LINE
LIQUID LINE
SERVICE VALVE
506637−01 11/10
Figure 16. Determining Charge Method
Page 22
CHECKING AIR FLOW AT INDOOR COIL
Check airflow using the Delta−T (
DT) process using the illustration in figure 17.
Temp.
of air
entering
indoor
coil ºF
A
Wet−bulb ºF
53º
DRY
BULB
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
74 21 21 21 20 19 19 18 17 16 16 15 14 13 12
Dry−bulb
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
T
C
Drop
19º
All temperatures are
expressed in ºF
DT
air flowair flow
INDOOR
COIL
1. Determine the desired DTMeasure entering air temper-
ature 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 coilMeasure the coil’s dry
bulb entering and leaving air temperatures (A and C). Temperature Drop Formula: (T
3. Determine if fan needs adjustmentIf the difference between
B
A
72º
B
64º
WET
BULB
DRY
BULB
the measured T
+
3º, no adjustment is needed. See examples: Assume DT =
15 and A temp. = 72º, these C temperatures would necessitate stated actions:
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
4. Adjust the fan speedSee indoor unit instructions to in-
– DT = ºF ACTION
Drop
and the desired DT (T
Drop
) = A minus C.
Drop
–DT) is within
Drop
crease/decrease fan speed.
Changing air flow affects all temperatures; recheck temperatures to confirm that the temperature drop and DT are within
3º.
+
Figure 17. Checking Indoor Airflow over Evaporator Coil using Delta−T Chart
CHARGING METHOD
WEIGH IN
64ºF (17.7ºC) and Below
CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE
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:
Amount specified on
nameplate
Adjust amount. for variation
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.
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.
NOTE The above nameplate is for illustration purposes only. Go to actual nameplate on outdoor unit for charge information.
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)
Figure 18. Using HFC−410A Weigh In Method
Page 23
XC16 SERIES
START: Measure outdoor ambient temperature
USE WEIGH-IN METHOD
DO NOT CHARGE UNIT
Weigh-in or remove refrigerant
(Results of charging at low
based upon line length
temperatures not reliable)
64ºF and
BELOW
APPROACH TXV
If refrigerant is added or
removed, retest to confirm
that unit is properly
charged.
ABOVE
ABOVE or
BELOW
65ºF
and
1. Connect gauge set as illustrated in figure 15.
2. Confirm proper airflow across coil using figure 17.
3. Compare unit pressures with table 4, Normal
Operating Pressures.
4. Set thermostat to call for heat (must have a cooling
load between 70-80ºF (21−26ºC).
5. When heat demand is satisfied, set thermostat to call
for cooling.
6. Allow temperatures and pressures to stabilize.
7. Record outdoor ambient temperature:
AMBº =_________
8. Record liquid line temperature:
LIQº = __________
9. Subtract to determine approach (APPº):
LIQº_____ − AMBº _____ = APPº_____
10. Compare results with table below.
APPº (Approach) Values(F:+/−1.0° [C: +/−0.6°])
If value is greater than shown (high
approach), add refrigerant; if less
than shown (liquid temperature too
close to ambient temperature, low
approach), remove refrigerant.
Figure 19. Using HFC−410A Approach (TXV) Charge Method
START: Measure outdoor ambient temperature
USE WEIGH-IN METHOD
DO NOT CHARGE UNIT
Weigh-in or remove refrigerant
(Results of charging at low
based upon line length
temperatures not reliable)
64ºF and
ABOVE or
BELOW
BELOW
C
SUBCOOLING TXV
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 sections of air intake panels and move coverings sideways until
the liquid pressure is in the above noted ranges.
If refrigerant is
added or removed,
verify charge using
the Approach
Method.
If value is
MORE than
shown, remove
refrigerant.
ºF (ºC)* −024 −036 −048 −060
Any 6 (3.3) 6 (3.3) 8 (4.4) 4 (2.2)
*Temperature of air entering outdoor coil
65ºF
and
ABOVE
CARDBOARD OR
PLASTIC SHEETS
Models
1. Connect gauge set as illustrated in figure 15.
2. Confirm proper airflow across coil using figure 17.
3. Compare unit pressures with table 4, Normal
Operating Pressures.
4. Set thermostat to call for heat (must have a cooling
load between 70-80ºF (21−26ºC)
5. Measure outdoor ambient temperature
6. When heat demand is satisfied, set thermostat to call
for cooling
7. Allow temperatures and pressures to stabilize.
NOTE − If necessary, block outdoor coil to maintain
325 − 375 psig.
8. Record liquid line temperature:
LIQº = ______
9. Measure liquid line pressure and use the value to
determine saturation temperature (see table 3):
SATº = ______
10. Subtract to determine subcooling (SCº):
SATº_____ − LIQº _____ = SCº _____
11. Compare results with table below.
SCº (Subcooling) Values (F:+/−1.0° [C: +/−0.6°])
506637−01 11/10
Models
If value is LESS
than shown, add
refrigerant.
MORE or
LESS
ºF (ºC)* −024 −036 −048 −060
Any 5 (2.7) 6 (3.3) 6 (3.3) 9 (5.0)
*Temperature of air entering outdoor coil
Figure 20. Using HFC−410A Subcooling (TXV) Charge Method
Page 24
Table 3. HFC−410A Temperature (°F) − Pressure (Psig)
Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig
°F
32 100.8 48 137.1 63 178.5 79 231.6 94 290.8 11 0 365.0
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 11 2 375.1 127 457.6 143 559.1
35 107.1 51 144.8 66 187.7 82 242.7 97 303.8 11 3 380.2 128 463.5 144 565.9
36 109.2 52 147.4 67 190.9 83 246.5 98 308.2 11 4 385.4 129 469.5 145 572.8
37 111.4 53 150.1 68 194.1 84 250.3 99 312.7 11 5 390.7 130 475.6 146 579.8
38 113.6 54 152.8 69 197.3 85 254.1 100 317.2 116 396.0 131 481.6 147 586.8
39 115.8 55 155.5 70 200.6 86 258.0 101 321.8 117 401.3 132 487.8 148 593.8
40 118.0 56 158.2 71 203.9 87 262.0 102 326.4 118 406.7 133 494.0 149 601.0
41 120.3 57 161.0 72 207.2 88 266.0 103 331.0 119 412.2 134 500.2 150 608.1
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
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
system. Minor variations in these pressures may be due to differences in installations.
IMPORTANT
Significant deviations could mean that the system is not properly charged or that a
problem exists with some component in the system.
Temp. of air
entering
outdoor coil
5F (5C)
Liquid Suction Liquid Suction Liquid Suction Liquid Suction
−024 −036 −048 −060
First Stage (Low Capacity)
65 (18.3) 215 144 226 142 224 142 215 136
75 (23.9) 247 146 261 144 258 144 250 139
85 (29.4) 288 148 304 145 299 146 291 142
95 (35.0) 332 151 352 147 345 148 337 144
105 (40.6) 381 153 405 150 395 150 388 146
115 (46.1) 435 155 460 150 450 153 444 148
Second Stage (High Capacity)
65 (18.3) 225 140 228 144 235 135 220 130
75 (23.9) 258 142 262 146 269 137 256 133
85 (29.4) 301 144 306 148 313 139 299 136
95 (35.0) 346 146 353 150 361 141 347 138
105 (40.6) 397 149 405 151 412 143 402 141
115 (46.1) 452 151 462 154 471 146 462 143
*These are typical pressures only. Indoor indoor match up, indoor air quality, and indoor load will cause the pressures to vary.
System Operation
TWO−STAGE COMPRESSOR
The two−stage scroll compressor operates much like the
standard scroll compressor. The two−stage compressor
steps between low capacity and high capacity as required
to meet cooling demand. The steps occur when gas is
bypassed through a vent port in the first suction pocket.
This bypassing of gas allows the compressor to operate at
Full capacity is achieved by blocking the vent port with a
slider ring. The slider ring (vent port cover) is controlled by
a 24VDC internal solenoid in the open position allowing low
capacity. When energized the internal solenoid closes the
slider ring, blocking the vent port and bringing the
compressor to full capacity. Stepping can occur during a
single thermostat demand as the motor runs continuously
while the compressor steps from low to full capacity.
low capacity if thermostat demand allows, creating a more
cost effective and efficient compressor.
Page 25
XC16 SERIES
UNIT COMPONENTS
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 outdoor unit and indoor blower cycle on demand from
the room thermostat. When the thermostat blower switch
is in the ON position, the indoor blower operates
continuously.
High Pressure Switch (S4)
XC16 units are equipped with a high-pressure switch that
is located in the liquid line of the compressor as illustrated
in Unit Dimensions on page 2. The switch is a Single Pole,
Single Throw (SPST), manual−reset switch with red cap
that is normally closed and removes power from the
compressor when discharge pressure rises above factory
setting at 590 + 10 psi.
Low Pressure Switch (S87)
XC16 units are also equipped with a low pressure switch
that is located in the vapor line of the compressor. The
switch (SPST, auto−reset, normally closed) removes
power from the compressor when vapor line pressure
drops below factory setting at 40 + 5 psi.
Crankcase Thermostat (S40) (−048 and −060 Units
Only)
Compressor in the XC16−048 and −060 units are equipped
with a 70 watt, belly band type crankcase heater. HR1
prevents liquid from accumulating in the compressor. HR1
is controlled by a thermostat located on the liquid line.
When liquid line temperature drops below 50° F the
thermostat closes energizing HR1. The thermostat will
open, de−energizing HR1 once liquid line temperature
reaches 70° F .
Liquid Line Filter Drier
A filter drier is factory-installed as illustrated in Unit
Dimensions on page 2, with each XC16 unit to ensure a
clean, moisture−free system. A replacement filter drier is
available from Lennox. Refer to Lennox Repair Part
Program.
Maintenance
DEALER
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:
Outdoor Unit
1. Clean and inspect the outdoor coil. The coil may be
flushed with a water hose. Ensure the power is turned
off before you clean the coil.
2. Outdoor fan motor is prelubricated and sealed. No
further lubrication is needed.
3. Visually inspect connecting lines and coils for
evidence of oil leaks.
506637−01 11/10
4. Check wiring for loose connections.
5. Check for correct voltage at the unit (with the unit
operating).
6. Check amp−draw outdoor fan motor.
UNIT NAMEPLATE: _________ ACTUAL: __________
NOTE − If owner reports insufficient cooling, the unit should
be gauged and refrigerant charge checked.
Outdoor Coil
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)
Outdoor Coil The outdoor coil may be flushed with
a water hose.
Outdoor Coil (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. 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.
3. Check blower drive belt for wear and proper tension.
4. Check all wiring for loose connections
5. Check for correct voltage at unit (blower operating).
6. Check amp−draw on blower motor.
UNIT NAMEPLATE: _________ ACTUAL: __________
INDOOR COIL
1. Clean coil, if necessary.
2. Check connecting lines and coils for signs of oil leaks.
3. Check condensate line and clean, if necessary.
TWO−STAGE COMPRESSOR CHECKS
Use the checklist procedure on page 28, to verify part-load
and full-load capacity operation of two-stage modulation
compressors.
IMPORTANT
This performance check is ONLY valid on systems that
have clean indoor and outdoor coils, proper airflow over
coils, and correct system refrigerant charge. All
components in the system must be functioning proper to
correctly perform compressor modulation operational
check. (Accurate measurements are critical to this test
as indoor system loading and outdoor ambient can affect
variations between low and high capacity readings).
Tools Required
Refrigeration gauge set
Page 26
Digital volt/amp meter
Electronic temperature thermometer
On-off toggle switch
Procedure
NOTE − Block outdoor coil to maintain a minimum of 375
psig during testing).
1. Turn main power OFF to outdoor unit.
2. Adjust room thermostat set point 5ºF above the room
temperature.
3. Remove control access panel. Install refrigeration
gauges on unit. Attach the amp meter to the common
(black wire) wire of the compressor harness. Attach
thermometer to discharge line as close as possible to
the compressor.
4. Turn toggle switch OFF and install switch in series with
Y2 wire from room thermostat.
5. Cycle main power ON.
6. Allow pressures and temperatures to stabilize before
taking measurements (may take up to 10 minutes).
7. Record all of the readings for the Y1 demand.
8. Close switch to energize Y2 demand. Verify power is
going to compressor solenoid.
9. Allow pressures and temperatures to stabilize before
taking any measured reading (this may take up to 10
minutes).
10. Record all of the readings with the Y1 and Y2 demand.
11. If temperatures and pressures change in the direction
noted in chart, the compressor is properly modulating
from low to high capacity. (If no amperage, pressures
or temperature readings change when this test is
performed, the compressor is not modulating between
low and high capacity and replacement is necessary).
12. After testing is complete, return unit to original set up.
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.
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.
Outdoor Coil
The outdoor unit must be properly maintained to ensure its
proper operation.
Please contact your dealer to schedule proper
inspection and maintenance for your equipment.
Make sure no obstructions restrict airflow to the
outdoor unit.
Grass clippings, leaves, or shrubs crowding the unit
can cause the unit to work harder and use more
energy.
Keep shrubbery trimmed away from the unit and
periodically check for debris which collects around the
unit.
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.
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. 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 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:
Verify room thermostat settings are correct.
Verify that all electrical disconnect switches are ON.
Check for any blown fuses or tripped circuit breakers.
Verify unit access panels are in place.
Verify air filter is clean.
If service is needed, locate and write down the unit
model number and have it handy before calling.
Page 27
XC16 SERIES
Accessories
For update−to−date information, see any of the following
publications:
Lennox Product Catalog
Lennox Price Book
Lennox XC16 Engineering Handbook
Checklists
Two−Stage Modulation Compressors Field Operational Checklist
Unit Readings Y1 − First-Stage
COMPRESSOR
Voltage Same
Amperage Higher
OUTDOOR UNIT FAN
MOTOR
Amperage Same or Higher
TEMPERATURE
Ambient Same
Outdoor Coil Discharge Air Higher
Compressor Discharge Line Higher
Indoor Return Air Same
Indoor Coil Discharge Air Lower
PRESSURES
Suction (Vapor) Lower
Liquid Higher
Expected results during Y2
demand (Toggle switch On)
Start−Up and Performance Checklist
Job Name Job no. Date
Y2 − Second-Stage
Job Location City State
Installer City State
Unit Model No. Serial No. Service Technician
Nameplate Voltage
Rated Load Ampacity Compressor Outdoor Fan
Maximum Fuse or Circuit Breaker
Electrical Connections Tight? Indoor Filter clean? Supply Voltage (Unit Off)
Indoor Blower RPM S.P. Drop Over Indoor (Dry) Outdoor Coil Entering Air Temp.
Discharge Pressure Suction Pressure Refrigerant Charge Checked?
Refrigerant Lines: Leak Checked? Properly Insulated? Outdoor Fan Checked?
Service Valves: Fully Opened? Caps Tight? Thermostat
Voltage With Compressor Operating Calibrated? Properly Set? Level?
506637−01 11/10
Page 28
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