Lenox P506640-01, XP16 User Manual
INSTALLATION
E20 Lennox Industries Inc.
Dallas, Texas, USA
These instructions are intended as a
general guide and do not supersede
local codes in any way. Consult
authorities having jurisdiction before
installation.
RETAIN THESE INSTRUCTIONS FOR FUTURE
REFERENCE
NOTICE TO INSTALLER
BRAZING LINE SET TO SERVICE VALVES
It is imperative to follow the brazing technique illustrated starting on
page 11 to avoid damaging the service valve’s internal seals.
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, HFCs, and HCFCs) 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 XP16 Units
HEAT PUMPS
506640−01
12/10
Supersedes 11/10
TABLE OF CONTENTS
Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .
General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Number Identification 2. . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . .
Caps and Fasteners Torque Requirements 3. . . . . . . .
Operating Gauge Set and Service Valves 3. . . . . . . . .
Recovering Refrigerant from Existing System 5. . . . .
New Outdoor Unit Placement 6. . . . . . . . . . . . . . . . . . .
Removing and Installing Panels 8. . . . . . . . . . . . . . . . .
Line Set Requirements 9. . . . . . . . . . . . . . . . . . . . . . . . .
Brazing Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Indoor Refrigerant Metering Device Removal and
Flushing Line Set and Indoor Coil 14. . . . . . . . . . . . . . . .
Installing New Indoor Metering Device 15. . . . . . . . . . . .
Leak Test Line Set and Indoor Coil 16. . . . . . . . . . . . . . .
Evacuating Line Set and Indoor Coil 17. . . . . . . . . . . . .
Electrical Connections 18. . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start−Up 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing and Weighing In Refrigerant for Units
Delivered Void of Charge 24. . . . . . . . . . . . . . . . . . . . . . .
Optimizing System Refrigerant Charge 26. . . . . . . . . . .
System Operation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defrost System 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two−Stage Modulation Compressors Checks 40. . . . . .
Maintenance 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklists 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Litho U.S.A.
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox XP16 Engineering Handbook.
Coils previously charged with HCFC−22 must be
flushed.
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.
12/10 506640−01
Page 1
Shipping and Packing List
Check unit for shipping damage. Consult last carrier
immediately if damage is found.
1 − Assembled outdoor unit
General
The XP16 outdoor unit uses HFC−410A refrigerant. This
unit must be installed with a matching indoor blower coil
and line set as outlined in the XP16 Lennox Engineering
Handbook. Elite® Series outdoor units are designed for
use in check / expansion valve (CTXV) systems only and
are not to be used with other refrigerant flow control
devices. An indoor coil check / expansion valve approved
for use with HFC−410A must be ordered separately and
installed prior to operating the unit.
*2P1210* *P506640-01*
Model Number Identification
Refrigerant Type
X = R−410A
Unit Type
P = Heat Pump
Series
Unit Dimensions − inches (mm)
C
DISCHARGE AIR
P 16 036− −
X −05
230
Nominal Cooling Capacity
024 = 2 tons
036 = 3 tons
048 = 4 tons
060 = 5 tons
LIQUID LINE
CONNECTION
ELECTRICAL
INLETS
VAPOR LINE
CONNECTION
4−3/4
4−1/4
(121)
(108)
Minor Revision Number
Voltage
230 = 208/230V−1ph−60hz
B
A
2 (51)
1 (25)
D
E
F
SIDE VIEW
G
K
J
H
XP16 BASE WITH LEGS
UNIT SUPPORT
FEET
8−1/2
(216)
8−3/4
(222)
SIDE VIEW
5−1/2
(140)
13−1/2
(343)
XP16−024 BASE SECTION
9−1/2
(241)
8−1/4
(210)
UNIT SUPPORT FEET
Mode Number A B C D E F G H J K
XP16−024−230 35 (889) 27 (686) 28 (711) − − − − − − −
XP16−036−230 39 (991) 30−1/2 (775) 35 (889) 13−7/8 (352) 7−3/4 (197) 3−1/4 (83) 27−1/8 (689) 3−5/8 (92) 4−1/2 (114) 20−5/8 (524)
XP16−048−230 35 (889) 35−1/2 (902)
39−1/2
(1003)
16−7/8 (429) 8−3/4 (222) 3−1/8 (79) 30−3/4 (781) 4−5/8 (117) 3−3/4 (95) 26−7/8 (683)
XP16−060−230 45 (1143 35−1/2 (902)
39−1/2
(1003)
Page 2
Typical Unit Parts Arrangement
FOR COIL SENSOR (RT21)
LOCATION SEE DETAIL A
GROUND
SINGLE POLE
LUG AMBIENT
CONTACTOR
(K1)
TEMPERATURE
SENSOR (RT13)
DETAIL A
DUAL RUN CAPACITOR (C12)
(−024, −036 AND −048 ONLY)
SINGLE RUN CAPACITOR (C1)
(−060 ONLY)
DEMAND DEFROST
CONTROL (A108)
DISCHARGE LINE
SENSOR (RT28)
REVERSING
VALVE (L1)
TRUE SUCTION
PORT
HIGH PRESSURE
SWITCH (S4)
EXPANSION VALVE
SENSING BULB
LIQUID VALVE AND GAUGE
PORT / LIQUID LINE
CONNECTIONS
VAPOR VALVE AND GAUGE PORT /
SUCTION LINE CONNECTIONS
COMPRESSOR
CHECK /
EXPANSION
VALV E
LIQUID LINE
BI−FLOW FILTER
DRIER
LOW PRESSURE
SWITCH (S87)
XP16−036
COIL SENSOR − NINTH
HAIRPIN UP FROM THE
BOTTOM ON INSIDE
ROW.
XP16−024
COIL SENSOR −THIRD
HAIRPIN DOWN FROM
THE TOP ON INSIDE
ROW.
Figure 1. Unit Parts Arrangement
Caps and Fasteners Torque Requirements
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
Corp.0807−L5 (C−08−1) for further details and
information.
XP16−048
COIL SENSOR − EIGHT HAIRPIN
UP FROM THE BOTTOM ON
INSIDE ROW.
XP16−060
COIL SENSOR −
SIXTH HAIRPIN UP
FROM THE BOTTOM
ON INSIDE ROW.
When servicing or repairing HVAC equipment and
components, ensure the fasteners are appropriately
tightened. Table 1 list torque values for various caps and
fasteners.
Table 1. Torque Requirements
Parts Recommended Torque
Service valve cap 8 ft.− lb. 11 N M
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
Page 3
XP16 SERIES
Operating Gauge Set and Service Valves
USING MANIFOLD GAUGE SET
IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted
snugly over the cap before tightening.
OPERATING SERVICE VALVES
The liquid and vapor line service valves are used for
refrigerant recovery, flushing, leak testing, evacuating,
weighing in refrigerant and optimizing system charge.
Each valve is equipped with a service port which has a
factory−installed valve core. Figure 2 provides information
on how to access and operate both angle− and ball−type
service valves.
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 to open
the service valve.
SERVICE PORT
CORE
SERVICE PORT CAP
SERVICE PORT CORE
(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE
When checking the system charge, only use a manifold
gauge set that features low−loss anti−blow back fittings.
Manifold gauge set used for HFC−410A refrigerant
systems must be capable of handling the higher system
operating pressures. The manifold gauges should be rated
for:
S High side Pressure range of 0 − 800 pound−force per
square inch gauge (psig)
S Low side Use with 30" vacuum to 250 psig with
dampened speed to 500 psig
S Manifold gauge set hoses must be rated for use to 800
psig of pressure with a 4000 psig burst rating.
TO INDOOR
UNIT
TO OUTDOOR
UNIT
VALVE STEM
SHOWN
CLOSED
INSERT HEX−HEAD
2
EXTENSION HERE
TO INDOOR
UNIT
TO OUTDOOR UNIT
When service valve is OPEN, the service port is open to line set,
indoor and outdoor unit.
STEM CAP
Operating Ball−Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. Use an appropriately sized wrenched to open.
ATo open rotate stem
counterclockwise
90°.
BTo close rotate stem
clockwise 90°.
SERVICE PORT
SERVICE PORT CORE
SERVICE PORT CAP
TO OUTDOOR UNIT
NOTE A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
TO INDOOR UNIT
BALL (SHOWN CLOSED)
VALVE STEM
2
REMOVE
1
STEM CAP
When service valve stem is in the CLOSED position,
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:
S With torque wrench: Finger tighten and torque cap per table 1.
S Without torque wrench: Finger tighten and use an appropriately sized
wrench to turn an additional 1/6 turn clockwise.
Reinstall Stem Cap:
Stem cap protects the valve stem from damage and
serves as the primary seal. Replace the stem cap and
tighten as follows:
S With Torque Wrench: Finger tighten and then
torque cap per table 1.
S Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional 1/12 turn clockwise.
9
10
9
10
8
8
1
11
7
11
7
REMOVE
STEM CAP
1/6 TURN
12
1
2
3
4
5
6
1/12 TURN
12
1
2
4
5
6
3
Figure 2. Angle and Ball−Type Service Valves
Page 4
Recovering Refrigerant from Existing System
DISCONNECT POWER
Disconnect all power to the existing outdoor unit at the disconnect
1
switch and/or main fuse box/breaker panel.
MAIN FUSE
BOX/BREAKER
PANEL
DISCONNECT
SWITCH
RECOVERING REFRIGERANT
3
Remove existing HCFC−22 refrigerant using one of the following procedures:
METHOD 1:
Use 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.
Recover all HCFC−22 refrigerant from the existing system using a recovery
machine and clean recovery cylinder. Check gauges after shutdown to confirm
that the entire system is completely void of refrigerant.
METHOD 2:
Use Method 2 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.
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.
CONNECT MANIFOLD GAUGE SET
Connect a manifold gauge set, clean recovery cylinder and a
2
recovery machine to the service ports of the existing unit..
NOTE Use the recovery machine instructions to make
the correct manifold gauge set connections for recovery
refrigerant. The illustration below is a typical connection.
MANIFOLD GAUGES
RECOVERY MACHINE
LOW
CLEAN RECOVERY
CYLINDER
OUTDOOR UNIT
METHOD 2 LIMITATIONS
NOTE When using Method 2, the listed devices
below could prevent full system charge recovery into
the outdoor unit:
S Outdoor unit’s high or low−pressure switches (if
applicable) when tripped can cycle the
compressor OFF.
S Compressor can stop pumping due to tripped
internal pressure relief valve.
S Compressor has internal vacuum protection that
is designed to unload the scrolls (compressor
stops pumping) when the pressure ratio meets a
certain value or when the suction pressure is as
high as 20 psig. (Compressor suction
pressures should never be allowed to go into
a vacuum. Prolonged operation at low suction
pressures will result in overheating of the
scrolls and permanent damage to the scroll
tips, drive bearings and internal seals.)
Once the compressor can not pump down to a lower
pressure due to any of the above mentioned 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.
HIGH
Figure 3. Refrigerant Recovery
IMPORTANT
The Environmental Protection Agency (EPA) prohibits the intentional venting of HFC refrigerants during maintenance,
service, repair and disposal of appliance. Approved methods of recovery, recycling or reclaiming must be followed.
WARNING
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.
Page 5
XP16 SERIES
New Outdoor Unit Placement
CAUTION
In order to avoid injury, take proper precaution when lifting heavy objects.
Remove existing outdoor unit prior to placement of new
outdoor unit. See Unit Dimensions on page 2 for sizing
mounting slab, platforms or supports. Refer to figure 4 for
mandatory installation clearance requirements.
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
S Some localities are adopting sound ordinances based
on the unit’s sound level registered from the adjacent
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 5,
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 5,
detail B.
NOTE If necessary for stability, anchor unit to slab as
described in figure 5, detail D.
ELEVATING THE UNIT
Units are outfitted with elongated support feet as illustrated
in figure 5, 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.
ROOF MOUNTING
Install the unit a minimum of 6 inches (152 mm) above the
roof surface to avoid ice build−up around the unit. Locate
the unit above a load bearing wall or area of the roof that
can adequately support the unit. Consult local codes for
rooftop applications. See figure 5, detail F for other roof top
mounting considerations.
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.
CLEARANCE ON ALL SIDES INCHES (MILLIMETERS)
6 (152)
12 (305)
36 (914)
ACCESS PANEL
CONTROL PANEL
ACCESS
LOCATION
30 (762)
LINE SET
CONNECTIONS
NOTES:
S Clearance to one of the other three
sides must be 36 inches (914mm).
S Clearance to one of the remaining
two sides may be 12 inches
(305mm) and the final side may be
6 inches (152mm).
MINIMUM CLEARANCE BETWEEN TWO UNITS
24
(610)
Figure 4. Installation Clearances
MINIMUM CLEARANCE
ABOVE UNIT
48 (1219)
Page 6
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.
Elevated Slab Mounting
DETAIL C
LEG DETAIL
2" (50.8MM) SCH 40
FEMALE THREADED
2" (50.8MM) SCH 40
MALE THREADED
Use additional 2" SCH 40 male threaded adapters which
can be threaded into the female threaded adapters to
make additional adjustments to the level of the unit.
DETAIL E
using Feet Extenders
ADAPTER
ADAPTER
Deck Top Mounting
BASE
GROUND LEVEL
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")
Stabilizing bracket (18 gauge metal 2" (50.8mm) width; height as required); bend to form
right angle as exampled below.
DETAIL F
If unit coil cannot be mounted away from prevailing winter winds, a wind barrier should be
constructed. Size barrier at least the same height and width as outdoor unit. Mount barrier 24
inches (610 mm) from the sides of the unit in the direction of prevailing winds as illustrated.
Slab Side Mounting
COIL
BASE PAN
REQUIRED)
AND FLAT WASHER
CORNER POST
Roof Top Mounting
PREVAILING WINTER WINDS
WIND BARRIER
INLET AIR
One bracket per side
(minimum). For extra
stability, two brackets per
side, two inches (51mm)
from each corner.
SAME FASTENERS AS
SLAB SIDE MOUNTING.
Figure 5. Placement, Slab Mounting and Stabilizing Unit
MINIMUM ONE
PER SIDE
FOR EXTRA
STABILITY
Page 7
INLET AIR
INLET AIR
INLET AIR
XP16 SERIES
Removing and Installing Panels
LOUVERED PANEL REMOVAL
Remove the louvered panels as follows:
1. Remove two screws, allowing the panel to swing open
slightly.
2. Hold the panel firmly throughout this procedure. Rotate
bottom corner of panel away from hinged corner post until
lower three tabs clear the slots as illustrated in detail B.
3. Move panel down until lip of upper tab clears the top slot in
corner post as illustrated in detail A.
LOUVERED PANEL INSTALLATION
Position the panel almost parallel with the unit as illustrated in
detail D with the screw side as close to the unit as possible.
Then, in a continuous motion:
1. Slightly rotate and guide the lip of top tab inward as
illustrated in detail A and C; then upward into the top
slot of the hinge corner post.
2. Rotate panel to vertical to fully engage all tabs.
3. Holding the panel’s hinged side firmly in place, close
the right−hand side of the panel, aligning the screw
holes.
4. When panel is correctly positioned and aligned, insert
the screws and tighten.
Detail C
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
HOLES
Detail A
Detail B
ROTATE IN THIS DIRECTION;
ANGLE MAY BE TOO
EXTREME
THEN DOWN TO REMOVE
HOLD DOOR FIRMLY TO THE HINGED
PANEL
SIDE TO MAINTAIN
FULLY−ENGAGED TABS
PREFERRED ANGLE
FOR INSTALLATION
Detail D
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO
PARALLEL WITH THE UNIT AS POSSIBLE) WHILE
INSTALLING PANEL.
Figure 6. Removing and Installing Panels
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.
Page 8
Line Set Requirements
This section provides information on: installation of new or
replacement line set.
S Adding Polyol ester oil requirements
S New or replacement line set installation
S Using existing line set.
ADDING POLYOL ESTER OIL REQUIREMENTS
IMPORTANT
Mineral oils are not compatible with HFC−410A. If oil
must be added, it must be a Polyol Ester oil.
The compressor is charged with sufficient Polyol Ester oil
(POE) for line set lengths up to 50 feet. Recommend
adding oil to system based on the amount of refrigerant
charge in the system. Systems with 20 pounds or less of
refrigerant required no oil to be added.
For systems over 20 pounds − add one ounce for every five
(5) pounds of HFC−410A refrigerant.
Recommended topping−off POE oils are Mobil EAL
ARCTIC 22 CC or ICI EMKARATEt RL32CF.
NEW OR REPLACEMENT LINE SET INSTALLATION
Field refrigerant piping consists of both liquid and vapor
lines from the outdoor unit to the indoor coil. Use Lennox
L15 (sweat, non−flare) series line set, or field−fabricated
refrigerant line sizes as specified in table 2.
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 7 for recommended
installation practices.
NOTE When installing refrigerant lines longer than 50
feet, see the Lennox Refrigerant Piping Design and
Fabrication Guidelines, CORP. 9351−L9, or contact
Lennox Technical Support Product Applications for
assistance. To obtain the correct information from Lennox,
be sure to communicate the following information:
Table 2. Refrigerant Line Set Inches (mm)
Model
XP16−024−230 3/8" (10 mm) 3/4" (19 mm) 3/8" (10 mm) 3/4" (19 mm) L15−41 15 ft. − 50 ft. (4.6m − 15 m)
XP16−036−230
XP16−048−230
XP16−060−230 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
Liquid Line Suction Line Liquid Line Suction Line L15 Line Set
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
S Model (XP16) and size of unit (e.g. −036).
S Line set diameters for the unit being installed as listed
in table 2 and total length of installation.
S Number of elbows vertical rise or drop in the piping.
USING EXISTING LINE SET
Things to consider:
S Liquid line that meter the refrigerant, such as RFC1
liquid line, must not be used in this application.
S Existing line set of proper size as listed in table 2 may
be reused.
S If system was previously charged with HCFC−22
refrigerant, then existing line set must be flushed (see
Flushing Line Set and Indoor Coil on page 14).
If existing line set is being used, then proceed to Brazing
Connections on page 11.
IMPORTANT
Lennox highly recommends changing line set when
converting the existing system from HCFC−22 to
HFC−410A. If that is not possible and the line set is the
proper size as reference in table 2, use the procedure
outlined under Flushing Line Set and Indoor Coil on page
13.
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.
Page 9
XP16 SERIES
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 7. Line Set Installation
Page 10
Brazing Connections
Use the procedures outline in figures 8 and 9 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).
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.
CAUTION
Brazing alloys and flux contain materials which are
hazardous to your health.
Avoid breathing vapors or fumes from brazing
operations. Perform operations only in well−ventilated
areas.
Wear gloves and protective goggles or face shield to
protect against burns.
Wash hands with soap and water after handling brazing
alloys and flux.
Page 11
XP16 SERIES
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 8. Brazing Procedures
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).
Page 12
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
7
service valves to cool piping. Once piping is cool, remove all water saturated cloths.
SUCTION / VAPOR LINE
SERVICE VALVE
WATER SATURATED
CLOTH
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
Figure 9. Brazing Procedures (continued)
Page 13
XP16 SERIES
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