Lenox Air Conditioner 506637 01 User Manual

INSTALLATION  
INSTRUCTIONS  
E 2010 Lennox Industries Inc.  
Dallas, Texas, USA  
Elite® Series XC16 Units  
AIR CONDITIONER  
506637−01  
11/10  
Litho U.S.A.  
Supersedes 506101−01  
TABLE OF CONTENTS  
Shipping and Packing List . . . . . . . . . . . . . . . . . . . . . .  
Model Number Identification . . . . . . . . . . . . . . . . . . . .  
Unit Parts Arrangement . . . . . . . . . . . . . . . . . . . . . . . .  
Operating Gauge Set and Service Valves . . . . . . . . .  
Recovering Refrigerant from Existing System . . . . .  
Removing and Installing Panels . . . . . . . . . . . . . . . . .  
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.  
New or Replacement Line Set . . . . . . . . . . . . . . . . . . . 10  
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  
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.  
Servicing Units Delivered Void of Charge . . . . . . . . . 21  
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.  
General  
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.  
IMPORTANT  
This unit must be matched with an indoor coil as speci-  
fied inLennox XC16 Engineering Handbook. Coils pre-  
viously charged with HCFC−22 must be flushed.  
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.  
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.  
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.  
1 ꢀ Assembled outdoor unit.  
506637−01  
11/10  
Page 1  
*2P1110*  
*P506637-01*  
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Typical Unit Parts Arrangement  
CONTROL PANEL  
SINGLE POLE CONTACTOR (K1)  
GROUND LUG  
DUAL RUN CAPACITOR  
(C12)  
COMPRESSOR  
COMPRESSOR  
HARNESS  
CRANKCASE  
THERMOSTAT  
(S40) −048 AND  
−060 UNITS ONLY  
HIGH PRESSURE  
SWITCH (MANUAL  
RESET) (S4)  
LIQUID LINE FILTER  
DRIER (SINGLE FLOW)  
LOW PRESSURE  
SWITCH (S87)  
SUCTION LINE  
SERVICE VALVE  
LIQUID LINE SERVICE  
VALVE  
FIELD CONNECTION  
FOR SUCTION LINE  
FIELD CONNECTION  
FOR LIQUID LINE SET  
PLUMBING AND SWITCHES COMPONENTS  
Figure 1. Typical Parts Arrangements  
Page 3  
XC16 SERIES  
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IMPORTANT  
To prevent stripping of the various caps used, the  
appropriately sized wrench should be used and fitted  
snugly over the cap before tightening.  
WARNING  
Electric Shock Hazard. Can cause injury  
or death. Unit must be grounded in  
accordance with national and local  
codes.  
Table 1. Torque Requirements  
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.  
Parts  
Recommended Torque  
Service valve cap  
Sheet metal screws  
Machine screws #10  
Compressor bolts  
Gauge port seal cap  
8 ft.− lb.  
11 NM  
16 in.− lb.  
28 in.− lb.  
90 in.− lb.  
8 ft.− lb.  
2 NM  
3 NM  
10 NM  
11 NM  
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.  
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 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.  
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.  
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.  
Page 4  
506637−01 11/10  
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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  
CLOSED) INSERT HEX  
WRENCH HERE  
TO INDOOR  
UNIT  
(VALVE STEM SHOWN OPEN)  
INSERT HEX WRENCH HERE  
SERVICE PORT  
CORE  
STEM CAP  
TO OUTDOOR UNIT  
ANGLE−TYPE SERVICE VALVE  
(FRONT−SEATED CLOSED)  
ANGLE−TYPE SERVICE VALVE  
(BACK−SEATED OPENED)  
When service valve is OPEN, the service port is  
open to linE set, indoor and outdoor unit.  
WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN  
TO THE LINE SET AND INDOOR UNIT.  
To Access Service Port:  
Operating Ball Type Service Valve:  
A service port cap protects the service port core from contamination and  
serves as the primary leak seal.  
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°.  
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:  
TO INDOOR UNIT  
1/6 TURN  
S
S
With torque wrench: Finger tighten and  
torque cap per table 1.  
12  
6
1
5
11  
10  
Without torque wrench: Finger tighten and  
use an appropriately sized wrench to turn  
an additional 1/6 turn clockwise.  
2
TO OPEN ROTATE STEM  
COUNTERCLOCKWISE 90°.  
9
3
BALL (SHOWN  
CLOSED)  
4
8
7
VALVE  
TO CLOSE ROTATE STEM  
STEM  
Reinstall Stem Cap:  
CLOCKWISE 90°.  
Stem cap protects the valve stem from damage and serves as the  
primary seal. Replace the stem cap and tighten as follows:  
SERVICE PORT  
1/12 TURN  
SERVICE PORT  
CORE  
S
S
With Torque Wrench: Finger tighten and  
then torque cap per table 1.  
12  
6
1
5
11  
10  
SERVICE PORT  
CAP  
Without Torque Wrench: Finger tight-  
en and use an appropriately sized  
wrench to turn an additional 1/12 turn  
clockwise.  
2
9
3
STEM CAP  
4
TO OUTDOOR  
UNIT  
8
7
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  
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Recovering Refrigerant from Existing System  
RECOVERING  
REFRIGERANT FROM SYSTEM  
CONNECT MANIFOLD GAUGE SET  
DISCONNECT POWER  
Disconnect all power to the existing outdoor unit at the disconnect  
Connect a gauge set, clean recovery cylinder and a recovery  
machine to the service ports of the existing unit. Use the  
instructions provided with the recovery machine to make the  
connections.  
2
1
switch or main fuse box/breaker panel.  
MAIN FUSE BOX/BREAKER PANEL  
MAIN FUSE  
BOX/BREAKER  
PANEL  
MANIFOLD GAUGES  
RECOVERY MACHINE  
DISCONNECT  
SWITCH  
LOW  
HIGH  
OUTDOOR UNIT  
CLEAN RECOVERY  
CYLINDER  
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.  
METHOD 1:  
Us this method if the existing outdoor unit is not equipped with shut−off valves, or if the unit is not operational and you plan to use the existing  
HCFC−22 to flush the system.  
Remove all HCFC−22 refrigerant from the existing system. Check gauges after shutdown to confirm that the entire system is completely void of  
refrigerant.  
METHOD 2:  
Use this method if the existing outdoor unit is equipped with manual shut−off valves, and you plan to use new HCFC−22 refrigerant to flush the  
system.  
The following devices could prevent full system charge recovery into the outdoor unit:  
S
S
S
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
B
Start the existing HCFC−22 system in the cooling mode and close the liquid line valve.  
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
D
When the low side system pressures reach 0 psig, close the vapor line valve.  
Check gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system.  
Page 6  
506637−01 11/10  
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CLEARANCE ON ALL SIDES ꢀ INCHES (MILLIMETERS)  
6 (152)  
ACCESS PANEL  
MINIMUM CLEARANCE  
ABOVE UNIT  
NOTES:  
S
Clearance to one of the other three  
sides must be 36 inches (914mm).  
30 (762)  
12 (305)  
S
Clearance to one of the remaining  
two sides may be 12 inches  
(305mm) and the final side may be  
6 inches (152mm).  
48 (1219)  
LINE SET  
CONNECTIONS  
36 (914)  
MINIMUM CLEARANCE BETWEEN  
TWO UNITS  
24 (610)  
Figure 3. Installation Clearances  
PLACING UNIT ON SLAB  
New Outdoor Unit Placement  
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.  
CAUTION  
In order to avoid injury, take proper precaution when  
lifting heavy objects.  
NOTE ꢀ If necessary for stability, anchor unit to slab as  
described in figure 4, detail D.  
See Unit Dimensions on page 3 for sizing mounting slab,  
platforms or supports. Refer to figure 3 for mandatory  
installation clearance requirements.  
ELEVATING THE UNIT  
Units are outfitted with elongated support feet as illustrated  
POSITIONING CONSIDERATIONS  
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.  
Consider the following when positioning the unit:  
S
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.  
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.  
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.  
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  
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ꢀ Outside Unit Placement  
DETAIL A  
Install unit away from windows.  
ꢀ Slab Mounting at Ground Level  
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.  
BUILDING  
STRUCTURE  
MOUNTING  
SLAB  
GROUND LEVEL  
TWO 90° ELBOWS INSTALLED IN LINE SET WILL  
REDUCE LINE SET VIBRATION.  
STABILIZING UNIT ON UNEVEN SURFACES  
DETAIL CElevated Slab Mounting  
using Feet Extenders  
ꢀ Slab Side Mounting  
DETAIL D  
#10 1/2" LONG SELF−DRILLING  
SHEET METAL SCREWS  
COIL  
STABILIZING BRACKET (18 GAUGE  
METAL ꢀ 2" WIDTH; HEIGHT AS  
REQUIRED)  
BASE PAN  
#10 1−1/4" LONG HEX HD SCREW  
AND FLAT WASHER  
CORNER POST  
Concrete slab ꢀ use two plastic anchors (hole  
drill 1/4")  
BASE  
Wood or plastic slab ꢀ no plastic anchor (hole  
drill 1/8")  
DETAIL E ꢀ Deck Top Mounting  
Stabilizingbracket (18 gauge metal ꢀ 2" (50.8mm) width; height as required); bend to form  
right angle as exampled below.  
LEG DETAIL  
MINIMUM ONE  
PER SIDE  
2" (50.8MM) SCH 40  
FEMALE THREADED  
ADAPTER  
2" (50.8MM) SCH 40  
MALE THREADED  
ADAPTER  
SAME FASTENERS AS  
FOR EXTRA  
SLAB SIDE MOUNTING.  
STABILITY  
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.  
One bracket per side (minimum). For extra stability, two brackets per side, two inches  
(51mm) from each corner.  
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.  
Figure 4. Placement, Slab Mounting and Stabilizing Unit  
Page 8  
506637−01 11/10  
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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.  
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:  
NOTICE  
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).  
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.  
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.  
LOUVERED PANEL REMOVAL  
Remove the louvered panels as follows:  
PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR  
ENTER) TOP SLOT FOR REMOVING (OR INSTALLING) PANEL.  
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.  
SCREW  
HOLES  
3. Move panel down until lip of upper tab clears the top slot in corner post as  
illustrated in detail A.  
LIP  
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:  
DETAIL A  
1. Slightly rotate and guide the lip of top tab inward as illustrated indetail 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.  
DETAIL B  
4. When panel is correctly positioned and aligned, insert the screws and  
tighten.  
Detail C  
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL  
WITH THE UNIT AS POSSIBLE) WHILE INSTALLING PANEL.  
ROTATE IN THIS DIRECTION;  
THEN DOWN TO REMOVE  
PANEL  
HOLD DOOR FIRMLY TO THE HINGED  
SIDE TO MAINTAIN  
FULLY−ENGAGED TABS  
ANGLE MAY BE TOO  
EXTREME  
PREFERRED ANGLE  
FOR INSTALLATION  
Figure 5. Removing and Installing Panels  
Page 9  
XC16 SERIES  
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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.  
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.  
NOTE ꢀ When installing refrigerant lines longer than 50  
feet, see the Lennox Refrigerant Piping Design and  
Fabrication Guidelines, CORP. 9351−L9, or contact  
Lennox Technical Support Product Applications for  
assistance.  
IMPORTANT  
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.  
To obtain the correct information from Lennox, be sure to  
communicate the following information:  
S
S
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.  
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.  
S
Number of elbows vertical rise or drop in the piping.  
The compressor is charged with sufficient Polyol ester oil  
for line set lengths up to 50 feet. Recommend adding oil to  
system based on the amount of refrigerant charge in the  
system. No need to add oil in system with 20 pounds of  
refrigerant or less. For systems over 20 pounds − add one  
ounce of every five pounds of refrigerant.  
Recommended topping−off POE oils are Mobil EAL  
ARCTIC 22 CC or ICI EMKARATEt RL32CF.  
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).  
IMPORTANT  
Mineral oils are not compatible with HFC−410A. If oil  
must be added, it must be a Polyol Ester oil.  
Table 2. Refrigerant Line Set ꢀ Inches (mm)  
Field Connections  
Recommended Line Set  
Model  
Liquid Line  
Suction Line  
Liquid Line  
Suction Line  
L15 Line Set  
XC16−024−230  
XC16−036−230  
XC16−048−230  
XC16−060−230  
3/8" (10 mm)  
3/8" (10 mm)  
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)  
7/8" (22 mm)  
3/8" (10 mm)  
3/8" (10 mm)  
7/8" (22 mm)  
L15−65 ꢀ 15 ft. − 50 ft. (4.6 m − 15 m)  
Field Fabricated  
1−1/8" (29 mm)  
1−1/8" (29 mm)  
NOTE ꢀ Some applications may required a field provided 7/8" to 1−1/8" adapter  
Page 10  
506637−01 11/10  
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Line Set Isolation ꢀ The following illustrations are examples of proper refrigerant line set isolation:  
REFRIGERANT LINE SET ꢀ INSTALLING  
VERTICAL RUNS (NEW CONSTRUCTION SHOWN)  
REFRIGERANT LINE SET ꢀ TRANSITION  
FROM VERTICAL TO HORIZONTAL  
NOTE ꢀ Insulate liquid line when it is routed through areas where the  
surrounding ambient temperature could become higher than the  
temperatureof the liquid line or when pressure drop is equal to or greater  
than 20 psig.  
ANCHORED HEAVY NYLON  
WIRE TIE OR AUTOMOTIVE  
AUTOMOTIVE  
MUFFLER-TYPE HANGER  
MUFFLER-TYPE HANGER  
OUTSIDE WALL  
LIQUID LINE  
VAPOR LINE  
WALL  
STUD  
WIRE TIE  
INSIDE WALL  
STRAP  
WOOD BLOCK  
BETWEEN STUDS  
STRAP LIQUID LINE TO  
VAPOR LINE  
NON−CORROSIVE  
METAL SLEEVE  
WIRE TIE  
LIQUID LINE  
NON−CORROSIVE  
METAL SLEEVE  
WOOD BLOCK  
WIRE TIE  
VAPOR LINE − WRAPPED  
IN ARMAFLEX  
STRAP  
REFRIGERANT LINE SET ꢀ INSTALLING  
HORIZONTAL RUNS  
SLEEVE  
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)  
VAPOR LINE WRAPPED  
WITH ARMAFLEX  
8 FEET (2.43 METERS)  
OUTSIDE  
WALL  
STRAPPING  
MATERIAL (AROUND  
VAPOR LINE ONLY)  
FLOOR JOIST OR  
LIQUID  
LINE  
ROOF RAFTER  
TAPE OR  
WIRE TIE  
8 FEET (2.43 METERS)  
PVC  
PIPE  
CAULK  
NON−CORROSIVE  
METAL SLEEVE  
FIBERGLASS  
INSULATION  
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  
NOTE ꢀ Similar installation practices should be used if line set is  
to be installed on exterior of outside wall.  
FLOOR JOIST OR  
ROOF RAFTER  
Figure 6. Line Set Installation  
Page 11  
XC16 SERIES  
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Brazing Connections  
Use the procedures outline in figures 7 and 8 for brazing  
line set connections to service valves.  
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.  
WARNING  
Polyol Ester (POE) oils used with HFC−410A  
refrigerant absorb moisture very quickly. It is very  
important that the refrigerant system be kept closed  
as much as possible. DO NOT remove line set caps  
or service valve stub caps until you are ready to make  
connections.  
IMPORTANT  
Allow braze joint to cool before removing the wet rag  
from the service valve. Temperatures above 250ºF can  
damage valve seals.  
WARNING  
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.  
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  
Fire, Explosion and Personal Safety  
Hazard.  
WARNING  
Failure to follow this warning could  
result in damage, personal injury or  
death.  
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).  
Never use oxygen to pressurize or  
purge refrigeration lines. Oxygen,  
when exposed to a spark or open  
flame, can cause fire and/or an ex-  
plosion, 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 12  
506637−01 11/10  
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CAP AND CORE REMOVAL  
CUT AND DEBUR  
Cut ends of the refrigerant lines square (free from nicks or dents)  
and debur the ends. The pipe must remain round. Do not crimp end  
of the line.  
Remove service cap and core from  
both the suction / vapor and liquid line  
service ports.  
2
1
CUT AND DEBUR  
SERVICE PORT  
CAP  
SERVICE  
PORT  
CORE  
LINE SET SIZE MATCHES  
SERVICE VALVE CONNECTION  
SERVICE  
PORT  
CORE  
SERVICE VALVE  
CONNECTION  
SERVICE  
PORT CAP  
COPPER TUBE  
STUB  
LIQUID LINE SERVICE  
VALVE  
SUCTION / VAPOR LINE  
SERVICE VALVE  
REDUCER  
LINE SET SIZE IS SMALLER  
THAN CONNECTION  
DO NOT CRIMP SERVICE VALVE  
CONNECTOR WHEN PIPE IS  
SMALLER THAN CONNECTION  
REFRIGERANT LINE  
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
B
C
Connect gauge set low pressure side to  
liquid line service valve (service port).  
USE REGULATOR TO FLOW  
NITROGEN AT 1 TO 2 PSIG.  
LOW  
HIGH  
Connect gauge set center port to bottle of  
nitrogenwith regulator.  
Remove core from valve in suction / vapor  
line service port to allow nitrogen to escape.  
ATTACH  
GAUGES  
B
SUCTION / VAPOR SERVICE PORT MUST BE  
OPEN TO ALLOW EXIT POINT FOR NITROGEN  
SUCTION /  
VAPOR LINE  
SERVICE  
VALVE  
C
VAPOR LINE  
OUTDOOR  
UNIT  
INDOOR  
UNIT  
NITROGEN  
LIQUID LINE SERVICE  
VALVE  
WHEN BRAZING LINE SET TO  
SERVICE VALVES, POINT FLAME  
AWAY FROM SERVICE VALVE.  
LIQUID LINE  
A
Figure 7. Brazing Procedures  
Page 13  
XC16 SERIES  
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WRAP SERVICE VALVES  
To help protect service valve seals during brazing, wrap water saturated cloths around service valve bodies and copper tube stubs. Use  
additionalwater saturated cloths underneath the valve body to protect the base paint.  
4
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  
out of the suction / vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set connections  
5
6
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  
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.  
WATER SATURATED  
CLOTH  
LIQUID LINE  
WARNING  
SUCTION / VAPOR LINE  
SERVICE VALVE  
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.  
WHEN BRAZING LINE SET TO  
SERVICE VALVES, POINT FLAME  
AWAY FROM SERVICE VALVE.  
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  
WATER SATURATED  
CLOTH  
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  
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.  
7
Figure 8. Brazing Procedures (continued)  
Page 14  
506637−01 11/10  
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Flushing Line Set and Indoor Coil  
TYPICAL EXISTING FIXED ORIFICE  
REMOVAL PROCEDURE (UNCASED  
COIL SHOWN)  
TYPICAL EXISTING EXPANSION VALVE REMOVAL  
PROCEDURE (UNCASED COIL SHOWN)  
OR  
1B  
1A  
STUB END  
TWO PIECE PATCH PLATE  
(UNCASED COIL ONLY)  
LIQUID LINE  
ORIFICE  
HOUSING  
CHECK  
EXPANSION  
VALVE  
DISTRIBUTOR TUBES  
LIQUID LINE ORIFICE HOUSING  
DISTRIBUTOR  
TUBES  
®
TEFLON  
RING  
®
TEFLON RING  
FIXED ORIFICE  
BRASS NUT  
®
TEFLON  
RING  
SENSING  
LINE  
DISTRIBUTOR  
ASSEMBLY  
DISTRIBUTOR  
ASSEMBLY  
EQUALIZER  
LINE  
REMOVE AND DISCARD  
®
WHITE TEFLON SEAL  
(IF PRESENT)  
LIQUID LINE ASSEMBLY  
(INCLUDES STRAINER)  
LIQUID LINE  
ASSEMBLY WITH  
BRASS NUT  
A
B
On fully cased coils, remove the coil access and plumbing panels.  
Remove any shipping clamps holding the liquid line and distributor as-  
sembly.  
MALE EQUALIZER  
LINE FITTING  
VAPOR  
LINE  
C
Using two wrenches, disconnect liquid line from liquid line orifice hous-  
ing. Take care not to twist or damage distributor tubes during this pro-  
cess.  
LIQUID  
LINE  
SENSING BULB  
A
B
On fully cased coils, remove the coil access and plumbing panels.  
D
E
Remove and discard fixed orifice, valve stem assembly if present and  
®
Teflon washer as illustrated above.  
Remove any shipping clamps holding the liquid line and distributor  
assembly.  
Use a field−provided fitting to temporary reconnect the liquid line to the  
indoor unit’s liquid line orifice housing.  
C
Disconnect the equalizer line from the check expansion valve  
equalizer line fitting on the vapor line.  
D
E
Remove the vapor line sensing bulb.  
CONNECT GAUGES AND EQUIPMENT FOR  
FLUSHING PROCEDURE  
Disconnect the liquid line from the check expansion valve at the liquid  
line assembly.  
2
INVERTED HCFC−22  
GAUGE  
MANIFOLD  
F
Disconnect the check expansion valve from the liquid line orifice  
housing.Take care not to twist or damage distributor tubes during this  
process.  
CYLINDER CONTAINS  
CLEAN HCFC−22 TO BE  
USED FOR FLUSHING.  
A
®
G
H
Remove and discard check expansion valve and the two Teflon rings.  
LOW  
HIGH  
1
Use a field−provided fitting to temporary reconnect the liquid line to the  
indoor unit’s liquid line orifice housing.  
NEW  
OUTDOOR  
UNIT  
VAPOR LINE  
SERVICE VALVE  
FLUSHING LINE SET  
OPENED  
CLOSED  
The line set and indoor unit coil must be flushed with at least the  
same amount of clean refrigerant that previously charged the  
system. Check the charge in the flushing cylinder before  
proceeding.  
EXISTING  
INDOOR  
UNIT  
3
B
LIQUID LINE SERVICE  
VALVE  
A
Set the recovery machine for liquid recovery and start the  
recovery machine. Open the gauge set valves to allow the  
TANK  
RETURN  
rBecovery machine to pull a vacuum on the existing system line  
set and indoor unit coil.  
C
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.  
INLET  
D
RECOVERY  
CYLINDER  
DISCHARGE  
RECOVERY MACHINE  
A
Inverted HCFC−22 cylinder with clean refrigerant to the vapor service  
valve.  
C
D
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.  
B
C
HCFC−22 gauge set (low side) to the liquid line valve.  
HCFC−22 gauge set center port to inlet on the recovery machine with an  
empty recovery tank to the gauge set.  
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.  
D
Connect recovery tank to recovery machines per machine instructions.  
Figure 9. Installing Indoor Expansion Valve  
Page 15  
XC16 SERIES  
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Installing Indoor Metering Device  
This outdoor unit is designed for use in systems that use  
expansion valve metering devices at the indoor coil.  
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.  
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  
1/2 Turn  
A
B
Remove the field−provided fitting that temporary  
reconnectedthe liquid line to the indoor unit’s distributor  
assembly.  
INDOOR EXPANSION VALVE INSTALLATION  
TWO PIECE  
12  
PATCH PLATE  
(Uncased Coil Shown)  
1
11  
10  
®
(UNCASED  
STUB  
END  
2
Install one of the provided Teflon rings around the  
stubbed end of the expansion valve and lightly lubricate  
LIQUID LINE  
ORIFICE  
COIL ONLY)  
9
3
EXPANSION  
VALVE  
4
8
®
the connector threads and expose surface of the Teflon  
ring with refrigerant oil.  
HOUSING  
5
7
6
DISTRIBUTOR  
TUBES  
®
TEFLON  
RING  
C
D
E
Attach the stubbed end of the expansion valve to the  
liquid line orifice housing. Finger tighten and use an  
appropriatelysized wrench to turn an additional 1/2 turn  
clockwise as illustrated in the figure above, or 20 ft−lb.  
®
®
Place the remaining Teflon washer around the other  
end of the expansion valve. Lightly lubricate connector  
TEFLON  
RING  
SENSING  
LINE  
®
threads and expose surface of the Teflon ring with  
refrigerantoil.  
DISTRIBUTOR  
ASSEMBLY  
EQUALIZER  
LINE  
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.  
LIQUID LINE  
ASSEMBLY WITH  
BRASS NUT  
SENSING BULB INSTALLATION  
A
Attach the vapor line sensing bulb in the proper  
orientationas illustrated to the right using the clamp and  
screws provided.  
1/8 Turn  
MALE EQUALIZER LINE  
FITTING (SEE  
VAPOR  
LINE  
EQUALIZER LINE  
INSTALLATION FOR  
FURTHER DETAILS)  
NOTE ꢀ Confirm proper thermal contact between vapor line  
and expansion bulb before insulating the sensing bulb once  
installed.  
12  
1
5
11  
10  
2
LIQUID LINE  
9
3
4
8
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.  
7
Sensing bulb insulation is required if  
mountedexternal to the coil casing. sensing  
bulb installation for bulb positioning.  
6
ON LINES SMALLER THAN  
7/8", MOUNT SENSING  
BULB AT EITHER THE 3 OR  
9 O’CLOCK POSITION.  
VAPOR LINE  
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.  
12  
BULB  
BULB  
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.  
FLARE SEAL CAP  
FLARE NUT  
VAPOR LINE  
ON 7/8" AND LARGER LINES,  
MOUNT SENSING BULB AT  
EITHER THE 4 OR 8 O’CLOCK  
POSITION. NEVER MOUNT ON  
BOTTOM OF LINE.  
COPPER FLARE  
SEAL BONNET  
OR  
12  
MALE BRASS EQUALIZER  
LINE FITTING  
BULB  
BULB  
NOTE ꢀ NEVER MOUNT ON BOTTOM OF LINE.  
VAPOR LINE  
Figure 10. Installing Indoor Expansion Valve  
Page 16  
506637−01 11/10  
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Leak Test Line Set and Indoor Coil  
IMPORTANT  
The Environmental Protection Agency (EPA) prohibits  
the intentional venting of HFC refrigerants during  
maintenance, service, repair and disposal of appliance.  
Approved methods of recovery, recycling or reclaiming  
must be followed.  
WARNING  
When using a high pressure gas such as  
dry nitrogen to pressurize a refrigeration  
or air conditioning system, use a  
regulator that can control the pressure  
down to 1 or 2 psig (6.9 to 13.8 kPa).  
IMPORTANT  
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.  
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 properly flush the system per the  
instructions below will void the warranty.  
Failure to follow this warning may result in personal injury  
or death.  
CONNECT GAUGE SET  
A
Connect an HFC−410A manifold gauge set high pressure  
hose to the vapor valve service port.  
LOW  
HIGH  
MANIFOLD GAUGE SET  
1
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.  
OUTDOOR UNIT  
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.  
A
B
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  
following procedure to test for leaks:  
2
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
D
Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set.  
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
F
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.  
After leak testing disconnect gauges from service ports.  
Figure 11. Leak Test  
Page 17  
XC16 SERIES  
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Evacuating Line Set and Indoor Coil  
CONNECT GAUGE SET  
NOTE ꢀ Remove cores from service valves (if not already done).  
LOW  
HIGH  
1
A
Connect low side of manifold gauge  
set with 1/4 SAE in−line tee to vapor line  
service valve  
B
C
D
Connect high side of manifold gauge  
set to liquid line service valve  
OUTDOOR  
UNIT  
MANIFOLD  
GAUGE SET  
A34000 1/4 SAE TEE WITH  
SWIVEL COUPLER  
Connect micron gauge available  
connector on the 1/4 SAE in−line tee.  
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.  
A
500  
MICRON  
GAUGE  
C
TO VAPOR  
SERVICE VALVE  
NITROGEN  
HFC−410A  
B
VACUUM PUMP  
TO LIQUID LINE  
SERVICE VALVE  
D
EVACUATE THE SYSTEM  
RECOMMEND  
MINIMUM 3/8" HOSE  
A
B
Open both manifold valves and start the vacuum pump.  
Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury).  
2
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:  
S
S
S
S
S
S
S
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
E
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.  
Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and indoor unit until the  
absolutepressure 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.  
When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to an  
F
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.  
Perform the following:  
G
1/6 TURN  
S
S
S
Close manifold gauge valves.  
Shut off HFC−410A cylinder.  
12  
1
5
11  
7
2
4
10  
Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core  
tool while maintaining a positive system pressure.  
9
3
8
S
Replace stem caps and secure finger tight, then tighten an additional one−sixth (1/6) of a turn as illustrated.  
6
Figure 12. Evacuating System  
Page 18  
506637−01 11/10  
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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.  
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.  
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).  
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.  
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  
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  
Use the transformer provided with the furnace or air  
handler for low-voltage control power (24VAC − 40 VA  
minimum)  
INSTALL THERMOSTAT  
SIZE CIRCUIT AND INSTALL DISCONNECT  
SWITCH  
Install room thermostat (ordered separately) on an inside wall  
2approximately 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.  
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.  
MAIN FUSE  
BOX/BREAKER  
PANEL  
THERMOSTAT  
DISCONNECT  
SWITCH  
5 FEET  
(1.5M)  
NOTE ꢀ 24VAC, Class II circuit connections are made in the control  
panel.  
NOTE ꢀ Units are approved for use only with copper conductors.  
Ground unit at disconnect switch or to an earth ground.  
HIGH VOLTAGE FIELD WIRING  
FACTORY WIRING  
UNIT LOW VOLTAGE CONNECTIONS  
3
LOW VOLTAGE (24V) FIELD WIRING  
WIRE RUN LENGTH  
AWG# INSULATION TYPE  
C
WIRE NUTS  
LESS THAN 100’ (30 METERS)  
MORE THAN 100’ (30 METERS)  
18  
16  
TEMPERATURE RATING  
35ºC MINIMUM.  
A
B
C
Run 24VAC control wires through cutout with grommet.  
Run 24VAC control wires through wire tie.  
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.  
CUTOUT WITH  
GROMMET  
A
24V CONTROL WIRES  
D
TIGHTEN WIRE TIE  
B
Page 19  
XC16 SERIES  
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Figure 13. Typical Unit Wiring Diagram  
Page 20  
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FAN MOTOR (B4)  
DUAL RUN CAPACI-  
TOR (C12)  
CONTACTOR  
K1  
LOW PRESSURE  
SWITCH (S87)  
HIGH PRESSURE  
SWITCH (S4)  
COMPRES-  
SOR (B1)  
GROUND  
LUG  
CRANKCASE  
THERMOSTAT  
(S40)  
CRANKCASE  
HEATER (HR1)  
Figure 14. Typical Factory Wiring Diagram  
Servicing Units Delivered Void of Charge  
Unit Start−Up  
If the outdoor unit is void of refrigerant, clean the system  
using the procedure described below.  
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. Leak check system using procedure outlined on page  
17.  
2. Evacuate the system using procedure outlined on  
page 18.  
1. Rotate fan to check for binding.  
2. Inspect all factory− and field−installed wiring for loose  
connections.  
3. Use nitrogen to break the vacuum and install a new  
filter drier in the system.  
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. Evacuate the system again using procedure outlined  
5. Weigh in refrigerant using procedure outlined in figure  
18.  
4. Replace the stem caps and tighten to the value listed  
in table 1.  
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.  
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.  
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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.  
System Refrigerant  
This section outlines procedures for:  
7. Recheck voltage while the unit is running. Power must  
be within range shown on the nameplate.  
1. Connecting gauge set for testing and charging;  
2. Checking and adjusting indoor airflow;  
3. Adding or removing refrigerant.  
8. Check system for sufficient refrigerant by using the  
procedures listed under System Charge.  
MANIFOLD GAUGE SET  
GAUGE SET  
B
CONNECTION  
HIGH  
LOW  
CONNECTIONS FOR TESTING AND CHARGING  
SUCTION LINE  
SERVICE PORT  
OUTDOOR UNIT  
REFRIGERANT TANK  
CHARGE IN  
LIQUID PHASE  
A
VAPOR LINE  
SERVICE VALVE  
DIGITAL SCALE  
TEMPERATURE  
SENSOR  
D
TEMPERATURE SENSOR  
(LIQUID LINE)  
C
LIQUID LINE  
SERVICE VALVE  
TO LIQUID  
LINE SERVICE  
VALVE  
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.  
Figure 15. Gauge Set Setup and Connections  
START: Determine how refrigerant is metered  
WHEN TO CHARGE?  
S
S
Warm weather best  
TXV  
Can charge in colder weather  
CHARGE METHOD? Determine by:  
S
S
Metering device type  
OUTDOOR AMBIENT  
TEMPERATURE  
Outdoor ambient temperature  
REQUIREMENTS:  
S
S
S
S
Sufficient heat load in structure  
Indoor temperature between 70-80ºF (21−26ºC)  
Manifold gauge set connected to unit  
Thermometers:  
65ºF (18.3ºC)  
and ABOVE  
64ºF (17.7ºC)  
and BELOW  
to measure outdoor ambient temperature  
to measure liquid line temperature  
to measure suction line temperature  
APPROACH OR  
SUBCOOLING  
WEIGH-IN  
(SECOND STAGE − HIGH  
CAPACITY)  
Figure 16. Determining Charge Method  
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CHECKING AIR FLOW AT INDOOR COIL  
Check airflow using the Delta−T (DT) process using the illustration in figure 17.  
DT  
Temp.  
of air  
entering  
indoor  
coil ºF  
1. Determine the desired DTꢀMeasure entering air temper-  
ature using dry bulb (A) and wet bulb (B). DT is the intersect-  
ing value of A and B in the table (see triangle).  
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  
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  
2. Find temperature drop across coilꢀMeasure the coil’s dry  
bulb entering and leaving air temperatures (A and C). Tem-  
A
perature Drop Formula: (T  
) = A minus C.  
Drop  
Wet−bulb ºF  
57 58 59 60 61 62 63 64 65 66 67 68 69 70  
B
3. Determine if fan needs adjustmentꢀIf the difference between  
the measured T and the desired DT (T DT) is within  
Drop  
Drop  
+3º, no adjustment is needed. See examples: Assume DT =  
15 and A temp. = 72º, these C temperatures would necessi-  
tate stated actions:  
A
T
Drop  
C
72º  
19º  
53º  
Cº  
T
DT  
=
ºF ACTION  
Drop  
19  
B
air flow  
air flow  
53º  
58º  
62º  
15  
15  
15  
=
=
=
4
Increase the airflow  
DRY  
BULB  
DRY  
BULB  
64º  
14  
−1 (within +3º range) no change  
10  
−5 Decrease the airflow  
WET  
BULB  
INDOOR  
COIL  
All temperatures are  
expressed in ºF  
4. Adjust the fan speedꢀSee indoor unit instructions to in-  
crease/decrease fan speed.  
Changing air flow affects all temperatures; recheck tempera-  
tures 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  
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:  
64ºF (17.7ºC) and Below  
CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE  
Adjust amount. for variation  
in line set length listed on  
line set length table below.  
nameplate  
Amount specified on  
Total charge  
+
=
Refrigerant Charge per Line Set Length  
Ounces per 5 feet (g per 1.5 m)  
Liquid Line  
adjust from 15 feet (4.6 m) line set*  
Set Diameter  
3/8" (9.5 mm)  
3 ounce per 5’ (85 g per 1.5 m)  
*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.  
Figure 18. Using HFC−410A Weigh In Method  
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65ºF  
and  
ABOVE  
START: Measure outdoor ambient temperature  
3. Compare unit pressures with table 4, Normal  
OperatingPressures.  
4. Set thermostat to call for heat (must have a cooling  
load between 70-80ºF (21−26ºC).  
USE WEIGH-IN METHOD  
Weigh-in or remove refrigerant  
based upon line length  
ABOVE or  
BELOW  
5. When heat demand is satisfied, set thermostat to call  
for cooling.  
64ºF and  
BELOW  
6. Allow temperatures and pressures to stabilize.  
7. Record outdoor ambient temperature:  
AMBº =_________  
APPROACH TXV  
8. Record liquid line temperature:  
LIQº = __________  
If refrigerant is added or  
9. Subtract to determine approach (APPº):  
LIQº_____ − AMBº _____ = APPº_____  
10. Compare results with table below.  
removed, retest to confirm  
that unit is properly  
charged.  
APPº (Approach) Values(F:+/−1.0° [C: +/−0.6°])  
Models  
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.  
ºF (ºC)*  
Any  
−024  
−036  
−048  
−060  
6 (3.3)  
6 (3.3) 8 (4.4)  
4 (2.2)  
*Temperature of air entering outdoor coil  
Figure 19. Using HFC−410A Approach (TXV) Charge Method  
65ºF  
and  
ABOVE  
START: Measure outdoor ambient temperature  
3. Compare unit pressures with table 4, Normal  
OperatingPressures.  
4. Set thermostat to call for heat (must have a cooling  
load between 70-80ºF (21−26ºC)  
USE WEIGH-IN METHOD  
ABOVE or  
BELOW  
Weigh-in or remove refrigerant  
based upon line length  
5. Measure outdoor ambient temperature  
6. When heat demand is satisfied, set thermostat to call  
for cooling  
64ºF and  
BELOW  
7. Allow temperatures and pressures to stabilize.  
NOTE − If necessary, block outdoor coil to maintain  
325 − 375 psig.  
C
SUBCOOLING TXV  
8. Record liquid line temperature:  
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  
(2240−2585kPa).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.  
LIQº = ______  
9. Measure liquid line pressure and use the value to  
CARDBOARD OR  
PLASTIC SHEETS  
SATº = ______  
10. Subtract to determine subcooling (SCº):  
SATº_____ − LIQº _____ = SCº _____  
11. Compare results with table below.  
If refrigerant is  
If value is  
added or removed,  
verify charge using  
MORE than  
shown, remove  
refrigerant.  
the Approach  
Method.  
SCº (Subcooling) Values (F:+/−1.0° [C: +/−0.6°])  
Models  
ºF (ºC)*  
Any  
−024  
−036  
−048  
−060  
If value is LESS  
than shown, add  
refrigerant.  
5 (2.7)  
6 (3.3) 6 (3.3)  
9 (5.0)  
MORE or  
LESS  
*Temperature of air entering outdoor coil  
Figure 20. Using HFC−410A Subcooling (TXV) Charge Method  
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Table 3. HFC−410A Temperature (°F) − Pressure (Psig)  
°F  
Psig  
°F  
Psig  
°F  
Psig  
°F  
Psig  
°F  
Psig  
°F  
Psig  
°F  
Psig  
°F  
Psig  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
100.8  
102.9  
105.0  
107.1  
109.2  
111.4  
113.6  
115.8  
118.0  
120.3  
122.6  
125.0  
127.3  
129.7  
132.2  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
137.1  
139.6  
142.2  
144.8  
147.4  
150.1  
152.8  
155.5  
158.2  
161.0  
163.9  
166.7  
169.6  
172.6  
175.4  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
178.5  
181.6  
184.3  
187.7  
190.9  
194.1  
197.3  
200.6  
203.9  
207.2  
210.6  
214.0  
217.4  
220.9  
224.4  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
231.6  
235.3  
239.0  
242.7  
246.5  
250.3  
254.1  
258.0  
262.0  
266.0  
270.0  
274.1  
278.2  
282.3  
286.5  
94  
95  
290.8  
295.1  
299.4  
303.8  
308.2  
312.7  
317.2  
321.8  
326.4  
331.0  
335.7  
340.5  
345.3  
350.1  
355.0  
110  
111  
112  
113  
114  
115  
116  
117  
118  
119  
120  
121  
122  
123  
124  
365.0  
370.0  
375.1  
380.2  
385.4  
390.7  
396.0  
401.3  
406.7  
412.2  
417.7  
423.2  
428.8  
434.5  
440.2  
141  
142  
143  
144  
145  
146  
147  
148  
149  
150  
151  
152  
153  
154  
155  
545.6  
552.3  
559.1  
565.9  
572.8  
579.8  
586.8  
593.8  
601.0  
608.1  
615.4  
622.7  
630.1  
637.5  
645.0  
125  
126  
127  
128  
129  
130  
131  
132  
133  
134  
135  
136  
137  
138  
139  
445.9  
451.8  
457.6  
463.5  
469.5  
475.6  
481.6  
487.8  
494.0  
500.2  
506.5  
512.9  
519.3  
525.8  
532.4  
96  
97  
98  
99  
100  
101  
102  
103  
104  
105  
106  
107  
108  
47  
134.6  
78  
228.0  
109  
360.0  
140  
539.0  
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.  
Significant deviations could mean that the system is not properly charged or that a  
problem exists with some component in the system.  
IMPORTANT  
Temp. of air  
entering  
−024  
−036  
−048  
−060  
outdoor coil  
5F (5C)  
Liquid  
Suction  
Liquid  
Suction  
Liquid  
Suction  
Liquid  
Suction  
First Stage (Low Capacity)  
65 (18.3)  
75 (23.9)  
85 (29.4)  
95 (35.0)  
105 (40.6)  
115 (46.1)  
215  
247  
288  
332  
381  
435  
144  
146  
148  
151  
153  
155  
226  
261  
304  
352  
405  
460  
142  
144  
145  
147  
150  
150  
224  
258  
299  
345  
395  
450  
142  
144  
146  
148  
150  
153  
215  
250  
291  
337  
388  
444  
136  
139  
142  
144  
146  
148  
Second Stage (High Capacity)  
65 (18.3)  
75 (23.9)  
85 (29.4)  
95 (35.0)  
105 (40.6)  
115 (46.1)  
225  
258  
301  
346  
397  
452  
140  
142  
144  
146  
149  
151  
228  
262  
306  
353  
405  
462  
144  
146  
148  
150  
151  
154  
235  
269  
313  
361  
412  
471  
135  
137  
139  
141  
143  
146  
220  
256  
299  
347  
402  
462  
130  
133  
136  
138  
141  
143  
*These are typical pressures only. Indoor indoor match up, indoor air quality, and indoor load will cause the pressures to vary.  
Full capacity is achieved by blocking the vent port with a  
slider ring. The slider ring (vent port cover) is controlled by  
System Operation  
TWO−STAGE COMPRESSOR  
The two−stage scroll compressor operates much like the  
a 24VDC internal solenoid in the open position allowing low  
capacity. When energized the internal solenoid closes the  
standard scroll compressor. The two−stage compressor  
slider ring, blocking the vent port and bringing the  
steps between low capacity and high capacity as required  
compressor to full capacity. Stepping can occur during a  
to meet cooling demand. The steps occur when gas is  
single thermostat demand as the motor runs continuously  
bypassed through a vent port in the first suction pocket.  
while the compressor steps from low to full capacity.  
This bypassing of gas allows the compressor to operate at  
low capacity if thermostat demand allows, creating a more  
cost effective and efficient compressor.  
Page 25  
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UNIT COMPONENTS  
4. Check wiring for loose connections.  
5. Check for correct voltage at the unit (with the unit  
operating).  
IMPORTANT  
6. Check amp−draw outdoor fan motor.  
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.  
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)  
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)  
S
Outdoor Coil ꢀ The outdoor coil may be flushed with  
a water hose.  
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.  
S
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.  
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.  
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.  
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 .  
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.  
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.  
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.  
Maintenance  
DEALER  
IMPORTANT  
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:  
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).  
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.  
Tools Required  
3. Visually inspect connecting lines and coils for  
evidence of oil leaks.  
S
Refrigeration gauge set  
Page 26  
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Outdoor Coil  
The outdoor unit must be properly maintained to ensure its  
proper operation.  
S
S
S
Digital volt/amp meter  
Electronic temperature thermometer  
On-off toggle switch  
S
S
S
Please contact your dealer to schedule proper  
inspection and maintenance for your equipment.  
Procedure  
NOTE − Block outdoor coil to maintain a minimum of 375  
psig during testing).  
Make sure no obstructions restrict airflow to the  
outdoor unit.  
1. Turn main power OFF to outdoor unit.  
Grass clippings, leaves, or shrubs crowding the unit  
can cause the unit to work harder and use more  
energy.  
2. Adjust room thermostat set point 5ºF above the room  
temperature.  
S
Keep shrubbery trimmed away from the unit and  
periodically check for debris which collects around the  
unit.  
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.  
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.  
4. Turn toggle switch OFF and install switch in series with  
Y2 wire from room thermostat.  
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.  
5. Cycle main power ON.  
6. Allow pressures and temperatures to stabilize before  
taking measurements (may take up to 10 minutes).  
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.  
7. Record all of the readings for the Y1 demand.  
8. Close switch to energize Y2 demand. Verify power is  
going to compressor solenoid.  
2. Disposable Filter ꢀ Disposable filters should be  
replaced with a filter of the same type and size.  
9. Allow pressures and temperatures to stabilize before  
taking any measured reading (this may take up to 10  
minutes).  
NOTE If you are unsure about the filter required for your  
system, call your Lennox dealer for assistance.  
10. Record all of the readings with the Y1 and Y2 demand.  
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.  
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).  
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.)  
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.  
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:  
IMPORTANT  
S
S
S
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S
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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.  
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.  
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  
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Accessories  
For update−to−date information, see any of the following  
publications:  
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Lennox Product Catalog  
Lennox Price Book  
S
Lennox XC16 Engineering Handbook  
Checklists  
Two−Stage Modulation Compressors Field Operational Checklist  
Expected results during Y2  
demand (Toggle switch On)  
Unit Readings  
Y1 − First-Stage  
Y2 − Second-Stage  
COMPRESSOR  
Voltage  
Same  
Amperage  
Higher  
OUTDOOR UNIT FAN  
MOTOR  
Amperage  
Same or Higher  
TEMPERATURE  
Ambient  
Same  
Higher  
Higher  
Same  
Lower  
Outdoor Coil Discharge Air  
Compressor Discharge Line  
Indoor Return Air  
Indoor Coil Discharge Air  
PRESSURES  
Suction (Vapor)  
Liquid  
Lower  
Higher  
Start−Up and Performance Checklist  
Job Name  
Job Location  
Installer  
Job no.  
City  
Date  
State  
State  
City  
Unit Model No.  
Serial No.  
Service Technician  
Nameplate Voltage  
Rated Load Ampacity  
Compressor  
Outdoor Fan  
Maximum Fuse or Circuit Breaker  
Electrical Connections Tight?  
Indoor Blower RPM  
-
Indoor Filter clean?  
-
Supply Voltage (Unit Off)  
S.P. Drop Over Indoor (Dry)  
Suction Pressure  
Outdoor Coil Entering Air Temp.  
Refrigerant Charge Checked?  
Discharge Pressure  
-
-
Refrigerant Lines: Leak Checked? - Properly Insulated?  
Service Valves: Fully Opened? - Caps Tight?  
-
-
Outdoor Fan Checked?  
Thermostat  
Voltage With Compressor Operating  
Calibrated? - Properly Set? - Level?  
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Page 28  
506637−01 11/10  
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