Lennox Signature XC17 User manual

04/10 506510−01
*2P0410* *P506510-01*
Page 1
E2010 Lennox Industries Inc.
Dallas, Texas, USA
NOTICE
A thermostat is not included and must be ordered
separately.
The Lennox ComfortSense®7000 thermostat may be
used, as well as other thermostats.
In all cases, setup is critical to ensure proper system
operation.
Field wiring is illustrated in diagrams, which begin on
Page 19.
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.
General
This single−stage outdoor unit is designed for use with
HFC−410A refrigerant only. This unit must be installed
with an approved indoor air handler or coil. See the
Lennox XC17 Engineering Handbook for approved
indoor component matchups.
IMPORTANT
This model is designed for use in expansion valve
systems only. An indoor expansion valve approved for
use with HFC−410A refrigerant must be ordered
separately, and installed prior to operating the system.
INSTALLATION
INSTRUCTIONS
Dave Lennox Signature®
Collection XC17 Units
AIR CONDITIONER
506510−01
04/10
Supersedes 506498−01
RETAIN THESE INSTRUCTIONS FOR FUTURE
REFERENCE
TABLE OF CONTENTS
General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Number Identification 2. . . . . . . . . . . . . . . . . . . .
Unit Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . . . .
Operating Gauge Set and Service Valves 4. . . . . . . . .
Recovering Refrigerant from Existing System 6. . . . .
New Outdoor Unit Placement 7. . . . . . . . . . . . . . . . . . .
Removing and Installing Panels 10. . . . . . . . . . . . . . . . .
New or Replacement Line Set 11. . . . . . . . . . . . . . . . . . .
Flushing the System 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing the System 16. . . . . . . . . . . . . . . . . . . . . . .
Evacuating the System 16. . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Control Jumpers and Terminals 22. . . . . . . . . . . . .
Field Control Wiring 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Unit Delivered Void of Charge 26. . . . . . . . . .
Unit Start−Up 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Refrigerant 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and Temperature Pressures 30. . . . . . . . . . .
System Operations 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Control LED Alert Codes 35. . . . . . . . . . . . . . . . . .
Maintenance (Dealer and Homeowner) 42. . . . . . . . . . .
Start−Up and Performance Checklist 48. . . . . . . . . . . . .
Shipping and Packing List
Check unit for shipping damage. Consult last carrier
immediately if damage is found.
1  Assembled outdoor unit.
1  Bag assembly which includes the following:
1  Bushing (for low voltage wiring)
2  Isolation grommets for liquid and suction lines
Litho U.S.A.
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Page 2
506510−01
Unit Dimensions − Inches (mm) and Parts Arrangement
4−5/8
(117)
39.40"
(1003) 35.50"
(902)
18.60"
(470)
8.00" (203)
1 (25)
LIQUID
LINE
INLET
SUCTION LINE
INLET
ELECTRICAL INLETS
BASE WITH ELONGATED LEGS
SIDE VIEW ACCESS VIEW
DISCHARGE AIR
[−024] 41 (1040)
[−030 THROUGH
−060] 47 (1194)
16−7/8
(429)
8−3/4
(222)
26−7/8
(683)
3−3/4 (95)
30−3/4
(781)
3−1/8
(79)
UNIT SUPPORT
FEET
Model Number Identification
C 17 036− −
Unit Type
C = Air Conditioner
Series
Nominal Cooling Capacity
024 = 2 tons
030 = 2.5 tons
036 = 3 tons
042 = 3.5 tons
048 = 4 tons
060 = 5 tons
Minor Revision Number
230
Voltage
230 = 208/230V−1ph−60hz
Refrigerant Type
X = R−410A
X 2−
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Page 3
XC17 SERIES
Typical Unit Parts Arrangement
LIQUID LINE FILTER
DRIER (SINGLE FLOW)
HIGH PRESSURE SWITCH
FIELD CONNECTION
FOR LIQUID LINE SET
LIQUID LINE SERVICE
VALVE
LIQUID LINE SERVICE
VALVE PORT
SUCTION LINE SERVICE
VALVE PORT
SUCTION LINE SERVICE
VALVE
FIELD CONNECTION
FOR SUCTION LINE
MUFFLER
HIGH DISCHARGE
LINE TEMPERATURE
SENSOR
LOW PRESSURE SWITCH HIGH PRESSURE SWITCH
THERMOSTAT
COMPRESSOR
HARNESS
SR1 SOUND DOME
VIBRATION ISOLATOR
SLEEVE LOCATIONS (DO
NOT REMOVE)
GROUND LUG
HIGH VOLTAGE FIELD
CONNECTIONS
CONTACTOR−1POLE (K1−1)
MAIN CONTROL
CAPACITOR (C12)
CONTROL BOX
PLUMBING, SWITCHES AND SENSOR COMPONENTS
SLEEVE
WIRE TIE
OUTDOOR AMBIENT
TEMPERATURE
SENSOR
FAN MOTOR CONTROL 
PULSE−WIDTH MODULATION (PWM)
FAN MOTOR SURGE
PROTECTION
Figure 1. Typical Parts Arrangements
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506510−01
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.
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.
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox’ Engineering Handbook. Coils
previously charged with HCFC−22 must be flushed.
WARNING
Electric Shock Hazard. Can cause injury
or death. Unit must be grounded in
accordance with national and local
codes.
Line voltage is present at all components
when unit is not in operation on units with
single-pole contactors. Disconnect all
remote electric power supplies before
opening access panel. Unit may have
multiple power supplies.
Operating Gauge Set and Service Valves
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
TORQUE REQUIREMENTS
When servicing or repairing heating, ventilating, and air
conditioning components, ensure the fasteners are
appropriately tightened. Table 1 lists torque values for
fasteners.
IMPORTANT
Only use Allen wrenches of sufficient hardness (50Rc −
Rockwell Harness Scale minimum). Fully insert the
wrench into the valve stem recess.
Service valve stems are factory−torqued (from 9 ft−lbs for
small valves, to 25 ft−lbs for large valves) to prevent
refrigerant loss during shipping and handling. Using an
Allen wrench rated at less than 50Rc risks rounding or
breaking off the wrench, or stripping the valve stem
recess.
See the Lennox Service and Application Notes #C−08−1
for further details and information.
IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted
snugly over the cap before tightening.
Table 1. Torque Requirements
Parts Recommended Torque
Service valve cap 8 ft.− lb. 11 NM
Sheet metal screws 16 in.− lb. 2 NM
Machine screws #10 28 in.− lb. 3 NM
Compressor bolts 90 in.− lb. 10 NM
Gauge port seal cap 8 ft.− lb. 11 NM
USING MANIFOLD GAUGE SET
When checking the system charge, only use a manifold
gauge set that features low loss anti−blow back fittings.
Manifold gauge set used with HFC−410A refrigerant
systems must be capable of handling the higher system
operating pressures. The gauges should be rated for use
with pressures of 0 − 800 psig on the high side and a low
side of 30" vacuum to 250 psig with dampened speed to
500 psi. Gauge hoses must be rated for use at up to 800
psig of pressure with a 4000 psig burst rating.
OPERATING SERVICE VALVES
The liquid and vapor line service valves are used for
removing refrigerant, flushing, leak testing, evacuating,
checking charge and charging.
Each valve is equipped with a service port which has a
factory−installed valve stem. Figure 2 provides information
on how to access and operating both angle and ball service
valves.
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XC17 SERIES
(VALVE STEM SHOWN
CLOSED) INSERT HEX
WRENCH HERE
VALVE STEM
FRONT-SEATED
TO OUTDOOR
UNIT
SERVICE PORT
CORE
TO INDOOR
UNIT
SERVICE PORT
SERVICE PORT CAP
CLOSED TO BOTH
INDOOR AND OUTDOOR
UNITS
STEM CAP
ANGLE−TYPE
SERVICE VALVE
(FRONT−SEATED
CLOSED)
SERVICE PORT
SERVICE PORT
CORE
TO OUTDOOR UNIT
STEM CAP
(VALVE STEM
SHOWN OPEN)
INSERT HEX
WRENCH HERE
SERVICE PORT CAP
TO INDOOR
UNIT
OPEN TO BOTH INDOOR AND
OUTDOOR UNITS
ANGLE−TYPE SERVICE VALVE
(BACK−SEATED OPENED)
BALL (SHOWN CLOSED)
SERVICE PORT CORE
TO INDOOR UNIT
TO OUTDOOR UNIT
TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°.
TO CLOSE ROTATE STEM
CLOCKWISE 90°.
SERVICE PORT
SERVICE PORT CAP
STEM CAP
VALVE STEM
WHEN SERVICE VALVE IS CLOSED, THE SERVICE PORT IS OPEN TO THE
LINE SET AND INDOOR UNIT.
BALL−TYPE SERVICE
VALVE
SERVICE VALVES
VARIOUS TYPES
WHEN SERVICE VALVE IS OPEN, THE SERVICE PORT IS OPEN TO LINE SET,
INDOOR AND OUTDOOR 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 fol-
lows: 12
3
4
5
6
7
8
9
10
11 12
1/6 TURN
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.
Operating Ball Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. Use an appropriately sized wrenched to open. To open valve, rotate stem counterclockwise 90°. To close rotate stem clockwise 90°.
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:
SWith Torque Wrench: Finger tighten and then torque cap per Table 1.
SWithout Torque Wrench: Finger tighten and use an appropriately sized wrench to turn
an additional 1/12 turn clockwise.
NOTE  A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
12
3
4
5
6
7
8
9
10
11 12
1/6 TURN
SWith Torque Wrench: Finger tighten and torque cap per Table 1.
SWithout Torque Wrench: Finger tighten and use an appropriately
sized wrench to turn an additional 1/6 turn clockwise.
Figure 2. Angle and Ball Service Valves
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Page 6
506510−01
Recovering Refrigerant from Existing System
SERVICE
DISCONNECT
SWITCH
MAIN FUSE BOX/BREAKER PANEL
Disconnect all power to the existing outdoor unit at the disconnect
switch or main fuse box/breaker panel.
DISCONNECT POWER CONNECT MANIFOLD GAUGE SET
MANIFOLD GAUGES
RECOVERY MACHINE
CLEAN RECOVERY
CYLINDER
OUTDOOR UNIT
HIGH
LOW
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.
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:
SOutdoor unit’s high or low−pressure switches (if applicable) when tripped can cycle the compressor OFF.
SCompressor can stop pumping due to tripped internal pressure relief valve.
SCompressor 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:
AStart the existing HCFC−22 system in the cooling mode and close the liquid line valve.
BUse 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.
CWhen the low side system pressures reach 0 psig, close the vapor line valve.
DCheck gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system.
RECOVERING
REFRIGERANT FROM SYSTEM
Remove existing HCFC−22 refrigerant using one of the following procedures:
RECOVERING REFRIGERANT
IMPORTANT  Some system configurations may contain higher than normal refrigerant charge due to either large internal coil volumes,
and/or long line sets.
12
3
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XC17 SERIES
CONTROL PANEL
ACCESS
LOCATION
6 (152)
36 (914)
12 (305) 30 (762)
LINE SET
CONNECTIONS
24 (610)
LINE SET
CONNECTIONS
ACCESS PANEL
REAR VIEW OF UNIT
48 (1219)
MINIMUM CLEARANCE BETWEEN
TWO UNITS
CLEARANCE ON ALL SIDES  INCHES (MILLIMETERS)
ACCESS PANEL
MINIMUM CLEARANCE
ABOVE UNIT
NOTES:
SClearance to one of the other three
sides must be 36 inches (914mm).
SClearance to one of the remaining
two sides may be 12 inches
(305mm) and the final side may be
6 inches (152mm).
Figure 3. Installation Clearances
New Outdoor Unit Placement
CAUTION
In order to avoid injury, take proper precaution when
lifting heavy objects.
See Unit Dimensions on page 3 for sizing mounting slab,
platforms or supports. Refer to Figure 3 for mandatory
installation clearance requirements.
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
SSome 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.
SWhen possible, do not install the unit directly outside
a window. Glass has a very high level of sound
transmission. For proper placement of unit in relation
to a window see the provided illustration in Figure 4,
Detail A.
PLACING UNIT ON SLAB
When installing unit at grade level, the top of the slab
should be high enough above grade so that water from
higher ground will not collect around the unit. The slab
should have a slope tolerance as described in Figure 4,
Detail B.
NOTE  If necessary for stability, anchor unit to slab as
described in Figure 4, Detail D.
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506510−01
ELEVATING THE UNIT
Units are outfitted with elongated support feet as illustrated
in Figure 4, Detail C.
If additional elevation is necessary, raise the unit by
extending the height of the unit support feet. This may be
achieved by using a 2 inch (50.8mm) Schedule 40 female
threaded adapter.
The specified coupling will fit snuggly into the recessed
portion of the feet. Use additional 2 inch (50.8mm)
Schedule 40 male threaded adaptors which can be
threaded into the female threaded adaptors to make
additional adjustments to the level of the unit.
NOTE  Keep the height of extenders short enough to
ensure a sturdy installation. If it is necessary to extend
further, consider a different type of field−fabricated
framework that is sturdy enough for greater heights.
STABILIZING UNIT ON UNEVEN SURFACES
IMPORTANT
Unit Stabilizer Bracket Use (field−provided):
Always use stabilizers when unit is raised above the
factory height. (Elevated units could become unstable in
gusty wind conditions).
Stabilizers may be used on factory height units when
mounted on unstable an uneven surface.
With unit positioned at installation site, perform the
following:
1. Remove two side louvered panels to expose the unit
base.
2. Install the brackets as illustrated in Figure 4, Detail D
using conventional practices.
3. Replace the panels after installation is complete.
ROOF MOUNTING
Install the unit a minimum of 6 inches (152 mm) above the
roof surface to avoid ice build−up around the unit. Locate
the unit above a load bearing wall or area of the roof that
can adequately support the unit. Consult local codes for
rooftop applications.
If unit coil cannot be mounted away from prevailing winter
winds, a wind barrier should be constructed. Size barrier at
least the same height and width as outdoor unit. Mount
barrier 24 inches (610 mm) from the sides of the unit in the
direction of prevailing winds.
NOTICE
Roof Damage!
This system contains both refrigerant and oil. Some
rubber roofing material may absorb oil and cause the
rubber to swell when it comes into contact with oil. The
rubber will then bubble and could cause leaks. Protect
the roof surface to avoid exposure to refrigerant and oil
during service and installation. Failure to follow this
notice could result in damage to roof surface.
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XC17 SERIES
LEG DETAIL
BASE
2" (50.8MM) SCH 40
FEMALE THREADED
ADAPTER
ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY, TWO
BRACKETS PER SIDE, 2" (50.8MM) FROM EACH CORNER.
CONCRETE SLAB  USE TWO PLASTIC
ANCHORS (HOLE DRILL 1/4")
COIL
BASE PAN
CORNER POST
STABILIZING BRACKET (18 GAUGE
METAL  2" WIDTH; HEIGHT AS
REQUIRED)
Slab Side Mounting
#10 1/2" LONG SELF−DRILLING
SHEET METAL SCREWS
#10 1−1/4" LONG HEX HD SCREW
AND FLAT WASHER
MINIMUM ONE
PER SIDE
STABILIZING BRACKET (18 GAUGE METAL
 2" (50.8MM) WIDTH; HEIGHT AS
REQUIRED); BEND TO FORM RIGHT ANGLE
FOR EXTRA
STABILITY
Deck Top Mounting
Elevated Slab Mounting using Feet
Extenders
Stabilizing Unit on Uneven Surfaces
WOOD OR PLASTIC SLAB  NO PLASTIC ANCHOR
(HOLE DRILL 1/8")
TWO 90° ELBOWS INSTALLED IN LINE SET WILL
REDUCE LINE SET VIBRATION.
INSTALL UNIT LEVEL OR, IF ON A SLOPE, MAINTAIN SLOPE TOLERANCE
OF 2 DEGREES (OR 2 INCHES PER 5 FEET [50 MM PER 1.5 M]) AWAY
FROM BUILDING STRUCTURE.
MOUNTING
SLAB
BUILDING
STRUCTURE
GROUND LEVEL
Outside Unit Placement Slab Mounting at Ground Level
INSTALL UNIT AWAY FROM WINDOWS
SAME FASTENERS AS
SLAB SIDE MOUNTING.
IMPORTANT  To help stabilize an outdoor unit, some installations may require strap-
ping the unit to the pad using brackets and anchors commonly available in the market-
place.
DETAIL A DETAIL B
DETAIL C DETAIL D
2" (50.8MM) SCH 40
MALE THREADED
ADAPTER
Use additional 2" SCH 40 male threaded adapters
which can be threaded into the female threaded
adapters to make additional adjustments to the level
of the unit.
Figure 4. Placement, Slab Mounting and Stabilizing Unit
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Page 10
506510−01
Removing and Installing Panels
REMOVE 4 SCREWS TO
REMOVE PANEL FOR
ACCESSING COMPRESSOR
AND CONTROLS.
POSITION PANEL WITH HOLES
ALIGNED; INSTALL SCREWS
AND TIGHTEN.
ACCESS PANEL REMOVAL
Removal and reinstallation of the access
panel is as illustrated.
Detail A
Detail C
Detail B
ROTATE IN THIS DIRECTION; THEN
DOWN TO REMOVE PANEL
SCREW
HOLES
LIP
PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR ENTER) TOP SLOT
FOR REMOVING (OR INSTALLING) PANEL.
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL
WITH THE UNIT AS POSSIBLE) WHILE INSTALLING PANEL.
PREFERRED
ANGLE FOR
INSTALLATION
Detail D
ANGLE MAY BE
TOO EXTREME
HOLD DOOR FIRMLY ALONG THE
HINGED SIDE TO MAINTAIN
FULLY−ENGAGED TABS
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 pan-
el, aligning the screw holes.
4. When panel is correctly positioned and aligned, insert the screws and tighten.
PANELS
ACCESS AND LOUVERED
IMPORTANT  Do not allow panels to hang on unit by top tab. Tab is for align-
ment and not designed to support weight of panel.
IMPORTANT  To help stabilize an outdoor unit, some installations may require
strapping the unit to the pad using brackets and anchors commonly available in the
marketplace.
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 ob-
jects 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.
WARNING
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