Lennox XC25-024-230-01 Manual

12013 Lennox Industries Inc.
Corp. 1253-L11
July 24, 2013
XC25
INSTALLATION AND SERVICE
PROCEDURE
Service Literature
Dave Lennox Signature®Collection XC25 Series Units
IMPORTANT
XC25 units have refrigerant piping requirements that are unique to
this unit. Size and install the refrigerant piping per table 2 (page 14)
to ensure proper unit operation.
This unit is an integral component of a system that requires an
iComfort Wi-Fi®thermostat and iComfort™-enabled air handler
or furnace.
XC25
iComfort Wi-Fi®
iComfort™-enabled
air handler or
furnace
IMPORTANT:
Before applying any power (main, solar or low voltage) to the
outdoor unit, confirm the iComfort Wi-Fi®thermostat has
software Version 2.1 or higher installed. (Reference the iComfort
Wi-Fi®thermostat manual.)
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.
WARNING
Electrical Hazard
High Voltage
Wait 5 Minutes
Electrical components may hold charge. Do
not remove this panel or service this area for
5 minutes after the power has been removed.
TABLE OF CONTENTS
I. OVERVIEW
Model Number Identification 2....................
Typical Serial Number Identification 2..............
Specifications 2.................................
Electrical Data 3................................
Unit Dimensions 4..............................
Typical Unit Parts Arrangement 5.................
Operating Service Valves 7.......................
General 7.....................................
II. INSTALLATION
Unit Placement 9...............................
Removing and Installing Panels 12.................
New or Replacement Line Set 13..................
Brazing Connections 16...........................
Flushing the System 19...........................
Leak Testing the System 21.......................
Evacuating the System 21.........................
Electrical 24.....................................
Servicing Unit Delivered Void of Charge 29..........
Unit Start-Up 29.................................
III. SYSTEM OPERATION AND SERVICE
7-Segment Alert and System Status Codes 30.......
Outdoor Control Push-Button Operation 35..........
Configuring Unit 39...............................
Reconfiguring Outdoor Control using iComfort Wi-Fi®
Thermostat 40...................................
System Overview 40.............................
Maintenance 41..................................
SunSource®Home Energy System 41..............
Unit Wiring Diagrams 42..........................
Factory Wiring Diagrams 45.......................
Unit Sequence of Operations 47...................
Component Testing 50............................
System Refrigerant 69............................
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.

2
XC25
I. OVERVIEW
Model Number identification
C 25 XXX
− −
Unit Type
C = AIR CONDITIONER
Series
Nominal Cooling Capacity
024 = 2 tons
036 = 3 tons
048 = 4 tons
060 = 5 tons
Minor Revision Number
230
Voltage
230 = 208/230V-1ph-60hz
Refrigerant Type
X = R-410A
X-02
Typical Serial Number Identification
8 09 C
Year Code
08 = 2008
09 = 2009
10 = 2010
Month Code
A = January
B = February
C = March
05716
5 (or 6) Digit Unique Number
Location Code
19 = Saltillo, Mexico
58 = Marshalltown, IA
5
Specifications
Model Number
Unit Outdoor Fan
Sound Rating Number (dB)1Factory Refrigerant
Charge2Number of Blades Diameter - inches.
Maximum Minimum
XC25-024-230-01 70 59 13 lbs, 10 oz 5 26
Model Number
Unit Outdoor Fan
Sound Rating Number (dB)1Factory Refrigerant
Charge2Number of Blades Diameter - inches.
Maximum Minimum
XC25-036-230-01 73 59 10 lbs, 12 oz 5 26
Model Number
Unit Outdoor Fan
Sound Rating Number (dB)1Factory Refrigerant
Charge2Number of Blades Diameter - inches.
Maximum Minimum
XC25-048-230-01 74 66 14 lbs, 9 oz 5 26
Model Number
Unit Outdoor Fan
Sound Rating Number (dB)1Factory Refrigerant
Charge2Number of Blades Diameter - inches.
Maximum Minimum
XC25-060-230-01 74 64 14 lbs, 8 oz 5 26
1Tested according to AHRI Standard 270-2008 test conditions.
2Factory refrigerant charge is sufficient for refrigerant line lengths up to 15 feet.

3
XC25
Electrical Data
208/230V-60 Hz-1 Ph
Model Number
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Maximum
Over-
current
Protection
(amps)1
Minimum
Circuity
Ampacity2
Rated
Load
Amps
(RLA)
Locked
Rotor
Amps
(LRA)
Motor
HP
CFM RPM WATTS Full
Load
Amps
(FLA)
MAX MIN MAX MIN MAX MIN
XC25-024-230-01 25 14.9 10.30 18.0 1/3 3020 1950 500 350 80 32 2.0
208/230V-60 Hz-1 Ph
Model Number
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Maximum
Over-
current
Protection
(amps)1
Minimum
Circuity
Ampacity2
Rated
Load
Amps
(RLA)
Locked
Rotor
Amps
(LRA)
Motor
HP
CFM RPM WATTS Full
Load
Amps
(FLA)
MAX MIN MAX MIN MAX MIN
XC25-036-230-01 30 19.5 14.00 18.0 1/3 4100 1950 650 350 157 32 2.0
208/230V-60 Hz-1 Ph
Model Number
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Maximum
Over-
current
Protection
(amps)1
Minimum
Circuity
Ampacity2
Rated
Load
Amps
(RLA)
Locked
Rotor
Amps
(LRA)
Motor
HP
CFM RPM WATTS Full
Load
Amps
(FLA)
MAX MIN MAX MIN MAX MIN
XC25-048-230-01 50 32.9 24.70 29.0 1/3 4220 3020 675 500 185 82 2.0
208/230V-60 Hz-1 Ph
Model Number
Unit Compressor Outdoor Fan (RPM varies with compressor RPM)
Maximum
Over-
current
Protection
(amps)1
Minimum
Circuity
Ampacity2
Rated
Load
Amps
(RLA)
Locked
Rotor
Amps
(LRA)
Motor
HP
CFM RPM WATTS Full
Load
Amps
(FLA)
MAX MIN MAX MIN MAX MIN
XC25-060-230-01 50 34.1 25.70 29.0 1/3 4385 3020 700 500 212 82 2.0
1HACR type circuit breaker or fuse.
2Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.

4
XC25
Unit Dimensions -- Inches (mm)
4-5/8
(117)
BASE WITH ELONGATED LEGS
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
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox Product Specification bulletin.
Coils previously charged with HCFC-22 must be
flushed.
CAUTION
Physical contact with metal edges and corners while
applying excessive force or rapid motion can result in
personal injury. Be aware of, and use caution when
working nearby these areas during installation or while
servicing this equipment.
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.

5
XC25
Typical Unit Parts Arrangement
GROUND LUGS
OUTDOOR
CONTROL
INVERTER REACTOR,
230V, 4KW
DC INVERTER
CONTROL
CONTACTOR-SPST
(25FLA/35RES)
GROUND LUGS
CONTACTOR-SPST
(35FLA/40RES)
OUTDOOR CONTROL
INVERTER NOISE FILTER FOR
6KW INVERTER (208/240V,
60HZ, CURRENT RANGE 30A
MAXIMUM, INDUCTANCE
4.3MH)
INVERTER REACTOR,
230V, 6KW
CONTROL PANEL FOR
XC25-024 AND -036
CONTROL PANEL FOR
XC25-048 AND -060
DC INVERTER
CONTROL
Figure 1. Control Panel Components

6
XC25
Typical Plumbing Components
VAPOR VALVE
AND GAUGE
PORT
LIQUID LINE BI-FLOW
FILTER DRIER
(HFC-410A)
LIQUID VALVE AND
GAUGE PORT
LIQUID LINE SENSOR
LOW PRESSURE SWITCH - NORMALLY OPEN, SWITCH CLOSES
WHEN SYSTEM PRESSURES GO ABOVE 90±5, AND OPENS
WHEN SYSTEM PRESSURES DROP BELOW 40±5 PSIG
HIGH PRESSURE SWITCH - NORMALLY CLOSED. SWITCH OPENS
WHEN SYSTEM PRESSURES REACH 590±15, AND CLOSES WHEN
SYSTEM PRESSURES DROP BELOW 418±15 PSIG
CRANKCASE HEATER THERMOSTAT
(S40) OPENS AT 70ºF, CLOSES AT 50ºF
COMPRESSOR TOP CAP
SWITCH (THERMAL)
VARIABLE-CAPACITY
COMPRESSOR - HFC-410A,
3-PHASE
Figure 2. Plumbing (Component Locations and Specifications)
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox Product Specification bulletin.
Coils previously charged with HCFC-22 must be
flushed.
CAUTION
Physical contact with metal edges and corners while
applying excessive force or rapid motion can result in
personal injury. Be aware of, and use caution when
working nearby these areas during installation or while
servicing this equipment.

7
XC25
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.
General
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
The XC25 is a high-efficiency residential split-system air
conditioner, which features a variable-capacity scroll com
pressor and uses HFC-410A refrigerant. Units are
available in 2, 3, 4 and 5-ton sizes. The series is designed
for use with an expansion valve (approved for use with
HFC-410A) in the indoor unit only.
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 sys
tems must be capable of handling higher system operating
pressures. The gauges should be rated for use with pres
sures 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 or up to 800 psig of
pressure with a 4000 psig burst rating.
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
TORQUE REQUIREMENTS
When servicing or repairing HVAC 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 re
moving refrigerant, flushing, leak testing, evacuating,
checking charge and charging.
Each valve is equipped with a service port which has a fac
tory-installed valve stem. Figure 3 provides information on
how to access and operating both angle and ball service
valves.
IMPORTANT
Only use hex 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 a
hex 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.
WARNING
The State of California has determined that this product
may contain or produce a chemical or chemicals, in very
low doses, which may cause serious illness or death. It
may also cause cancer, birth defects, or reproductive
harm.
IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted
snugly over the cap before tightening.

8
XC25
(VALVE STEM SHOWN
CLOSED) INSERT HEX
WRENCH HERE
SERVICE PORT CORE
SERVICE PORT CAP
ANGLE-TYPE SERVICE VALVE
(FRONT-SEATED CLOSED)
TO OUTDOOR UNIT
STEM CAP
(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE
TO INDOOR
UNIT
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
SERVICE VALVES ANGLE AND BALL
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°.
12
3
4
5
6
7
8
9
10
11 12
1/12 TURN
To Access Service Port:
A service port cap protects the service port core from contamination and
serves as the primary leak seal.
1. Remove service port cap with an appropriately sized wrench.
2. Connect gauge set to service port.
3. When testing is completed, replace service port cap and tighten as
follows:
DWith torque wrench: Finger tighten and
torque cap per table 1.
DWithout torque wrench: Finger tighten and
use an appropriately sized wrench to turn
an additional 1/6 turn clockwise.
12
3
4
5
6
7
8
9
10
11 12
1/6 TURN
When service valve is CLOSED, the service port is open
to the line set and indoor unit.
When service valve is OPEN, the service port is
open to line set, indoor and outdoor unit.
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:
DWith Torque Wrench: Finger tighten and then
torque cap per table 1.
DWithout 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.
Figure 3. Angle and Ball-Type Service Valves

9
XC25
II. INSTALLATION
Unit Placement
CAUTION
In order to avoid injury, take proper precaution when lift
ing heavy objects.
See Unit Dimensions on page 4 for sizing mounting slab,
platforms or supports. Refer to figure 4 for mandatory
installation clearance requirements.
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
DSome localities are adopting sound ordinances based
on the unit sound level registered from the adjacent
property, not from the installation property. Install the
unit as far as possible from the property line.
DWhen possible, do not install the unit directly outside
a window. Glass has a very high level of sound trans
mission. For proper placement of unit in relation to a
window see figure 5, detail A.
PLACING UNIT ON SLAB
When installing unit at grade level, the top of the slab
should be high enough above grade so that water from
higher ground will not collect around the unit. The slab
should have a slope tolerance as described in figure 5, de
tail B.
NOTE - If necessary for stability, anchor unit to slab as de
scribed in figure 5, detail D.
ELEVATING THE UNIT
Units are outfitted with elongated support feet as illustrated
in figure 5, detail C.
If additional elevation is necessary, raise the unit by ex
tending the height of the unit support feet. Use a 2-inch
(50.8mm) Schedule 40 female threaded adapter to raise
the height of the unit.
The specified coupling will fit snugly into the recessed por
tion 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 en
sure a sturdy installation. If it is necessary to extend the
height further than what is stable, consider a different type
of field-fabricated framework that is sturdy enough for
greater heights.
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:
DCLEARANCE TO ONE OF THE THREE
SIDES MUST BE 36 INCHES (914MM).
DCLEARANCE TO ONE OF THE
REMAINING TWO SIDES MAY BE 12
INCHES (305MM) AND THE FINAL
SIDE MAY BE 6 INCHES (152MM).
NOTE - Dimensions are not to scale.
Figure 4. Installation Clearances

10
XC25
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.
1. Remove the louvered panel from each side to expose
the unit base.
2. Install the brackets as illustrated in figure 5, detail D us
ing conventional practices.
3. Replace the panels after installation is complete.
ROOF MOUNTING
Locate the unit above a load-bearing wall or area of the roof
that can adequately support the unit. Consult local codes
for rooftop applications.
NOTICE
Roof Damage!
This system contains both refrigerant and oil. Some
rubber roofing material may absorb oil and cause the
rubber to swell when it comes into contact with oil. The
rubber will then bubble and could cause leaks. Protect
the roof surface to avoid exposure to refrigerant and oil
during service and installation. Failure to follow this
notice could result in damage to roof surface.