Lennox Elite series User manual

¢>,2008 Lennox industries Inc.
DatIas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
_, WARNING
AI_CAUTION
AIMPORTANT
INSTALLATION
INSTRUCTIONS
Elite ®Series XP16 Series
Units
HEAT PUMPS _ Technical
505,329M J_.LLPublications
04/08 LithoU.S.A.
Supersedes 01/08
Shipping and Packing List ...................... 1
XP16 Heat Pumps ............................. 1
Unit Dimensions ............................... 2
General Information ........................... 3
Recovering Refrigerant from Existing System ..... 5
Removing Existing Outdoor Unit ................. 6
Positioning New Outdoor Unit ................... 6
Removing and Installing Panels ................. 7
New or Replacement Line Set ................... 9
Brazing Connections ........................... 11
Removing Indoor Unit Metering Device ........... 11
Flushing the System ........................... 12
Installing New Indoor Unit Metering Device ........ 13
Testing for Leaks .............................. 13
Evacuating the System ......................... 15
Servicing Unit Delivered Void of Charge ........... 16
Electrical Connections ......................... 16
Start-Up and Charging Procedures ............... 17
System Operation ............................. 17
Charge using the Subcooling Method ............ 21
System Operation ............................. 21
Defrost System ............................... 21
Maintenance .................................. 25
Homeowner Information ........................ 26
Checklists .................................... 28
Check unit for shipping damage. Consult last carrier
immediately if damage is found.
1 -Assembled XP16 outdoor unit
AIMPORTANT The XP16 Heat Pumps, 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
XP f 6 Engineering Handbook.
This outdoor unit is designed for use in systems that use
check thermal expansion valve (CTXV) refrigerant
metering devices.
04/08
IIIHIIIIII]]IIII]IIIIIIIII]IIIIIIIII] Page 1 505,329M IIII]III]]IIIIIIIII]IIHI]I]IIIIIIIIIIIII]]IIIII

TOP VIEW
UNIT SUPPORT
q CDISCHARGE AIR t
RUN
CAPACITOR
SUCTION LINE
CONNECTION
4N/4
L_I !(108)
t
SIDE VIEW
LIQUID LINE
CONNECTION
FEETx_
%
8-1/2
(_ 13 1
(216)
t
8-3/4
(222)
1
I LIQUID LINE
F -- CONNECTION
ELECTRICAL
INLETS
//q/
4-3/4
(121)
DEFROST
BOARD
CONTACTOR
REVERSING
VALVE
LIQUID LINE
CONNECTIONS
OUTDOOR FAN
COMPRESSOR
HIGH PRESSURE SWITCH
DRIER
LOW PRESSURE SWITCH
• VAPOR LINE
VAPOR VALVE AND GAUGE
PORT/SUCTION LINE
CONNECTIONS
XP16 PARTS ARRANGEMENT
[
A
L
2 (51)
tt 1 (25)
\I I i i
SIDE VIEW
XP16-024 BASE SECTION
t
9N/2
(241)
t
8-1/4
(210)
f
UNIT SUPPORT FEET _ _-
D
E
® @ ® K
J
XP16 A
-024 31 (787)
-036 35 (889)
-048 45 (1143)
-060 39 (991)
BCD
27 (686) 28 (711)
30-1/2 (775) 35 (889) 13-7/8 (352)
30-1/2 (775) 35 (889)
30-1/2 (775) 35 (889) 16-7/8 (429)
7-3/4 (197)
8-3/4 (222)
3-1/4 (83)
3-1/8 (79)
XP16 BASE WITH ELONGATED LEGS
G H J K
3-5/8 (92)
4-5/8 (117)
4-1/2 (114)
3-3/4 (95)
27-1/8 (689)
30-3/4 (781)
20-5/8 (524)
26-7/8 (683)
505329M 04/08
Page 2

WARNING 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
IMPORTANT
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
who have jurisdiction before installation.
When servicing or repairing HVAC components, ensure
the fasteners are appropriately tightened. Table 1 shows
torque values for fasteners.
Table 1 Torque Requirements
Parts Recommended Torque
Service valve cap 8 ft Ib 11 NM
Sheet metal screws 16 in Ib 2 NM
Machine screws #10 28 in Ib 3 NM
Compressor bolts 90 in Ib 10 NM
Gauge port seal cap 8 ft Ib 11 NM
USING MANIFOLD GAUGE SETS
When checking the system charge only use a manifold
gauge set that features low loss anti-blow back fittings
See figure 2 for a typical manifold gauge connection setup
Manifold gauge sets 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 on the high side and a low side of
30" vacuum to 250 psi with dampened speed to 500 psi
Gauge hoses must be rated for use at up to 800 psi of
pressure with a 4000 psi burst rating
I/6 TURN 1/12 TURN
9
8 4
Figure 1Cap Tightening Distances
IMPORTANT
To Access Angle-Type 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 to the service port
3 When testing iscompleted replace service port cap and
tighten as follows:
•With Torque Wrench: Finger tighten and then
tighten per table 1
• Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 1
Page 3
XP16 SERIES

DISTRIBUTOR
CBECK REV " sAT:UvA E
EXPANSION VALVE _ \
DR,ER OUTo tOR "-
LOW HIGH MUFFLER
PRESSURE PRESSURE ___ ]
LIOUID *o
_ CHECK EXPANSION VALVE --
NOTE -Arrows indicate direction
of refrigerant flow.
INDOOR UNIT
INDOOR
COIL
Figure 2. Typical Manifold Gauge Connection Setup
To Open and Close Angle-Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak-free seal,
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,
3. Replace the stem cap and tighten as follows:
• With Torque Wrench: Tighten finger tight and then
tighten per table 1,
• Without Torque Wrench: Finger tighten and use an
appropriately sized wrenched to turn an additional
1/12 turn clockwise as illustrated in figure 1.
SERVICE PORT
CAP _-
SERVICE PORT
SERVICE PORT
CLOSED) INSERT HEX
WRENCH HERE
VALVE STEM
FRONT-SEATED
TOINDOOR
UNIT
TO OUTDOOR
STEM CAP
CLOSED TO BOTHINDOOR
AND OUTDOOR UNITS
Figure 3. Angle-Type Service Valve
(Font-Seated Closed)
NOTE -A label with specific torque requirements may be
affixed to the stem cap. If the label is present, use the
specified torque.
NOTE- To prevent stripping of the cap, the wrench should
be appropriately sized and fit snugly over the cap before
tightening the cap.
SERVICE PORT CAP
SERVICE PORT SERVICE PORT
CORE
OPEN TO BOTH (VALVE STEM SHOWN OPEN)
INDOOR AND INSERT HEX WRENCH HERE
OUTDOOR UNITS
TO INDOOR
UNIT STEM CAP
TO OUTDOOR UNIT
Figure 4. Angle-Type Service Valve
(Back-Seated Opened)
To Access Bali-Type 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 to the service port.
3. When testing is completed, replace service port cap and
tighten as follows:
•With Torque Wrench: Finger tighten and then
tighten per table 1,
•Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/6 turn clockwise as illustrated in figure 1.
505329M 04/08
Page 4

OPEN TO LINE SET WHEN VALVE IS CLOSED,
TO BOTH LINE SET AND UNIT WHEN VALVE IS
OPEN.
TO INDOOR UNIT
TO OPEN ROTATE STEM
COUNTERCLOCKWISE 90°.
TO CLOSE ROTATE STEM
CLOCKWISE 90 °.
BALL (SHOWN
CLOSED)
VALVE
STEM
CORE
SERVICE PORT CAP
TO OUTDOOR UNIT STEM CAP
Figure 5. Bali-Type Service Valve
To Open and Close Bali-Type Service Valve:
A valve stem cap protects the valve stem from
contamination and assures a leak-free seal,
1. Remove stem cap with an appropriately sized wrench,
2. Use an appropriately sized wrenched to open. To open
valve, roate stem counterclockwise 90°, To close
rotate stem clockwise 90°.
3. Replace the stem cap and tighten as follows:
•With Torque Wrench: Finger tighten and then
tighten per table 1.
• Without Torque Wrench: Finger tighten and use an
appropriately sized wrench to turn an additional
1/12 turn clockwise as illustrated in figure 1,
NOTE -A label with specific torque requirements may be
affixed to the stem cap. If the label is present, use the
specified torque.
Remove existing HCFC-22 refrigerant using one of the
following procedures:
METHOD 1:
If the existing outdoor unit is not equipped with shut-off
valves, or if the unit is not operational and you plan to use
the existing HCFC-22 to flush the system,
NOTE -Use recovery machine instructions for specific
setup requirements,
1. Disconnect all power to the existing outdoor unit,
2. Connect to the existing unit a gauge set, clean
recovery cylinder and a recovery machine. Use the
instructions provided with the recovery machine on
how to setup the connections,
3. Remove all HCFC-22 refrigerant from the existing
system, Check gauges after shutdown to confirm that
the entire system is completely void of refrigerant,
RECOVERY MACHINE MANIFOLD GAUGES
/
OUTDOOR UNIT
Figure 6. Typical Refrigerant Recovery
(Method 1)
NOTE -Use recovery machine instructions for specific
setup requirements.
METHOD 2:
Use this method if the existing outdoor unit is equipped
with manual shut-off valves, and plan on using new
HCFC-22 refrigerant to flush the system,
IMPORTANT: Some system configurations may contain
higher than normal refrigerant charge due to either large
internal coil volumes, and/or long line sets, The following
conditions may cause the compressor to stop functioning:
The following devices could prevent full system charge
recovery into the outdoor unit:
• Outdoor unit's high or low-pressure switches (if
applicable) when tripped can cycled 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 suction 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:
1, Start the existing HCFC-22 system in the cooling
mode and close the liquid line valve.
2, Pump as much of the existing HCFC-22 refrigerant
with the compressor back into the outdoor unit until
you have reached the limitations of the outdoor
system, Turn the outdoor unit main power OFF and
use a recovery machine to remove the remaining
refrigerant in the system,
Page 5
XP16 SERIES

NOTE -It may be necessary to bypass the low pressure
switches if equipped to ensure complete refrigerant
evacuation.
3. When the low side system pressures reach 0 psig,
close the suction line valve,
4. Check gauges after shutdown to confirm that the
valves are not allowing refrigerant to flow back into the
low side of the system.
Perform the following task at the existing outdoor unit:
• Disconnect line set at the service valves,
• Disconnect electrical service at the disconnect switch.
• Remove old outdoor unit,
A CAUTION
See Unit Dimensions on page 3 for sizing mounting slab,
platforms or supports. Refer to figure 7 for mandatory
installation clearance requirements.
CONTROL PANEL
ACCESS LOCATION
* SEE NOTES BELOW THIS FIGURE FOR FURTHER DETAILS.
Figure 7. Installation Clearances
NOTES:
• Service clearance of 30 in. (762 mm) must be
maintained on one of the sides adjacent to the control
box.
• Clearance to one of the other three sides must be 36
in, (914 mm).
• Clearance to one of the remaining two sides may be
12 in, (305 mm) and the final side may be 6 in, (152
mm).
• 48 in. (1219 mm) clearance required on top of unit.
• A clearance of 24 in. (610 mm) must be maintained
between two units,
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
• Some localities are adopting sound ordinances based
on the unit's sound level registered from the adjacent
property, not from the installation property. Install the
unit as far as possible from the property line,
• When possible, do not install the unit directly outside
a window, Glass has a very high level of sound
transmission, For proper placement of unit in relation
to a window see the provided illustration in figure 8.
INSTALLUNITAWAY
FROMWINDOWS--------' II--
IIIIIHIlls
Figure 8. Outside Unit Placement
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 9,
NOTE -If necessary for stability, anchor unit to slab as
described in Stabilizing Unit on Uneven Surfaces on page
7,
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. iL
BUILDING
STRUCTURE_-r
MOUNTING
SLAB --T-
GROUNDLEVEL
Figure 9. Slab Mounting at Ground Level
ELEVATING THE UNIT (SMALL-BASE UNITS)
If additional elevation is necessary, raise the unit by
extending the length of the unit support feet. This may be
done by cutting four equal true-cut lengths of Schedule
(SCH) 40, 4" (101.6mm) piping to the height required as
illustrated in figure 10.
505329M 04/08
Page 6

BASE
LEG DETAIL
4" (101.6MM) SCH 40
Figure 10. Elevated Slab Mounting using Feet
Extenders (Small Base Units)
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.
The inside diameter of the 4" (101.6mm) piping is
approximately 0.25" (6.35mm) greater than the
pre-installed feet on the unit. Devise a shim that will take up
the space and hold the extenders onto the feet during this
procedure. Small strips of 0.125" (3.175mm) thick
adhesive foam may be used. One or two small 1"
(25.4mm) square strips should be adequate to hold the
extender in place.
ELEVATING THE UNIT (LARGER-BASE UNITS)
Unlike the small-base units which use round support feet,
the larger-base units are outfitted with elongated support
feet as illustrated in figure 11 which uses a similar method
for elevating the unit.
If additional elevation is necessary, raise the unit by
extending the length of the unit support feet. This may be
achieved by using a 2" SCH 40 female threaded adapter.
The specified coupling will fit snuggly into the recessed
portion ofthe feet. Use additional 2"SCH 40 male threaded
adaptors which can be threaded into the female threaded
adaptors tomake 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.
BASE
LEG DETAIL
2" (50.8MM) SCH 40
FEMALE THREADED
ADAPTER
Figure 11. Elevated Slab Mounting using Feet
Extenders (Larger Base Units)
ROOF MOUNTING
Install unit at a minimum of four inches above the surface
of the roof. Care must be taken to ensure weight of unit is
properly distributed over roof joists and rafters. Either
redwood or steel supports are recommended.
CAUTION
Page 7
XP16 SERIES

REMOVING PANELS
Remove the Iouvered panels as follows:
1. Remove two screws, allowing the panel to swing open
slightly as illustrated in figure 12.
NOTE -Hold the panel firmly throughout this procedure
2, Rotate bottom corner of panel away from hinge corner
post until lower three tabs clear the slots as illustrated
in figure 12, detail B.
3, Move panel down until lip of upper tab clears the top
slot in corner post as illustrated in figure 12, detail A,
INSTALLING PANEL
Install the Iouvered panels as follows:
1, Position the panel almost parallel with the unit as
illustrated in figure 13, detail D with the screw side as
close to the unit as possible.
2, With a continuous motion slightly rotate and guide the
lip of top tab inward as illustrated in figure 12, details
A and C, then upward into the top slot of the hinge
corner post.
3, Rotate panel to vertical to fully engage all tabs,
4, Holding the panel's hinged side firmly in place, close
the right-hand side of the panel, aligning the screw
holes.
5, When panel is correctly positioned and aligned, insert
the screws and tighten,
IMPORTANT! DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB. TAB IS
FOR ALIGNMENT AND NOT DESIGNED TO SUPPORT WEIGHT OF PANEL.
PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR ENTER)
TOP SLOT FOR REMOVING (OR INSTALLING) PANEL.
SCREW
HOLES _
LIP
\
DETAIL
ROTATE IN THIS DIRECTION;
THEN DOWN TO REMOVE
PANEL
Figure 12. Removing/Installing Louvered Panels
(Details A, B and C)
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT
AS POSSIBLE) WHILE INSTALLING PANEL.
HOLD DOOR FIRMLY TO THE HINGED
ANGLE MAY BE TOO SIDE TO MAINTAIN
EXTREME _-_ FULLY-ENGAGED TABS
PREFERRED ANGLE
FOR INSTALLATION _
Figure 13. Removing/Installing Louvered Panels
(Detail D)
STABILIZING UNIT ON UNEVEN SURFACES
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,
With unit positioned at installation site, remove two side
Iouvered panels to expose the unit base pan, Install the
brackets as illustrated in figure 14 and using conventional
practices; replace the panels after installation is complete,
Slab Side Mounting
k
#101/2" LONG SELF-
DRILLING
METAL SCREWS
STABILIZING
BRACKET (18 GAUGE
METAL - 2" WIDTH;
HEIGHT AS REQ'D)
#10 lq/4" LONG
HEX HD SCREW
- COIL
BASE PAN
CONCRETE SLAB - USE PLASTIC
PLASTIC ANCHOR (HOLE DRILL
1/4")PLASTIC SLAB - NO PLASTIC
ANCHOR (HOLE DRILL 1/8")
Deck Top
Mounting
STABILIZING BRACKET MINIMUM 1 J
(18 GAUGE METAL- 2" PER SIDE _
WIDTH; HEIGHT AS
REOD,;BENDTOFORM
liI "
FOR EXTRA
STABILITY
ONE BRACKET PER SIDE (MIN.); FOR EXTRA STABILITY,
2 BRACKETS PER SIDE, 2" FROM EACH CORNER.
Figure 14. Installing Stabilizer Brackets
505329M 04/08
Page 8

AIMPORTANT
This section provides information on installation or
replacement of existing line set. If line set are not being
installed then proceed to Brazing Connections on page 11.
If refrigerant lines are routed through a wall, 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. Also, consider the following when
placing and installing a high-efficiency air conditioner,
REFRIGERANT LINE SET
Field refrigerant piping consists of liquid and suction lines
from the outdoor unit (braze connections) to the indoor unit
coil (flare or sweat connections). Use Lennox L15 (sweat,
non-flare) series line set, or use field-fabricated refrigerant
lines as listed in table 2,
Table 2. Refrigerant Line Set
Model Field Connections Recommended Line Set
Liquid Suction Liquid Suction
Line Line Line Line L15 Line Set
L15-41
3/8". 3/4" 3/8" 3/4"
-024 (10 ram) (19 ram) (10 ram) (19 ram) 15 ft. - 50 ft.
(4.6m - 15 m)
L15-65
3/8". 718" 3/8" 7/8" 15ft,- 50 ft.
-048-036 (10 ram) (22 ram) (10 mm) (22 ram) (4.6 m- 15 m)
318". 1-1/8". 318" 1-1/8" Field
-060 (10 ram) (29 ram) (10 ram) (29 ram) Fabricated
NOTE -When installing refrigerant lines longer than 50
feet, see the Lennox Refrigerant Piping Design and
Fabrication Guidelines, or contact Lennox Technical
Support Product Applications for assistance. Toobtain the
correct information from Lennox, be sure to communicate
the following points:
• Model (XP16) and size of unit (e,g. -060).
• Line set diameters for the unit being installed as listed
in table 2 and total length of installation,
• Number of elbows and if there is a rise or drop of the
piping,
MATCHING WITH NEW OR EXISTING INDOOR COIL
AND LINE SET
The RFCl-metering line consisted of a small bore copper
line that ran from condenser to evaporator coil. Refrigerant
was metered into the evaporator by utilizing
temperature/pressure evaporation effects on refrigerant in
the small RFC line. The length and bore of the RFC line
corresponded to the size of cooling unit.
If the XP16 is being used with either a new or existing
indoor coil which is equipped with a liquid line which served
as a metering device (RFCI), the liquid line must be
replaced prior to the installation of the XP16 unit. Typically
a liquid line used to meter flow is 1/4" in diameter and
copper.
INSTALLING LINE SET
Line Set Isolation--This reference illustrates
procedures, which ensure proper refrigerant line set
isolation:
• Installation of line set on horizontal runs is
illustrated in figure 15,
• Installation of a transition from horizontal to
vertical is illustrated in figure 16,
• Installation of line set on vertical runs is illustrated in
figure 17,
TO HANG LINE SET FROM JOIST OR
RAFTER, USE EITHER METAL STRAPPING
MATERIAL OR ANCHORED HEAVY NYLON
WIRE TIES.
STRAPPING MATERIAL
(AROUND SUCTION
LINE ONLY)
8 FEET
WIRE TIE
(AROUND
/ SUCTION LINE
ONLY)
TAPE OR
WIRE TIE
METAL
SLEEVE
TAPE OR
WIRE TIE STRAP THE SUCTION LINE TO
THE JOIST OR RAFTER AT 8 FEET
INTERVALS THEN STRAP THE
LIQUID LINE TO THE SUCTION
LINE.
Figure 15. Refrigerant Line Set: Installing
Horizontal Runs
Page 9
XP16 SERIES

ANCHOREDHEAVY
NYLONWIRETIE
WALL
METALSLEEVE
AUTOMOTIVE
MUFFLER-TYPEHANGER
WALL
STUD
METALSLEEVE
S; sA cY, o 't
.X\ L,QU,DL,NE
k
\SUCTION LINE - WRAPPED IN
ARMAFLEX
STRAP LIQUID LINE TO
SUCTION LINE
_ LIQUID LINE
xSUCTION LINE - WRAPPED IN
ARMAFLEX
IMPORTANT - REFRIGERANT LINES MUST NOT CONTACT WALL.
LIQUID LINE
OUTSIDE WALL SUCTION LINE
NOTE - SIMILAR INSTALLATION
PRACTICES SHOULD BE USED
IF LINE SET IS TO BE INSTALLED
ON EXTERIOR OF OUTSIDE
WALL.
m
/ / I/ ////
WIRE TIE
INSIDE WALL
STRAP
SLEEVE
WIRE TIE
-- WOOD BLOCK
WIRE TIE
STRAP
IMPORTANT! REFRIGERANT
LINES MUST NOT CONTACT
STRUCTURE,
Figure 16. Refrigerant Line Set: Transition from
Vertical to Horizontal Figure 17. Refrigerant Line Set: Installing Vertical
Runs (New Construction Shown)
1
CUT AND DEBUR
INSTALL CORE ONLY FOR
3OTH SERVICE PORTS after they
have coolED.
INDOOR UNIT
REMOVE CAP AND CORE FROM
BOTH LIQUID AND SUCTION
SERVICE PORTS
outdoor
UNIT
SERVICE PORT MUST BE
OPEN TO ALLOW EXIT
POINT FOR NITROGEN SERVICE
_. SUCTION LINE _/VALVE
LIQUID LINE SERVICE_
VALVE
Figure 18. Brazing Connections
505329M 04/08
Page 10

Usethefollowingproceduretobrazethelinesettothenew
airconditionerunit.Figure18is providedasa general
guidefor preparingto brazethe line set to the air
conditionerunit.
WARNING
WARNÁNG
_WARNING
1. Cut ends of the refrigerant lines square (free from
nicks or dents). Debur the ends. The pipe must remain
round, do not pinch end of the line.
2. Remove service cap and core from both the suction
and liquid line service ports.
3. Connect gauge low pressure side to liquid line service
valve.
4. To protect components during brazing, wrap a wet
cloth around the liquid line service valve body and
copper tube stub and use another wet cloth
underneath the valve body to protect the base paint.
Also, shield the light maroon R-410A sticker.
5. Flow regulated nitrogen (at 1 to 2 psig) through the
refrigeration gauge set into the valve stem port
connection on the liquid line service valve and out of
the valve stem port connection on the suction service
valve.
NOTE - The RFCIV or TXV metering device at the indoor
unit will allow low pressure nitrogen to flow through the
system.)
NO TE - Use silver alloy brazing rods with five or six percent
minimum silver alloy for copper-to-copper brazing or 45
percent silver alloy for copper-to-brass or copper-to-steel
brazing.
6, Braze the liquid line to the liquid line service valve.
Turn off nitrogen flow. Repeat procedure starting at
paragraph 4 for brazing the suction line to the suction
service valve.
7, After all connections have been brazed, disconnect
manifold gauge set the from service ports and remove
wrapping. Reinstall the service port core for both of the
outdoor unit's service valves,
Remove the existing HCFC-22 refrigerant flow control
orifice or thermal expansion valve from the indoor coil. The
existing indoor unit HCFC-22 metering device is not
approved for use with HFC-410A refrigerant and may
prevent proper flushing.
REPLACEMENT PARTS
If replacement parts are necessary for the indoor unit,
order kit 69J46. The kit includes:
• 10 -- Brass nuts for liquid line assemblies
• 20 -- Teflon rings
• 10 -- Liquid line orifice housings
• 10 -- Liquid line assemblies
PISTON
LIQUID LINE ORIFICE HOUSINGS (10) / RETAINER
TEFLON RINGS (20)
..(_J jBRASS NUTS (10) _
--/"1 .STRANER
,, O%ER
LIQUID LINE ASSEMBLIES
(INCLUDES STRAINER) (10) LIQUID LINE
ASSEMBLY
Figure 19.69J46 Kit Components
TYPICAL FIXED ORIFICE REMOVAL PROCEDURE
1. On fully cased coils, remove the coil access and
plumbing panels.
2. Remove any shipping clamps holding the liquid line
and distributor assembly.
3. Using two wrenches, disconnect liquid line from liquid
line orifice housing. Take care not to twist or damage
distributor tubes during this process.
4. Remove and discard fixed orifice, valve stem
assembly if present and Teflon washer as illustrated in
figure 20.
Page 11
XP16 SERIES

5. Use a field-provided fitting to temporary reconnect the
liquid line to the indoor unit's liquid line orifice housing,
DISTRIBUTOR TUBES
LIQUID LINE ORIFICE HOUSING
TEFLON RING Remove and discard valve
FIXED stem assembly (if present)
BRASS NUT
/
" j ....
VA_ ?'"%%_'2s_ASS_"_T
VALVESTEMCAP (Uncased Coil Shown
Figure 20. Typical Fixed Orifice Removal
TYPICAL TXV REMOVAL PROCEDURE
1. On fully cased coils, remove the coil access and
plumbing panels,
2. Remove any shipping clamps holding the liquid line
and distributor assembly,
3. Disconnect the equalizer line from the TXV equalizer
line fitting on the suction line,
(Uncased Coil Shown)
TWO PIECE
PATCH PLATE
UNCASED COIL LIQUID LINE STUB END
ONLY) ORIFICE HOUSING
DISTRIBUTOR TXV
TUBES
RING
SENSING
LINE
/
MALE EQUALIZER LINE /
FITTING /SUCTION
SENSING BULB L_, LIQUID
LINE
Figure 21. Typical TXV Removal
4. Remove the suction line sensing bulb.
5. Disconnect the liquid line from the TXV at the liquid line
assembly,
6. Disconnect the TXV from the liquid line orifice housing.
Take care not to twist or damage distributor tubes
during this process,
7. Remove and discard TXV and the two Teflon rings as
illustrated.
8. Use a field-provided fitting to temporary reconnect the
liquid line to the indoor unit's liquid line orifice housing,
AIMPORTANT
AIMPORTANT
IMPORTANT
CAUTION
505329M 04/08
Page 12

Iftheoriginalsystemused:
• HCFC-22refrigerant,thenflushthesystemusingthe
procedureprovidedinthissection,
• HFC-410Arefrigerant,thenproceedtoInstalling New
Refrigerant Metering Device.
INVERTED HCFC-22 CYLINDER
/CONTAINS CLEAN HCFC-22 TO
BE USED FOR FLUSHING. GAUGE
!O_ U'! MANIFOLD
LOW HIGH
I PRESSURE PRESSURE
suc t'_
SERVICE VALVE _ _ I : _'_ :I '_J
/\/\ _=n _ _ i-gh,
/\ _ i I u" w _ ,_ 'U
OPENEDIIII CLOSED
RECOVERY
CYLINDER
RECOVERY MACHINE
NOTE - THE INVERTED HCFC-22 CYLINDER MUST CONTAIN AT LEAST THE SAME
AMOUNT OF REFRIGERANT AS WAS RECOVERED FROM THE EXISTING SYSTEM,
Figure 22. Typical Flushing Connection
REQUIRED EQUIPMENT
Equipment required to flush the existing line set and indoor
unit coil:
• Two clean HCFC-22 recovery bottles,
• Oilless recovery machine with pump-down feature,
• Two gauge sets (one for HCFC-22; one for
HFC-410A).
FLUSHING PROCEDURE
1. Connect the following:
• HCFC-22 cylinder with clean refrigerant to the
suction service valve,
• HCFC-22 gauge set to the liquid line valve,
• Recovery machine with an empty recovery tank to
the gauge set,
2. Set the recovery machine for liquid recovery and start
the recovery machine. Open the gauge set valves to
allow the recovery machine to pull a vacuum on the
existing system line set and indoor unit coil.
3. Invert the cylinder of clean HCFC-22 and open its
valve to allow liquid refrigerant to flow into the system
through the suction 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.
4. After all of the liquid refrigerant has been recovered,
switch the recovery machine to suction recovery so
that all of the HCFC-22 suction is recovered. Allow the
recovery machine to pull a vacuum on the system,
5. 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.
XP16 units use CTXV for metering refrigerant only. This
section provides instructions on installing CTXV
refrigerant metering device.
1/2 TURN
Figure 23. Tightening Distance
TYPICAL CTXV INSTALLATION PROCEDURE
The CTXV unit can be installed internal or external to the
indoor coil. In applications where an uncased coil is being
installed in a field-provided plenum, install the CTXV in a
manner that will provide access for field servicing of the
CTXV, Refer to Figure 24 for reference during installation
of CTXV unit.
TWOPIECE (Uncased Coil Shown)
PATCH PLATE
UNCASED COIL
ONLY) LIQUID LINE
..'_ORIFICE STUB END
HOUSING
DISTRIBUTOR CTXV
TUBES. - RING
SENSING
LINE
MALE EQUALIZER LINE
FITTING (SEE FIGURE 26
FOR FURTHER DETAILS) LINE
SENSING BULB INSULATION IS
REQUIRED IF MOUNTED EXTERNAL
TO THE COIL CASING SEE FIGURE 25
FOR BULB POSITIONING.
LIQUID
LINE
Figure 24. Typical CTXV Installation
1, Remove the field-provided fitting that temporary
reconnected the liquid line to the indoor unit's
distributor assembly,
Page13
XP16 SERIES

2. Install one of the provided Teflon rings around the
stubbed end of the CTXV and lightly lubricate the
connector threads and expose surface of the Teflon
ring with refrigerant oil.
3. Attach the stubbed end of the CTXV to the liquid line
orifice housing, Finger tighten and use an appropriately
sized wrench to turn an additional 1/2 turn clockwise
as illustrated in figure 23, or 20 ft-lb,
4. Place the remaining Teflon washer around the other
end of the CTXV. Lightly lubricate connector threads
and expose surface of the Teflon ring with refrigerant
oil,
5. Attach the liquid line assembly to the CTXV. Finger
tighten and use an appropriately sized wrench to turn
an additional 1/2 turn clockwise as illustrated in figure
23, or 20 ft-lb,
6. Attach the suction line sensing bulb in the proper
orientation as illustrated in figure 25 using the clamp
and screws provided,
NOTE -Insulating the sensing bulb once installed may be
required when the bulb location is external to the coil
casing.
ON LINES SMALLER THAN
SUCTION LINE 7/8", MOUNT SENSING BULB
AT EITHER THE 3 OR 9
'Lr"* _,,,_ __,_,"_ __CK POSITION.
'X_L,,'*"L_"
BULB\_
SUCTION LINE
(BULB .
ON 7/8" AND LARGER LINES,
MOUNT SENSING BULB AT
EITHER THE 4 OR 8 O'CLOCK
'TO%M%EVL%MOUNT
NOTE - NEVER MOUNT ON BOTTOM OF LINE.
Figure 25. TXV Sensing Bulb Installation
7. Remove and discard either the flare seal cap or flare
nut with copper flare seal bonnet from the equalizer
line port on the suction line as illustrated in figure 26.
AIMPORTANT
FLARE SEAL_
CAP ÷J_ FLARE NUT
X COPPER
OR --FLARE SEAL
BONNET
J
•_MALE BRASS EQUALIZER
LINE FITTING
SUCTION LINE
Figure 26. Copper Flare Seal Bonnet Removal
8. Connect the equalizer line from the CTXV to the
equalizer suction port on the suction line. Finger
tighten the flare nut plus 1/8 turn (7 ft-lbs) as illustrated
in figure 23,
NOTE -To prevent any possibility of water damage,
properly insulate all parts of the CTXV assembly that may
sweat due to temperature differences between the valve
and its surrounding ambient temperatures,
See the Lennox XP16 Engineering Handbook for
approved CTXV kit match-ups and application
information.
The reference CTXV kits include:
O_TEFLON
RINGS (2) _ I_
STRAP (1)
Figure 27. CTXV Kit Components
After the line set has been connected tothe indoor unit and
air conditioner, check the line set connections and indoor
unit for leaks. Use the following procedure to test for leaks:
IMPORTANT
505329M 04/08
Page 14

,A WARNING
,WARNING
7. After leak testing disconnect gauges from service
ports.
Evacuating the system of non-condensables is critical for
proper operation of the unit. Non-oondensables are
defined as any gas that will not condense under
temperatures and pressures present during operation of
an air conditioning system. Non-condensables and water
suction combine with refrigerant to produce substances
that corrode copper piping and compressor parts.
,A WARNING
,WARNING
1. Connect an HFC-410A manifold gauge set high
pressure hose to the suction valve service port.
(Normally, the high pressure hose is connected to the
liquid line port; however, connecting it to the suction
port better protects the manifold gauge set from high
pressure damage.)
2. 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 (suction only).
3. 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.
4. Connect a cylinder of dry nitrogen with a pressure
regulating valve to the center port of the manifold
gauge set,
5. Adjust dry nitrogen pressure to 150 psig (1034 kPa).
Open the valve on the high side dthe manifold gauge
set in order to pressurize the line set and the indoor unit,
6. 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.
IMPORTANT
1. Connect manifold gauge set to the service valve ports
as follows:
• low pressure gauge to suction line service valve
• high pressure gauge to liquid line service valve
2. Connect micron gauge.
3. Connect the vacuum pump (with vacuum gauge) to
the center port of the manifold gauge set,
4. Open both manifold valves and start the vacuum
pump.
5. Evacuate the line set and indoor unit to an absolute
pressure of 23,000 microns (29.01 inches of
mercury),
NOTE -During the early stages of evacuation, it is
desirable to close the manifold gauge valve at least once to
determine if there is a rapid rise in sure 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.
6. When the absolute pressure reaches 23,000 microns
(29.01 inches of mercury), close the manifold gauge
valves, turn off the vacuum pump and disconnect the
manifold gauge center port hose from vacuum pump.
Attach the manifold center port hose to a dry nitrogen
cylinder with pressure regulator set to 150 psig (1034
kPa) and purge the hose. Open the manifold gauge
valves to break the vacuum in the line set and indoor
unit. Close the manifold gauge valves.
Page15
XP16 SERIES

7, 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,
8, Reconnect the manifold gauge to the vacuum pump,
turn the pump on, and continue to evacuate the line set
and indoor unit until the absolute pressure does not
rise above 500 microns (29.9 inches of mercury) within
a 20-minute period after shutting off the vacuum pump
and closing the manifold gauge valves.
9, When the absolute pressure requirement above has
been met, disconnect the manifold hose from the
vacuum pump and connect it to an upright cylinder d
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,
10. Close manifold gauge valves and shut off the
HFC-410A cylinder and remove the manifold gauge
set,
If the system is void of refrigerant, clean the system using
the procedure described below,
1, Use nitrogen to pressurize the system and check for
leaks. Repair all leaks,
2, Evacuate the system to remove as much of the
moisture as possible,
3. Use nitrogen to break the vacuum and install a new
filter drier in the system.
4, Evacuate the system again. Then, weigh the
appropriate amount of HFC-410A refrigerant as listed
on unit nameplate into the system.
5, 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.
In the U,S.A., wiring must conform with current local codes
and the current National Electric Code (NEC). In Canada,
wiring must conform with current local codes and the current
Canadian Electrical Code (CEC),
Refer to the furnace or blower coil installation instructions
for additional wiring application diagrams and refer to unit
nameplate for minimum circuit ampacity and maximum
overcurrent protection size,
230VAC SUPPLY VOLTAGE
The XP16 outdoor unit is rated for 230VAC applications
only, A hard-start kit is required for applications where the
supply voltage is less than 230VAC,
24VAC TRANSFORMER
Use the transformer provided with the furnace or coil
blower for low-voltage control power (24VAC - 40 VA
minimum)
NOTE -The addition of accessories to the system could
exceed the 40 VA power requirement of the
factory-provided transformer, Measure the system's
current and voltage after installation is complete to
determine transformer loading. If loading exceeds the
factory-provided transformer capacity, a larger
field-provided transformer will need to be installed in the
system. _WARNING
WIRING CONNECTIONS
1, Install line voltage power supply to unit from a properly
sized disconnect switch.
2, Ground unit at unit disconnect switch or to an earth
ground.
NOTE -Connect conduit to the unit using a proper conduit
fitting. Units are approved for use only with copper
conductors. See figure 28 for high voltage field wiring
diagram. A complete unit wiring diagram is located on the
back side of the unit's access panel.
Old'DOOR
FAN
ro--oq
K31
ohvo_l
i__..._._I_WlIN
LLII_LE-CAPAC ][TOR
CIZ
OUAL
CAPACITOR
AI_
OEFROST
CONTROL
E
GROUND_
LUG
CONTACTOR
m
GROUND
z_
208 =
60/I
mlmLZ
mLI
LINE VOLTAGE
FIELD INSTALLED
z_ NOTE-
FOR USE WITH COPPER CONDUCTORS ONLY, REFER TO UNIT RATING PLATE FOR
MINZMUM CZRCUIT AMPACITY AN0 MAXIMUM 0VER-CURRENT PROTECTION SIZE
Figure 28. Outdoor Unit Typical Field Wiring
NOTE -For proper voltages, select thermostat wire
gauge per the following chart:
Table 3. Wire Run Length
Wire run length AWG # Insulation type
less than 100' (30m) 18 color-coded, temperature
more than 100' (30m) 16 rating 35°C minimum
3, Install room thermostat (ordered separately) on an
inside wall approximately in the center of the
conditioned area and 5 feet (1.5 m) from the floor,
NOTE -Thermostat should not be installed on an outside
wall or where it can be effected by sunlight, drafts or
vibrations,
4. Install low voltage wiring from outdoor to indoor unit
and from thermostat to indoor unit (figures 29 and 30),
NOTE -24VAC, Class II circuit connections are made in
the low voltage junction box,
Page 16
505329M 04/08

( ANDINDOORUNIT.)
OUTDOORUNITq ]NDOOR UN T TB11
I_11 iL_I"- i
I It tE_ t
Id_Pt- i- q_]- 4
ivl t t E_l t
ILSLFt--i---_4- 4
1@4-t- t_ a
I_1t tE_-,L_J
ou, _Lt --t 4
t _ J I J
SOME CONNECTIONS MAY NOT APPLY. REFER TO SPECIFIC THERMOSTAT
A2 THERMOSTAT
@
Figure 29. Outdoor Unit and Blower Unit
Thermostat Designations
{SOME CONNECTIONS MAY NOT APPLY. REFER TO SPECIFIC THERMOSTAT
A_J_J _N R H T_N
rc_3-1_vT-_x_TM_,S,GNATURESTAT
OUTDOOR UNIT 1 ITB1 I A2 THERMOSTAT
[ L_
I-- __ I -- _y1) I OUTDOOR
-_ i I _ _ i SENSOR; USE
I -- -- TWISTED PAIR
,!
I-- Qg)_---I-- _ 1
/
[IL J
Figure 30. Outdoor Unit and CB31MV/CBX32MV
Thermostat Designations
SA HIGH
PRESS_E
SWITCH LIi
SB7 LOW
PRESSURE
SWITCH
©
LI _
REVERSING z_-
VALVE_
®
RT13 A_BIENT
SENGDE
®
RT21 DEFROST
COlLSENGOR
®
RT28
DISCHARRE
SENSOR
@
C12 B4
DUAL FAN
CAPACITOR
L2
/i',ROTE-
FOR USE WITH COPPER CO_DBCTORSONLY.
REFER TO UNIT RATING PLATE FOR
MINIMUM CIRCUIT AMPACITY AND
MAXIMUM OVER-CURRENT PROTECTION SIZE
AREFER TO COMPRESSORIN UNIT
FOR ACTUAL TERMINAL ARRANGE_NT,
Z_ WARNING-
ELECTRIC SHOCKHAZARD,CANCAUSE INJURY
OR DEATH.UNIT MUSTBE OROUNOEDIN
ACCORDANCE WITH RATIONAL AND LOCAL CODES, /_ Gll- AND KSR ARE OPTIONAL LOW AMBIENT CONTROLS
Z_ REMOVE3UMPORFOR TWO STAGE COOL
Z_ RYI4 SENSOR,OUTDOORTENP (OPTIONAL}
OPTIONAL HARO START KIT MAY DE REUUIREO ON
APPLICATIONGWHERE VOLTASES ARE LESS THAN
EGOVOLT. KIT INCLUDES K31 AND C7 WITH
ALL NECESSARYWIRING.
w
JZ [[_@ BLUE cWRIIRMEpED
TERM,NAL
•-- --JII DEFROSTBOARDDETAIL
SHIPPEDASSHOWNABOVEWITHTERMINAL
il
iCRIMPED TO BLUE WIRE; USE TERMINAL OR
CUT OFF TERMINAL AND SPLICE BLUE WIRE
WITH Y2 WIRE TO INDOOR UNIT,
DENOTESOPTIONAL CONPONENTS
LINE VOLTAGE FIELD INSTALLED
J J J CLASS II VOLTAGEFIELD INSTALLED
/_k L34 SECONDSTAGE, SOLENOID IS LOCATED IN
COI_RESSOR. COIL IS 25VOC, 00 NOT CONNECT
24VAC TO COIL TERMINALS.
Z_ S4O _ NRI ARE USED ON 04G AND 060 UNITS ONLY
IMPORTANT
1. Rotate fan to check for binding.
Figure 31. XP16 Wiring
2. Inspect all factory- and field-installed wiring for loose
connections.
3. After evacuation is complete, open both the liquid and
vapor line service valves to release the refrigerant
charge contained in outdoor unit into the system.
4. Replace the stem caps and tighten to the value listed
in table 1.
5. Check voltage supply at the disconnect switch. The
voltage must be within the range listed on the unit's
nameplate. If not, do not start the equipment until you
Page 17
XP16 SERIES

have consulted with the power company and the
voltage condition has been corrected.
6, Set the thermostat for a cooling demand. Turn on
power to the indoor indoor unit and close the outdoor
unit disconnect switch to start the unit.
7. Recheck voltage while the unit is running. Power must
be within range shown on the nameplate,
8, Check system for sufficient refrigerate by using the
procedures listed under Testing and Charging
System,
TESTING AND CHARGING SYSTEM
This system uses HFC-410A refrigerant which operates at
much higher pressures than HCFC-22. The pre-installed
liquid line filter drier is approved for use with HFC-410A
only. Do not replace it with components designed for use
with HCFC-22, This unit is NOT approved for use with coils
which use capillary tubes as a refrigerant metering device.
SETTING UP TO CHECK CHARGE
1. Close manifold gauge set valves. Connect the center
manifold hose to an upright cylinder of HFC-410A,
2, Connect the manifold gauge set to the unit's service
ports as illustrated in figure 2.
•low pressure gauge to vapor service port
• high pressure gauge to liquid service port
COOLING MODE INDOOR AIRFLOW CHECK
Check airflow using the Delta-T (DT) process using the
illustration in figure 32,
HEATING MODE INDOOR AIRFLOW CHECK
Blower airflow (CFM) may be calculated by energizing
electric heat and measuring:
• Temperature rise between the return air and supply air
temperatures at the indoor coil blower unit,
• Measuring voltage supplied to the unit,
• Measuring amperage being drawn by the heat unit(s).
Then, apply the measurements taken in following formula
to determine CFM:
CFM = Amps x Volts x 3.41
1.98 x Temperature rise (F)
CALCULATING CHARGE
If the system is void of refrigerant, first, locate and repair
any leaks and then weigh in the refrigerant charge into the
unit, To calculate the total refrigerant charge:
Additional charge
Amount Adjust amount, for specified per
specified variation in line set indoor unit
on length listed on table match-up listed in Total
nameplate in figure 33. tables 4 through 7. charge
+ + =
Temp. } DT
ofair 180 24 24 24 23 23 22 22 22 20 19 18 17 16 15
entering.._178 23 23 23 22 22 21 21 20 19 18 17 16 15 14
indoor _ I _
coilOF _l.u 22 22 22 21 21 20 19 19 18 17 16 15 14 13
I_'174 21 21 21 20 19 19 18 17 16 16 15 14 13 12
_[72 20 20 19 18 17 17 16,/_15 14 13 12 11 10
70 19 19 18 18 17 17 16 15 15 14 13 12 11 10
Wet-bulb°F 57 58 59 60 61 62 63 64 65 66 67 68 69 70 [
n
90 DRY
BULB
All temperatures are iNDOOR WET
expressed in °F COiL BULB
Step 1. Determine the desired DT--Measure entering air tempera-
ture using dry bulb (A) and wet bulb (B). DT is the intersecting value of
A and B in the table (see triangle).
Step 2. Find temperature drop across coil--Measure the coil's dry
bulb entering and leaving air temperatures (A and C). Temperature
Drop Formula: (TDrop) = Aminus C.
Step 3. Determine if fan needs adjustment--If the difference be-
tween the measured TDrop and the desired DT (TDropiDT) is within
±3°, no adjustment is needed, See examples: Assume DT = 15 and A
temp. = 72°, these C temperatures would necessitate stated actions:
C° TDrop- DT = °F ACTION
53° 19 - 15 = 4 Increase the airflow
58° 14 - 15 = -1 (within +3° range) nochange
62° 10 - 15 = -5 Decrease the airflow
Step 4. Adjust the fan speed--See indoor unit instructions to in-
crease/decrease fan speed.
Changing air flow affects all temperatures; recheck temperatures to
confirm that the temperature drop and DT are within +3°.
Figure 32. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart
WEIGH
Refrigerant Charge per Line Set Length
Liquid Line Ounces per 5 feet (g per 1.5 m)
Set Diameter adjust from 15 feet (4.6 m) line set*
3/8" (9.5 mm) 3 ounce per 5' (85 g per 1.5 m)
NOTE - *If line length is greater than 15 ft. (4.6 m), add this
amount. If line length is less than !5 ft. (4.6 m), subtract this
amount.
LENNOX
_i|m[IWiIiiiHi
1. Check Liquid and suction line pressures
2. Compare unit pressures with tables 8 and
9, Normal Operating Pressures.
3. Conduct leak check; evacuate as
previously outlined,
4. Weigh in the unit nameplate charge plus
any charge required for line set differences
over feet,
This nameplate isfor illustration purposes
only. Go to actual nameplate on outdoor
unit for charge information.
Figure 33. Using Weigh In Method
505329M 04/08
Page 18

8UBCOOLING 2
USE COOLING
MODE
60°F (15 °) --
USE HEATING
MODE
Check the airflow as illustrated in figure 32 to be sure the indoor airflow is as required.
(Make any air flow adjustments before continuing with the following procedure0
Measure outdoor ambient temperature; determine whether to use cooling mode or
heating mode to check charge.
3 Connect gauge set.
4 Check liquid and vapor line pressures. Compare pressures with either heat or cooling mode
normal operating pressures in tables 8 and 9 (second stage - high capacity),
NOTE -The reference table is a general guide. Expect m#nor pressure variations. Significant
differences may mean improper charge or other system problem.
5 Set thermostat for heat/cool demand, depending on mode being used:
Using cooling mode--When the outdoor ambient temperature is 60°F (15°C) and above.
Target subcooling values (second stage - high capacity) in table 8 are based on 70 to 80°F
(21-27°C) indoor return air temperature; if necessary, operate heating to reach that
temperature range; then set thermostat to cooling mode setpoint to 68°F (20°C) which should
call for second stage (high capacity) cooling. When pressures have stabilized, continue with
step 6.
%
SATo
LIQo -
SCo =
Using heating mode--When the outdoor ambient temperature is below 60°F (15°C). Target
subcooling values (second stage - high capacity) in table 9 are based on 65-75°F (18-24°C)
indoor return air temperature; if necessary, operate cooling to reach that temperature range;
then set thermostat to heating mode setpoint to 77°F (25°C) which should call for second stage
(high capacity) heating. When pressures have stabilized, continue with step 6.
6 Read the liquid line temperature; record in the LIQ° space.
7 Read the liquid line pressure; then find its corresponding temperature in the temperature/
pressure chart listed in table 10 and record it in the SAT° space.
8 Subtract LIQ° temp. from SAT ° temp. to determine subcooling; record it in SC ° space.
9 Compare SC° results with table below, being sure to note any additional charge for line set
and/or match-up.
10 If subcooling value is greater than shown in tables 4 through 7 for the applicable unit, remove
refrigerant; if less than shown, add refrigerant.
11 If refrigerant is added or removed, repeat steps 4 through 10 to verify charge.
Figure 34. Using Subcooling Method -- Second Stage (High Capacity)
Table 4. XP16-024 Target
INDOOR HEAT Subcooling **Add
MATCHUP PUMP Heat Cool charge
(+5°F) (+I°F)
CBX26UH-018 20 8 1 5
CBX26UH-024 20 8 1 5
CB27UH-024 12 6 O 12
CB27UH-030 13 9 1 12
CB3OU 21/26 12 6 O 12
CB3OU 31 13 9 1 12
CBX32M-018/024 12 6 O 12
CBX32M-030 13 9 1 12
CBX32MV 024/030 13 9 1 12
CBX32MV 036 12 9 O 10
CH33-25B 17 4 O O
CH33-36A-2F 12 6 O 10
CH3_36B_F 17 4 O O
CH33 36C 2F 12 7 1 2
CR33-24A/B-F 20 4 O O
CR33-3O/36A/B/C-F 20 8 1 6
CR33 48 21 9 O 3
CX34_5A/_6F 12 6 O 12
CX34-31A/B-6F 20 9 1 12
CX34-36A/B/C-6F 17 5 O 5
CX34 38A/B 6F SerialNo#before6007K 31 7 O 8
CX34_8A/_6F SerialNo#6007Kandafter 10 8 O 11
CX34-19 18 4 O 1
Table 5. XP16-036
Target
INDOOR HEAT Subcooling **Add
MATCHUP PUMP Heat Cool charge
(*5°F) (*I°F)
ililili'11" .....
CH23_1 17 7 O 13
CH23-65 12 8 1 10
CBX26UHq330 25 8 1 14
CBX26UH 036 25 8 1 14
CB27UH-036 17 8 2 4
CB27UH-042 17 8 2 4
CB3OU_I 17 6 O O
CB3OU-41/46 17 8 2 4
CBX32M-030 17 6 O O
CBX32M-036 17 8 2 4
CBX32MV-024/030 17 6 O O
CBX32MV 036 17 8 2 4
C33 44C 17 8 1 14
CH33-42B-2F 17 7 O 13
CH33_44/48_2F 12 8 1 8
CH33_48C_F 10 8 1 6
CH33-43B 9 10 1 6
CH33_49C 9 10 1 6
CR33_48B/C_ 25 8 2 O
CR33-50/60C-F 25 9 0 14
CX34 38A/B_F se.al No#before6007K 31 7 1 5
CX34 38A/B 6FSet_alNo#6OOTKandafter 10 8 1 12
CX34-43B/C-6F 10 8 1 6
CX34 6OD 9 9 O 14
**Amount of charge required in additional to charge shown on unit nameplate.
(Remember to consider Iine set length difference.)
Page 19
XP16 SERIES

Table 6. XP16-048
Target
INDOOR HEAT Subcooling **Add
MATCHUP PUMP Heat Cool charge
(+5°F) (+I°F)
CH23 68 15 13 0 7
CB27UH-048 17 7 0 0
CB27UH-060 17 7 0 0
CB30U 51, 65 17 7 0 0
CBX32M-048, -060 17 7 0 0
CBX32MV-068 16 10 0 3
CH33 60D 2F 18 4 0 2
CH33-62D-2F 15 10 0 4
CR33-60 40 4 0 2
CX34 60D 6F 18 4 0 2
CX34-62D-6F 16 8 0 2
Table 7. XP16-060
Target
INDOOR HEAT Subcooling **Add
MATCHUP PUMP Heat Cool charge
(+5°F) (+I°F)
CH23 68 13 14 3 3
CH23-65 18 2 0 0
CBX26UH-060 13 14 3 5
CB27UH-060 13 10 2 1
CBX32M-060 13 10 2 1
CBX32MV-068 13 12 2 9
CH33 60D 2F 15 6 1 3
CH33-62D-2F 13 12 2 10
CR33-50/60C-F 30 6 1 3
CR33 60D F 30 6 1 3
CX34-49C-6F 13 9 1 14
CX34-60D-6F 15 6 1 3
CX34 62C 6F 13 11 2 6
CX34-62D-6F 13 11 2 5
NOTE -Use the tables 8 and 9 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.
Table 8. Normal Operating Pressures - Cooling 1
XP 16 -024 -036 -048 -060
°F (°C) 2 Liq IVap Liq IVap Liq IVap Liq IVap
First Stage (Low Capacity) Pressure 3
65 (18.3} 232 146 225 144 235 144 225 138
75 (23.9} 264 148 261 147 268 145 264 141
85 (29.4) 307 149 302 149 310 147 305 142
95 (35.6) 353 151 349 151 356 148 352 146
165 (46.6) 403 153 397 153 407 150 405 148
115(46.1) 460 155 461 157 466 152 459 150
Second Stage (High Capacity) Pressure 3
65 (18.3) 240 143 239 139 244 140 241 134
75 (23.9) 279 145 278 141 283 141 280 136
85 (29.4) 322 147 322 143 326 144 324 137
95 (35.6) 371 149 367 146 374 147 373 138
165 (46.6) 423 151 426 148 427 148 425 142
115(46.1) 485 154 489 151 491 151 486 146
Table 9. Normal Operating Pressures - Heating 1
XP 16 -024 -036 -048 -060
°F (°C) 2Liq IVap Liq IVap Liq IVap Liq IVap
First Stage (Low Capacity) Pressure 3
46 (4.4) 337 93 328 98 369 75 351 63
50 (16) 322 117 333 118 366 114 335 92
Second Stage (High Capacity) Pressure 3
26 (-7.0) 279 62 296 62 311 58 308 59
36 (-1.6) 288 76 309 75 334 72 323 70
46 (4.4) 302 93 322 92 354 89 318 69
56(16) 306 112 336 113 381 108 329 82
1 Most-popular-match-up pressures. Indoor match up, indoor air quality, and indoor load
cause pressures to vary.
2 Temperature of the air entering the outdoor coil.
3 Liquid -+10 & Vapor -+5psig.
Table 10. HFC-410A Temp. (°F) - Pressure (Psig)
°F Psig °F Psig °F Psig °F Psig
32 100.8 63 178.5 94 290.8 125 445.9
33 102.9 64 181.6 95 295.1 126 451.8
34 105.0 65 184.3 96 299.4 127 457.6
35 107.1 66 187.7 97 303.8 128 463.5
36 109.2 67 190.9 98 308.2 129 469.5
37 111.4 68 194.1 99 312.7 130 475.6
38 113.6 69 197.3 100 317.2 131 481.6
39 115.8 70 200.6 101 321.8 132 487.8
40 118.0 71 203.9 102 326.4 133 494.0
41 120.3 72 207.2 103 331.0 134 500.2
42 122.6 73 210.6 104 335.7 135 506.5
43 125.0 74 214.0 105 340.5 136 512.9
44 127.3 75 217.4 106 345.3 137 519.3
45 129.7 76 220.9 107 350.1 138 525.8
46 132.2 77 224.4 108 355.0 139 532.4
47 134.6 78 228.0 109 360.0 140 539.0
48 137.1 79 231.6 110 365.0 141 545.6
49 139.6 80 235.3 111 370.0 142 552.3
50 142.2 81 239.0 112 375.1 143 559.1
51 144.8 82 242.7 113 380.2 144 565.9
52 147.4 83 246.5 114 385.4 145 572.8
53 150.1 84 250.3 115 390.7 146 579.8
54 152.8 85 254.1 116 396.0 147 586.8
55 155.5 86 258.0 117 401.3 148 593.8
56 158.2 87 262.0 118 406.7 149 601.0
57 161.0 88 266.0 119 412.2 150 608.1
58 163.9 89 270.0 120 417.7 151 615.4
59 166.7 90 274.1 121 423.2 152 622.7
60 169.6 91 278.2 122 428.8 153 630.1
61 172.6 92 282.3 123 434.5 154 637.5
62 175.4 93 286.5 124 440.2 155 645.0
INSTALLING SERVICE VALVE CAPS
Disconnect gauge set and re-install both the liquid and
suction service valve caps,
INSTALL CAPS
OUTDOOR UNIT /
SERVICE VALVES_
Figure 35. Installing Service Valve Caps
505329M 04/08
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