Lennox Elite XP16-024-230 User manual

12/10 506640−01
*2P1210* *P506640-01*
Page 1
E20 Lennox Industries Inc.
Dallas, Texas, USA
These instructions are intended as a
general guide and do not supersede
local codes in any way. Consult
authorities having jurisdiction before
installation.
RETAIN THESE INSTRUCTIONS FOR FUTURE
REFERENCE
NOTICE TO INSTALLER
BRAZING LINE SET TO SERVICE VALVES
It is imperative to follow the brazing technique illustrated starting on
page 11 to avoid damaging the service valve’s internal seals.
WARNING
Improper installation, adjustment, alteration, service or
maintenance can cause personal injury, loss of life, or
damage to property.
Installation and service must be performed by a licensed
professional installer (or equivalent) or a service agency.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting of
refrigerant (CFCs, HFCs, and HCFCs) as of July 1,
1992. Approved methods of recovery, recycling or
reclaiming must be followed. Fines and/or incarceration
may be levied for noncompliance.
IMPORTANT
This unit must be matched with an indoor coil as
specified in Lennox XP16 Engineering Handbook.
Coils previously charged with HCFC−22 must be
flushed.
CAUTION
Physical contact with metal edges and corners while
applying excessive force or rapid motion can result in
personal injury. Be aware of, and use caution when
working near these areas during installation or while
servicing this equipment.
INSTALLATION
INSTRUCTIONS
Elite®Series XP16 Units
HEAT PUMPS
506640−01
12/10
Supersedes 11/10
TABLE OF CONTENTS
Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . .
General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Number Identification 2. . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . .
Caps and Fasteners Torque Requirements 3. . . . . . . .
Operating Gauge Set and Service Valves 3. . . . . . . . .
Recovering Refrigerant from Existing System 5. . . . .
New Outdoor Unit Placement 6. . . . . . . . . . . . . . . . . . .
Removing and Installing Panels 8. . . . . . . . . . . . . . . . .
Line Set Requirements 9. . . . . . . . . . . . . . . . . . . . . . . . .
Brazing Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Indoor Refrigerant Metering Device Removal and
Flushing Line Set and Indoor Coil 14. . . . . . . . . . . . . . . .
Installing New Indoor Metering Device 15. . . . . . . . . . . .
Leak Test Line Set and Indoor Coil 16. . . . . . . . . . . . . . .
Evacuating Line Set and Indoor Coil 17. . . . . . . . . . . . .
Electrical Connections 18. . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start−Up 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing and Weighing In Refrigerant for Units
Delivered Void of Charge 24. . . . . . . . . . . . . . . . . . . . . . .
Optimizing System Refrigerant Charge 26. . . . . . . . . . .
System Operation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defrost System 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two−Stage Modulation Compressors Checks 40. . . . . .
Maintenance 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklists 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List
Check unit for shipping damage. Consult last carrier
immediately if damage is found.
1 − Assembled outdoor unit
General
The XP16 outdoor unit uses HFC−410A refrigerant. This
unit must be installed with a matching indoor blower coil
and line set as outlined in the XP16 Lennox Engineering
Handbook. Elite®Series outdoor units are designed for
use in check / expansion valve (CTXV) systems only and
are not to be used with other refrigerant flow control
devices. An indoor coil check / expansion valve approved
for use with HFC−410A must be ordered separately and
installed prior to operating the unit.
Litho U.S.A.

Page 2
Model Number Identification
P 16 036− −
Unit Type
P = Heat Pump
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−05
Unit Dimensions − inches (mm)
ELECTRICAL
INLETS
SIDE VIEW
DISCHARGE AIR
VAPOR LINE
CONNECTION
LIQUID LINE
CONNECTION
4−1/4
(108)
4−3/4
(121)
1 (25)
2 (51)
SIDE VIEW
CB
A
UNIT SUPPORT
FEET
8−1/2
(216) D
G
K
J
E
F
XP16−024 BASE SECTION
8−3/4
(222)
5−1/2
(140)
9−1/2
(241)
8−1/4
(210)
13−1/2
(343)
UNIT SUPPORT FEET
XP16 BASE WITH LEGS
H
Mode Number A B C D E F G H J K
XP16−024−230 35 (889) 27 (686) 28 (711) −−−−−−−
XP16−036−230 39 (991) 30−1/2 (775) 35 (889) 13−7/8 (352) 7−3/4 (197) 3−1/4 (83) 27−1/8 (689) 3−5/8 (92) 4−1/2 (114) 20−5/8 (524)
XP16−048−230 35 (889) 35−1/2 (902) 39−1/2
(1003)
16−7/8 (429) 8−3/4 (222) 3−1/8 (79) 30−3/4 (781) 4−5/8 (117) 3−3/4 (95) 26−7/8 (683)
XP16−060−230 45 (1143 35−1/2 (902) 39−1/2
(1003)

Page 3
XP16 SERIES
Typical Unit Parts Arrangement
CHECK /
EXPANSION
VALVE
VAPOR VALVE AND GAUGE PORT /
SUCTION LINE CONNECTIONS
EXPANSION VALVE
SENSING BULB
LOW PRESSURE
SWITCH (S87)
LIQUID LINE
BI−FLOW FILTER
DRIER
HIGH PRESSURE
SWITCH (S4)
COMPRESSOR
LIQUID VALVE AND GAUGE
PORT / LIQUID LINE
CONNECTIONS
REVERSING
VALVE (L1)
DEMAND DEFROST
CONTROL (A108)
SINGLE POLE
CONTACTOR
(K1)
GROUND
LUG AMBIENT
TEMPERATURE
SENSOR (RT13)
TRUE SUCTION
PORT
DISCHARGE LINE
SENSOR (RT28)
XP16−024
COIL SENSOR −THIRD
HAIRPIN DOWN FROM
THE TOP ON INSIDE
ROW.
XP16−036
COIL SENSOR − NINTH
HAIRPIN UP FROM THE
BOTTOM ON INSIDE
ROW.
XP16−048
COIL SENSOR − EIGHT HAIRPIN
UP FROM THE BOTTOM ON
INSIDE ROW.
XP16−060
COIL SENSOR −
SIXTH HAIRPIN UP
FROM THE BOTTOM
ON INSIDE ROW.
DUAL RUN CAPACITOR (C12)
(−024, −036 AND −048 ONLY)
DETAIL A
FOR COIL SENSOR (RT21)
LOCATION SEE DETAIL A
SINGLE RUN CAPACITOR (C1)
(−060 ONLY)
Figure 1. Unit Parts Arrangement
Caps and Fasteners Torque Requirements
IMPORTANT
Only use Allen wrenches of sufficient hardness (50Rc −
Rockwell Harness Scale minimum). Fully insert the
wrench into the valve stem recess.
Service valve stems are factory−torqued (from 9 ft−lbs for
small valves, to 25 ft−lbs for large valves) to prevent
refrigerant loss during shipping and handling. Using an
Allen wrench rated at less than 50Rc risks rounding or
breaking off the wrench, or stripping the valve stem
recess.
See the Lennox Service and Application Notes
Corp.0807−L5 (C−08−1) for further details and
information.
When servicing or repairing HVAC equipment and
components, ensure the fasteners are appropriately
tightened. Table 1 list torque values for various caps and
fasteners.
Table 1. Torque Requirements
Parts Recommended Torque
Service valve cap 8 ft.− lb. 11 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

Page 4
Operating Gauge Set and Service Valves
IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted
snugly over the cap before tightening.
OPERATING SERVICE VALVES
The liquid and vapor line service valves are used for
refrigerant recovery, flushing, leak testing, evacuating,
weighing in refrigerant and optimizing system charge.
Each valve is equipped with a service port which has a
factory−installed valve core. Figure 2 provides information
on how to access and operate both angle− and ball−type
service valves.
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 for HFC−410A refrigerant
systems must be capable of handling the higher system
operating pressures. The manifold gauges should be rated
for:
SHigh side  Pressure range of 0 − 800 pound−force per
square inch gauge (psig)
SLow side  Use with 30" vacuum to 250 psig with
dampened speed to 500 psig
SManifold gauge set hoses must be rated for use to 800
psig of pressure with a 4000 psig burst rating.
INSERT HEX−HEAD
EXTENSION HERE
SERVICE PORT CORE
SERVICE PORT CAP
SERVICE PORT
CORE
TO OUTDOOR UNIT STEM CAP
(VALVE STEM SHOWN OPEN)
INSERT HEX WRENCH HERE
TO INDOOR
UNIT
BALL (SHOWN CLOSED)
SERVICE PORT CORE
TO INDOOR UNIT
TO OUTDOOR UNIT
AToopen rotate stem
counterclockwise
90°.
BToclose rotate stem
clockwise 90°.
SERVICE PORT
SERVICE PORT CAP
REMOVE
STEM CAP
VALVE STEM
Operating Angle−Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. Use a service wrench with a hex−head extension (3/16" for liquid line valve sizes and 5/16"
for vapor line valve sizes) to back the stem out counterclockwise as far as it will go to open
the service valve.
Operating Ball−Type Service Valve:
1. Remove stem cap with an appropriately sized wrench.
2. Use an appropriately sized wrenched to open.
1
2
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
contaminationand 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:
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.
12
3
4
5
6
7
8
9
10
11 12
1/6 TURN
When service valve stem is in the CLOSED position,
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:
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.
TO INDOOR
UNIT
TO OUTDOOR
UNIT
REMOVE
STEM CAP
1
2
VALVE STEM
SHOWN
CLOSED
1
2
Figure 2. Angle and Ball−Type Service Valves

Page 5
XP16 SERIES
Recovering Refrigerant from Existing System
Disconnect all power to the existing outdoor unit at the disconnect
switch and/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 manifold gauge set, clean recovery cylinder and a
recovery machine to the service ports of the existing unit..
METHOD 1:
Use Method 1 if the existing outdoor unit is not equipped with shut−off valves, or
if the unit is not operational and you plan to use the existing HCFC−22 to flush
the system.
Recover all HCFC−22 refrigerant from the existing system using a recovery
machine and clean recovery cylinder. Check gauges after shutdown to confirm
that the entire system is completely void of refrigerant.
METHOD 2:
Use Method 2 if the existing outdoor unit is equipped with manual shut−off valves,
and you plan to use new HCFC−22 refrigerant to flush the system.
Perform the following task:
A Start the existing HCFC−22 system in the cooling mode and close the liquid line
valve.
B Use the compressor to pump as much of the existing HCFC−22 refrigerant into
the outdoor unit until the outdoor system is full. Turn the outdoor unit main power
OFF and use a recovery machine to remove the remaining refrigerant from the
system.
NOTE  It may be necessary to bypass the low pressure switches (if equipped) to
ensure complete refrigerant evacuation.
C When the low side system pressures reach 0 psig, close the vapor line valve.
D Check gauges after shutdown to confirm that the valves are not allowing
refrigerant to flow back into the low side of the system.
Remove existing HCFC−22 refrigerant using one of the following procedures:
RECOVERING REFRIGERANT
12
3
DISCONNECT
SWITCH
MAIN FUSE
BOX/BREAKER
PANEL
NOTE  Use the recovery machine instructions to make
the correct manifold gauge set connections for recovery
refrigerant. The illustration below is a typical connection.
NOTE  When using Method 2, the listed devices
below 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 any of the above mentioned system
conditions, shut off the vapor valve. Turn OFF the main
power to unit and use a recovery machine to recover
any refrigerant left in the indoor coil and line set.
METHOD 2 LIMITATIONS
Figure 3. Refrigerant Recovery
IMPORTANT
The Environmental Protection Agency (EPA) prohibits the intentional venting of HFC refrigerants during maintenance,
service, repair and disposal of appliance. Approved methods of recovery, recycling or reclaiming must be followed.
WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly.
Failure to follow this warning may result in personal injury or death.

Page 6
New Outdoor Unit Placement
CAUTION
In order to avoid injury, take proper precaution when lift-
ing heavy objects.
Remove existing outdoor unit prior to placement of new
outdoor unit. See Unit Dimensions on page 2 for sizing
mounting slab, platforms or supports. Refer to figure 4 for
mandatory installation clearance requirements.
POSITIONING CONSIDERATIONS
Consider the following when positioning the unit:
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 5,
detail A.
PLACING UNIT ON SLAB
When installing unit at grade level, the top of the slab
should be high enough above grade so that water from
higher ground will not collect around the unit. The slab
should have a slope tolerance as described in figure 5,
detail B.
NOTE  If necessary for stability, anchor unit to slab as
described in figure 5, detail D.
ELEVATING THE UNIT
Units are outfitted with elongated support feet as illustrated
in figure 5, detail C.
If additional elevation is necessary, raise the unit by
extending the height of the unit support feet. This may be
achieved by using a 2 inch (50.8mm) schedule 40 female
threaded adapter.
The specified coupling will fit snuggly into the recessed
portion of the feet. Use additional 2 inch (50.8mm)
Schedule 40 male threaded adaptors which can be
threaded into the female threaded adaptors to make
additional adjustments to the level of the unit.
NOTE  Keep the height of extenders short enough to
ensure a sturdy installation. If it is necessary to extend
further, consider a different type of field−fabricated
framework that is sturdy enough for greater heights.
ROOF MOUNTING
Install the unit a minimum of 6 inches (152 mm) above the
roof surface to avoid ice build−up around the unit. Locate
the unit above a load bearing wall or area of the roof that
can adequately support the unit. Consult local codes for
rooftop applications. See figure 5, detail F for other roof top
mounting considerations.
NOTICE
Roof Damage!
This system contains both refrigerant and oil. Some
rubber roofing material may absorb oil and cause the
rubber to swell when it comes into contact with oil. The
rubber will then bubble and could cause leaks. Protect
the roof surface to avoid exposure to refrigerant and oil
during service and installation. Failure to follow this
notice could result in damage to roof surface.
CONTROL PANEL
ACCESS
LOCATION
6 (152)
36 (914)
12 (305) 30 (762)
LINE SET
CONNECTIONS
24
(610)
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 4. Installation Clearances

Page 7
XP16 SERIES
LEG DETAIL
BASE
2" (50.8MM) SCH 40
FEMALE THREADED
ADAPTER
Concrete slab  use two plastic anchors (hole
drill 1/4")
Wood or plastic slab  no plastic anchor (hole
drill 1/8")
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
Stabilizing bracket (18 gauge metal  2" (50.8mm) width; height as required); bend to form
right angle as exampled below.
FOR EXTRA
STABILITY
 Deck Top Mounting
Elevated Slab Mounting
using Feet Extenders
Install unit level or, if on a slope, maintain slope tolerance of two (2)
degrees (or two inches per five feet [50 mm per 1.5 m]) away from
building structure.
MOUNTING
SLAB
BUILDING
STRUCTURE
GROUND LEVEL
 Outside Unit Placement  Slab Mounting at Ground Level
SAME FASTENERS AS
SLAB SIDE MOUNTING.
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.
TWO 90° ELBOWS INSTALLED IN LINE SET WILL
REDUCE LINE SET VIBRATION.
Install unit away from windows.
One bracket per side
(minimum). For extra
stability, two brackets per
side, two inches (51mm)
from each corner.
DETAIL E
MINIMUM ONE
PER SIDE
DETAIL F
WIND BARRIER
INLET AIR
INLET AIR INLET AIR
INLET AIR
PREVAILING WINTER WINDS
 Roof Top Mounting
If unit coil cannot be mounted away from prevailing winter winds, a wind barrier should be
constructed. Size barrier at least the same height and width as outdoor unit. Mount barrier 24
inches (610 mm) from the sides of the unit in the direction of prevailing winds as illustrated.

Figure 5. Placement, Slab Mounting and Stabilizing Unit

Page 8
Removing and Installing Panels
LOUVERED PANEL REMOVAL
Remove the louvered panels as follows:
1. Remove two screws, allowing the panel to swing open
slightly.
2. Hold the panel firmly throughout this procedure. Rotate
bottom corner of panel away from hinged corner post until
lower three tabs clear the slots as illustrated in detail B.
3. Move panel down until lip of upper tab clears the top slot in
corner post as illustrated in detail A.
LOUVERED PANEL INSTALLATION
Position the panel almost parallel with the unit as illustrated in
detail D with the screw side as close to the unit as possible.
Then, in a continuous motion:
1. Slightly rotate and guide the lip of top tab inward as
illustrated in detail A and C; then upward into the top
slot of the hinge corner post.
2. Rotate panel to vertical to fully engage all tabs.
3. Holding the panel’s hinged side firmly in place, close
the right−hand side of the panel, aligning the screw
holes.
4. When panel is correctly positioned and aligned, insert
the screws and tighten.
Detail A
ROTATE IN THIS DIRECTION;
THEN DOWN TO REMOVE
PANEL
SCREW
HOLES
LIP
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.
MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO
PARALLEL WITH THE UNIT AS POSSIBLE) WHILE
INSTALLING PANEL.
PREFERRED ANGLE
FOR INSTALLATION
ANGLE MAY BE TOO
EXTREME
HOLD DOOR FIRMLY TO THE HINGED
SIDE TO MAINTAIN
FULLY−ENGAGED TABS
Detail C
Detail B
Detail D
Figure 6. Removing and Installing Panels
WARNING
To prevent personal injury, or damage to panels, unit or structure, be sure to observe the following:
While installing or servicing this unit, carefully stow all removed panels out of the way, so that the panels will not cause
injury to personnel, nor cause damage to objects or structures nearby, nor will the panels be subjected to damage (e.g.,
being bent or scratched).
While handling or stowing the panels, consider any weather conditions, especially windy conditions, that may cause
panels to be blown around and battered.

Page 9
XP16 SERIES
Line Set Requirements
This section provides information on: installation of new or
replacement line set.
SAdding Polyol ester oil requirements
SNew or replacement line set installation
SUsing existing line set.
ADDING POLYOL ESTER OIL REQUIREMENTS
IMPORTANT
Mineral oils are not compatible with HFC−410A.If oil
must be added, it must be a Polyol Ester oil.
The compressor is charged with sufficient Polyol Ester oil
(POE) for line set lengths up to 50 feet. Recommend
adding oil to system based on the amount of refrigerant
charge in the system. Systems with 20 pounds or less of
refrigerant required no oil to be added.
For systems over 20 pounds − add one ounce for every five
(5) pounds of HFC−410A refrigerant.
Recommended topping−off POE oils are Mobil EAL
ARCTIC 22 CC or ICI EMKARATEtRL32CF.
NEW OR REPLACEMENT LINE SET INSTALLATION
Field refrigerant piping consists of both liquid and vapor
lines from the outdoor unit to the indoor coil. Use Lennox
L15 (sweat, non−flare) series line set, or field−fabricated
refrigerant line sizes as specified in table 2.
If refrigerant lines are routed through a wall, then seal and
isolate the opening so vibration is not transmitted to the
building. Pay close attention to line set isolation during
installation of any HVAC system. When properly isolated
from building structures (walls, ceilings. floors), the
refrigerant lines will not create unnecessary vibration and
subsequent sounds. See figure 7 for recommended
installation practices.
NOTE  When installing refrigerant lines longer than 50
feet, see the Lennox Refrigerant Piping Design and
Fabrication Guidelines, CORP. 9351−L9, or contact
Lennox Technical Support Product Applications for
assistance. To obtain the correct information from Lennox,
be sure to communicate the following information:
SModel (XP16) and size of unit (e.g. −036).
SLine set diameters for the unit being installed as listed
in table 2 and total length of installation.
SNumber of elbows vertical rise or drop in the piping.
USING EXISTING LINE SET
Things to consider:
SLiquid line that meter the refrigerant, such as RFC1
liquid line, must not be used in this application.
SExisting line set of proper size as listed in table 2 may
be reused.
SIf system was previously charged with HCFC−22
refrigerant, then existing line set must be flushed (see
Flushing Line Set and Indoor Coil on page 14).
If existing line set is being used, then proceed to Brazing
Connections on page 11.
IMPORTANT
Lennox highly recommends changing line set when
converting the existing system from HCFC−22 to
HFC−410A.If that is not possible and the line set is the
proper size as reference in table 2, use the procedure
outlined under Flushing Line Set and Indoor Coil on page
13.
IMPORTANT
If this unit is being matched with an approved line set
or indoor unit coil which was previously charged with
mineral oil, or if it is being matched with a coil which
was manufactured before January of 1999, the coil
and line set must be flushed prior to installation. Take
care to empty all existing traps. Polyol ester (POE) oils
are used in Lennox units charged with HFC−410A
refrigerant. Residual mineral oil can act as an
insulator, preventing proper heat transfer. It can also
clog the expansion device, and reduce the system
performance and capacity.
Failure to properly flush the system per the
instructions below will void the warranty.
Table 2. Refrigerant Line Set  Inches (mm)
Model Field Connections Recommended Line Set
Liquid Line Suction Line Liquid Line Suction Line L15 Line Set
XP16−024−230 3/8" (10 mm) 3/4" (19 mm) 3/8" (10 mm) 3/4" (19 mm) L15−41  15 ft. − 50 ft. (4.6m − 15 m)
XP16−036−230
3/8" (10 mm) 7/8" (22 mm) 3/8" (10 mm) 7/8" (22 mm) L15−65  15 ft. − 50 ft. (4.6 m − 15 m)
XP16−048−230
XP16−060−230 3/8" (10 mm) 1−1/8" (29 mm) 3/8" (10 mm) 1−1/8" (29 mm) Field Fabricated
NOTE  Some applications may required a field provided 7/8" to 1−1/8" adapter

Page 10
ANCHORED HEAVY NYLON
WIRE TIE OR AUTOMOTIVE
MUFFLER-TYPE HANGER
STRAP LIQUID LINE TO
VAPOR LINE
WALL
STUD
LIQUID LINE
NON−CORROSIVE
METAL SLEEVE
VAPOR LINE − WRAPPED
IN ARMAFLEX
AUTOMOTIVE
MUFFLER-TYPE HANGER
REFRIGERANT LINE SET  TRANSITION
FROM VERTICAL TO HORIZONTAL
Line Set Isolation  The following illustrations are examples of proper refrigerant line set isolation:
STRAPPING
MATERIAL (AROUND
VAPOR LINE ONLY)
TAPE OR
WIRE TIE
WIRE TIE (AROUND
VAPOR LINE ONLY)
FLOOR JOIST OR
ROOF RAFTER
TAPE OR
WIRE TIE
To hang line set from joist or rafter, use either metal strapping material
or anchored heavy nylon wire ties.
8 FEET (2.43 METERS)
STRAP THE VAPOR LINE TO THE JOIST
OR RAFTER AT 8 FEET (2.43 METERS)
INTERVALS THEN STRAP THE LIQUID
LINE TO THE VAPOR LINE.
FLOOR JOIST OR
ROOF RAFTER
REFRIGERANT LINE SET  INSTALLING
HORIZONTAL RUNS
NOTE  Similar installation practices should be used if line set is
to be installed on exterior of outside wall.
PVC
PIPE
FIBERGLASS
INSULATION
CAULK
OUTSIDE
WALL
VAPOR LINE WRAPPED
WITH ARMAFLEX
LIQUID
LINE
OUTSIDE WALL LIQUID LINE
VAPOR LINE
WOOD BLOCK
BETWEEN STUDS
STRAP
WOOD BLOCK
STRAP
SLEEVE
WIRE TIE
WIRE TIE
WIRE TIE
INSIDE WALL
REFRIGERANT LINE SET  INSTALLING
VERTICAL RUNS (NEW CONSTRUCTION SHOWN)
NOTE  Insulate liquid line when it is routed through areas where the
surrounding ambient temperature could become higher than the
temperatureof the liquid line or when pressure drop is equal to or greater
than 20 psig.
NON−CORROSIVE
METAL SLEEVE
NON−CORROSIVE
METAL SLEEVE
8 FEET (2.43 METERS)
Figure 7. Line Set Installation

Page 11
XP16 SERIES
Brazing Connections
Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves.
WARNING
Polyol Ester (POE) oils used with HFC−410A
refrigerant absorb moisture very quickly. It is very
important that the refrigerant system be kept closed
as much as possible. DO NOT remove line set caps
or service valve stub caps until you are ready to make
connections.
WARNING
Danger of fire. Bleeding the refrigerant
charge from only the high side may result
in pressurization of the low side shell and
suction tubing. Application of a brazing
torch to a pressurized system may result
in ignition of the refrigerant and oil
mixture − Check the high and low
pressures before applying heat.
WARNING
When using a high pressure gas such as
dry nitrogen to pressurize a refrigeration
or air conditioning system, use a
regulator that can control the pressure
down to 1 or 2 psig (6.9 to 13.8 kPa).
CAUTION
Brazing alloys and flux contain materials which are
hazardous to your health.
Avoid breathing vapors or fumes from brazing
operations. Perform operations only in well−ventilated
areas.
Wear gloves and protective goggles or face shield to
protect against burns.
Wash hands with soap and water after handling brazing
alloys and flux.
IMPORTANT
Allow braze joint to cool before removing the wet rag
from the service valve. Temperatures above 250ºF can
damage valve seals.
IMPORTANT
Use silver alloy brazing rods with 5% minimum silver
alloy for copper−to−copper brazing. Use 45% minimum
alloy for copper−to−brass and copper−to−steel brazing.
WARNING
Fire, Explosion and Personal Safety
Hazard.
Failure to follow this warning could
result in damage, personal injury or
death.
Never use oxygen to pressurize or
purge refrigeration lines. Oxygen,
when exposed to a spark or open
flame, can cause fire and/or an ex-
plosion, that could result in property
damage, personal injury or death.

Page 12
ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE
VALVES
OUTDOOR
UNIT
LIQUID LINE
VAPOR LINE
LIQUID LINE SERVICE
VALVE
SUCTION /
VAPOR LINE
SERVICE
VALVE
ATTACH
GAUGES
INDOOR
UNIT
SUCTION / VAPOR SERVICE PORT MUST BE
OPEN TO ALLOW EXIT POINT FOR NITROGEN
A Connect gauge set low pressure side to
liquid line service valve (service port).
B Connect gauge set center port to bottle of
nitrogen with regulator.
C Remove core from valve in suction / vapor
line service port to allow nitrogen to escape.
NITROGEN
HIGHLOW
USE REGULATOR TO FLOW
NITROGEN AT 1 TO 2 PSIG.
B
A
C
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
Flow regulated nitrogen (at 1 to 2 psig) through the low−side refrigeration gauge set into the liquid line service port valve, and out of the suction /
vapor line service port valve.
CUT AND DEBUR CAP AND CORE REMOVAL
Cut ends of the refrigerant lines square (free from nicks or dents)
and debur the ends. The pipe must remain round. Do not crimp end
of the line.
Remove service cap and core from
both the suction / vapor and liquid line
service ports.
12
LIQUID LINE SERVICE
VALVE
SERVICE
PORT
CORE
SERVICE PORT
CAP
SERVICE
PORT
CORE
SERVICE
PORT CAP
CUT AND DEBUR
LINE SET SIZE MATCHES
SERVICE VALVE CONNECTION
COPPER TUBE
STUB
SERVICE VALVE
CONNECTION
REFRIGERANT LINE
DO NOT CRIMP SERVICE VALVE
CONNECTOR WHEN PIPE IS
SMALLER THAN CONNECTION
REDUCER
3
SUCTION / VAPOR LINE
SERVICE VALVE
LINE SET SIZE IS SMALLER
THAN CONNECTION
Figure 8. Brazing Procedures
WARNING
When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning
system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).

Page 13
XP16 SERIES
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
LIQUID LINE SERVICE VALVE
LIQUID LINE
BRAZE LINE SET
Wrap both service valves with water saturated cloths as illustrated here and as mentioned in step 4, before brazing to line set. Water
saturated cloths must remain water saturated throughout the brazing and cool−down process.
WATER SATURATED
CLOTH
IMPORTANT  Allow braze joint to cool. Apply
additional water saturated cloths to help cool brazed
joint. Do not remove water saturated cloths until piping
has cooled. Temperatures above 250ºF will damage
valve seals.
6
SUCTION / VAPOR LINE
WATER SATURATED
CLOTH
SUCTION / VAPOR LINE
SERVICE VALVE
After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water saturated cloths to both
service valves to cool piping. Once piping is cool, remove all water saturated cloths.
WHEN BRAZING LINE SET TO
SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
PREPARATION FOR NEXT STEP
7
WARNING
1. FIRE, PERSONAL INJURY, OR PROPERTY
DAMAGE may result if you do not wrap a water
saturated cloth around both liquid and suction line
service valve bodies and copper tube stub while
brazing in the line set! The braze, when complete,
must be quenched with water to absorb any residual
heat.
2. Do not open service valves until refrigerant lines and
indoor coil have been leak−tested and evacuated.
Refer to procedures provided in this supplement.
WRAP SERVICE VALVES
To help protect service valve seals during brazing, wrap water saturated cloths around service valve bodies and copper tube stubs. Use
additional water saturated cloths underneath the valve body to protect the base paint.
4
FLOW NITROGEN
Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and
out of the suction / vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set connections
5
Figure 9. Brazing Procedures (continued)

Page 14
Indoor Refrigerant Metering Device Removal and Flushing Line Set and Indoor Coil
Flushing is only required when the existing system used HCFC−22 refrigerant. If the existing system used HFC−410a, then
remove the original indoor coil metering device and proceed to Installing New Indoor Metering Device on page 15.
SENSING
LINE
TEFLON®RING
FIXED ORIFICE
BRASS NUT
LIQUID LINE ASSEMBLY
(INCLUDES STRAINER)
LIQUID LINE ORIFICE HOUSING
DISTRIBUTOR TUBES
DISTRIBUTOR
ASSEMBLY
REMOVE AND DISCARD
WHITE TEFLON®SEAL
(IF PRESENT)
A On fully cased coils, remove the coil access and plumbing panels.
B Remove any shipping clamps holding the liquid line and distributor as-
sembly.
C Using two wrenches, disconnect liquid line from liquid line orifice hous-
ing. Take care not to twist or damage distributor tubes during this pro-
cess.
D Remove and discard fixed orifice, valve stem assembly if present and
Teflon®washer as illustrated above.
E Use a field−provided fitting to temporary reconnect the liquid line to the
indoor unit’s liquid line orifice housing.
TYPICAL EXISTING FIXED ORIFICE
REMOVAL PROCEDURE (UNCASED
COIL SHOWN)
TYPICAL EXISTING EXPANSION VALVE REMOVAL
PROCEDURE (UNCASED COIL SHOWN)
TWO PIECE PATCH PLATE
(UNCASED COIL ONLY)
VAPOR
LINE
DISTRIBUTOR
ASSEMBLY
DISTRIBUTOR
TUBES
LIQUID
LINE
MALE EQUALIZER
LINE FITTING
EQUALIZER
LINE
CHECK
EXPANSION
VALVE
TEFLON®
RING
STUB END
TEFLON®
RING
SENSING BULB
LIQUID LINE
ORIFICE
HOUSING
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
A On fully cased coils, remove the coil access and plumbing panels.
B Remove any shipping clamps holding the liquid line and distributor
assembly.
C Disconnect the equalizer line from the check expansion valve
equalizer line fitting on the vapor line.
D Remove the vapor line sensing bulb.
E Disconnect the liquid line from the check expansion valve at the liquid
line assembly.
F Disconnect the check expansion valve from the liquid line orifice
housing. Take care not to twist or damage distributor tubes during this
process.
G Remove and discard check expansion valve and the two Teflon®rings.
H Use a field−provided fitting to temporary reconnect the liquid line to the
indoor unit’s liquid line orifice housing.
LOW HIGH
EXISTING
INDOOR
UNIT
GAUGE
MANIFOLD
INVERTED HCFC−22
CYLINDER CONTAINS
CLEAN HCFC−22 TO BE
USED FOR FLUSHING.
LIQUID LINE SERVICE
VALVE
INLET
DISCHARGE
TANK
RETURN
CLOSED
OPENED
RECOVERY
CYLINDER
RECOVERY MACHINE
NEW
OUTDOOR
UNIT
VAPOR LINE
SERVICE VALVE
VAPOR
LIQUID
1
A Inverted HCFC−22 cylinder with clean refrigerant to the vapor service
valve.
B HCFC−22 gauge set (low side) to the liquid line valve.
C HCFC−22 gauge set center port to inlet on the recovery machine with an
empty recovery tank to the gauge set.
D Connect recovery tank to recovery machines per machine instructions.
CONNECT GAUGES AND EQUIPMENT FOR
FLUSHING PROCEDURE
A
B
C
D
B
OR
FLUSHING LINE SET
A 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.
B Invert the cylinder of clean HCFC−22 and open its valve to allow
liquid refrigerant to flow into the system through the vapor line
valve. Allow the refrigerant to pass from the cylinder and through
the line set and the indoor unit coil before it enters the recovery
machine.
C After all of the liquid refrigerant has been recovered, switch the
recovery machine to vapor recovery so that all of the HCFC−22
vapor is recovered. Allow the recovery machine to pull down to 0
the system.
D 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.
The line set and indoor unit coil must be flushed with at least the
same amount of clean refrigerant that previously charged the
system. Check the charge in the flushing cylinder before
proceeding.
1A
2
3
1B
Figure 10. Removing Indoor Refrigerate Metering Device and Flushing Procedures

Page 15
XP16 SERIES
Installing New Indoor Metering Device
This outdoor unit is designed for use in HFC−410A systems that use a check / expansion valve metering device (purchased
separately) at the indoor coil.
See the Lennox XP16 Engineering Handbook for approved check / expansion valve kit match−ups. The check / expansion
valve device can be installed either internal or external to the indoor coil. In applications where an uncased coil is being
installed in a field−provided plenum, install the check / expansion valve in a manner that will provide access for field servicing
of the check / expansion valve (see figure 11).
A Attach the vapor line sensing bulb in the proper
orientation as illustrated to the right using the clamp and
screws provided.
NOTE  Confirm proper thermal contact between vapor line
and expansion bulb before insulating the sensing bulb once
installed.
B Connect the equalizer line from the check / expansion
valve to the equalizer vapor port on the vapor line. Finger
tighten the flare nut plus 1/8 turn (7 ft−lbs) as illustrated
below.
TWO PIECE
PATCH PLATE
(UNCASED
COIL ONLY)
VAPOR
LINE
LIQUID LINE
ORIFICE
HOUSING
DISTRIBUTOR
TUBES
LIQUID LINE
MALE EQUALIZER LINE
FITTING (SEE
EQUALIZER LINE
INSTALLATION FOR
FURTHER DETAILS)
SENSING
LINE
EQUALIZER
LINE
CHECK /
EXPANSION
VALVE
TEFLON®
RING
(Uncased Coil Shown)
Sensing bulb insulation is
required if mounted external to
the coil casing.
STUB
END
TEFLON®
RING
LIQUID LINE
ASSEMBLY WITH
BRASS NUT
DISTRIBUTOR
ASSEMBLY
A Remove the field−provided fitting that temporarily
reconnected the liquid line to the indoor unit’s distributor
assembly.
B Install one of the provided Teflon®rings around the
stubbed end of the check / expansion valve and lightly
lubricate the connector threads and expose surface of
the Teflon®ring with refrigerant oil.
C Attach the stubbed end of the expansion valve 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 the figure above, or 20 ft−lb.
D Place the remaining Teflon®washer around the other
end of the check / expansion valve. Lightly lubricate
connector threads and expose surface of the Teflon®
ring with refrigerant oil.
E Attach the liquid line assembly to the check / expansion
valve. Finger tighten and use an appropriately sized
wrench to turn an additional 1/2 turn clockwise as
illustrated in the figure above or 20 ft−lb.
ON 7/8" AND LARGER LINES,
MOUNT SENSING BULB AT
EITHER THE 4 OR 8 O’CLOCK
POSITION. NEVER MOUNT ON
BOTTOM OF LINE.
12
ON LINES SMALLER THAN
7/8", MOUNT SENSING
BULB AT EITHER THE 3 OR
9 O’CLOCK POSITION.
12
BULB
VAPOR LINE
VAPOR LINE
NOTE  NEVER MOUNT ON BOTTOM OF LINE.
BULB
BULB
BULB
VAPOR LINE
FLARE NUT
COPPER FLARE
SEAL BONNET
MALE BRASS EQUALIZER
LINE FITTING
FLARE SEAL CAP
OR
1
2
3
4
5
6
7
8
9
10
11 12
1/2 Turn
SENSING BULB INSTALLATION
EQUALIZER LINE INSTALLATION
1
2
3
4
5
6
7
8
9
10
11 12
1/8 Turn
Remove and discard either the flare seal cap or flare nut with
copper flare seal bonnet from the equalizer line port on the vapor
line as illustrated in the figure to the right.
INDOOR EXPANSION VALVE INSTALLATION
Figure 11. Installing Indoor Check / Expansion Valve

Page 16
Leak Test Line Set and Indoor Coil
IMPORTANT
Leak detector must be capable of sensing HFC refrigerant.
TO VAPOR
SERVICE VALVE
HFC−410A
MANIFOLD GAUGE SET
OUTDOOR UNIT
HIGHLOW
NITROGEN
A Connect an HFC−410A manifold gauge set high pressure hose to the
vapor valve service port.
NOTE  Normally, the high pressure hose is connected to the liquid
line port. However, connecting it to the vapor port better protects the
manifold gauge set from high pressure damage.
B With both manifold valves closed, connect the cylinder of HFC−410A
refrigerant to the center port of the manifold gauge set.
NOTE  Later in the procedure, the
HFC−410A container will be replaced by
the nitrogen container.
CONNECT GAUGE SET
A
B
Figure 12. Manifold Gauge Set Connections for Leak Testing
TEST FOR LEAKS
After the line set has been connected to the indoor and
outdoor units, check the line set connections and indoor
unit for leaks. Use the following procedure to test for leaks:
1. With both manifold valves closed, connect the cylinder
of HFC−410A refrigerant to the center port of the
manifold gauge set. Open the valve on the HFC−410A
cylinder (vapor only).
2. 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.
3. Connect a cylinder of dry nitrogen with a pressure
regulating valve to the center port of the manifold
gauge set.
4. Adjust dry nitrogen pressure to 150 psig (1034 kPa).
Open the valve on the high side of the manifold gauge
set in order to pressurize the line set and the indoor unit.
5. 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.
6. After leak testing disconnect gauges from service
ports.

Page 17
XP16 SERIES
Evacuating Line Set and Indoor Coil
Evacuating the system of non−condensables is critical for proper operation of the unit. Non−condensables are defined as any
gas that will not condense under 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 Open both manifold valves and start the vacuum pump.
B 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. A rapid rise in pressure
indicates a relatively large leak. If this occurs, repeat the leak testing procedure.
NOTE  The term absolute pressure means the total actual pressure within a given volume or system, above the absolute zero of
pressure. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure.
C When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), perform the following:
SClose manifold gauge valves
SClose valve on vacuum pump and turn off vacuum pump
SDisconnect manifold gauge center port hose from vacuum pump
SAttach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose.
SOpen manifold gauge valves to break the vacuum in the line set and indoor unit.
SClose manifold gauge valves.
D 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.
E 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.
F When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to an
upright cylinder of HFC−410A refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and
indoor unit.
G Perform the following:
OUTDOOR
UNIT
TO VAPOR
SERVICE VALVE
TO LIQUID LINE
SERVICE VALVE
MICRON
GAUGE
VACUUM PUMP
A34000 1/4 SAE TEE WITH
SWIVEL COUPLER
500
MANIFOLD
GAUGE SET
HFC−410A
RECOMMEND
MINIMUM 3/8" HOSE
AConnect low side of manifold gauge set
with 1/4 SAE in−line tee to vapor line
service valve
BConnect high side of manifold gauge
set to liquid line service valve
CConnect micron gauge available
connector on the 1/4 SAE in−line tee.
DConnect the vacuum pump (with
vacuum gauge) to the center port of the
manifold gauge set. The center port
line will be used later for both the
HFC−410A and nitrogen containers.
HIGHLOW
1
2
3
4
5
6
7
8
9
10
11 12
1/6 TURN
NITROGEN
1CONNECT GAUGE SET
A
B
C
D
2EVACUATE THE SYSTEM
NOTE  Remove cores from service valves (if not already done).
SClose manifold gauge valves.
SShut off HFC−410A cylinder.
SReinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core
tool while maintaining a positive system pressure.
SReplace stem caps and secure finger tight, then tighten an additional one−sixth (1/6) of a turn as illustrated.
Figure 13. Evacuating Line Set and Indoor Coil

Page 18
IMPORTANT
Use a thermocouple or thermistor electronic vacuum
gauge that is calibrated in microns. Use an instrument
capable of accurately measuring down to 50 microns.
WARNING
Danger of Equipment Damage. Avoid deep vacuum
operation. Do not use compressors to evacuate a
system. Extremely low vacuums can cause internal
arcing and compressor failure. Damage caused by
deep vacuum operation will void warranty.
Electrical Connections
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 air handler installation instructions
for additional wiring application diagrams and refer to unit
nameplate for minimum circuit ampacity and maximum
overcurrent protection size.
24VAC TRANSFORMER
Use the transformer provided with the furnace or air
handler for low-voltage control power (24VAC − 40 VA
minimum)
Refer to the unit nameplate for minimum circuit ampacity, and
maximum fuse or circuit breaker (HACR per NEC). Install power
wiring and properly sized disconnect switch.
NOTE  Units are approved for use only with copper conductors.
Ground unit at disconnect switch or to an earth ground.
SIZE CIRCUIT AND INSTALL DISCONNECT
SWITCH
1
NOTE  24VAC, Class II circuit connections are made in the control
panel.
Install room thermostat (ordered separately) on an inside wall
approximately in the center of the conditioned area and 5 feet
(1.5m) from the floor. It should not be installed on an outside wall
or where it can be affected by sunlight or drafts.
THERMOSTAT
5 FEET
(1.5M)
INSTALL THERMOSTAT
2
DISCONNECT
SWITCH
MAIN FUSE BOX/
BREAKER PANEL
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.

Page 19
XP16 SERIES
ARun 24VAC control wires through cutout with grommet.
BRun 24VAC control wires through wire tie.
CMake 24VAC control wire connections.
DTighten wire tie to security 24V control wiring.
HIGH VOLTAGE FIELD WIRING
LOW VOLTAGE (24V) FIELD WIRING
CUTOUT WITH
GROMMET
NOTE − For proper voltages, select thermostat wire (control wires)
gauge per table above.
WIRE RUN LENGTH AWG# INSULATION TYPE
LESS THAN 100’ (30 METERS) 18 TEMPERATURE RATING
MORE THAN 100’ (30 METERS) 16 35ºC MINIMUM.
24V CONTROL WIRES TIGHTEN WIRE TIE
LOW VOLTAGE CONNECTIONS
NOTE − Do not bundle any excess 24VAC control wires inside
control box.
NOTE − Wire tie provides low voltage wire strain relief and to maintain
separation of field installed low and high voltage circuits.
Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated. See figures 14 and 15 for typical field
connections when connecting unit to either a CBX32MV or CBX40UHV in non−communicating mode. For connections to other Lennox air handlers
or furnaces, see the ComfortSense® 7000 installation instruction for further match component wiring illustrations.
3
A
B
C
D
NOTE − Any excess high voltage field wiring
should be trimmed and secured away from
any low voltage field wiring.
GROUND
L2
NOTE − To facilitate a conduit, a cutout is lo-
cated in the bottom of the control box. Connect
conduit to the control box using a proper con-
duit fitting.
CONDUIT
CONDUIT
CUTOUT
OUTDOOR UNIT
CONTROL BOX
G
L1
HIGH VOLTAGE POWER SUPPLY CONNECTIONS
4

Page 20
CBX32MV
OR
CBX40UHV
HEAT PUMP UNIT
(TWO−STAGE) X2658 OUTDOOR SENSOR IS REQUIRED FOR OUTDOOR
TEMPERATURE DISPLAY, DEW POINT CONTROL, HEAT PUMP AND
DUAL FUEL BALANCE POINTS.
COMFORTSENSET
7000
RRR
W3 H
W2
W2
W1 W1 W1
O
OO
L
L
Y1
Y1
Y1
Y2Y2
G
G
CCC
T
T
D
B
Y2
DS
O. D.
SENSOR
(X2658)
Y2
OUT
BL
1
1
CUT ON−BOARD LINK R −O.
CUT ON−BOARD LINK R−DS WHEN DEHUMIDIFICATION TERMINAL IS USED.
CUT ON−BOARD LINK Y1−Y2 FOR TWO−STAGE HP
2
2
3
3FIELD PROVIDED JUMPER BETWEEN Y2 OUT BL ON HEAT PUMP
TO Y2 ON CBX40UHV.
CONNECTED ON UNIT WITH LSOM. RESISTOR KIT (CAT # 47W97)
IS REQUIRED WHEN CONNECTING THE COMFORTSENSE 7000
WITH THE LSOM 2.
Y1−Y2
2−STAGE
COMPR
R−O
HEAT
PUMP
R−DS
DEHUM
OR
HARMONY
CUT FOR OPTION
AIR
HANDLER
CONTROL
IMPORTANT − USE CARE WHEN CUTTING LINKS TO
PREVENT DAMAGE TO CONTROL. SEE CBX40UHV
INSTALLATION INSTRUCTION FOR FURTHER DETAILS.
Figure 14. Typical Field Wiring  Heat Pump Application with CBX32MV or CBX40UHV
YELLOW
BLUE (NOT REQUIRED FOR SINGLE STAGE)
RED
BLACK
PURPLE
PURPLE
BLACK
BLUE
RED
FAN RELAY (NOT REQUIRED
WITH SINGLE−SPEED
OUTDOOR FAN)
OUTDOOR
SENSOR
(X2658)
COMFORTSENSEt
7000 THERMOSTAT
OUTDOOR UNIT
CUT ON−BOARD LINK R −O.
CUT ON−BOARD LINK Y1−Y2 FOR TWO−STAGE A/C ONLY
CUT ON−BOARD LINK R−DS WHEN DEHUMIDIFICATION
TERMINAL IS USED.
T
T
BROWN (NOT USED FOR APPLICATIONS WITHOUT LSOM
Y1−Y2
2−STAGE
COMPR
R−O
HEAT
PUMP
R−DS
DEHUM
OR
HARMONY
CUT FOR OPTION
RESISTOR KIT (CAT # 47W97) IS REQUIRED
WHEN CONNECTING THE COMFORTSENSE
7000 WITH THE LSOM 2.
IMPORTANT − USE CARE WHEN CUTTING LINKS TO
PREVENT DAMAGE TO CONTROL. SEE CBX40UHV
INSTALLATION INSTRUCTION FOR FURTHER DETAILS.
CBX32MV OR
CBX40UHV
AIR
HANDLER
CONTROL
Figure 15. Heat Pump Application  Humiditrol ®and Second−Stage Outdoor Fan Relay Wiring with
CBX32MV or CBX40UHV