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INSTALLATION
INSTRUCTIONS
20 Lennox Industries Inc.
Dallas, Texas, USA
®
Elite Series XP16 Units
HEAT PUMPS
506640−01
These instructions are intended as a
12/10
Litho U.S.A.
general guide and do not supersede
Supersedes 11/10
local codes in any way. Consult
authorities having jurisdiction before
TABLE OF CONTENTS
installation.
Shipping and Packing List . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Model Numbe
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Model Number Identification XP16 −036 −230 −05 Refrigerant Type Minor Revision Number X = R−410A Voltage 230 = 208/230V−1ph−60hz Unit Type P = Heat Pump Nominal Cooling Capacity 024 = 2 tons 036 = 3 tons Series 048 = 4 tons 060 = 5 tons Unit Dimensions − inches (mm) C B DISCHARGE AIR LIQUID LINE CONNECTION ELECTRICAL INLETS A VAPOR LINE CONNECTION 2 (51) 4−3/4 4−1/4 (121) (108) 1 (25) SIDE VIEW SIDE VIEW UNIT SUPPORT FEET UNIT SUPPORT FEET 8−1/2 9−1/2 D (216) (241) K 8−3/4 8−1/4 (222) (210) E J
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Typical Unit Parts Arrangement FOR COIL SENSOR (RT21) LOCATION SEE DETAIL A COMPRESSOR DUAL RUN CAPACITOR (C12) (−024, −036 AND −048 ONLY) SINGLE RUN CAPACITOR (C1) (−060 ONLY) DEMAND DEFROST CONTROL (A108) DISCHARGE LINE SENSOR (RT28) REVERSING VALVE (L1) TRUE SUCTION PORT HIGH PRESSURE SWITCH (S4) EXPANSION VALVE CHECK / SENSING BULB EXPANSION VALVE LIQUID VALVE AND GAUGE PORT / LIQUID LINE LIQUID LINE CONNECTIONS BI−FLOW FILTER DRIER GROUND LOW PRESSURE SINGLE POLE LUG AMBIENT VAPOR VALVE AND
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Operating Gauge Set and Service Valves USING MANIFOLD GAUGE SET IMPORTANT When checking the system charge, only use a manifold gauge set that features low−loss anti−blow back fittings. To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted Manifold gauge set used for HFC−410A refrigerant snugly over the cap before tightening. systems must be capable of handling the higher system operating pressures. The manifold gauges should be rated OPERATING S
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Recovering Refrigerant from Existing System CONNECT MANIFOLD GAUGE SET DISCONNECT POWER Connect a manifold gauge set, clean recovery cylinder and a Disconnect all power to the existing outdoor unit at the disconnect 2 1 recovery machine to the service ports of the existing unit.. switch and/or main fuse box/breaker panel. NOTE Use the recovery machine instructions to make the correct manifold gauge set connections for recovery MAIN FUSE refrigerant. The illustration below is a typical connecti
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New Outdoor Unit Placement If additional elevation is necessary, raise the unit by CAUTION extending the height of the unit support feet. This may be achieved by using a 2 inch (50.8mm) schedule 40 female In order to avoid injury, take proper precaution when lift- threaded adapter. ing heavy objects. The specified coupling will fit snuggly into the recessed Remove existing outdoor unit prior to placement of new portion of the feet. Use additional 2 inch (50.8mm) outdoor unit. See Unit Dimensions
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Outside Unit Placement DETAIL A Slab Mounting at Ground Level DETAIL B Install unit away from windows. Install unit level or, if on a slope, maintain slope tolerance of two (2) degrees (or two inches per five feet [50 mm per 1.5 m]) away from building structure. BUILDING STRUCTURE MOUNTING SLAB GROUND LEVEL TWO 90° ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION. Elevated Slab Mounting Slab Side Mounting DETAIL D DETAIL C using Feet Extenders #10 1/2" LONG SELF−DRILLING SHEET
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Removing and Installing Panels LOUVERED PANEL REMOVAL IMPORTANT! DO NOT ALLOW PANELS TO HANG ON UNIT BY TOP TAB. TAB IS FOR Remove the louvered panels as follows: ALIGNMENT AND NOT DESIGNED TO SUPPORT WEIGHT OF PANEL. 1. Remove two screws, allowing the panel to swing open PANEL SHOWN SLIGHTLY ROTATED TO ALLOW TOP TAB TO EXIT (OR slightly. ENTER) TOP SLOT FOR REMOVING (OR INSTALLING) PANEL. 2. Hold the panel firmly throughout this procedure. Rotate bottom corner of panel away from hinged corner p
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Line Set Requirements This section provides information on: installation of new or Model (XP16) and size of unit (e.g. −036). replacement line set. Line set diameters for the unit being installed as listed Adding Polyol ester oil requirements in table 2 and total length of installation. New or replacement line set installation Number of elbows vertical rise or drop in the piping. Using existing line set. USING EXISTING LINE SET ADDING POLYOL ESTER OIL REQUIREMENTS Things to consider:
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Line Set Isolation The following illustrations are examples of proper refrigerant line set isolation: REFRIGERANT LINE SET TRANSITION REFRIGERANT LINE SET INSTALLING VERTICAL RUNS (NEW CONSTRUCTION SHOWN) FROM VERTICAL TO HORIZONTAL NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the ANCHORED HEAVY NYLON temperature of the liquid line or when pressure drop is equal to or greater WIRE TIE OR AUTOMOTIVE AUTOMOTIVE
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Brazing Connections Use the procedures outline in figures 8 and 9 for brazing line set connections to service valves. WARNING IMPORTANT Polyol Ester (POE) oils used with HFC−410A Allow braze joint to cool before removing the wet rag refrigerant absorb moisture very quickly. It is very from the service valve. Temperatures above 250ºF can important that the refrigerant system be kept closed damage valve seals. as much as possible. DO NOT remove line set caps or service valve stub caps until you ar
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CAP AND CORE REMOVAL CUT AND DEBUR Cut ends of the refrigerant lines square (free from nicks or dents) Remove service cap and core from 2 1 and debur the ends. The pipe must remain round. Do not crimp end both the suction / vapor and liquid line of the line. service ports. CUT AND DEBUR SERVICE PORT SERVICE PORT CAP CORE LINE SET SIZE MATCHES SERVICE VALVE CONNECTION SERVICE SERVICE VALVE PORT CONNECTION CORE SERVICE COPPER TUBE PORT CAP STUB LIQUID LINE SERVICE SUCTION / VAPOR LINE VALVE SERVI
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WRAP SERVICE VALVES To help protect service valve seals during brazing, wrap water saturated cloths around service valve bodies and copper tube stubs. Use 4 additional water saturated cloths underneath the valve body to protect the base paint. 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 5 out of the suction / vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set conne
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VAPOR LIQUID 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. TYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL REMOVAL PROCEDURE (UNCASED OR PROCEDURE (UNCASED COIL SHOWN) 1B 1A COIL SHOWN) STUB END TWO PIECE PAT
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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 v
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Leak Test Line Set and Indoor Coil IMPORTANT Leak detector must be capable of sensing HFC refrigerant. CONNECT GAUGE SET A Connect an HFC−410A manifold gauge set high pressure hose to the LOW HIGH vapor valve service port. NOTE Normally, the high pressure hose is connected to the liquid MANIFOLD GAUGE SET 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 ref
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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. CONNECT GAUGE SET LOW HIGH NOTE Remove cores from service valves (if not already done). 1
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Electrical Connections IMPORTANT In the U.S.A., wiring must conform with current local codes Use a thermocouple or thermistor electronic vacuum and the current National Electric Code (NEC). In Canada, gauge that is calibrated in microns. Use an instrument wiring must conform with current local codes and the current capable of accurately measuring down to 50 microns. Canadian Electrical Code (CEC). Refer to the furnace or air handler installation instructions for additional wiring application dia
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HIGH VOLTAGE FIELD WIRING LOW VOLTAGE CONNECTIONS LOW VOLTAGE (24V) FIELD WIRING 3 WIRE RUN LENGTH AWG# INSULATION TYPE LESS THAN 100’ (30 METERS) 18 TEMPERATURE RATING MORE THAN 100’ (30 METERS) 16 35ºC MINIMUM. NOTE − For proper voltages, select thermostat wire (control wires) gauge per table above. NOTE − Do not bundle any excess 24VAC control wires inside C control box. A Run 24VAC control wires through cutout with grommet. B Run 24VAC control wires through wire tie. C Make 24VA
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CUT FOR OPTION CUT FOR OPTION CBX32MV COMFORTSENSE HEAT PUMP UNIT OR 7000 X2658 OUTDOOR SENSOR IS REQUIRED FOR OUTDOOR (TWO−STAGE) CBX40UHV 1 TEMPERATURE DISPLAY, DEW POINT CONTROL, HEAT PUMP AND DUAL FUEL BALANCE POINTS. R RR CONNECTED ON UNIT WITH LSOM. RESISTOR KIT (CAT # 47W97) 2 IS REQUIRED WHEN CONNECTING THE COMFORTSENSE 7000 W3 H WITH THE LSOM 2. W2 W2 3 FIELD PROVIDED JUMPER BETWEEN Y2 OUT BL ON HEAT PUMP TO Y2 ON CBX40UHV. 1 W1 W1 W1 O. D. SENSOR AIR O O O (X2658) HANDLER CONTROL 2 L
