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Lennox International Inc. 506510-01 manual

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  • Page 1

    04/10 506510−01 *2P0410* *P506510-01* Page 1 E 2010 Lennox Industries Inc. Dallas, T exas, USA NOTICE A thermostat is not inc luded and must be ordered s epa r a t e ly . The Lennox Com fort Sense ® 7000 therm ostat may be used, as well as other therm ostats. In all cases, set up is critical to ensure proper system operation. Field wiring is ill[...]

  • Page 2

    Page 2 506510−01 Unit Dimensions − Inches (mm) and Parts Arrangement 4−5/8 (1 17) 39.40" (1003) 35.50" (902) 18.60" (470) 8.00" (203) 1 (25) LIQUID LINE INLET SUCTION LINE INLET ELECTRICAL INLETS BASE WITH ELONGA TED LEGS SIDE VIEW ACCESS VIEW DISCHARGE AIR [−024] 41 (1040) [−030 THROUGH −060] 47 (1 194) 16−7/8 (42[...]

  • Page 3

    Page 3 XC17 SERIES T ypical Unit Parts Arrangement LIQUID LINE FIL TER DRIER (SINGLE FLOW) HIGH PRESSURE SWITCH FIELD CONNECTION FOR LIQUID LINE SET LIQUID LINE SERVICE VA LV E LIQUID LINE SERVICE V AL VE POR T SUCTION LINE SERVICE V AL VE POR T SUCTION LINE SERVICE VA LV E FIELD CONNECTION FOR SUCTION LINE MUFFLER HIGH DISCHARGE LINE TEMPERA TURE [...]

  • Page 4

    Page 4 506510−01 CAUTION Physical contact with metal edges and corners while applying excessive force or rapid motion can result in personal injury . Be aware of, and use caution when working near these areas during installation or while servicing this equipment. IMPORT ANT Th e Clean Air Act of 1990 bans the intentional venting of refrigerant (C[...]

  • Page 5

    Page 5 XC17 SERIES (V AL VE STEM SHOWN CLOSED) INSERT HEX WRENCH HERE V A L VE STEM FRONT-SEA TED TO OUTDOOR UNIT SERVICE PORT CORE TO INDOOR UNIT SERVICE PORT SER VICE POR T CAP CLOSED TO BOTH INDOOR AND OUTDOOR UNITS STEM CAP ANGLE−TYPE SER VICE V AL VE (FRONT−SEA TED CLOSED) SER VICE PORT SER VICE POR T CORE TO OUTDOOR UNIT STEM CAP (V AL VE[...]

  • Page 6

    Page 6 506510−01 Recovering Refrigerant from Existing System SER VICE DISCONNECT SWITCH MAIN FUSE BOX/BREAKER P ANEL Disconnect all power to the existing outdoor unit at the disconnect switch or main fuse box/breaker panel. DISCONNECT POWER CONNECT MANIFOLD GAUGE SET MANIFOLD GAUGES RECOVER Y MACHINE CLEAN RECOVERY CYLINDER OUTDOOR UNIT HIGH LOW [...]

  • Page 7

    Page 7 XC17 SERIES CONTROL P ANEL ACCESS LOCA TION 6 (152) 36 (914) 12 (305) 30 (762) LINE SET CONNECTIONS 24 (610) LINE SET CONNECTIONS ACCESS P ANEL REAR VIEW OF UNIT 48 (1219) MINIMUM CLEARANCE BETWEEN TWO UNITS CLEARANCE ON ALL SIDES  INCHES (MILLIMETERS) ACCESS P ANEL MINIMUM CLEARANCE ABOVE UNIT NOTES: S Clearance to o ne of the othe r thr[...]

  • Page 8

    Page 8 506510−01 ELEV A TING THE UNIT Units are outfitted with elongated support feet as illustrated in Figure 4, Detail C. If additional elevation is necessary, raise the unit by extending the height of the unit support feet. This may be achieved by using a 2 inch (50.8mm) Schedule 40 female threaded adapter. The specified coupling will fit snug[...]

  • Page 9

    Page 9 XC17 SERIES LEG DET AIL BASE 2" (50.8MM) SCH 40 FEMALE THREADED ADAPTER ONE BRACKET PER SIDE (MIN.); FOR EXTRA ST ABILITY , TWO BRACKETS PER SIDE, 2" (50.8MM) FROM EACH CORNER. CONCRETE SLAB  USE TWO PLASTIC ANCHORS (HOLE DRILL 1/4") COIL BASE P A N CORNER POST ST ABILIZING BRACKET (18 GAUGE MET AL  2" WIDTH; HEIGHT[...]

  • Page 10

    Page 10 506510−01 Removing and Installing Panels REMOVE 4 SCREWS TO REMOVE P ANEL FOR ACCESSING COMPRESSOR AND CONTROLS. POSITION P ANEL WITH HOLES ALIGNED; INST ALL SCREWS AND TIGHTEN. ACCESS P ANEL REMOV AL Removal and reinstallation of the access panel is as illustrated. Det ail A Det ail C Det ail B ROT A TE IN THIS DIRECTION; THEN DOWN TO RE[...]

  • Page 11

    Page 1 1 XC17 SERIES New or Replacement Line Set REFRIGERANT LINE SET This section provides information on installation or replacement of existing line set. If new or replacement line set is not being installed then proceed to Brazing Connections on p age 13. IMPORT ANT Lennox highly recommends changing line set when converting the existing system [...]

  • Page 12

    Page 12 506510−01 ANCHORED H EA VY NYLON WIRE TIE OR AUT OMOTIVE MUFFLER-TYPE HANGER STRAP LIQUID LINE TO V APOR LINE W ALL STUD LIQUID LINE NON−CORROSIVE MET AL SLEEVE V APOR LINE − WRAPPED IN ARMAFLEX AUT OMOTIVE MUFFLER-TYPE HANGER REFRIGERANT LINE SET  TRANSITION FROM VERTICAL TO HORIZONT AL Line Set Isolation  The following illustr[...]

  • Page 13

    Page 13 XC17 SERIES CUT AND DEBUR CAP AND CORE REMOV AL Cut ends of the refrigerant lines square (free from nicks or dents) and debur the ends. The pipe must remain round and do not pinch end of the line. Remove service cap and core from b ot h t h e vapor and liquid line service ports. A TT ACHED GAUGES OUTDOOR UNIT LIQUID LINE vapor LINE LIQUID L[...]

  • Page 14

    Page 14 506510−01 Flushing the System SENSING LINE TEFLON RING FIXED ORIFICE (Uncased Coil Shown) BRASS NUT LIQUID LINE ASSEMBL Y (INCLUDES STRAINER) LIQUID LINE ORIFICE HOUSING DISTRIBUT OR TUBES DISTRIBUT OR ASSEMBL Y REMOVE AND DISCARD WHITE TEFLON SEAL (IF PRESENT) A On fully cased coils, remove the coil access and plumbing panels. B Remove a[...]

  • Page 15

    Page 15 XC17 SERIES A Attach the vapor line sensing bulb in the proper orientation as illustrated to the right using the clamp and screws pro- vided. NOTE  Confirm proper thermal contact between vapor line and check expansion bulb before insulating the sensing bulb once installed. B Connect the equalizer line from the check expansion valve to th[...]

  • Page 16

    Page 16 506510−01 INST ALLING ISOLA TION GROMMETS Locate the isolation grommet s (provided). Slide grommet s onto vapor and liquid lines. Insert grommets into piping p anel to isolate refrigerant lines from sheet met al edges. TWO ISOLA TION GROMMETS ARE PROVIDE FOR THE LIQUID AND SUCTION LINE PIPE P ANEL P ASS THROUGH. LIQUID LINE SUCTION LINE R[...]

  • Page 17

    Page 17 XC17 SERIES TO V APOR SER VICE V AL VE HFC−410A MANIFOLD GAUGE SET OUTDOOR UNIT HIGH LOW NITROGEN NOTE  Normally, the high pressure hose is connected to the liquid line port. How- ever, connecting it to the vapor port better protects the manifold gauge set from high pressure damage. A With both manifold valves closed, connect the cylin[...]

  • Page 18

    Page 18 506510−01 Evacuating the System A Open both manifold valves and start the vac uum 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 ear ly stages of evacuat ion, it is desir able to c los e the m anifold g auge valve at least once. A rapid rise in p re ss[...]

  • Page 19

    Page 19 XC17 SERIES IMPORT ANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument capable of accurately measuring down to 50 microns. W ARNING Danger of Equipm ent Damage. A void deep vacuum operation. Do not use compressors to evacuat e a system. Extremely low vacuu ms can cause internal arcin[...]

  • Page 20

    Page 20 506510−01 NOTE  For proper voltages, select thermostat wire (control wires) gauge per table below . WIRE RUN LENGTH A WG# INSULA TION TYPE LESS THAN 100’ (30 METERS) 18 TEMPERA TURE RATING MORE THAN 100’ (30 METERS) 16 35ºC MINIMUM. NOTE  Wire tie provides low voltage wire strain relief and to maintain separation of field insta[...]

  • Page 21

    Page 21 XC17 SERIES Figure 7. T ypical XC17 Wiring[...]

  • Page 22

    Page 22 506510−01 Main Control Jumpers and T erminals MAIN CONTROL  AIR CONDITIONER  ONE ST AGE T ABLE 3 PROVIDES ADDITIONAL INFORMA TION CONCERNING JUMPERS, LOOP , AND CONNECTIONS FOR THE MAIN CONTROL. DS13 and DS15 DS1 1 and DS14 LED ALER T CODES LED ALER T CODES CUT FOR HUMIDITROL  ENHANCED DEHU MIDI FI CA TIO N A CCESSO RY (ED A) APP[...]

  • Page 23

    Page 23 XC17 SERIES T able 3. Main Control Jumpers and T erminals Board ID Label Description E12 PSC Fan 240 VAC output connection for outdoor fan. E16 PSC Fan 240 VAC input connection for outdoor fan. E18 W 24VAC output for defrost auxiliary heat output. L Thermostat service light connection. Y2 24VAC thermostat input/output for second stage opera[...]

  • Page 24

    Page 24 506510−01 Field Control Wiring Y1 O R W1 G D R Y1 L C C Air Handler Control ComfortSense [ 7000 Thermostats Catalog # Y0349 or Y2081 One − Stage Air Conditioner Control B Y2 Y2 W O DS L T T W2 H W3 H O C L Y2 DS DH G R Y1 W2 W1 R connection required for outdoor unit with Control LSOM function. Resistor Kit (Cat# 47W97) is required when [...]

  • Page 25

    Page 25 XC17 SERIES Y1 O R W1 G D R Y1 L C C Furnace Control ComfortSense [ 7000 Thermostats Catalog # Y0349 or Y2081 One − Stage Air Conditioner Control B Y2 Y2 W O DS L T T W2 H H O C L Y2 DS DH G R Y1 W2 W1 R connection required for outdoor unit with Control LSOM function. Resistor Kit (Cat# 47W97) is required when using the ComfortSense 7000 [...]

  • Page 26

    Page 26 506510−01 Servicing Units Delivered V oid of Charge If the out door unit is void of refrigerant, clean the system using the procedure described below . 1. Leak check system using procedure outlined on Page 16. 2. Evacuate the system using procedure outlined on Page 18. 3. Use nitrogen to break the vacuum and install a new filter drier in [...]

  • Page 27

    Page 27 XC17 SERIES ADDING OR REMOVING REFRIGERANT This system uses HFC−410A refrigerant which operates at much higher pressures than HCFC−22. The pr e−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 wh[...]

  • Page 28

    Page 28 506510−01 Use WEIGH IN to initially charge a system when the out door unit is void of charge. T o verify charge and add or remove refrigerant use either APPROACH or SUBCOOLING methods. WHEN T O CHARGE? S W arm weather best S Can charge in colder weather CHARGE METHOD? Determine by: S Out door ambient temperature REQUIREMENTS: S Suf ficien[...]

  • Page 29

    Page 29 XC17 SERIES APPº (Approach) V alues(F:+/−1.0° [C: +/−0.6°])* If refrigerant added or removed, retest to confirm that unit is properly charged If value is greater than shown (high approach), add refrigerant; if less than shown (liquid temp too close to ambient temp, low approach), remove refrigerant. 1. Confirm proper airflow across c[...]

  • Page 30

    Page 30 506510−01 Operating and T emperature Pressures Minor variations in these pressures may be expected due to dif ferences in inst allations. Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system. T able 4. Normal Operating Pressures (Liquid +10 and Suction +5 psi[...]

  • Page 31

    Page 31 XC17 SERIES System Operation IMPORT ANT Some scroll compressor have internal vacuum protector that will unload scrolls when suction pressure goes below 20 psig. A hissing sound will be heard when the compressor is running unloaded. Protector will reset when low pressure in system is raised above 40 psig. DO NOT REPLACE COMPRESSOR. The Main [...]

  • Page 32

    Page 32 506510−01 TEST PINS FUNCTION Placing the JUMPER ON the field test pins (E33) (see Page 22 for location of TEST pins) allows the technician to S Clear compressor anti−short cycle delay. S Clear five−strike fault lockouts  High / Low pressure switches and High Discharge Temperature Sensor. NOTES: 1  Placing a JUMPER ON the TEST pi[...]

  • Page 33

    Page 33 XC17 SERIES T able 6. Ambient Sensor T emperature / Resist ance Range Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance 136.3 2680 56.8 16657 21.6 44154 −1 1.3 123152 133.1 2859 56.0 16973 21.0 44851 −1 1.9 125787 130.1 3040 55.3 17293 20.5 45560 −12.6 128508 127.3 [...]

  • Page 34

    Page 34 506510−01 T able 7. High Discharge Sensor T emperature / Resist ance Range Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance Degrees Fahrenheit Resistance 303.1 183 186.1 1052 136.8 2656 94.5 6613 298.1 195 185.0 1072 136.0 2698 93.6 6739 293.4 207 183.9 1093 135.2 2740 92.8 6869 289.0 220 182.8 111[...]

  • Page 35

    Page 35 XC17 SERIES T able 8. Sensor T emperature / Resist ance Range Sensor T emperature Range °F (°C) Resist ance values range (ohms) Pins/Wire Color Outdoor (Ambient) −40ºF to 140ºF (−40ºC to 60ºC) 280,000 to 3750 3 and 4 (Black) Discharge −35ºF to 310ºF (−37ºC to 154ºC) 41,000 to 103 1 and 2 (Y ellow) Note: Sensor resistance d[...]

  • Page 36

    Page 36 506510−01 Outdoor Main Control LEDs Solution Possible Cause(s) Condition DS1 1 Green Solution Possible Cause(s) Condition DS14 Red DS1 1 Green Solution Possible Cause(s) Condition DS14 Red OFF 1 Fast Flash then Pause Heating Low Capacity These are codes that show status of operation whether in low stage or high stage, heating or cooling, [...]

  • Page 37

    Page 37 XC17 SERIES T able 10. Compressor LED Alert Codes Out door Main Control LEDs Condition Possible Cause(s) Solution Clearing St atus DS15 Y ellow DS13 Red OFF ON Compressor Internal Overload Trip Thermostat demand signal Y1 is present, but compressor not running 1 Compressor protector is open. S Check for high head pressure S Check compressor[...]

  • Page 38

    Page 38 506510−01 Outdoor Main Control LEDs Clearing St atus Solution Possible Cause(s) Condition DS15 Y ellow Clearing St atus Solution Possible Cause(s) Condition DS13 Red 5 Flashes then Pause OFF Open Circuit Compressor has an open circuit due to power dis- connection, fuse is open or other similar conditions. 1 Outdoor unit power disconnect i[...]

  • Page 39

    Page 39 XC17 SERIES Figure 19. High Pressure Switch Operation[...]

  • Page 40

    Page 40 506510−01 Figure 20. Low Pressure Switch Operation[...]

  • Page 41

    Page 41 XC17 SERIES Figure 21. High Discharge T emperature Sensor Operation[...]

  • Page 42

    Page 42 506510−01 Maintenance W ARNING Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies. W ARNING Impr oper installation, adjustm ent, alt eration, ser vice or maintenanc e can cause perso[...]

  • Page 43

    Page 43 XC17 SERIES LED CODES AND SEQUENCE OF OPERA TIONS During s t art up, the LED will first display any error conditions (see table 12) if present. If no errors are detected then the LED code indicating one or two stage operation will display then a long p ause. The RPM indicator is displayed next. Af ter the RPM indicator i s displayed there i[...]

  • Page 44

    Page 44 506510−01 MAIN CONTROL CONTROL P ANEL F AN MOT OR CONTROL  PULSE−WIDTH MODULA TION (PWM) JUMPER OFF JUMPER ON J2 LED CFM Profile Pin Select VERIFY DC V O L T AGE OUTPUT USING F AN PWM OUT AND COM TERMINALS. SEE T ABLE 1 1 FOR OPTIMAL DC VOL T AG E BASED ON CFM PROFILE USED. COM F AN PWM OUT GREEN RED BROWN RED BLACK YELLOW YELLOW RED[...]

  • Page 45

    Page 45 XC17 SERIES MAIN CONTROL CONTROL P ANEL F AN MOT OR CONTROL  PULSE−WIDTH MODULA TION (PWM) COM YELLOW WIRE GREEN RED BROWN RED BLACK YELLOW YELLOW RED RED BLACK GREEN YELLOW BLACK PWM FAN CONTROL YELLOW BLACK YELLOW BLUE SEE T ABLE 11 FOR CFM PROFILE SELECTION OPTIONS. TO MAIN CONTROL EXT PWR/R BLACK WIRE Figure 24. T esting for Extern[...]

  • Page 46

    Page 46 506510−01 F AN MOT OR TEST PROCEDURE A simple test can be used to test the fan motor operation. A fully charged 9V battery will be required for this procedure. J2 F AN PWM OUT P ARK COM BLACK LEAD BROWN LEAD BROWN LEAD BLACK LEAD REMOVE BOTH LEADS FROM J2 TERMINALS CONNECT F AN MO TOR BLACK COMMON WIRE TO 9V BA TTERY NEGA TIVE TERMINAL F [...]

  • Page 47

    Page 47 XC17 SERIES F AN MOT OR SURGE PROTECTION Surge Protector (Metal Oxide V aristor − MOV) − A part designed to protect electrical devices from volt age spikes that are 3 to 4 times the normal circuit volt age (See Figure 26 for illustration of component). An MOV works as follows: It is essentially a batch of metallic−oxide grains sep ara[...]

  • Page 48

    Page 48 506510−01 Outdoor Coil Th e out door unit must be properly maint ained to ensure its proper operation. S Please cont act your dealer to schedule proper inspection and maintenance for your equipment. S Make sure no obstructions restrict airflow to the outdoor unit. S Grass clippings, leaves, or shrubs crowding the unit can cause the unit t[...]

  • Page 49

    Page 49 XC17 SERIES XC17 S tart−Up and Performance Checklist Suction Pressure: Liquid Pressure: Supply Air T emperature: Ambient T emperature: Return Air: T emperature: System Refrigerant Charge (Refer to manufacturer’s information on unit or installation instructions for required subcooling and approach temperatures.) Subcooling: A  B = SUB[...]