Lennox Collection XC21 System Manuals

A I R C O N D I T I O N E R S XC21 DAVE LENNOX SIGNATURE® COLLECTION R-410A - Two-Stage Compressor - SilentComfort™ Technology Bulletin No. 210586 October 2010 Supersedes September 2010 E N G I N E ER I N G D ATA SEER up to 21.00 2 to 5 Tons Cooling Capacity - 23,200 to 59,500 Btuh MODEL NUMBER IDENTIFICATION x c 21 - 036 - 230 - 5 Nominal SEER Unit Type C = Air Conditioner Refrigerant Type X = R-410A Nominal Cooling Capacity 024 = 2 tons 036 = 3 tons 048 = 4 tons 060 = 5 tons Minor Revision Number Voltage 230 = 208/230V-1ph-60hz XC21 - 2 to 5 Ton Air Conditioner / Page 2 FEATURES Equipment Warranty Compressor - ten year limited warranty in residential installations and five years in non-residential installations. All other covered components - ten years in residential installations and one year in non-residential installations. Refer to Lennox Equipment Limited Warranty certificate included with unit for specific details. ApplicationS SEER up to 21.00. 2 through 5 ton. Single phase power supply. Sound levels as low as 69 dB. Vertical air discharge allows concealment behind shrubs at grade level or out of sight on a roof. Matching add-on furnace indoor coils or air handlers provide a wide range of cooling capacities and applications. See AHRI System Matches. See Indoor Coils and Air Handlers tab sections for data. Units shipped completely factory assembled, piped, and wired. Each unit is test operated at the factory insuring proper operation. Installer must set air conditioner, connect refrigerant lines, and make electrical connections to complete job. Approvals Certified in accordance with USE certification program which is based on AHRI Standard 210/240-2008. Sound rated in Lennox reverberant sound test room in accordance with test conditions included in AHRI Standard 270-2008. Tested in the Lennox Research Laboratory environmental test room. Rated according to U.S. Department of Energy (DOE) test procedures. Air conditioners and components within bonded for grounding to meet safety standards for servicing required by ETL, NEC, and CEC. Units are ETL listed for the US and Canada. ISO 9001 Registered Manufacturing Quality System. Energy Star® certified units are designed to use less energy, help save money on utility bills, and help protect the environment. All models are listed in the GreenSpec® Directory, a leading resource of environmentally responsible products. For expanded ratings, see www.lennoxdavenet.com. REFRIGERATION SYSTEM R-410A Refrigerant Non-chlorine, ozone friendly, R-410A. Unit pre-charged with refrigerant. See Specification table. Outdoor Coil Fan with SilentComfort™ Technology Specially-designed, SilentComfort™ fan guard uses Passive Vortex Suppression to reduce air noise. Constructed of corrosion-resistant PVC (polyvinyl chloride) coated steel. Specially designed fan blades reduce operating sound levels. Direct drive fan moves large air volumes uniformly through entire condenser coil for high refrigerant cooling capacity. Vertical air discharge minimizes operating sounds and eliminates damage to lawn and shrubs. Fan motor is inherently protected. All models have a variable-speed outdoor fan motor for quiet operation. Motor totally enclosed for maximum protection from weather, dust and corrosion. Fan service access accomplished by removal of fan guard. A B C B C D E F G H K Contents AHRI System Matches................................................14 Dimensions..................................................................12 Electrical Data ............................................................10 Features........................................................................2 Field Wiring..................................................................11 Installation Clearances................................................11 Model Number Identification..........................................1 Optional Accessories...................................................10 Outdoor Sound Data....................................................11 Specifications..............................................................10 Sunsource® Home Energy System - Components........7 I J XC21 - 2 to 5 Ton Air Conditioner / Page 3 Copper Tube/Enhanced Fin Coil Lennox designed and fabricated coil. Ripple-edged aluminum fins. Copper tube construction. Lanced fins provide maximum exposure of fin surface to air stream resulting in excellent heat transfer. Fin collars grip tubing for maximum contact area. Flared shoulder tubing connections/silver soldering construction. Coil is factory tested under high pressure to insure leakproof construction. Entire coil is accessible for cleaning. High Pressure Switch Shuts off unit if abnormal operating conditions cause the discharge pressure to rise above setting. Protects compressor from excessive condensing pressure. Automatic reset. Low Pressure Switch Shuts off unit if suction pressure falls below setting. Provides loss of charge and freeze-up protection. Automatic reset. Hi-Capacity Liquid Line Drier Factory installed in the liquid line, the drier traps moisture or dirt that could contaminate the refrigerant system. 100% molecular-sieve bead type drier. OPTIONS Expansion Valve Kits Must be ordered extra and field installed on certain indoor units. See TXV Usage table on page 13. Chatleff style fitting. Freezestat Installs on or near the discharge line of the indoor coil or on the suction line. Senses suction line temperature and cycles the compressor off when suction line temperature falls below it’s setpoint. Opens at 29°F and closes at 58°F. Refrigerant Line Kits Refrigerant lines (suction & liquid) are shipped refrigeration clean. Lines are cleaned, dried, pressurized, and sealed at factory. Suction line fully insulated. L15 lines are stubbed at both ends. See Specifications table for selection. Not available for -060 model and must be field fabricated. D E F G COMPRESSOR Copeland Scroll Ultra Tech™ Two-Stage Compressor Compressor features high efficiency with uniform suction flow, constant discharge flow and high volumetric efficiency and quiet operation. Compressor consists of two involute spiral scrolls matched together to generate a series of crescent shaped gas pockets between them. During compression, one scroll remains stationary while the other scroll orbits around it. Gas is drawn into the outer pocket, the pocket is sealed as the scroll rotates. As the spiral movement continues, gas pockets are pushed to the center of the scrolls. Volume between the pockets is simultaneously reduced. When pocket reaches the center, gas is now at high pressure and is forced out of a port located in the center of the fixed scrolls. During compression, several pockets are compressed simultaneously resulting in a smooth continuous compression cycle. Continuous flank contact, maintained by centrifugal force, minimizes gas leakage and maximizes efficiency. Scroll compressor is tolerant to the effects of slugging and contaminants. If this occurs, scrolls separate, allowing liquid or contaminants to to be worked toward the center and discharged. On the fixed scroll there are two bypass ports in the first suction pocket. On the outside of the fixed scroll there is a “slider ring” that is controlled by an internal solenoid that will rotate and cover the bypass ports. When the thermostat calls for first-stage cooling, the bypass ports are open and the compressor operates at 67% capacity, creating more cost-effective and efficient compressor operation. The bypassed refrigerant is returned to the compressor housing through the bypass ports. When the thermostat calls for second-stage cooling, the internal solenoid is energized, the slider ring rotates and covers the bypass ports, and the compressor operates at full capacity. Low gas pulses during compression reduces operational sound levels. Compressor motor is internally protected from excessive current and temperature. H FEATURES XC21 - 2 to 5 Ton Air Conditioner / Page 4 COMPRESSOR (CONTINUED) Compressor is installed in the unit on specially formulated, resilient rubber mounts for better sound dampening and vibration free operation. Crankcase Heater Crankcase heater prevents migration of liquid refrigerant into compressor and ensures proper compressor lubrication. CONTROLS icomfort™ Control Advanced control communicates information about various operating parameters in the air conditioner to the optional icomfort Touch™ Communicating Thermostat to constantly maintain the highest level of comfort, performance and efficiency available. Connections for connecting a conventional heating/cooling thermostat are also provided on the control. Auto Configuration - On start-up the control automatically sends a description of the unit to the optional icomfort Touch™ Communicating Thermostat to automatically configure the number of stages and features available. Control also features: • Compressor anti-short cycle delay. User selectable with communicating thermostat - 1, 2, 3, 4 or 5 minutes. Default setting is 5 minutes. Compressor must operate in first stage a minimum of 5 seconds before second stage operation is permitted. • Low voltage protection prevents 2nd stage compressor operation when voltage is not within the specified range. • High and low pressure switch monitoring with provisions for lockout. • Five-Strike lockout protection protects compressor. • Discharge line temperature and sensor monitoring. • Lennox Humiditrol® Whole Home Dehumidification System (EDA) compatible. • EEPROM storage of all local configurations. I Lennox Systems Operations Monitor (icomfort™ Control Feature) Onboard Lennox® Systems Operations Monitor (LSOM) provides detailed information for proper preventative maintenance and fast, easy servicing. Displays the most common fault conditions (electrical and mechanical) through the icomfort Touch™ Communicating Thermostat or through the ALERT and TRIP lights on the control. ALERT LED (yellow) - communicates an abnormal system condition through a unique flash code. The ALERT LED will flash a number of times consecutively, pause and then repeat the process. The number of consecutive flashes, defined as the Flash Code, correlates to a particular abnormal condition. The codes can indicate one of the following: long run time, system pressure trip (discharge or suction pressure out-of-limits or compressor overloaded), short cycling, locked rotor, open circuit, open start circuit (current present only in run circuit), open run circuit (current present only in start circuit), welded contactor (compressor runs continuously), or low voltage (control circuit < 17VAC). TRIP LED (red) - indicates there is a demand signal from the thermostat but no current to the compressor is detected by the monitor. OPTIONS Compressor Low Ambient Cut-Off Non-adjustable switch (low ambient cut-out) prevents compressor operation when outdoor temperature is below 35°F. Compressor Hard Start Kit Single-phase units are equipped with a PSC compressor motor. This type of motor normally does not need a potential relay and start capacitor. In conditions such as low voltage, kit may be required to increase the compressor starting torque. Indoor Blower Off Delay Relay Delays the indoor blower-off time during the cooling cycle. Required if outdoor unit is used with a conventional heating-cooling thermostat and air handler (not icomfort™ control). See furnace or air handler specifications to determine if relay is needed. Indoor Blower Speed Relay Kit Relay kit provides optimum humidity control conditions by automatically reducing indoor blower speed during continuous fan or first-stage compressor operation. Low Ambient Kit Air conditioner will operate satisfactorily down to 45°F outdoor air temperature without any additional controls. Kit can be added in the field enabling unit to operate properly down to 30°F. A Freezestat should be installed on compressors equipped with a low ambient kit. A Compressor Low Ambient Cut-Off should be added to terminate compressor operation below recommended operation conditions. FEATURES

06/10 506518−01    Page 1 2010 Lennox Industries Inc. Dallas, Texas, USA NOTICE A thermostat is not included and must be ordered separately.  The Lennox icomfort Touch thermostat must be used in communicating applications.  In non−communicating applications, the Lennox ComfortSense® 7000 thermostat may be used, as well as other non−communicating thermostats. In all cases, setup is critical to ensure proper system operation. Field wiring examples for non−communicating applications begin on page 23. See the icomfort Touch thermostat Quick Start Guide for communicating and partial communicating field wiring connections. 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. General This outdoor unit is designed for use with HFC−410A refrigerant only. This unit must be installed with an approved indoor air handler or coil. See the Lennox XC21 Engineering Handbook for approved indoor component matchups. IMPORTANT This model is designed for use in expansion valve systems only. An indoor expansion valve approved for use with HFC−410A refrigerant must be ordered separately, and installed prior to operating the system. INSTALLATION INSTRUCTIONS Dave Lennox Signature® Collection XC21 System AIR CONDITIONER 506518−01 06/10 Supersedes 05/10 RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE TABLE OF CONTENTS General 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shipping and Packing List 1 . . . . . . . . . . . . . . . . . . . . . . Unit Dimensions 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Number Identification 2 . . . . . . . . . . . . . . . . . . . . Unit Parts Arrangement 3 . . . . . . . . . . . . . . . . . . . . . . . . Operating Gauge Set and Service Valves 4 . . . . . . . . . Recovering Refrigerant from Existing System 6 . . . . . New Outdoor Unit Placement 7 . . . . . . . . . . . . . . . . . . . Removing and Installing Panels 10 . . . . . . . . . . . . . . . . . New or Replacement Line Set 11 . . . . . . . . . . . . . . . . . . . Flushing the System 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Testing the System 16 . . . . . . . . . . . . . . . . . . . . . . . Evacuating the System 16 . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A175 Main Control Jumpers and Terminals 22 . . . . . . . Field Control Wiring 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing Unit Delivered Void of Charge 25 . . . . . . . . . . Unit Start−Up 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Refrigerant 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating and Temperature Pressures 29 . . . . . . . . . . . System Operations 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . A175 Main Control LED System Status and Alert Codes 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance (Dealer and Homeowner) 42 . . . . . . . . . . . Checklists 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shipping and Packing List Check unit for shipping damage. Consult last carrier immediately if damage is found. 1  Assembled outdoor unit. 1  Bag assembly which includes the following: 1  Bushing (for low voltage wiring) 2  Isolation grommets for liquid and suction lines Litho U.S.A. Page 2 506518−01 Unit Dimensions − Inches (mm) and Parts Arrangement 39−1/2 (1003) 35−1/2 (902) 47 (1194) 18−1/2 (470) 8 (203) 1 (25) 4−1/2 (114) LIQUID LINE INLET ELECTRICAL INLETS SIDE VIEW ACCESS VIEW DISCHARGE AIR 4−5/8 (117) BASE WITH ELONGATED LEGS 16−7/8 (429) 8−3/4 (222) 26−7/8 (683) 3−3/4 (95) 30−3/4 (781) 3−1/8 (79) SUCTION LINE INLET UNIT SUPPORT FEET Model Number Identification C 21 XXX Unit Type C = Air Conditioner Series Nominal Cooling Capacity 024 = 2 tons 036 = 3 tons 048 = 4 tons 060 = 5 tons Minor Revision Number 230 Voltage 230 = 208/230V−1ph−60hz Refrigerant Type X = R−410A X 05 Page 3 XC21 SERIES Typical Unit Parts Arrangement LIQUID LINE FILTER DRIER (SINGLE FLOW) LIQUID LINE SERVICE VALVE PORT SUCTION LINE SERVICE VALVE PORT FIELD CONNECTION FOR SUCTION LINE RT28 HIGH DISCHARGE LINE TEMPERATURE SENSOR S87 LOW PRESSURE SWITCH S4 HIGH PRESSURE SWITCH S40 CRANKCASE THERMOSTAT COMPRESSOR HARNESS FIELD CONNECTION FOR LIQUID LINE GROUND LUG HIGH VOLTAGE FIELD CONNECTIONS CONTACTOR−1 POLE (K1) A175 MAIN CONTROL CAPACITOR (C12) A177 FAN MOTOR CONTROL WIRE TIE RT13 OUTDOOR AMBIENT TEMPERATURE SENSOR FAN MOTOR SURGE PROTECTION SECOND GROUND LUG FOR SOURCESOURCE® Figure 1. Plumbing, Switches and Sensor Components Page 4 506518−01 WARNING This product and/or the indoor unit it is matched with may contain fiberglass wool. Disturbing the insulation during installation, maintenance, or repair will expose you to fiberglass wool dust. Breathing this may cause lung cancer. (Fiberglass wool is known to the State of California to cause cancer.) Fiberglass wool may also cause respiratory, skin, and eye irritation. To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor. Lennox Industries Inc. P.O. Box 799900 Dallas, TX 75379−9900 IMPORTANT This unit must be matched with an indoor coil as specified in Lennox’ Engineering Handbook. Coils previously charged with HCFC−22 must be flushed. IMPORTANT The Clean Air Act of 1990 bans the intentional venting of refrigerant (CFCs, HCFCs AND HFCs) as of July 1, 1992. Approved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarceration may be levied for noncompliance. 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. Operating Gauge Set and Service Valves These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation. TORQUE REQUIREMENTS When servicing or repairing heating, ventilating, and air conditioning components, ensure the fasteners are appropriately tightened. Table 1 shows torque values for fasteners. 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 #C−08−1 for further details and information. IMPORTANT To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening. 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 USING MANIFOLD GAUGE SET When checking the system charge, only use a manifold gauge set that features low loss anti−blow back fittings. Manifold gauge set used with HFC−410A refrigerant systems must be capable of handling the higher system operating pressures. The gauges should be rated for use with pressures of 0 − 800 psig on the high side and a low side of 30" vacuum to 250 psig with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psig of pressure with a 4000 psig burst rating. 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. Figure 2 provides information on how to access and operating both angle and ball service valves.