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Lennox XC20-036-230-01

Lennox XC20-036-230-01
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1
2015 Lennox Industries Inc.
Corp. 1407-L10
August 25, 2015
XC20
INSTALLATION AND SERVICE
PROCEDURE
Service Literature
Elite Series
®
XC20 Units
IMPORTANT
XC20 units have refrigerant piping requirements that are
unique to this unit. Size and install the refrigerant piping
per table 2 (page 14) to ensure proper unit operation.
This unit is an integral component of a system that requires an
iComfort Wi-Fi
®
or iComfort
®
S30 thermostat and
iComfort
®
-enabled air handler or furnace.
XC20
iComfort Wi-Fi
®
thermostat
iComfort
®
-enabled
air handler or
furnace
IMPORTANT:
Before applying any power (main or low voltage) to the outdoor
unit, confirm that the iComfort Wi-Fi
®
or iComfort
®
S30
thermostat has software Version 2.1 or higher installed.
(Reference the iComfort Wi-Fi
®
or iComfort
®
S30 thermostat
manual.)
iComfort
®
S30
thermostat
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.
TABLE OF CONTENTS
I. OVERVIEW
Model Number Identification 2....................
Typical Serial Number Identification 2..............
Specifications 2.................................
Electrical Data 3................................
Unit Dimensions 4..............................
Typical Unit Parts Arrangement 5.................
Operating Service Valves 7.......................
General 7.....................................
II. INSTALLATION
Unit Placement 9...............................
Removing and Installing Panels 12.................
New or Replacement Line Set 13..................
Brazing Connections 16...........................
Flushing the System 19...........................
Leak Testing the System 21.......................
Evacuating the System 21.........................
Electrical 24.....................................
Servicing Unit Delivered Void of Charge 29..........
Unit Start-Up 29.................................
III. SYSTEM OPERATION AND SERVICE
7-Segment Alert and System Status Codes 30.......
Outdoor Control Push-Button Operation 38..........
Configuring Unit 42...............................
Reconfiguring Outdoor Control using iComfort Wi-Fi
®
or
iComfort
®
S30 Thermostat 43.....................
System Overview 43.............................
Maintenance 44..................................
Unit Wiring Diagrams 45..........................
Factory Wiring Diagrams 48.......................
Unit Sequence of Operations 50...................
Component Testing 53............................
System Refrigerant 75............................
Appendix - Charging Sticker ....................
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.

Table of Contents

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Lennox XC20-036-230-01 Specifications

General IconGeneral
Cooling Capacity36, 000 BTU/h
SEER20
RefrigerantR-410A
Voltage230V
Phase1
Frequency60 Hz
Sound Level65 dB

Summary

I. OVERVIEW

Model Number Identification

Identifies the different components of the unit's model number for recognition.

Typical Serial Number Identification

Explains the structure and meaning of the unit's serial number for tracking.

Specifications

Lists key technical data such as sound rating, charge, and fan details.

Electrical Data

Provides detailed electrical specifications for safe installation and operation.

Unit Dimensions

Shows physical dimensions and mounting hole patterns for installation planning.

Typical Unit Parts Arrangement

Illustrates the layout of major components within the control panel for identification.

Typical Plumbing Components

Diagrams showing the location of key plumbing components like the compressor and drier.

Operating Service Valves

Explains the function and operation of the unit's service valves for refrigerant handling.

General

Provides general installation guidelines and system overview information.

SERVICE VALVES ANGLE AND BALL

Detailed instructions on operating angle-type and ball-type service valves.

II. INSTALLATION

Unit Placement

Guidelines for positioning the unit, including clearance and site selection.

STABILIZING UNIT ON UNEVEN SURFACES

Instructions for using stabilizers to secure the unit on uneven surfaces.

ROOF MOUNTING

Considerations for mounting the unit on a roof structure.

Placement and Slab Mounting

Details on unit placement, slab mounting, and stabilizing on uneven surfaces.

Removing and Installing Panels

Step-by-step guide for safely removing and reinstalling unit panels.

New or Replacement Line Set

Information and recommendations for installing new or replacement refrigerant line sets.

COOLING SYSTEM (HFC-410 A)

Guidelines for sizing refrigerant line sets for HFC-410A cooling systems.

SUCTION TRAPS

Specifies requirements for installing suction traps in certain system configurations.

LINE SET ISOLATION

Illustrates proper methods for isolating refrigerant lines to prevent vibration.

Brazing Connections

Provides procedures and safety precautions for brazing refrigerant line set connections.

PIPING PANEL REMOVAL AND LINE SET PREPARATION

Steps for preparing the piping panel and line set for brazing.

CAP AND CORE REMOVAL

Instructions for removing service port caps and cores.

ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION LINE SERVICE VALVES

Guide on connecting manifold gauges for brazing operations.

WRAP SERVICE VALVES

Procedure for protecting service valves during brazing with water-saturated cloths.

FLOW NITROGEN

Instructions for flowing nitrogen through the system during brazing.

BRAZE LINE SET

Details on the brazing process, including protecting components.

Flushing the System

Procedures for flushing the line set and indoor coil, especially for HCFC-22 conversions.

TYPICAL NEW CHECK EXPANSION VALVE INSTALLATION PROCEDURE

Steps for installing a new check expansion valve in the system.

SENSING BULB INSTALLATION

Instructions for correctly installing the sensing bulb.

EQUALIZER LINE INSTALLATION

Steps for installing the equalizer line connection.

Leak Testing the System

Procedures and important notes for leak testing the refrigeration system.

CONNECT GAUGE SET

Instructions for connecting the manifold gauge set for leak testing.

TEST FOR LEAKS

Detailed procedure for performing a system leak test.

CONNECT GAUGE SET

Steps for connecting gauges and vacuum pump for system evacuation.

EVACUATE THE SYSTEM

Procedures for evacuating the system to the required vacuum level.

Electrical

General electrical wiring requirements and codes.

24 VAC TRANSFORMER

Information on the 24VAC transformer used for low-voltage control.

SIZE CIRCUIT AND INSTALL DISCONNECT SWITCH

Guidance on sizing circuits and installing disconnect switches.

INSTALL THERMOSTAT

Recommendations for thermostat installation location and height.

ROUTE CONTROL WIRES

Instructions for routing low-voltage control wiring.

ROUTE HIGH VOLTAGE AND GROUND WIRES

Guidance on routing high-voltage wiring and ground connections.

ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures

Precautions to prevent damage to electronic components from static discharge.

Outdoor Control Terminal Designations and InputOutputs

Table detailing the function of each terminal on the outdoor control board.

Outdoor Control Terminal Designations and Input Outputs

Further details on outdoor control terminal designations and input/outputs.

Servicing Units Delivered Void of Charge

Unit Start-Up

Procedures for starting up the unit after servicing or installation.

III. SYSTEM OPERATION AND SERVICE

7-Segment Alert and System Status Codes

Explanation of alert and status codes displayed on the 7-segment display.

7-Segment Display Alert Codes and Inverter LED Flash Codes

Lists alert codes and their possible causes and clearing methods.

7-Segment Display Alert Codes and Inverter LED Flash Codes

Lists alert codes and their possible causes and clearing methods.

7-Segment Display Alert Codes and Inverter LED Flash Codes

Lists alert codes and their possible causes and clearing methods.

7-Segment Display Alert Codes and Inverter LED Flash Codes

Lists alert codes and their possible causes and clearing methods.

7-Segment Display Alert Codes and Inverter LED Flash Codes

Lists alert codes and their possible causes and clearing methods.

POWER-UP RESET:

Explains the power-up sequence and status displays on the 7-segment display.

Idle mode - System is energized with no demand

Describes the idle mode status display and its meaning.

Fan Test and Display String Option

Details on using the 7-segment display for testing fan operation.

Error Code Recall Mode

Procedure for recalling stored error codes from the control.

FIELD TEST MODE OPERATION

Overview of the field test mode for diagnostics.

Diagnostic Mode

Explains how to access and use the diagnostic mode.

Outdoor Fan Mode

Describes the operation of the outdoor fan in diagnostic mode.

PUMP-DOWN MODE OPERATION

Instructions for operating the unit in pump-down mode.

PUSH - BUTTON OPERATION

Guide to using the push-button for accessing modes like diagnostic and error recall.

Unit Selection Code for Outdoor Control

Explains how to set the unit selection code for proper configuration.

TYPICAL 7-SEGMENT ACTIVE COOLING OR HEATING DEMAND DISPLAY STRING

Example of the 7-segment display during operation, showing various parameters.

How to enable liquid line temperature information on a 7-segment display

Procedure to enable display of liquid line and coil temperatures on the 7-segment display.

Configuring Unit

Configuring Unit Selection Code

Steps to manually assign the unit selection code for system configuration.

Reconfiguring Outdoor Control using iComfort Wi-Fi or iComfort S30 Thermostat

System Overview

Refers to thermostat installer setup guide for configuration procedures.

COMPRESSOR PROTECTION - FIVE-STRIKE LOCKOUT

Explanation of the compressor protection feature and lockout mechanism.

Diagnostic Information

Lists diagnostic information available via the thermostat.

Maintenance

Outdoor Unit

Maintenance checklist for the outdoor unit, including cleaning and checks.

Outdoor Coil

Specific maintenance advice for the outdoor coil, including flushing.

Indoor Unit

Maintenance checklist for the indoor unit.

Indoor Coil

Specific maintenance advice for the indoor coil.

Locations with Possibility of Heavy Snow or Freezing Rain Accumulation

Recommendations for units in areas prone to snow or freezing rain.

Unit Wiring Diagrams

Typical Unit Wiring (XC20-024 and -036)

Wiring diagram for specific XC20 models.

Typical Unit Wiring (XC20-048 and -060)

Wiring diagram for specific XC20 models.

Factory Wiring Diagrams

Typical Factory Wiring (XC20-024 and -036)

Detailed factory wiring diagram for specific unit models.

Typical Factory Wiring (XC20-048 and -060)

Detailed factory wiring diagram for specific unit models.

Unit Sequence of Operation

24 Volt Power-Up or Outdoor Reset

Flowchart describing the unit's startup sequence and operation.

Low Pressure Switch (S87) Sequence of Operation (All Versions)

Flowchart detailing the operation sequence of the low-pressure switch.

High Pressure Switch (S4) Sequence of Operation (All Versions)

Flowchart detailing the operation sequence of the high-pressure switch.

Component Testing

Verifying High Pressure and Low Pressure Switch Operation

Procedures for testing the high and low pressure switches.

High and Low Pressure Switch Errors

Lists alert codes related to high and low pressure switches and their causes.

Compressor Operation, Checkout and Status Error Codes

Details on compressor operation, testing, and related error codes.

STATUS CODES:

Explains status codes displayed for compressor operation.

ERROR CODES:

Lists compressor-related error codes and their remedies.

ERROR CODES:

Lists compressor-related error codes and their remedies.

Crankcase Heater, Checkout and Status Error Codes

CRANKCASE HEATER (HR1)

Information about the crankcase heater operation.

CRANKCASE HEATER THERMOSTAT (S40)

Details on the thermostat controlling the crankcase heater.

Compressor Sound Cover

Describes the function and features of the compressor sound cover.

Liquid Line Filter Drier

Explains the purpose and specifications of the liquid line filter drier.

Top Cap Switch Operation, Checkout and Status Error Codes

Top Cap Thermal Sensor Switch (S173)

Details on the operation and testing of the top cap thermal switch.

Reactor Operations, Checkout and Status Error Codes

Explanation of reactor operation, testing, and error codes.

Line Filter (Electromagnetic Compatibility Circuit - EMC) Operations, Checkout and Status Error Codes

Outdoor Fan Operation and Checkout

VAC Voltage Check

Procedure for checking VAC voltage to the outdoor fan motor.

VDC Voltage Check

Procedure for checking VDC output from the control to the fan motor.

STATUS OR ERROR CODES:

Notes on status/error codes related to the outdoor fan motor.

Ferrites

Explanation of ferrites and their purpose in controlling RF interference.

Outdoor Control Operation, Checkout and Status Error Codes

STATUS CODES:

Lists status codes for the outdoor control.

ERROR CODES:

Lists error codes related to the outdoor control and their causes/clearing.

Unit Sensor Operations, Checkout and Status Error Codes

Details component sensor operations, testing, and error codes.

Pins 5 and 6 (No Sensor)

Details about the absence of a sensor and the use of a resistor for continuity.

Ambient Temperature Sensor (RT13)

Information about the ambient temperature sensor and fault conditions.

Liquid Line Temperature Sensor (RT36)

Information about the liquid line temperature sensor and fault conditions.

CHECKOUT

Instructions for checking sensor operation by reading resistance.

ERROR CODES:

DC Inverter Control Operation, Checkout, Status Error Codes

Details inverter components, operation, checkout, status, and error codes.

OPERATION OF COMPONENTS:

Describes the operation of EMC, Converter, PFC, IPM, and Communication circuits.

STATUS CODES:

Lists status codes for the inverter.

ERROR CODES:

Lists error codes related to the inverter.

Emergency 24 VAC System Operation

System Refrigerant

Important notes regarding system refrigerant and charging procedures.

ADDING OR REMOVING REFRIGERANT

Guidance on adding or removing HFC-410A refrigerant.

INDOOR AIRFLOW CHECK

Procedure for checking indoor airflow using Delta-T.

GAUGE SET CONNECTIONS FOR TESTING AND CHARGING

Diagram and instructions for connecting gauge sets for charging.

AIRFLOW INDOOR COIL

Chart and instructions for checking indoor airflow and adjusting fan speed.

WEIGH-IN CHARGING METHOD

Method for weighing in refrigerant based on line set length and diameter.

SUBCOOLING CHARGING METHOD

Method for verifying refrigerant charge using subcooling.

Charging Temperatures and Pressures - High Speed Only

Tables providing charging data based on temperatures and pressures.

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