Lennox XC21 Series Unit Information
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Lennox XC21 Series Unit Information

Lennox xc21 (hfc?410a) series high efficiency residential split?system air conditioner
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Service Literature
THIS SERVICE MANUAL IS APPLICABLE TO BUILD
XC21−XXX−230−04 OR LATER.
NOTICE
A thermostat is not included and must be ordered
separately.
D The Lennox icomfort Touch™ thermostat must be used
in communicating applications.
D In
non−communicating
®
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
applications begin on page 24.
See the icomfort Toucht 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.
Accessories
For update−to−date information, see any of the following
publications:
S
Lennox XC21 Engineering Handbook
S
Lennox Product Catalog
S
Lennox Price Book
Corp. 1007−L2
Revised October 12, 2010
XC21 (HFC−410A) SERIES UNITS
(non−icomfortt and icomfortt ENABLED)
applications,
the
Lennox
for
non−communicating
Page 1

TABLE OF CONTENTS

Model Number Identification
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Component Field Configuration and
Troubleshooting
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The XC21 is a high efficiency residential split−system air
conditioner unit, which features a one−stage scroll
compressor, icomfortt control and HFC−410A refrigerant.
Units are available in 2, 3, 4 and 5−ton sizes. This model
series is designed for use with an expansion valve
metering device only. Refer to the XC17 Engineering
Handbook for ordering the correct indoor coil expansion
valve.
This model is also SunSourcet ready beginning with
XC21−XXX−230−05 build.
This document provides information only on build
XC21−XXX−230−04 and later which features the new air
conditioner control hardware and other enhancements.
Refer to Corp. 0504−L2 for earlier model version service
related information.
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2010 Lennox Industries Inc.
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Summary of Contents for Lennox XC21 Series

  • Page 1: Table Of Contents

    ........D The Lennox icomfort Touch™ thermostat must be used System Refrigerant .

  • Page 2: Typical Serial Number Identification

    Model Number Identification C 21 XXX Refrigerant Type Minor Revision Number X = R−410A Voltage 230 = 208/230V−1ph−60hz Unit Type C = Air Conditioner Nominal Cooling Capacity 024 = 2 tons 036 = 3 tons Series 048 = 4 tons 060 = 5 tons Typical Serial Number Identification 8 09...

  • Page 3: Electrical Data

    Electrical Data 208/230V−60 Hz−1 Ph Unit Compressor Condenser Fan Maximum Locked Over− Minimum Model Number Rated Load Rotor Nominal Nominal Full Load current Circuity Motor HP Amps (RLA) RPM 1−Stage RPM 2−Stage Amps (FLA) Amps Protection Ampacity (LRA) (amps) XC21−024−230−04 15.7 10.3 52.0...

  • Page 4: Unit Dimensions

    Unit Dimensions − Inches (mm) and Parts Arrangement DISCHARGE 39−1/2 35−1/2 ELECTRICAL (1003) (902) INLETS (1194) SUCTION LINE 4−1/2 INLET (114) LIQUID LINE INLET 18−1/2 (470) 8 (203) SIDE VIEW 1 (25) ACCESS VIEW UNIT SUPPORT FEET 26−7/8 (683) 16−7/8 (429) 8−3/4 (222)

  • Page 5: Unit Parts Arrangement

    Typical Unit Parts Arrangement SECOND GROUND LUG FOR SOURCESOURCE ® (BUILD −05 AND LATER) FAN MOTOR CONTROL (A177) GROUND LUG (BUILD −05 AND LATER) CONTACTOR−1 POLE (K1) HIGH VOLTAGE FIELD CONNECTIONS WIRE TIE OUTDOOR AMBIENT TEMPERATURE CAPACITOR (C12) SENSOR (RT13) MAIN CONTROL (A175) FAN MOTOR SURGE PROTECTION (BUILD...

  • Page 6: Operating Gauge Set And Service Valves

    This unit must be matched with an indoor coil as See the Lennox Service and Application Notes #C−08−1 specified in Lennox’ Engineering Handbook. Coils for further details and information. previously charged with HCFC−22 must be flushed.

  • Page 7: Service Valves

    SERVICE VALVES ANGLE AND BALL 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.

  • Page 8: Unit Placement

    MINIMUM CLEARANCE CLEARANCE ON ALL SIDES INCHES (MILLIMETERS) ABOVE UNIT 6 (152) ACCESS PANEL NOTES: CONTROL PANEL Clearance to one of the other three 48 (1219) ACCESS sides must be 36 inches (914mm). LOCATION 30 (762) 12 (305) Clearance to one of the remaining two sides may be 12 inches (305mm) and the final side may be 6 inches (152mm).
  • Page 9 STABILIZING UNIT ON UNEVEN SURFACES ROOF MOUNTING IMPORTANT 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 Unit Stabilizer Bracket Use (field−provided): can adequately support the unit.
  • Page 10 DETAIL D DETAIL C Slab Side Mounting #10 1/2" LONG SELF−DRILLING SHEET METAL SCREWS COIL STABILIZING BRACKET (18 GAUGE METAL 2" WIDTH; HEIGHT AS BASE PAN REQUIRED) #10 1−1/4" LONG HEX HD SCREW AND FLAT WASHER CORNER POST BASE CONCRETE SLAB PLASTIC ANCHORS (HOLE DRILL 1/4")

  • Page 11: Removing And Installing Panels

    Removing and Installing Panels ACCESS PANEL REMOVAL PANELS Removal and reinstallation of the access panel is as illustrated. ACCESS AND LOUVERED REMOVE 4 SCREWS TO WARNING REMOVE PANEL FOR ACCESSING COMPRESSOR To prevent personal injury, or damage to panels, unit or structure, be sure to ob- AND CONTROLS.

  • Page 12: New Or Replacement Line Set

    To obtain the correct information from Lennox, be sure to New or Replacement Line Set communicate the following information: REFRIGERANT LINE SET Model (XC21) and size of unit (e.g. −036). This section provides information on installation or Line set diameters for the unit being installed as listed replacement of existing line set.
  • Page 13 LINE SET IMPORTANT Refrigerant lines must not contact structure. INSTALLATION REFRIGERANT LINE SET INSTALLING Line Set Isolation The following illustrations are VERTICAL RUNS (NEW CONSTRUCTION SHOWN) examples of proper refrigerant line set isolation: NOTE Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the REFRIGERANT LINE SET TRANSITION...

  • Page 14: Brazing Connections

    Brazing Connections IMPORTANT Use the procedures outline in figures 8 and 9 for brazing Connect gauge set low pressure side to vapor line line set connections to service valves. service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port WARNING valve.
  • Page 15 CAP AND CORE REMOVAL PIPING PANEL REMOVAL AND PREPARING LINE Remove service cap and core from both the suction and liquid line service ports. Remove piping panel for easier access to service valves. Cut ends SERVICE PORT CAP of the refrigerant lines square (free from nicks or dents) and debur the ends.
  • Page 16 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. FLOW NITROGEN WARNING Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service 1.

  • Page 17: Flushing The System

    Flushing the System TYPICAL CHECK EXPANSION VALVE FLUSHING REMOVAL PROCEDURE (Uncased Coil Shown) STUB END LINE SET AND INDOOR COIL (1 OF 2) TWO PIECE PATCH PLATE LIQUID LINE CHECK (UNCASED COIL ONLY) ORIFICE EXPANSION TYPICAL FIXED ORIFICE REMOVAL PROCEDURE HOUSING VALVE DISTRIBUTOR...
  • Page 18 FLUSHING LINE SET AND INDOOR COIL (2 OF 2) TYPICAL CHECK EXPANSION VALVE INSTALLATION PROCEDURE This outdoor unit is designed for use in systems that use check expansion valve metering device. See the Lennox XC21 Engineering Hand- book for approved check expansion valve kit match−ups and application information.

  • Page 19: Leak Testing The System

    Polyol ester (POE) oils are death. used in Lennox units charged with HFC−410A Never use oxygen to pressurize or refrigerant. Residual mineral oil can act as an insulator, purge refrigeration lines. Oxygen, preventing proper heat transfer.

  • Page 20: Leak Test

    LEAK TEST LINE SET AND INDOOR COIL 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. CONNECT GAUGE SET Connect an HFC−410A manifold gauge set high pressure hose to the vapor valve service port.

  • Page 21: Evacuating The System

    Evacuating the System EVACUATING MANIFOLD LINE SET AND INDOOR COIL GAUGE SET CONNECT GAUGE SET HIGH NOTE Remove cores from service valves (if not al- ready done). Connect low side of manifold gauge set with 1/4 SAE in−line tee to vapor line service valve A34000 1/4 SAE TEE WITH Connect high side of manifold gauge...

  • Page 22: Electrical

    defined as any gas that will not condense under IMPORTANT temperatures and pressures present during operation of an air conditioning system. Non−condensables and water Use a thermocouple or thermistor electronic vacuum suction combine with refrigerant to produce substances gauge that is calibrated in microns. Use an instrument that corrode copper piping and compressor parts.
  • Page 23 ROUTE CONTROL WIRES NON−COMMUNICATING Install low voltage control wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated. CONTROL BOX Run 24VAC control wires through hole with grommet. Make 24VAC control wire connections to main control (A175). NOTE Do not bundle any excess 24VAC control wires inside control box.

  • Page 24: Field Control Wiring

    Field Control Wiring Air Handler ComfortSense[ 7000 Thermostats Catalog # Y0349 or Y2081 XC21 Two−Stage Air Conditioner Control On−board link Low voltage thermostat wiring Flat metal jumper 1. Thermostat T terminals are used for outdoor sensor input. Use for thermostat’s outdoor temperature display (optional). ®...
  • Page 25 Furnace ComfortSense[ 7000 Thermostats Catalog # Y0349 or Y2081 XC21 Two−Stage Air Conditioner Control On−board link Low voltage thermostat wiring 1. Thermostat T terminals are used for outdoor sensor input. Use for thermostat’s outdoor temperature display (optional). ® 2. R to L connection is required for this model when using the ComfortSense 7000 −...

  • Page 26: Air Conditioner Control (A175) Jumpers And Terminals

    Air Conditioner Control (A175) Jumpers and Terminals Table 3. Main Control Jumpers and Terminals TWO−STAGE Board ID Label Description Table 3 provides additional information concerning PSC Fan 240 VAC output connection for outdoor fan. jumpers, links, and connections for the A175 Main PSC Fan 240 VAC input connection for outdoor fan.

  • Page 27: Unit Start−Up

    nameplate. If not, do not start the equipment until you Unit Start−Up have consulted with the power company and the voltage condition has been corrected. IMPORTANT 6. Set the thermostat for a cooling demand. Turn on If unit is equipped with a crankcase heater, it should be power to the indoor indoor unit and close the outdoor energized 24 hours before unit start−up to prevent unit disconnect switch to start the unit.
  • Page 28 ADDING OR REMOVING REFRIGERANT This system uses HFC−410A refrigerant which operates at much higher pressures than HCFC−22. The pre−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 which use capillary tubes or fixed orifices as a refrigerant metering device.
  • Page 29 WEIGH IN to initially charge a system when the outdoor unit is void of charge. To verify charge and add or APPROACH SUBCOOLING remove refrigerant use either methods. WHEN TO CHARGE? START: Determine the correct charge method: Warm weather best Can charge in colder weather CHARGE METHOD? Determine by: Outdoor ambient temperature...
  • Page 30 APPROACH 1. Confirm proper airflow across coil using Figure 14. TEST AND CHARGE METHOD 2. Compare unit pressures with table 4, Normal Operating Pressures. 65ºF (18.3ºC) and Above 3. Use APPROACH to correctly charge unit or to verify the charge is If refrigerant added or removed, retest to confirm that unit is properly correct.

  • Page 31: Operating And Temperature Pressures

    Operating and Temperature Pressures Minor variations in these pressures may be expected due to differences in installations. Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system. Use this table to perform maintenance checks; it is not a procedure for charging the system.

  • Page 32: System Operations

    Table 5. HFC−410A Temperature (°F) − Pressure (Psig) °F °C Psig °F °C Psig −40 −40.0 11.6 15.6 −35 −37.2 14.9 18.3 −30 −34.4 18.5 21.1 −25 −31.7 22.5 23.9 −20 −28.9 26.9 26.7 −15 −26.1 31.7 29.4 −10 −23.3 36.8 32.2 −5...
  • Page 33 COIL TEMPERATURE SENSOR assembly that plugs directly into the main control. Through these sensors, the main control can monitor outdoor This model does not use a coil temperature sensor. The ambient and discharge line temperature fault conditions. cable assembly attached to the main control’s E30 As the detected temperature changes, the resistance connection has a 10K resister installed between pins 5 and across the sensor changes.
  • Page 34 Table 7. Ambient Sensor (RT13) Temperature / Resistance Range Degrees Degrees Degrees Degrees Resistance Resistance Resistance Resistance Fahrenheit Fahrenheit Fahrenheit Fahrenheit 136.3 2680 56.8 16657 21.6 44154 −11.3 123152 133.1 2859 56.0 16973 21.0 44851 −11.9 125787 130.1 3040 55.3 17293 20.5 45560...
  • Page 35 Table 8. High Discharge (RT28) Sensor Temperature / Resistance Range Degrees Degrees Degrees Degrees Resistance Resistance Resistance Resistance Fahrenheit Fahrenheit Fahrenheit Fahrenheit 303.1 186.1 1052 136.8 2656 94.5 6613 298.1 185.0 1072 136.0 2698 93.6 6739 293.4 183.9 1093 135.2 2740 92.8 6869...

  • Page 36: System Status, Fault And Lockout Led Codes

    System Status, Fault and Lockout LED IMPORTANT Codes DS15 and DS13 compressor LED fault and lockout LED codes are displayed using various LEDs located on codes do not provide safety protection. The is a the air conditioner control (A175). See page 26 for location monitoring function only and cannot control or shut down of air conditioner control LEDs.
  • Page 37 System fault and lockout LED (DS11 / DS14) alarm codes takes precedence over system status LED codes (cooling, heating stages or defrost/dehumidification). Only the latest active LED fault or lockout alarm code if present will be displayed. If no fault or lockout codes are active, then system status LEDs are routinely displayed.
  • Page 38 System fault and lockout LED (DS11 / DS14) alarm codes takes precedence over system status LED codes (cooling, heating stages or defrost/dehumidification). Only the latest active LED fault or lockout alarm code if present will be displayed. If no fault or lockout codes are active, then system status LEDs are routinely displayed.
  • Page 39 Air Conditioner icomfort icomfort Control LEDs Possible Possible Toucht Toucht Condition Condition Solution Solution Clearing Status Clearing Status Cause(s) Cause(s) DS15 DS13 Thermostat Thermostat Yellow Display Display Low refrigerant charge. Evaporator blower is not running. Check blower relay coil and contacts Check blower motor capacitor Check blower motor for failure or blockage Check evaporator blower wiring and...
  • Page 40 Air Conditioner icomfort icomfort Control LEDs Possible Possible Toucht Toucht Condition Condition Solution Solution Clearing Status Clearing Status Cause(s) Cause(s) DS15 DS13 Thermostat Thermostat Yellow Display Display Outdoor unit power disconnect is open. Unit circuit breaker or fuse(s) is open. Unit contactor has failed to close.
  • Page 41 Verifying Correct DC Output Voltage (J2) Field Configuration and Testing The following three methods can be used to determine This section provides procedures for configuring, adjusting whether the fan motor (B4) is operating at the correct and testing various components of this unit. RPMs based on unit size.
  • Page 42 Table 12. Fan Motor Control (A177) Flash and Pause Durations XC21−XXX−230−05 AND LATER Flash or Pause State Duration Flash Flash Three flashes per second Slow Flash One flash per second Short Pause Two seconds of OFF time. Long Pause Five seconds of OFF time. Table 13.
  • Page 43 DEMAND BEGINS DEFAULT MISMATCHED REPLACE FAN MOTOR FAN MOTOR CONTROL BOARD LED CONTINUOUS FAST SPEED USED FLASH DEFAULT FAN REPLACE FAN MOTOR MOTOR FAILURE LED CONSTANT ON CONTROL BOARD SPEED USED FAN MOTOR LED STAGE INDICATOR: ONE STAGE ECM1/Y1 RPM SET PER ONE SLOW FLASH AND (LOW) ONLY...

  • Page 44: Control Panel

    CFM Profile Pin Select FAN MOTOR CONTROL (A177) PULSE−WIDTH MODULATION (PWM) JUMPER JUMPER CONTROL PANEL MAIN CONTROL (A175) VERIFY DC VOLTAGE OUTPUT USING FAN PWM OUT AND COM TERMINALS. SEE TABLE 15 FOR OPTIMAL DC VOLTAGE BASED ON CFM PROFILE USED. FAN PWM OUT GREEN GREEN...
  • Page 45 CONTROL PANEL FAN MOTOR CONTROL (A177) PULSE−WIDTH MODULATION (PWM) INPUT VOLTAGES DURING DEMAND ECM/Y1 ONLY − 24VDC BOTH ECM/Y1 AND ECM/Y2 − 24VDC AT EACH INPUT ECM/Y2 ONLY − 24VDC YELLOW WIRE MAIN CONTROL BLUE WIRE (A175) BLACK WIRE ONE YELLOW WIRE FROM PS (E24) TERMINAL ON MAIN CONTROL.
  • Page 46 Fan Motor (B4) 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. FAN MOTOR TEST THIS IS A TEST THAT WILL VERIFY THAT THE MOTOR DOES OPERATE. 1.
  • Page 47 TOP GRILLE OR FAN MOTOR MOUNT ADJUSTMENT FOR FAN CLEARANCE Sometimes during shipping, either the fan motor mounting or top grille may become out of alignment. This may cause the fan motor blade to not clear the orifice ring. If this situation occurs, simply adjust either or both the fan motor mount or top grille positions to allow proper clearance.
  • Page 48 AIR CONDITIONER CONTROL (A175) UNIT alert code 313, indoor and outdoor unit capacity mismatch NOMINAL CAPACITY CODE CONFIGURATION error code, or alert code 34, must program unit capacity for outdoor unit. Use figure 26 to configure the unit normal In a communicating system, the unit capacity code must be configured if the room thermostat is indicating either an capacity code.

  • Page 49: Maintenance

    6. Inspect drain holes in coil compartment base and clean if necessary. Lennox Industries Inc. P.O. Box 799900 NOTE - If insufficient cooling occurs, the unit should be Dallas, TX 75379−9900 gauged and refrigerant charge should be checked.

  • Page 50: Sunsource ® Home Energy System

    The SolarSynct package consists of the following components: S Lennox ® Solar Subpanel installed in a Dave Lennox ® Signature Collection air conditioner or heat pump unit. S Solar modules (1 to 15 may be used to vary the amount of electricity generated).
  • Page 51 Start−Up and Performance Checklist Customer Address Indoor Unit Model Serial Outdoor Unit Model Serial Notes: START UP CHECKS Refrigerant Type: First Stage: Rated Load Amps Actual Amps Rated Volts Actual Volts Second Stage: Rated Load Amps Actual Amps Rated Volts Actual Volts Condenser Fan Full Load Amps Actual Amps: First Stage...

  • Page 52: Unit Wiring Diagrams

    Unit Wiring Diagrams Figure 28. Typical XC21 Wiring (non−icomfortt enabled (XC21−XXX−230−04 build) Page 52 XC21...
  • Page 53 Figure 29. Typical XC21 Wiring (with icomfortt enabled, Surge Protection and Fan Motor Control (A177) Rewired) (XC21−XXX−230−05 build) XC21 Page 53...

  • Page 54: Unit Sequence Of Operations

    Figure 30. Typical XC21 Wiring (with icomfortt enabled, New Fan Motor with built−in surge protection and External Surge Protection Device Removed (XC21−XXX−230−06 build) Unit Sequence of Operations The following figures illustrated the overall unit sequence of operations along with various pressure switches and temperature sensor operations.
  • Page 55 On 24VAC power−up or air conditioner control (A175) reset, the air conditioner control shall perform the following tasks: 1. Start the anti−short cycle delay. 2. Check temperature sensor and pressure switches at the start of cooling demand. 3. Air Conditioner control responds to the thermostat input after the anti−short cycle timer expires.
  • Page 56 INITIAL TRIP COMPRESSOR PRESSURE SWITCH IS CLOSED Y1 DEMAND CONTACTOR SWITCH (S87) IGNORED FOR ENERGIZED 90 SECONDS PRESSURE SWITCH IS CLOSED OR OUTDOOR CLOSED OPEN AMBIENT TEMPERATURE IS 15ºF SWITCH (S87) OR BELOW COMPRESSOR If 5−strike counter has four or less strikes when Y1 demand CONTACTOR is terminated or satisfied, the strike counter will reset to DE−ENERGIZED...
  • Page 57 HIGH COMPRESSOR PRESSURE Y1 DEMAND CLOSED CONTACTOR SWITCH (S4) ENERGIZED HIGH PRESSURE CLOSED OPEN SWITCH (S4) COMPRESSOR If 5−strike counter has four or less strikes when Y1 demand CONTACTOR DE−ENERGIZED is terminated or satisfied, the strike counter will reset to zero.
  • Page 58 If temperature is at or above 279ºF. DISCHARGE COMPRESSOR Y1 DEMAND CLOSED SENSOR CONTACTOR (RT28)* ENERGIZED HIGH PRESSURE CLOSED OPEN SWITCH (S4) COMPRESSOR CONTACTOR If 5−strike counter has four or less strikes when Y1 demand DE−ENERGIZED is terminated or satisfied, the strike counter will reset to zero.

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