LENNOX EL15KC1 Outdoor Air Conditioner Installation Guide

Installation Guide for LENNOX models including: EL15KC1 Outdoor Air Conditioner, EL15KC1, Outdoor Air Conditioner, Air Conditioner

Lennox Technical Publications

INSTALLATION INSTRUCTIONS

1 февр. 2025 г. — For more in-depth information, consult the Installation and Service Procedures manual, available on. LennoxPros.com or through the Technical Support department ...

[PDF] INSTALLATION INSTRUCTIONS - Lennox

Install power wiring and properly sized disconnect switch. NOTE - Units are approved for use only with copper conductors. Ground unit at disconnect switch ...

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508492-01

©2024 Lennox Industries Inc. Dallas, Texas, USA
THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional HVAC installer or equivalent, or service agency.
WARNING
To prevent serious injury or death: 1. Lock-out/tag-out before performing maintenance. 2. If system power is required (e.g., smoke detector
maintenance), disable power to blower, remove fan belt where applicable, and ensure all controllers and thermostats are set to the "OFF" position before performing maintenance. 3. Always keep hands, hair, clothing, jewelry, tools, etc. away from moving parts. IMPORTANT: Special procedures are required for cleaning the all-aluminum coil in this unit. See page 21 in this instruction for information.
STEP 1 SETTING THE UNIT Clearances

INSTALLATION INSTRUCTIONS
Elite® Series EL15KC1 Units
AIR CONDITIONER 508492-01 8/2024
General
This EL15KC1 outdoor air conditioner with all-aluminum coil is designed for use with R-454B refrigerant only. This unit must be installed with an approved indoor air handler or coil. For AHRI Certified system match-ups and expanded ratings, visit www.LennoxPros.com. These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.
NOTICE!
Charging information is given on the charging procedure sticker on the unit access panel. For more in-depth information, consult the Installation and Service Procedures manual, available on LennoxPros.com or through the Technical Support department at 800-453-6669.
CAUTION
As with any mechanical equipment, contact with sharp sheet metal edges can result in personal injury. Take care while handling this equipment and wear gloves and protective clothing.
NOTE This unit EL15KC1 is a PARTIAL UNIT AIR CONDITIONER, complying with PARTIAL UNIT requirements of this Standard, and must only be connected to other units that have been confirmed as complying to corresponding PARTIAL UNIT requirements of this Standard, UL 60335-2-40/CSA C22.2 No. 60335-2-40, or UL 1995/ CSA C22.2 No 236.

See NOTES

Control Box

NOTES: Service clearance of 30 in. must be maintained on one of the sides adjacent to the control box.
Clearance to one of the other three sides must be 36 in.
Clearance to one of the remaining two sides may be 12 in. and the final side may be 6 in.
A clearance of 24 in. must be maintained between two units.
48 in. clearance required on top of unit.

NOTICE: Specific applications may require adjustment of the listed installation clearances to provide protection for the unit from physical damage or to avoid conditions which limit operating efficiency. (Example: Clearances may have to be increased to prevent snow or ice from falling on the top of the unit. Additional clearances may also be required to prevent air recirculation when the unit is installed under a deck or in another tight space.)
Page 1

WARNING
· The appliance shall be stored in a room without continuously operating ignition sources (for example: open flames, an operating gas appliance, or an operating electric heater).
· Do not pierce or burn.
· Be aware that refrigerants may not contain an odor.
CAUTION
Servicing shall be performed only as recommended by the manufacturer.
WARNING
Ducts connected to an appliance shall not contain a potential ignition source
WARNING
Every working procedure that affects safety means shall only be carried out by competent persons. This appliance is not to be used by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure they do not play with the appliance.
IMPORTANT
Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during the period that the work is carried out.
IMPORTANT
Verify cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects.
IMPORTANT
Pipe work, including piping material, pipe routing, and installation shall include protection from physical damage in operation and service, and be in compliance with national and local codes and standards, such as ASHRAE 15, ASHRAE 15.2, IAPMO Uniform Mechanical Code, ICC International Mechanical Code, or CSA B52. All field joints shall be accessible for inspection prior to being covered or enclosed.

CAUTION
Under no circumstances shall potential sources of ignition be used in the searching for or detection of refrigerant leaks. A halide torch (or any other detector using a naked flame) shall not be used. The following leak detection methods are deemed acceptable for all refrigerant systems.
Electronic leak detectors may be used to detect refrigerant leaks but, in the case of flammable refrigerants, the sensitivity may not be adequate, or may need recalibration. (Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used. Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed, and the appropriate percentage of gas (25 % maximum) is confirmed. Leak detection fluids are also suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work. If a leak is suspected, all naked flames shall be removed/extinguished. If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak.
CAUTION
Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use matches, candles, flame or other sources of ignition to check for gas leaks.
WARNING
PARTIAL UNITS shall only be connected to an appliance suitable for the same refrigerant.

Page 2

IMPORTANT
When breaking into the refrigerant circuit to make repairs or for any other purpose conventional procedures shall be used. However, for flammable refrigerants it is important that best practice be followed and, since flammability is a consideration, procedures such as safely remove refrigerant following local and national regulations, purging the circuit with inert gas, evacuating (optional for A2L), purging with inert gas (optional for A2L), or opening the circuit by cutting or brazing be adhered to. The refrigerant charge shall be recovered into the correct recovery cylinders if venting is not allowed by local and national codes. For appliances containing flammable refrigerants, the system shall be purged with oxygen-free nitrogen to render the appliance safe for flammable refrigerants.
This process might need to be repeated several times. Compressed air or oxygen shall not be used for purging refrigerant systems. For appliances containing flammable refrigerants, refrigerants purging shall be achieved by breaking the vacuum in the system with oxygenfree nitrogen and continuing to fill until the working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum (optional for A2L). This process shall be repeated until no refrigerant is within the system (optional for A2L). When the final oxygenfree nitrogen charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. Ensure that the outlet for the vacuum pump is not close to any potential ignition sources and that ventilation is available.
IMPORTANT
In addition to conventional charging procedures, the following requirements shall be followed.
·Ensure that contamination of different refrigerants does not occur when using charging equipment. Hoses or lines shall be as short as possible to minimize the amount of refrigerant contained in them.
·Cylinders shall be kept in an appropriate position according to the instructions.
·Ensure that the REFRIGERATING SYSTEM is earthed prior to charging the system with refrigerant.
·Label the system when charging is complete (if not already).
·Extreme care shall be taken not to overfill the REFRIGERATING SYSTEM.
Prior to recharging the system, it shall be pressuretested with the appropriate purging gas. The system shall be leak tested on completion of charging, but prior to commissioning. A follow up leak test shall be carried out prior to leaving the site.

IMPORTANT
When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely.
When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cylinders for holding the total system charge is available. All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant (i. e. special cylinders for the recovery of refrigerant). Cylinders shall be complete with pressure-relief valve and associated shut-off valves in good working order. Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of all appropriate refrigerants including, when applicable, flammable refrigerants. In addition, a set of calibrated weighing scales shall be available and in good working order. Hoses shall be complete with leak-free disconnect couplings and in good condition. Before using the recovery machine, check that it is in satisfactory working order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a refrigerant release. Consult manufacturer if in doubt.
The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant waste transfer note arranged. Do not mix refrigerants in recovery units and especially not in cylinders.
If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that flammable refrigerant does not remain within the lubricant. The evacuation process shall be carried out prior to returning the compressor to the suppliers. Only electric heating to the compressor body shall be employed to accelerate this process. When oil is drained from a system, it shall be carried out safely.
IMPORTANT
After completion of field piping for split systems, the field pipework shall be pressure tested with an inert gas and then vacuum tested prior to refrigerant charging, according to the following requirements;
Field-made refrigerant joints indoors shall be tightness tested. The test method shall have a sensitivity of .2 oz. per year of refrigerant or better, under pressure.
No leak shall be detected.

Page 3

NOTE R-454b is a A2L refrigerant. The system installation must meet the following parameters based upon total refrigerant charge (line set included). TAmin (Total minimum conditioned area)is the minimum allowable conditioned area based upon the total system charge at sea level. Values must be multiplied by altitude adjustment factor at installed altitude. Qmin table refers to minimum airflow requirements during refrigerant leak mitigation by the refrigerant detection system, based upon total system charge.
See tables below.

Charge (lb) Charge (kg) Minimum Conditioned Area (ft2) Minimum Conditioned Area (m2)

TAmin Table

10.0

15.0

4.5

6.8

149.9

224.9

13.9

20.9

20.0 9.1 299.9 27.9

25.0 11.3 374.8 34.8

30.0 13.6 449.8 41.8

NOTE Multiply values in TAmin table by the Altitude Adjustment Factors to correct TAmin based on installed altitude.

Altitude Adjustment Factor

Altitude (m)

200

400

600

800

1000

1200

1400

Altitude (ft)

660

1310

1970

2620

3280

3940

4590

Adj. Factor

1.02

1.05

1.04

1.1

Altitude (m)

1600

1800

2000

2200

2400

2600

2800

3000

Altitude (ft)

5250

5910

6560

7220

7870

8530

9190

9840

Adj. Factor

1.12

1.15

1.18

1.21

1.25

1.28

1.32

1.36

1600 5250 1.12 3200 10500 1.4

Qmin Table

Refrigerant Charge lb (kg)

CFM Required

Refrigerant Charge lb (kg)

5 (2.3)

135

18 (8.1)

6 (2.7)

162

19 (8.6)

7 (3.2)

189

20 (9.1)

8 (3.6)

216

21 (9.5)

9 (4.1)

244

22 (10)

10 (4.5)

271

23 (10.4)

11 (5)

298

24 (10.9)

12 (5.4)

325

25 (11.3)

13 (5.9)

352

26 (11.7)

14 (6.4)

379

27 (12.2)

15 (6.8)

406

28 (12.7)

16 (7.3)

433

29 (13.2)

17 (7.7)

460

30 (13.6)

NOTE Qmin minimum airfow requirement for refrigerant leak mitigation.

CFM Required 487 514 541 568 595 622 649 676 704 731 758 785 812

Page 4

Unit Dimensions

LIQUID LINE CONNECTION
C
ELECTRICAL INLETS
A
SUCTION LINE CONNECTION

SIDE VIEW

Model EL15KC1-018-230

A 27 (686)

EL15KC1-024-230 31 (787)

EL15KC1-030-230 EL15KC1-048-230

31 (787)

EL15KC1-036-230 EL15KC1-042-230 EL15KC1-060-230

35 (889) 39 (991)

B 27 (686)
27 (686)
30-1/2 (775)
30-1/2 (775) 30-1/2 (775)

4-1/2" (108)

4-3/4" (121)

B
TOP VIEW

C
28 (711)
28 (711)

EL15KC1 Dimensions - in. (mm)

See EL15KC1-018 and EL15KC1-024 base section below.

35 (889)

13-7/8 (352)

7-3/4 (197)

3-1/4 (83)

27-1/8 (689)

3-5/8 (92)

35 (889)
35 (889)

13-7/8 (352)
13-7/8 (352)

7-3/4 (197)
7-3/4 (197)

3-1/4 (83)
3-1/4 (83)

27-1/8 (689)
27-1/8 (689)

3-5/8 (92)
3-5/8 (92)

I
4-1/2 (114) 4-1/2 (114) 4-1/2 (114)

J
20-5/8 (524) 20-5/8 (524) 20-5/8 (524)

UNIT SUPPORT FEET

8-1/2" (216)

9-1/2" (241)

8-3/4 (222)

8-1/4" (210)

5-1/2" (140)

13-1/2" (343)

EL15KC1-018 & EL15KC1-024 BASE SECTION (SMALL)

D J

E I

EL15KC1-030 TO -060 BASE WITH ELONGATED LEGS

Page 5

STEP 1 SETTING THE UNIT (Continued) Unit Placement
NOTICE!
Roof Damage! This system contains both refrigerant and oil. Some rubber roofing material may absorb oil, causing the rubber to degrade. Failure to follow this notice could result in damage to roof surface.
IMPORTANT
This unit must be matched with an indoor coil as specified with AHRI. For AHRI Certified system matchups and expanded ratings, visit www.LennoxPros.com.
WARNING
To prevent personal injury, as well as damage to panels, unit or structure, observe the following: While installing or servicing this unit, carefully stow all removed panels so that the panels will not cause injury to personnel, objects or nearby structures. Also, take care to store panels where they will not be subject to damage (e.g., being bent or scratched). While handling or stowing the panels, consider any weather conditions (especially wind) that may cause panels to be blown around and damaged.
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.
IMPORTANT
Exhaust vents from dryers, water heaters and furnaces should be directed away from the outdoor unit. Prolonged exposure to exhaust gases and the chemicals contained within them may cause condensation to form on the steel cabinet and other metal components of the outdoor unit. This will diminish unit performance and longevity

PLACEMENT
Install unit away from windows.

TWO 90° ELBOWS INSTALLED IN LINE SET WILL REDUCE LINE SET VIBRATION.
FIGURE 1
SLAB MOUNTING
Install unit level or, if on a slope, maintain slope tolerance of 2 degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from building structure.
BUILDING STRUCTURE

GROUND LEVEL

MOUNTING SLAB

FIGURE 2
IMPORTANT
This model is designed for use in check / expansion valve systems only. An indoor expansion valve approved for use with R-454B refrigerant must be ordered separately and installed prior to operating the system.
The maximum altitude of use is 10,000 ft (3048 m). This unit is a partial unit air conditioner, complying with partial unit requirements of this international standard, and must be only connected to other units that have been confirmed as complying to corresponding partial unit requirements of this international standard.

Page 6

STEP 2 REFRIGERANT PIPING
IMPORTANT
If this unit is being matched with a approved lineset that was previously charged with mineral oil, the line set must be flushed prior to installation. Take care to empty all existing traps. Polyolester (POE) oils are used in Lennox units charged with R-454B refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the expansion device and reduce system performance and capacity. Failure to properly flush the system per this instruction and the detailed Installation and Service Procedures manual will void the warranty.

IMPORTANT
Braze-free fittings must conform with UL207 or ISO14903 (latest edition).
Flush the existing line set per the following instructions. For more information, refer to the Installation and Service Procedures manual available on LennoxPros.com. CAUTION - DO NOT attempt to flush and re-use existing line sets or indoor coil when the system contains contaminants (i.e., compressor burn out).
If a new line set is being installed, size the piping per table 1.

Model Number
EL15KC1-018-230 EL15KC1-024-230 EL15KC1-030-230
EL15KC1-036-230

TABLE 1 REFRIGERANT LINE SET INCHES (MM)

Valve Size Connections

Liquid Line

Suction Line

L15 Line Set Model

Recommended Line Sets

Line Set Length

Catalog Number

3/8" (10 mm)

3/4" (19 mm)

L15-41-20 L15-41-30 L15-41-40 L15-41-50

20 feet (6.1 m) 30 feet (9.1 m) 40 feet (12.2 m) 50 feet (15.2 m)

89J56 89J57 89J58 89J59

L15-65-30

30 feet (9.1 m)

89J60

EL15KC1-042-230

3/8" (10 mm)

7/8" (22 mm)

L15-65-40

40 feet (12.2 m)

89J61

EL15KC1-048-230 EL15KC1-060-230

L15-65-50

50 feet (15.2 m)

3/8" (10 mm)

1-1/8" (29 mm) *

Field-fabricated

N/A

* Some applications may require a field-provided 1-1/8" to 7/8" adapter.

89J62 N/A

NOTE - When installing refrigerant lines longer than 50 feet, refer to the Refrigerant Piping Design and Fabrication Guidelines manual available on LennoxPros.com (Corp. 9351-L9), or contact the Technical Support Department Product Application group for assistance.
NOTE - For new or replacement line set installation, refer to Service and Application Note - Corp. 9112-L4 (C-91-4).

Line Set Joints Furnace Application
Evaporator primary line set joints in all applications shall have a line set joint sleeve.
Evaporator primary line sets should not have additional joints not covered by line set joint sleeve.
If additional joints are present, the system installation shall comply with one of the options below:
Option 1 - Furnace is installed as a direct vent appliance;
Option 2 - Furnace/Evaporator installation is in a space greater than the minimum conditioned area (Amin);
Option 3 - Furnace/Evaporator installation is connected to a space greater than the minimum conditioned area (Amin) through an opening of at least 15 in² (4-inch diameter hole equivalent) located below the level of the furnace burners;
Option 4 - Have a second refrigerant detection sensor installed below the level of the burners (see Secondary Sensor Installation section).

Multiple Systems Installed in Same Space
For any A2L refrigerant system with additional joints not covered by line set joint sleeves, each system in the same space must have refrigerant detection sensor installed below the level of the burners (see Secondary Sensor Installation section). If all the systems in the same space are installed with direct vent application, then additional refrigerant detection sensor is not needed
Secondary Sensor Installation
If secondary refrigerant sensor is required, it shall be mounted as follows:
Upflow Applications: Mounted on an unused side furnace return air connection at least 9 inches above the floor and within 9 inches from front of furnace.
Downflow Applications: Mounted on one side of the evaporator coil 9 inches above the floor and within 9 inches from front of coil.
Horizontal Applications: Mounted on the bottom side return furnace air connection within 9 inches of both the blower deck and front of furnace.

Page 7

Connect the refrigerant sensor to the second sensor input on the RDS Control. Refer to the instructions provided with the sensor or the RDS controller to enable the second sensor.
WARNING
When using a high pressure gas such as nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).
WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly.
Failure to follow this warning may result in personal injury or death.
WARNING
Fire, Explosion and Personal Safety hazard. Failure to follow this warning could result in damage, personal injury or death. Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when exposed to a spark or open flame, can cause fire and/ or an explosion, that could result in property damage, personal injury or death.

WARNING
Polyolester (POE) oils used with R-454B refrigerant absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as possible. DO NOT remove line set caps or service valve stub caps until you are ready to make connections.
WARNING
Every working procedure that affects safety means shall only be carried out by competent persons. This appliance is not to be used by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Examples of such working procedures are breaking into the refrigerating circuit, opening of sealed components, and opening of ventilated enclosures.

Page 8

LINE SET

IMPORTANT -- Refrigerant lines must not contact structure.

INSTALLATION
Line Set Isolation - The following illustrations are examples of proper refrigerant line set isolation:

REFRIGERANT LINE SET -- TRANSITION FROM VERTICAL TO HORIZONTAL

ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE
MUFFLER-TYPE HANGER

AUTOMOTIVE MUFFLER-TYPE HANGER

REFRIGERANT LINE SET -- INSTALLING VERTICAL RUNS (NEW CONSTRUCTION SHOWN)

NOTE - Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig.

IMPORTANT - Refrigerant lines must not contact wall

OUTSIDE WALL

SUCTION LINE

LIQUID LINE

WALL STUD

STRAP LIQUID LINE TO SUCTION LINE

NON-CORROSIVE METAL SLEEVE

LIQUID LINE
SUCTION LINE WRAPPED IN ARMAFLEX

WOOD BLOCK BETWEEN STUDS

WIRE TIE INSIDE WALL STRAP NON-CORROSIVE METAL SLEEVE WIRE TIE
WOOD BLOCK WIRE TIE STRAP

REFRIGERANT LINE SET -- INSTALLING HORIZONTAL RUNS

To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties.

8 FEET (2.43 METERS)

WIRE TIE (AROUND SUCTION LINE ONLY)

STRAPPING MATERIAL (AROUND
SUCTION LINE ONLY)

FLOOR JOIST OR ROOF RAFTER

TAPE OR WIRE TIE

8 FEET (2.43 METERS)

NON-CORROSIVE METAL SLEEVE

TAPE OR WIRE TIE
FLOOR JOIST OR ROOF RAFTER

STRAP THE SUCTION LINE TO THE JOIST OR RAFTER AT 8 FEET (2.43 METERS) INTERVALS THEN STRAP THE LIQUID LINE TO THE SUCTION LINE.

SLEEVE

SUCTION LINE WRAPPED WITH ARMAFLEX

OUTSIDE WALL

LIQUID LINE

PVC PIPE

CAULK
FIBERGLASS INSULATION

NOTE - Similar installation practices should be used if line set is to be installed on exterior of outside wall.

FIGURE 3

Page 9

STEP 2 REFRIGERANT PIPING (Continued)

1A TYPICAL EXISTING FIXED ORIFICE REMOVAL PROCEDURE (UNCASED COIL SHOWN)
DISTRIBUTOR TUBES LIQUID LINE ORIFICE HOUSING
TEFLON® RING FIXED ORIFICE

1B TYPICAL EXISTING EXPANSION VALVE REMOVAL PROCEDURE (UNCASED COIL SHOWN)

TWO-PIECE PATCH PLATE (UNCASED COIL ONLY)
DISTRIBUTOR TUBES

STUB END
LIQUID LINE ORIFICE HOUSING

CHECK EXPANSION
VALVE
TEFLON® RING

BRASS NUT

TEFLON® RING

SENSING LINE

DISTRIBUTOR ASSEMBLY

REMOVE AND DISCARD WHITE TEFLON® SEAL
(IF PRESENT)

LIQUID LINE ASSEMBLY (INCLUDES STRAINER)

A - On fully cased coils, remove the coil access and plumbing panels.

DISTRIBUTOR ASSEMBLY

EQUALIZER LINE

LIQUID LINE ASSEMBLY WITH
BRASS NUT

B sembly.
C - Using two wrenches, disconnect liquid line from liquid line ing. T cess.
D - Remove and discard fixed orifice, valve stem assembly (if present) and Teflon® washer as illustrated above.
E - Use a field-provided fitting to temporarily reconnect the liquid line to the indoor unit's liquid line orifice housing.

MALE EQUALIZER LINE FITTING
SENSING BULB

VAPOR LINE

LIQUID LINE

A - On fully cased coils, remove the coil access and plumbing panels.
B - Remove any shipping clamps from the liquid line and distributor assembly.
C - Disconnect the equalizer line from the check expansion valve equalizer line fitting on the vapor line.

2 CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE

D - Remove the vapor line sensing bulb.
E - Disconnect the liquid line from the check expansion valve at the liquid line assembly.

CYLINDER CONTAINING CLEAN HCFC-22 TO BE USED FOR FLUSHING (Positioned to deliver liquid
A refrigerant)

GAUGE MANIFOLD

F - Disconnect the check expansion valve from the liquid line orifice housing. Take care not to twist or damage distributor tubes during this process.
G - Remove and discard check expansion valve and the two Teflon®

LOW

HIGH

rings.

VAPOR LINE SERVICE VALVE

NEW OUTDOOR

H - Use a field-provided fitting to temporarily reconnect the liquid line to the indoor unit's liquid line orifice housing.

EXISTING INDOOR
UNIT

UNIT
B

OPENED

CLOSED

3FLUSHING LINE SET The line set and indoor unit coil must be flushed with at least the same amount of clean refrigerant that previously charged the system. Check the charge in the flushing cylinder before proceeding.

VAPOR LIQUID

LIQUID LINE SERVICE VALVE
RECOVERY CYLINDER
D

TANK RETURN

INLET

DISCHARGE

RECOVERY MACHINE

A - Set the recovery machine for liquid recovery and start the recovery machine. Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line set and indoor
unit coBil.
B - Position the cylinder of clean HCFC-22 for delivery of liquid refrigerant and open its valve to allow liquid refrigerant to flow into the system through the vapor line valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery machine.

C - After all of the liquid refrigerant has been recovered, switch the

A - HCFC-22 cylinder with clean refrigerant (positioned to deliver liquid refrigerant) to the vapor service valve.

recovery machine to vapor recovery so that all of the HCFC-22 vapor is recovered. Allow the recovery machine to pull the system

B - HCFC-22 gauge set (low side) to the liquid line valve.

down to 0.

C - HCFC-22 gauge set center port to inlet on the recovery machine with an D - Close the valve on the inverted HCFC-22 drum and the gauge set

empty recovery tank connected to the gauge set.

valves. Pump the remaining refrigerant out of the recovery

D - Connect recovery tank to recovery machine per machine instructions.

machine and turn the machine off.

FIGURE 4

Page 10

STEP 2 REFRIGERANT PIPING Brazing Procedures

1CUT AND DEBUR Cut ends of the refrigerant lines square (free from nicks or dents) and debur the ends. The pipe must remain round. Do not crimp end of the line.

2 CAP AND CORE REMOVAL Remove service cap and core from both the vapor and liquid line service ports.

CUT AND DEBUR

LINE SET SIZE MATCHES SERVICE VALVE CONNECTION

COPPER TUBE STUB

SERVICE VALVE CONNECTION

REDUCER

SERVICE PORT CAP

SERVICE PORT CORE

SERVICE PORT CORE
LIQUID LINE SERVICE VALVE

SERVICE PORT CAP
VAPOR LINE SERVICE VALVE

LINE SET SIZE IS SMALLER THAN CONNECTION
REFRIGERANT LINE

DO NOT CRIMP SERVICE VALVE CONNECTOR WHEN PIPE IS
SMALLER THAN CONNECTION

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

Flow regulated nitrogen (at 1 to 2 psig) through the low-side refrigeration gauge set into the liquid line service port valve, and out of the vapor line service port valve.

A - Connect gauge set low pressure side to liquid line service valve (service port).
B - Connect gauge set center port to bottle of nitrogen with regulator.

LOW

HIGH

USE REGULATOR TO FLOW NITROGEN AT 1 TO 2 PSIG.

C - Remove core from valve in vapor line service port to allow nitrogen to escape.

ATTACH GAUGES

VAPOR SERVICE PORT MUST BE OPEN
C TO ALLOW EXIT POINT FOR NITROGEN

INDOOR UNIT

VAPOR LINE

VAPOR LINE SERVICE VALVE

B
OUTDOOR UNIT

LIQUID LINE

LIQUID LINE SERVICE VALVE

NITROGEN
A WHEN BRAZING LINE SET TO SERVICE VALVES, POINT FLAME AWAY FROM SERVICE VALVE.

FIGURE 5

CAUTION
Brazing alloys and flux contain materials which are hazardous to your health.
Avoid breathing vapors or fumes from brazing operations. Perform operations only in well-ventilated areas.
Wear gloves and protective goggles or face shield to protect against burns.
Wash hands with soap and water after handling brazing alloys and flux.

WARNING
Danger of fire. Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing. Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture. Check the high and low pressures before applying heat.

Page 11

4 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.
5 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 out of the vapor valve stem port. See steps 3A, 3B and 3C on manifold gauge set connections.
6 BRAZE LINE SET Wrap both service valves with water-saturated cloths as illustrated here and as mentioned in step 4, before brazing to line set. Cloths must remain water-saturated throughout the brazing and cool-down process.
LIQUID LINE SERVICE VALVE

WHEN BRAZING LINE SET TO SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.
IMPORTANT -- Allow braze joint to cool. Apply additional water-saturated cloths to help cool brazed joint. Do not remove water-saturated cloths until piping has cooled. Temperatures above 250ºF will damage valve seals.
WARNING
FIRE, PERSONAL INJURY, OR PROPERTY DAMAGE may result if you do not wrap a water-saturated cloth around both liquid and suction line service valve bodies and copper tube stub while brazing the line set! The braze, when complete, must be quenched with water to absorb any residual heat. Do not open service valves until refrigerant lines and indoor coil have been leak-tested and evacuated. Refer to Installation and Service Procedures manual found on LennoxPros.com.

WATER-SATURATED CLOTH
LIQUID LINE
VAPOR LINE SERVICE VALVE
WHEN BRAZING LINE SET TO SERVICE VALVES, POINT FLAME
AWAY FROM SERVICE VALVE.

VAPOR LINE

WATER-SATURATED CLOTH

7 PREPARATION FOR NEXT STEP After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water-saturated cloths to both services valves to cool piping. Once piping is cool, remove all water-saturated cloths.

FIGURE 6

Page 12

STEP 2 REFRIGERANT PIPING Install Indoor Expansion Valve
This outdoor unit is designed for use in systems that include an expansion valve metering device (purchased separately) at the indoor coil. See the EL15KC1 Product Specifications bulletin (EHB) for approved expansion valve kit match-ups and application information. The check expansion valve unit must be installed inside unit cabinet. In applications where an uncased coil is being installed in a field-provided plenum, install the check/expansion valve in a manner that will provide access for future field service of the expansion valve. Refer to below illustration for reference during installation of expansion valve unit.

INDOOR EXPANSION VALVE INSTALLATION

TWO PIECE PATCH PLATE
(UNCASED COIL ONLY)
DISTRIBUTOR TUBES

(Uncased Coil Shown)

LIQUID LINE ORIFICE HOUSING

STUB END

CHECK EXPANSION
VALVE
TEFLON® RING

DISTRIBUTOR ASSEMBLY

TEFLON® RING
EQUALIZER LINE

SENSING LINE

1/2 Turn 3 - Install one of the provided Teflon® rings around the

stubbed end of the check expansion valve and lightly
lubricate the connector threads and expose surface of the Teflon® ring with refrigerant oil.

11 12 10
9

1 2 3

4 - Attach the stubbed end of the check expansion valve to the liquid line orifice housing. Finger tighten and use an

8 76

4 5

appropriately sized wrench to turn an additional 1/2 turn

clockwise as illustrated in the figure above, or tighten to

20 ft-lb.

5 - Place the remaining Teflon® washer around the other
end of the check expansion valve. Lightly lubricate connector threads and expose surface of the Teflon®
ring with refrigerant oil.

6 - Attach the liquid line assembly to the check expansion valve. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or tighten to 20 ft-lb.

MALE EQUALIZER LINE FITTING (SEE
EQUALIZER LINE INSTALLATION FOR FURTHER DETAILS)

LIQUID LINE ASSEMBLY WITH
BRASS NUT

SENSING BULB INSTALLATION
1 - Attach the vapor line sensing bulb in the proper orientation as illustrated belowusing the clamp and screws provided.

VAPOR LINE

ON LINES SMALLER THAN 3/4", MOUNT SENSING BULB AT EITHER THE 1 OR 11 O'CLOCK POSITION.

LIQUID LINE

Sensing bulb insulation is required if mounted external to the coil casing. sensing bulb installation for bulb positioning.
EQUALIZER LINE INSTALLATION
1 - Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure below.
2 - Remove the field-provided

ON 3/4" AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 3 OR 9 O'CLOCK POSITION.

sembly.

NOTE - NEVER MOUNT THE SENSING BULB ON BOTTOM OF LINE.

FLARE SEAL CAP

FLARE NUT

NOTE - Though it is preferred to have the sensing bulb

installed on a horizontal run of the vapor line, installation

on a vertical run of piping is acceptable if necessary.

COPPER FLARE SEAL BONNET

See figure to right for proper bulb orientation on vert-

ical run of piping.

MALE BRASS EQUALIZER LINE FITTING

NOTE - Confirm proper thermal contact between vapor line and check/expansion bulb before insulating the sensing bulb once installed.

1/8 Turn

VAPOR LINE

2 - Connect the equalizer line from the check expansion valve tothe equalizer vapor port on the vapor line. Finger tighten the flare nut plus 1/8 turn (7 ft-lbs) as illustrated to the right.

11 12 1

76 5

FIGURE 7

Page 13

STEP 3 LEAK TEST AND EVACUATION
LEAK TEST

LOW

HIGH MANIFOLD GAUGE SET

OUTDOOR UNIT

NITROGEN

TO VAPOR SERVICE VALVE
NOTE - Position canister to deliver liquid refrigerant.
R-454B

1CONNECT GAUGE SET A - Connect the high pressure hose of an R-454B manifold gauge set to the vapor valve service port.
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.
B - With both manifold valves closed, connect the cylinder of R-454B refrigerant to the center port of the manifold gauge set.
NOTE - Later in the procedure, the R-454B container will be replaced by the nitrogen container.
2TEST FOR LEAKS After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the following procedure to test for leaks:
A - With both manifold valves closed, connect the cylinder of R-454B refrigerant to the center port of the manifold gauge set. Open the valve on the R-454B cylinder (vapor only).
B - Open the high pressure side of the manifold to allow R-454B into the line set and indoor unit. Weigh in a trace amount of R-454B. [A trace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kPa) pressure.] Close the valve on the R-454B cylinder and the valve on the high pressure side of the manifold gauge set. Disconnect the R-454B cylinder.
C - Connect a cylinder of nitrogen with a pressure regulating valve to the center port of the manifold gauge set.
D - Adjust nitrogen pressure to 160 psig (1103 kPa). Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor unit.
E - After a few minutes, open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector. Once leak detector is confirmed operational, leak check the entire system (field joints and line set included) to a sensitivity of 5 grams per year of refrigerant.
F - After leak testing, disconnect gauges from service ports.

FIGURE 8

Page 14

3 EVACUATION CONNECT GAUGE SET NOTE - Remove cores from service valves (if not already done).

A - Connect low side of manifold gauge set with 1/4 SAE in-line tee to vapor line service valve
B - Connect high side of manifold gauge set to liquid line service valve
C - Connect available micron gauge connector on the 1/4 SAE in-line tee.
D - Connect the vacuum pump (with vacuum gauge) to the center port of the manifold gauge set. The center port line will be used later for both the R-454B and nitrogen containers. NOTE ister to deliver liquid NITROGEN refrigerant.

OUTDOOR UNIT
A

1/4 SAE TEE WITH SWIVEL COUPLER

500

MICRON GAUGE

LOW
MANIFOLD GAUGE SET
TO VAPOR SERVICE VALVE

R-454B

VACUUM PUMP

TO LIQUID LINE SERVICE VALVE

HIGH

4 EVACUATE THE SYSTEM

RECOMMEND MINIMUM 3/8" HOSE

A - Open both manifold valves and start the vacuum 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 early stages of evacuation, it is desirable to close the manifold gauge valve at least once. A rapid rise in pressure indicates a relatively large leak. If this occurs, repeat the leak testing procedure.

NOTE - The term absolute pressure means the total actual pressure above absolute zero within a given volume or system. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure.

C - When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), perform the following:

WARNING !

Close manifold gauge valves. Close valve on vacuum pump.

Possible equipment damage.

Turn off vacuum pump.

Avoid deep vacuum operation. Do not use

Disconnect manifold gauge center port hose from vacuum pump.

compressors to evacuate a system.

Attach manifold center port hose to a nitrogen cylinder with pressure Extremely low vacuum can cause internal

regulator set to 160 psig (1103 kPa) and purge the hose.

arcing and compressor failure. Damage

Open manifold gauge valves to break the vacuum in the line set and indoor caused by deep vacuum operation will

unit.

void warranty.

Close manifold gauge valves.

D - Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the

nitrogen from the line set and indoor unit.

E - Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and indoor unit until the

absolute pressure does not rise above 500 microns (29.9 inches of mercury) within a 20-minute period after shutting off the vacuum pump

and closing the manifold gauge valves.

F - When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to a

cylinder of R-454B positioned to deliver liquid refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the

line set and indoor unit.

G - Perform the following: Close manifold gauge valves.

1/6 TURN

Shut off R-454B cylinder.
Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core tool while maintaining a positive system pressure.

11 12 1

Replace stem caps and finger tighten them, then tighten an additional one-sixth (1/6) of a turn as illustrated.

9
8 76

3 4
5

FIGURE 9

Page 15

STEP 4 ELECTRICAL Circuit Sizing and Wire Routing
In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC).
Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size.
24VAC TRANSFORMER
Use the transformer provided with the furnace or air handler for low-voltage control power (24VAC - 40 VA minimum)
REFRIGERANT DETECTION SYSTEM
Unit must be installed with Lennox Approved Refrigerant detection system (RDS) and sensor.
Do not operate system until refrigerant detection system is verified to be in good working order.
WARNING
Electric Shock Hazard. Can cause injury or death. Unit must be properly 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.

WARNING
Fire Hazard. Use of aluminum wire with this product may
result in a fire, causing property damage, severe injury or death. Use copper wire only with this product.

WARNING
Failure to use properly sized wiring and circuit breaker
may result in property damage. Size wiring and circuit breaker(s) per Product Specifications bulletin (EHB) and unit rating plate.

ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures

WARNING
Electrostatic discharge can affect electronic components. Take care during unit installation and service to protect the unit's electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the unit, the control and the technician at the same electrostatic potential. Touch hand and all tools on an unpainted unit surface before performing any service procedure to neutralize electrostatic charge.

SIZE CIRCUIT AND INSTALL SERVICE DISCONNECT SWITCH
Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR per NEC). Install power wiring and properly sized disconnect switch.
MAIN FUSE BOX/BREAKER
PANEL
DISCONNECT SWITCH

INSTALL THERMOSTAT
Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and 5 feet (1.5m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight or drafts.
THERMOSTAT

5 FEET (1.5M)

NOTE - Units are approved for use only with copper conductors. Ground unit at disconnect switch or connect to an earth ground.

NOTE - 24VAC, Class II circuit connections are made in the control panel.

FIGURE 10

Page 16

STEP 4 ELECTRICAL (Continued) High Voltage and Field Control Wiring

Unit Low Voltage Wiring
C WIRE NUTS
A CUTOUT WITH GROMMET B 24V CONTROL WIRES

BLACK YELLOW

HIGH VOLTAGE FIELD WIRING FACTORY WIRING LOW VOLTAGE (24V) FIELD WIRING

WIRE RUN LENGTH LESS THAN 100' (30 METERS) MORE THAN 100' (30 METERS)

AWG# INSULATION TYPE 18 TEMPERATURE RATING 16 35ºC MINIMUM.

A - Run 24VAC control wires through cutout with grommet. B - Run 24VAC control wires through wire tie. C - Make 24VAC control wire connections using field-provided
wire nuts. D - Tighten wire tie to security 24V control wiring.
NOTE - FOR PROPER VOLTAGES, SELECT THERMOSTAT WIRE (CONTROL WIRES) GAUGE PER TABLE ABOVE.
NOTE - WIRE TIE PROVIDES LOW VOLTAGE WIRE STRAIN RELIEF AND MAINTAINS SEPARATION OF FIELD-INSTALLED LOW AND HIGH VOLTAGE CIRCUITS.
NOTE - DO NOT BUNDLE ANY EXCESS 24VAC CONTROL WIRES INSIDE CONTROL BOX.

D TIGHTEN WIRE TIE

FIGURE 11
Single-Stage Outdoor Unit with Single-Stage Indoor Unit

OPTIONAL N.C. CONDENSATE FLOAT SWITCH
Thermostat W1
G
R C Y1
Black C
Yellow Y1
Outdoor Unit

1 W1

SW2 SENSOR #1

G LED
SW1
O/B

RDS Blower Control Board 24 Volt

Cat # (27A02)

TSTAT

ZONING ALARM
NO COM NC NO COM NC

RDS Sensor
2 W1 W2
G O/B
R DS
C Y1 Y2
INDOOR

Indoor Unit W1
G
R C Y1 Single-Stage Furnace / Single-Stage Air Handler

1 Thermostat / Outdoor Unit Terminal Block (BLACK)
2 Indoor Unit Terminal Block (BLUE) Class II Voltage field wiring

FIGURE 12

Page 17

STEP 5 UNIT START-UP
IMPORTANT
If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start-up to prevent compressor damage as a result of slugging.
1 - Rotate fan to check for binding.
2 - Inspect all factory- and field-installed wiring for loose connections.
3 - After evacuation is complete, open the liquid line and vapor line service valve stems to release the refrigerant charge (contained in outdoor unit) into the system.
4 - Replace the stem caps and tighten to the value listed in table 2.
5 - Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit's nameplate. If not, do not start the equipment until you have consulted with the power company and the voltage condition has been corrected.
6 - Connect manifold gauge set for testing and charging.
7 - Set the thermostat for a cooling demand. Turn on power to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit.
8 - Recheck voltage while the unit is running. Power must be within range shown on the unit nameplate.
9 - Check system for sufficient refrigerant using the procedures outlined under Checking Refrigerant Charge.
10 - Test functionality of Refrigerant Detection System.
OPERATING MANIFOLD GAUGE SET AND 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. Figures 13 and 14 provide information on how to access and operate both angle- and ball-type service valves.
Torque Requirements
When servicing or repairing heating, ventilating and air conditioning components, ensure the fasteners are appropriately tightened. Table 2 lists torque values for fasteners.

TABLE 2 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

IMPORTANT
To prevent stripping of the various caps used, the
appropriately sized wrench should be used and fitted snugly over the cap before tightening.

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 R-454B 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 BALL-TYPE SERVICE VALVE
1 - Remove stem cap with an appropriately sized wrench.
2 - Use an appropriately sized wrench to open. To open valve, rotate stem counterclockwise 90°. To close, rotate stem clockwise 90°.

TO OPEN, ROTATE STEM COUNTERCLOCKWISE 90°.
TO CLOSE, ROTATE STEM CLOCKWISE 90°.
SERVICE PORT SERVICE PORT
CORE SERVICE PORT
CAP
FIGURE 13

BALL (SHOWN CLOSED)
VALVE STEM
STEM CAP

Page 18

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.
SERVICE PORT CAP
SERVICE PORT CORE
(VALVE STEM SHOWN OPEN) INSERT HEX WRENCH HERE

STEM CAP
ANGLE-TYPE SERVICE VALVE (BACK-SEATED OPENED)
When service valve is OPEN, the service port is open to line set, indoor and outdoor unit.

(VALVE STEM SHOWN CLOSED) INSERT HEX WRENCH HERE
ANGLE-TYPE SERVICE VALVE (FRONT-SEATED CLOSED)

When service valve is CLOSED, the service port is open to the line set and indoor unit.
NOTE - A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque.
FIGURE 14

ACCESS SERVICE PORT
A service port cap protects the service port core from contamination and serves as the primary leak seal.

1 - Remove service port cap with an appropriately sized wrench.

2 - Connect gauge set to service port.

3 - When testing is completed, replace service port cap and tighten as follows:

With torque wrench, finger tighten and torque

cap per table 2.

1/6 TURN

Without torque wrench, finger tighten and use an appropriately sized wrench to turn an additional 1/6 turn clockwise.

11 12 10

1 2

Reinstall Stem Cap

9 87 6

43 5

Stem cap protects the valve stem from damage and serves as the primary seal. Replace the stem cap and tighten as follows:

With torque wrench, finger tighten and then torque cap per table 2.
Without torque wrench, fi en and use an appropriately sized wrench to turn an additional 1/12 turn clockwise.

1/12 TURN

11 12 10

1 2

8 7

4 5

FIGURE 15

Charging
Verify the unit is electrically grounded before charging the system. Extreme care shall be taken not to overfill the refrigerating system.
Charge should be checked and adjusted using information outlined in this section and in the tables provided on the charging label on the unit's control access panel.
R454B is a zeotropic blend of two refrigerants. At any given refrigerant pressure, R454B will have two saturation temperatures, a saturated liquid temperature and a saturated vapor temperature. See R454B Refrigerant Pressure Temperature Chart in the installation and service manual for saturation temperatures.
R454B Units must be charged with liquid refrigerant. Follow conventional charging procedures when charging the system. The technician is required to mark the total charge of the installed system on the unit nameplate, which includes the nameplate charge (factory charge) and additional charge that is added to the system at the time of installation.
The R454B refrigerant cylinders are provided with a ¼ LH flare connection, therefore a ¼ LH female flare adapter will be required. Connect manifold gauges and hoses following conventional charging procedures. Position the R454B refrigerant cylinder to deliver liquid refrigerant.
EL15KC1 unit is factory-charged with enough R454B refrigerant to accommodate a 15-foot length of refrigerant piping. For line lengths over 15 feet, add 3 oz of refrigerant for every 5 feet of piping beyond 15 feet.
Initiate a call for cooling and allow the refrigerant pressures and temperatures to stabilize. Adjust the charge to using the subcooling method. The unit charging label provides the target Subcooling Values. Record the liquid line temperature. Measure the liquid line pressure and use the value to determine the Saturated Liquid Temperature. Calculate subcooling by subtracting the liquid line temperature from the Saturated liquid temperature.
Subcooling = Saturated Liquid Temperature Liquid Line Temperature
Compare the results with the unit charging label.
Once system charging has been completed, the additional charge and total charge must be marked on the unit nameplate. Total Charge = Factory Charge + Additional charge. The total charge is marked on the space adjacent to "Total Charge". See nameplate below.
Detailed information is given in the EL15KC1 Installation and Service Procedures manual, which is available on LennoxPros.com.

Page 19

(NOTE - The nameplate is shown for illustration purposes only. Go to actual nameplate on outdoor unit for charge information.)

Start-Up Test Procedure
The RDS Blower Control Board is equipped with a Test/ Reset button. After the RDS Blower Control Board has been mounted and wired, restore power to the HVAC system. The system will then run through a purge sequence for five (5) minutes. After the purge sequence is complete, proceed to testing cooling demand and heating demand.
Cooling Demand
1 - Prompt a cooling demand at the thermostat.
2 - Press the Test button on the RDS Blower Control Board. The system then executes a leak detection response.
3 - Observe the following sequence: a. The LED indicator flashes the sequence for leak detection (flashing blue). b. The blower powers up.
c. The outdoor compressor powers down.
4 - Press the Test button to terminate the simulated Leak Detected mode upon test completion.
Heating Demand
1 - Prompt a heating demand at the thermostat.
2 - Press the Test button on the RDS Blower Control Board. The system then executes a leak detection response.
3 - Observe the following sequence: a. The LED indicator flashes the sequence for leak detection (flashing blue). b. The blower powers up.
c. The gas burners power down.
d. The outdoor compressor powers down.
4 - Press the Test button to terminate the simulated Leak Detected mode upon test completion.
The installation of the RDS Blower Control Board is complete after both sequences are successfully completed

Homeowners Information
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.
In order to ensure peak performance, your system must be properly maintained. Clogged filters and blocked airflow prevent your unit from operating at its most efficient level. The system should be inspected and serviced before each cooling and heating season by a licensed professional HVAC service technician (or equivalent).
Homeowner Maintenance
The following maintenance may be performed by the homeowner.
· Contact a licensed professional HVAC technician to schedule inspection and maintenance appointments for your equipment before each heating and cooling season.
· Check the indoor unit filter each month and replace the filter, if necessary.
· Have your Lennox dealer show you where your indoor unit filter is located. It will be either at the indoor unit (installed internal or external to the cabinet) or behind a return air grille in the wall or ceiling. Check the filter monthly and clean or replace it as needed. Disposable filters should be replaced with a filter of the same type and size.
· Check the indoor unit drain line for obstructions monthly. The indoor coil is equipped with a drain pan to collect condensate formed as your system removes humidity from the inside air. Have your dealer show you the location of the drain line and how to check for obstructions. (This would also apply to an auxiliary drain, if installed.)
· Check the area around the outdoor unit monthly and remove any obstructions that may restrict airflow to the outdoor unit. This would include grass clippings, leaves, or papers that may have settled around the unit.

Page 20

· Trim shrubbery away from the unit and periodically check for debris which collects around the unit.
· During the winter months, keep the snow level below the louvered panels.
NOTE - The filter and all access panels must be in place any time the unit is in operation. If you are unsure about the filter required for your system, call your Lennox dealer for assistance.
IMPORTANT
Sprinklers and soaker hoses should not be installed where they could cause prolonged exposure to the outdoor unit by treated water. Prolonged exposure of the unit to treated water (i.e., sprinkler systems, soakers, waste water, etc.) will corrode the surface of the steel and aluminum parts, diminish performance and affect longevity of the unit.
Thermostat Operation See the thermostat homeowner manual for instructions on how to operate your thermostat.
Pre-Service Check If your system fails to operate, check the following before calling for service: · Verify room thermostat settings are correct.
· Verify that all electrical disconnect switches are ON.
· Check for any blown fuses or tripped circuit breakers.
· Verify unit access panels are in place.
· Verify air filter is clean.
If service is needed, locate and write down the unit model number and have it handy before calling.
Professional Maintenance
NOTICE !
Failure to follow instructions will cause damage to the unit.
This unit is equipped with an aluminum coil. Aluminum coils may be damaged by exposure to solutions with a pH below 5 or above 9. The aluminum coil should be cleaned using potable water at a moderate pressure (less than 50psi). If the coil cannot be cleaned using water alone, Lennox recommends use of a coil cleaner with a pH in the range of 5 to 9. The coil must be rinsed thoroughly after cleaning.
In coastal areas, the coil should be cleaned with potable water several times per year to avoid corrosive buildup (salt).
Your heating and air conditioning system should be inspected and maintained twice each year (before the start of the cooling and heating seasons) by a licensed professional HVAC technician. You can expect the technician to check the following items. These checks may only be conducted by a licensed professional HVAC technician.

Outdoor Unit
1 - Inspect component wiring for loose, worn or damaged connections. Also check for any rubbing or pinching of wires. Confirm proper voltage plus amperage of outdoor unit.
2 - Check the cleanliness of outdoor fan and blade condition (cracks) and clean or replace them, if necessary.
3 - Inspect base pan drains for debris and clean as necessary.
4 - Inspect the condition of refrigerant piping and confirm that pipes are not rubbing copper-to-copper. Also, check the condition of the insulation on the refrigerant lines. Repair, correct, or replace as necessary.
5 - Test capacitor. Replace as necessary.
6 - Inspect contactor contacts for pitting or burn marks. Replace as necessary.
7 - Check outdoor fan motor for worn bearings/ bushings. Replace as necessary.
8 - Inspect and clean outdoor coils, if necessary and note any damage to coils or signs of leakage.
Indoor Unit (Air Handler or Furnace)
1 - Inspect component wiring for loose, worn or damaged connections. Confirm proper voltage plus amperage of indoor unit.
2 - Inspect and clean or replace air filters in indoor unit.
3 - Check the cleanliness of indoor blower and clean blower, if necessary.
4 - Inspect the indoor coil drain pans and condensate drains for rust, debris, obstructions, leaks or cracks. Pour water in pans to confirm proper drainage from the pan through to the outlet of the pipe. Clean or replace as necessary.
5 - Inspect and clean indoor coil, if necessary.
6 - Inspect the condition of the refrigerant lines and confirm that pipes are not rubbing copper-tocopper. Also, ensure that refrigerant pipes are not being affected by indoor air contamination. Check condition of insulation on the refrigerant lines. Repair, correct, or replace as necessary.
7 - Inspect the duct system for leaks or other problems. Repair or replace as necessary.
8 - Check for bearing/bushing wear on indoor blower motor. Replace as necessary.
9 - If your system is matched with a gas- or oil-fired furnace for heating, indoor unit service will also include inspection and cleaning of the burners, and a full inspection of the gas valve, heat exchanger and flue (exhaust) system.
10 - Check functionality of Refrigerant Detection System.
11 - Inspect refrigerant detection sensor.

Page 21

General System Test with System Operating
1 - Your technician should perform a general system test. He will turn on the air conditioner to check operating functions such as the startup and shutoff operation. He will also check for unusual noises or odors, and measure indoor/outdoor temperatures and system pressures as needed. He will check the refrigerant charge per the charging sticker information on the outdoor unit.
2 - Verify that system total static pressure and airflow settings are within specific operating parameters.
3 - Verify correct temperature drop across indoor coil.
Decommissioning
Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good practice that all refrigerants are recovered safely.
Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of recovered refrigerant. It is essential that electrical power is available before starting decommissioning.
a) Become familiar with the equipment and its operation.
b) Isolate system electrically.
c) Before attempting the procedure, ensure that: · mechanical handling equipment is available, if required,
for handling refrigerant cylinders;
· all personal protective equipment is available and being used correctly;
· the recovery process is supervised at all times by a competent person;

· recovery equipment and cylinders conform to the appropriate standards.
d) Pump down refrigerant system, if possible.
e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.
f) Make sure that cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine and operate in accordance with instructions.
h) Do not overfill cylinders (no more than 80% volume liquid charge).
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
j) When the cylinders have been filled correctly and the process completed, make sure that the cylinders and the equipment are removed from site promptly and all isolation valves on the equipment are closed off.
k) Recovered refrigerant shall not be charged into another REFRIGERATING SYSTEM unless it has been cleaned and checked.
IMPORTANT
Equipment shall be labelled stating that it has been decommissioned and emptied of refrigerant. The label shall be signed and dated. Ensure that there are labels on the equipment that state the flammability of the refrigerant used.

Page 22

R-454B Refrigerant Pressure-Temperature Chart

Pressure (psig)

Saturated Liquid
Temp (°F)

Saturated Vapor
Temp (°F)

Pressure (psig)

Saturated Liquid
Temp (°F)

Saturated Vapor
Temp (°F)

Pressure (psig)

Saturated Liquid
Temp (°F)

Saturated Vapor
Temp (°F)

Pressure (psig)

Saturated Liquid
Temp (°F)

Saturated Vapor
Temp (°F)

-58.9

-57.1

158

58.9

-19.2

-17.2

160

59.6

-13.9

-11.8

165

61.4

-9.0

-6.9

170

63.1

-4.4

-2.3

175

64.9

-0.2

1.9

180

66.6

3.7

5.9

185

68.2

7.5

9.7

190

69.8

11.0

13.2

195

71.4

14.4

16.6

200

73.0

17.6

19.8

202

73.6

20.6

22.9

204

74.2

23.6

25.9

206

74.9

26.4

28.7

208

75.5

29.1

31.4

210

76.1

31.7

34.0

212

76.7

100

34.3

36.6

214

77.3

102

35.3

37.6

216

77.9

104

36.2

38.6

218

78.4

106

37.2

39.5

220

79.0

108

38.1

40.5

222

79.6

110

39.1

41.4

224

80.2

112

40.0

42.4

226

80.8

114

40.9

43.3

228

81.3

116

41.8

44.2

230

81.9

118

42.7

45.1

232

82.4

120

43.6

46.0

234

83.0

122

44.5

46.9

236

83.6

124

45.4

47.7

238

84.1

126

46.2

48.6

240

84.7

128

47.1

49.4

242

85.2

130

47.9

50.3

244

85.8

132

48.8

51.1

246

86.3

134

49.6

51.9

248

86.8

136

50.4

52.8

250

87.4

138

51.2

53.6

252

87.9

140

52.0

54.4

254

88.4

142

52.8

55.2

256

88.9

144

53.6

56.0

258

89.5

146

54.3

56.7

260

90.0

148

55.1

57.5

262

90.5

150

55.9

58.3

264

91.0

152

56.6

59.0

266

91.5

154

57.4

59.8

268

92.0

156

58.1

60.5

270

92.5

61.3

272

93.0

95.4

362

113.4

115.6

62.0

274

93.5

95.9

364

113.8

116.0

63.8

276

94.0

96.4

366

114.2

116.4

65.5

278

94.5

96.9

368

114.6

116.8

67.3

280

95.0

97.4

370

115.0

117.2

69.0

282

95.5

97.9

372

115.4

117.6

70.6

284

96.0

98.4

374

115.8

118.0

72.2

286

96.5

98.8

376

116.2

118.4

73.8

288

97.0

99.3

378

116.6

118.8

75.4

290

97.5

99.8

380

117.0

119.2

76.0

292

97.9

100.3

382

117.4

119.6

76.6

294

98.4

100.7

384

117.7

119.9

77.3

296

98.9

101.2

386

118.1

120.3

77.9

298

99.4

101.7

388

118.5

120.7

78.5

300

99.8

102.2

390

118.9

121.1

79.1

302

100.3

102.6

392

119.3

121.5

79.7

304

100.8

103.1

394

119.7

121.9

80.2

306

101.2

103.5

396

120.1

122.2

80.8

308

101.7

104.0

398

120.5

122.6

81.4

310

102.1

104.4

400

120.8

123.0

82.0

312

102.6

104.9

405

121.8

123.9

82.6

314

103.0

105.4

410

122.7

124.9

83.1

316

103.5

105.8

415

123.6

125.8

83.7

318

103.9

106.2

420

124.6

126.7

84.3

320

104.4

106.7

425

125.5

127.6

84.8

322

104.8

107.1

430

126.4

128.5

85.4

324

105.3

107.6

435

127.3

129.4

86.0

326

105.7

108.0

440

128.2

130.2

86.5

328

106.2

108.5

445

129.0

131.1

87.1

330

106.6

108.9

450

129.9

132.0

87.6

332

107.0

109.3

460

131.6

133.7

88.1

334

107.5

109.7

470

133.3

135.3

88.7

336

107.9

110.2

480

135.0

137.0

89.2

338

108.3

110.6

490

136.7

138.6

89.7

340

108.8

111.0

500

138.3

140.2

90.3

342

109.2

111.5

510

139.9

141.8

90.8

344

109.6

111.9

520

141.5

143.3

91.3

346

110.0

112.3

530

143.0

144.8

91.8

348

110.5

112.7

540

144.5

146.3

92.4

350

110.9

113.1

550

146.1

147.8

92.9

352

111.3

113.5

560

147.5

149.2

93.4

354

111.7

114.0

570

149.0

150.7

93.9

356

112.1

114.4

580

150.5

152.1

94.4

358

112.5

114.8

590

151.9

153.5

94.9

360

112.9

115.2

600

153.3

154.8

Note

1. R-454B is a zeotropic blend and must be charged with liquid refrigerant only. 2. Saturated liquid temperature is used to calculate liquid subcooling. 3. Saturated vapor temperature is used to to calculate suction superheat. 4. See unit charging label for subcooling values and additional charging information.

Page 23

EL15KC1 Start-Up and Performance Checklist
Customer Indoor Unit Model Outdoor Unit Model Notes:

Address Serial Serial

START UP CHECKS Refrigerant Type:

Rated Load Amps: Condenser Fan Full Load Amps

Actual Amps Rated Volts Actual Amps:

Actual Volts

COOLING MODE Suction Pressure:

Liquid Pressure:

Supply Air Temperature:

Ambient Temperature: Return Air: Temperature:

System Refrigerant Charge (Refer to manufacturer's information on unit or installation instructions for required subcooling and approach temperatures.)

Subcooling:

A -- B = SUBCOOLING

Saturated Condensing Temperature (A) minus Liquid Line Temperature (B)

Approach:

A -- B = APPROACH

Liquid Line Temperature (A) minus Outdoor Air Temperature (B)

Indoor Coil Temperature Drop (18 to 22°F)

A -- B = COIL TEMP DROP

Return Air Temperature (A) minus Supply Air Temperature (B)

Page 24

References

HVAC Supplier | LennoxPros

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