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GCS16 Series - HvacPartsShop.com

1. INDOOR BLOWER RELAY K20 CAPACITOR C7 FIGURE 3 GCS16 20 HEAT EXCHANGE ASSEMBLY HEAT EXCHANGER COLLECTOR BOX LIMIT 510 location ROLLOUT SWITCH location SENSOR location FLUE BAFFLES low NOX models only IGNITOR location B Heating Components Heating components are illustrated in figures 3 and 4 1 Heat Exchanger Figure 4 All units use an aluminized steel tubular heat exchanger Each tube has a matching inshot burner Combustion takes place at each tube entrance and is drawn upwards through each tube by the combustion air blower Heat is transferred from all surfaces of the heat exchanger tubes The supply air blower controlled by the ignition control forces air across all surfaces of the tubes to extract the heat of the combustion The shape of the tubes ensure maximum heat exchange 2 Burner Assembly Figure 4 The burners are controlled by the spark electrode flame sensing electrode gas valve GV1 and combustion air blow er B6 The spark
2. m GCS20 GCS20 GCS20 GCS20 GCS20 GCS20 GCS20 GCS20 GCS20 9ueb vo 024 50 030 75 036 90 042 75 042 120 048 75 048 120 060 75 060 120 Nominal Tonnage 2 2 1 2 3 3 1 2 4 5 Btuh 50 000 75 000 90 000 75 000 120 000 75 000 120 000 75 000 120 000 Input Heating kW 147 22 0 26 4 22 0 35 2 22 0 35 2 22 0 35 2 Capacity Btuh 40 000 60 000 72 000 60 000 96 000 60 000 96 000 60 000 96 000 Output kw 11 7 17 6 20 5 17 6 28 1 17 6 28 1 17 6 28 1 XA F U E 80 096 Sound Rating Number db 80 78 82 Total Cooling Btuh 24 600 30 400 33 600 41 000 48 000 58 000 Capacit xARI pacity 7 2 8 9 9 8 12 0 14 1 17 0 Standard 210 240 Total Unit Watts 2420 3140 3500 4165 4775 5985 Ratings SEER Btuh Watts 11 00 11 3 11 30 11 00 EER Btuh Watts 10 2 9 70 9 60 9 8 10 1 9 7 4 Ibs 5 oz 4 Ibs 10 2 4 Ibs 6 oz 5 Ibs 2 oz 7 Ibs 3 oz 7 Ibs 5 oz Refrigerant Charge HCFC 22 20 210kg 3 02 kg 2 32 kg 3 26 kg 3 32 kg Blower in 9x8 10x8 11 1 2 x 9 E t wheel nominal vaporator diameter x width mm 229 X 203 254 X 203 292 x 228 Blower Motor output hp W 1 3 249 1 2 373 3 4 560 Net face area sq ft m2 3 2 0 30 4 1 0 38 4 1 0 38 5 3 0 49 6 2 0 58 Evaporator Tube diameter in Coil mm
3. PRESSURI BS Ss IMOTOR BLOWER 0 SWITCH LIMIT PRIMARY GAS 84 MOTOR OUTDOOR ST P D Bo MOTOR BLOWER at oh H i VALVE GAS 50 LOW AMBIENT 755 JACK TEST J38 JACK MOTOR_ SPEED CHANGI 245 JACK BLOWER MOTOR K1 1 CONTACTOR COMPRESSOR IK3 1 2 ICONTACTOR BLOWER RELAY K1i3 1 2 IRI Y COMB R BLOWER 45 RELA ONOMIZER BLOWER PS9 TRANSEORMER CONTROL NSFORMER COMB ON A BLOWER TRANSEORMER BLOWER MOTOR ORMER MB K DENOTES OPTIONAL COMPONENTS LO MED bs EQUIPMENT GROUND K36 1 J38 HI COOL HEAT USE COPPER CONDUCTORS ONLY DISCONNECT ALL POWER BEFORE SERVICING IF ANY WIRE IN THE APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE THERMOSTAT HEAT ANTICIPATION SETTING 0 7 WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEAT T MUST GRI UNIT M ACCORDANCE WITH NATIONAL AND LOCAL CODES LINE VOLTAGE FIELD INSTALLED WIRING DIAGRAM 5 04 ROOFTOP HI vV J38 MED GCS16 6GCS20 036 048 060 5 6 8 6 J HEAT COOL SECTION B36 Supersedes Form No New Form No 534 552W 534 59W 2004 Litho U S A Page 47 5 516 20 SEQUENCE OF OPERATION United Technologies Ignition Control P Y G J Volt
4. 14 BLOWER DATA GCSC20 manufactured April 2002 and later BLOWER DATA GCS20 All air data is measured external to the unit with dry coil and without air filter GCS20 048 75 GCS20 048 120 GCS20 060 75 and GCS20 060 120 BLOWER PERFORMANCE 230 VOLTS For 208V unit operation derate air volume by 7 External Air Volume at Various Blower Speeds Pressure Medium Low Low in w g Pa cfm L s cfm L s 00 0 1880 885 1620 765 05 10 1865 880 1615 765 10 25 1855 875 1610 760 15 35 1840 870 1605 755 20 50 1825 860 1595 755 25 60 1810 855 1585 750 30 75 1795 845 1575 740 40 100 1760 830 1545 730 50 125 1715 810 1510 710 60 150 1670 790 1470 695 70 175 1620 765 1420 670 80 200 1565 740 1370 645 90 225 1505 710 1310 620 1 00 250 1440 680 1245 585 GCS20 048 75 GCS20 048 120 GCS20 060 75 GCS20 060 120 BLOWER PERFORMANCE 460 VOLTS 2 Down Flow Air Openings Horizontal Air Openings xiernal Statie Air Volume at Various Blower Speeds Air Volume at Various Blower Speeds High Medium Low High Medium Low in w g Pa cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s 00 0 955 05 10 945 10 25 940 15 35 930 20 50 920 25 60 910 30 75 900 40 100 880 50 125 855 60 150 825 70 175 795 80 200 765 90 225 1820 860 1695 800 1550 730 1805 850 1675 790 1550
5. Outer 14 30 1 33 sq ft m Inner coil 5 90 0 55 13 70 1 27 Coil Tube diameter in mm amp No of rows 3 8 9 5 1 4 3 8 9 5 2 Fins per inch m 20 787 Diameter in mm amp No of blades 24 610 4 Condenser Air volume cfm L s 3880 1830 3770 1780 Fan Motor horsepower W 1 4 187 Motor watts 340 360 Gas Supply Connections fpt in mm 1 2 12 7 Recommended Gas Supply Pressure Natural Gas TO in w c kPa LPG Propane 11 2 7 Condensate drain size mpt in mm 3 4 19 No amp size of cleanable polyurethane filters in mm 1 20 x 25 x 1 508 x 635 x 25 Net weight of basic unit Ibs kg 496 225 526 239 Shipping weight of basic unit Ibs 1 package 605 274 635 288 Electrical characteristics 60hz 208 230v 1 ph 208 230v or 460v 3 ph 208 230v 1 ph 208 230 460v 575v 3 ph 208 230 1 ph 208 230v or 460v 3 ph 208 230v 1 ph 208 230v 460v or 575v 3 ph Sound Rating Number in accordance with test conditions included in ARI Standard 270 Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations Certified in accordance with the USE certification program which is based on ARI Standard 210 240 95 F 35 F outdoor air temperature and 80 F 27 C db 67 F 19 C wb entering evaporator coil air Page 3 SPECIFICATIONS GCS20
6. LENNOX virrwicormanon 8518 w rr sss a Service Literature Revised 12 2004 2 to 5 Ton GCS16 GCS20 SERIES UNITS GCS16 20 series units in the 2 to 5 ton 7 0 to 17 0 kW cooling size are packaged combination gas heat dx cool units designed for commercial applications Gas heat sec tions are available with Lennox new tubular heat exchang er in 50 000 75 000 90 000 and 120 000 14 7 22 0 26 4 35 2 kW Btuh input sizes Three phase GCS20 units manufatured April 2002 and lat er have a 12 0 seer rating Revised specifications electrical data and blower data are included in this manual All GCS20 model units and GCS16 036 and 048 utilize scroll compressor The scroll compressor offers high volu metric efficiency quiet operation and the ability to start un der system load Continuous flank contact maintained by centrifugal force minimizes gas leakage and maximizes ef ficiency The motor is internally protected from excessive GCS16 SHOWN current and temperature GCS16 024 030 060 mod els will be equipped with a reciprocating compressor The reciprocating compressor is hermetically sealed for trouble service life i the scroll the re AWARN NG ciprocating compressor has a built in protection device Electric shock hazard Can cause injury against excessive current and temperatures or death Before attempting to perform The GCS16 20 is designed to accept any of several differ electr
7. HONEYWELL VR8205 SERIES GAS VALVE MANIFOLD PRESSURE ADJUSTMEN SCREW MANIFOLD PRESSURE OUTLET GAS VALVE SHOWN IN OFF POSITION WHITE RODGERS 36E GAS VALVE MANIFOLD PRESSURE ADJUSTMENT MANIFOLD PRESSURE OUTLET GAS VALVE SHOWN IN OFF POSITION FIGURE 18 5 Honeywell VR8205 Turn knob on gas valve clockwise until it stops Depress knob and turn clockwise 499 to OFF White Rodgers 36E Turn knob on gas valve 180 ther way to OFF 6 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from your neighbor s phone Follow the gas supplier s in structions If you don t smell gas go to next step N Honeywell 8205 Turn knob gas valve counter clockwise 8 until it stops Allow knob to pop up and continue counterclockwise to ON position White Rodgers 36E Turn knob on valve 180 either way to ON Page 30 8 Replace heat section access panel 9 Turn on electrical power to unit If using electro me chanical thermostat set to desired setting 10 The combustion air inducer will start The burners will light within 40 seconds 11 If unit does not light first time gas line not fully purged it will attempt up to two more ignitions before locking out 12 If lockout occurs repeat steps 1 through 10 13 If the appliance will not operate follow the instructions To Turn Off Gas To Unit and call your
8. 575 G voltage units use a line to 460V autotransformer to power the indoor blower and outdoor motor This autotrans former is also connected directly to line voltage and is pow ered at all times It has a maximum VA rating of 3 4A 9 Potential Relay K31 amp Start Capacitor C7 Relay K31 and capacitor C7 are used on GCS16 024 030 and 060 single phase units K31 is a potential relay which controls operation of the starting circuit The relay is nor mally closed when the compressor contactor K1 is de ener gized C7 is a compressor capacitor connected to a set of N C K31 contacts and is used to assist the compressor at start up When K1 energizes the compressor immediately begins start up K31 remains de energized during com pressor start up and start capacitor C7 remains in the cir cuit As the compressor gains speed K31 is energized by the electromotive forces generated by the compressor When K31 energizes its contacts open to take C7 out of the circuit GCS16 GCS20 CONTROL PANEL 3 5 through 5 TON UNITS IGNITION CONTROL C A I PROVE SWITCH 3 S48 COOLING SPEED RELAY K3 RELAY 2 13 G A PROVE SWITCH S18 NDOOR BLOWER DELAY RELAY 2 TRANSFOMER TRANSFOMER T1 T1 2 2 5 5 TON P VAC UNITS COOLING COOLING CONTACTOR CONTACTOR K1 K1 3 TRANSFORMER T3 J VAC HARD START L 3 RELAY 31 TRANSFOMER D ac X G J VAC Sg S z UH JU J
9. 620 90 225 2100 990 1910 900 1730 815 1500 710 90 225 2130 1005 1950 920 1745 825 1510 715 1 00 250 2010 950 1820 860 1645 775 1 00 250 2020 955 1845 870 1640 775 NOTE All air data is measured external to the unit with dry and without air NOTE All air data is measured external to the unit with dry coil and without air filter For 208v unit operation derate air volume by 7 filter For 208v unit operation derate air volume by 7 Page 11 BLOWER DATA GCS16 20 Cont GCS16 048 120 GCS20 042 048 120 BLOWER GCS16 048 120 GCS20 042 048 120 BLOWER PERFORMANCE 230v Down Flow Air Openings PERFORMANCE 230v Horizontal Air Openings External Air Volume at Various Blower Speeds External Air Volume at Various Blower Speeds pue High Man Medium Medium Low paate High gr Medium Medium in w g Pa cfm L s 1 5 cfm L s cfm 1 6 L s w g Pa cfm L s cfm L s cfm L s cfm L s cfm Lis 0 0 2775 1310 2505 1180 2270 1070 1970 930 1710 805 0 0 2700 1275 2470 1165 2235 1055 1900 895 1650 780 05 12 2725 1285 2465 1165 2240 1055 1950 920 1685 795 05 12 2675 1265 2450 1155 2225 1050 1890 890 1640 775 25 2675 1265 2430 1145 2210 1045 1925 910 1665 785 2
10. amp No of rows ee a Fins per inch m 15 590 area Outer Coil 8 7 0 81 14 3 1 33 sq ft m inner Coil 8 4 0 78 5 9 0 55 13 7 1 27 Condenser Coil Tube diameter in mm amp No 3 8 9 5 2 3 8 9 5 1 4 3 8 9 5 2 of rows I i Fins per inch m 20 787 Diameter in mm amp No of RUE 20 508 4 24 610 4 Condenser Air volume cfm L s 2200 1040 3880 1830 3770 1780 Fan Motor output hp W 1 6 124 1 4 187 Motor watts 240 340 360 Gas Supply Connections fpt in mm 1 2 13 Recommended Gas Natural TAT Supply Pressure wc in kPa LPG Propane 11 2 7 Condensate drain size mpt in mm 3 4 19 No amp size of cleanable polyurethane mom poyu 1 16 x 25 x 1 406 x 635 x 25 1 20 x 25 x 1 508 x 635 x 25 Net weight of basic unit Ibs kg 1 Pkg 406 184 494 224 527 239 541 245 Ship weight of basic unit Ibs kg 1 Pkg 472 214 603 274 636 288 650 295 208 230 1 ph a 1ph E v 1 phase Electrical characteristics 60 hertz 208 230v 1 phase 208 203v or 208 230v 1 phase 208 203v or 460v 3phase v 3 pl Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations Sound Rating Number in accordance with test conditions included in ARI Standard 270 Certified in accordance with the USE certification program which is based on ARI Standard 210 240 95 F 35 C outdoor air t
11. fore servicing Electrical shock resulting in death or injury may result if power is not dis connected 1 Transformer 1 All GCS16 20 series units use single line voltage to 24VAC transformer mounted in the control box The trans former supplies power to control circuits in the unit Trans formers are rated at 7 and use two primary voltage taps as shown in figure 2 208 240 VOLT TRANSFORMER PRIMARY SECONDARY ORANGE 240 VOLTS RED 208 VOLTS FIGURE 2 2 Cooling Contactor K1 K1 is a line voltage contactor with a 24V coil used to ener gize the compressor and condenser fan in response to ther mostat demand GCS16 20 single phase units use single pole double break contactors Three phase units use three pole double break contactors 3 Indoor Blower Relay K3 Cooling Speed All units use a DPDT relay to energize the indoor blower motor The relay coil is energized by blower demand from indoor thermostat terminal G cooling demand or fan switch in ON position When the coil is energized a set of N O contacts closes to energize the blower motor on high speed When de energized a set of N C contacts allows the fan limit control relay to energize the blower on heating speed refer to unit wiring diagram 4 Combustion Air Inducer Relay K13 Relay K13 is a DPDT relay located inside the control box K13 is energized by heating demand from the thermostat and is energized throughout the hea
12. 795 05 12 2735 1290 2450 1155 2205 1040 1930 910 1655 780 05 12 2765 1305 2475 1170 920 1670 790 25 2705 1275 2430 1145 2190 1035 1915 905 1640 775 25 2735 1290 2450 1155 910 1655 780 15 37 2670 1260 2405 1135 2170 1025 1900 895 1620 765 15 37 2705 1275 2430 1145 2190 1035 1915 905 1640 775 20 50 2635 1245 2380 1125 2145 1010 1880 885 1605 760 20 50 2670 1260 2405 1135 2170 1025 1900 895 1620 765 25 62 2600 1225 2355 1110 2125 1005 1860 880 1585 750 25 62 2635 1245 2380 1125 2145 1010 1880 885 1605 760 130 75 2530 1195 2300 1085 2075 980 1820 860 1540 725 130 75 2600 1225 2355 1110 2125 1005 1860 880 1585 750 40 100 2455 1160 2240 1055 2025 955 1775 840 1495 705 40 100 2530 1195 2300 1085 2075 980 1820 860 1540 725 125 2380 1125 2180 1030 1970 930 1725 815 1445 680 125 2455 1160 2240 1055 2025 955 1775 840 1495 705 60 150 2300 1085 2110 995 1910 900 1670 790 1385 655 60 150 2380 1125 2180 1030 1970 930 1725 815 1445 680 70 175 2260 1065 2075 980 1875 885 1640 775 1355 640 70 175 2300 1085 2110 995 1910 900 1670 790 1385 655 180 200 2175 1025 2000 945 1805 850 1570 740 1290 610 180 200 2220 1050 2035 960 1835 865 1600 755 1310
13. 840 1660 785 NOTE All air data is measured external to the unit with dry and without air filter For 208v unit operation derate air volume by 7 NOTE All air data is measured external to the unit with dry coil and without air filter For 208v unit operation derate air volume by 7 GCS16 20 060 75 BLOWER PERFORMANCE 230v Down Flow Air Openings GCS16 20 060 75 BLOWER PERFORMANCE 230v Horizontal Air Openings External Static Pressure w g 0 0 05 12 10 25 15 37 20 50 25 62 130 75 40 100 125 60 150 170 175 180 200 90 225 1 00 250 Air Volume at Various Blower Speeds High Us 1315 1300 1285 1270 1260 1245 1230 1205 1175 1140 1105 1070 1030 985 cfm 2785 2755 2725 2695 2670 2640 2610 2550 2485 2415 2345 2270 2185 2085 Medium High Lis 1195 1185 1175 1160 1145 1135 1120 1095 1070 1040 1020 995 960 920 cfm 2530 2510 2488 2455 2430 2400 2375 2320 2265 2200 2165 2105 2035 1950 Medium cfm 2270 2255 2240 2220 2200 2180 2160 2120 2075 2025 1965 1900 1830 1750 Medium Low L s Us 1 6 1070 1980 935 1715 810 1065 1965 925 1700 800 1055 1950 920 1690 800 1050 1935 915 1680 795 1040 1920 905 1670 790 1030 1905 900 1655 780 1020 1895 895 1645 775 1000 1865 880
14. Ibs kg 1 pkg 603 274 650 295 650 295 650 295 650 295 Electrical characteristics 60 hz 208 203v 3 ph 208 203v 3 ph 208 203v 3ph 208 203v 3 ph 208 203v 3 ph 460v 3 ph 460v 3 ph 460v 3 ph 460v 3 ph 460v 3 ph Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations Sound Rating Number in accordance with test conditions included in ARI Standard 270 Certified in accordance with the USE certification program which is based on ARI Standard 210 240 95 F 35 C outdoor air temperature and 80 F 27 C db 67 F 19 5 C wb entering evaporator air Page 5 OPTIONAL ACCESSORIES GCS16 20 Model No 024 030 036 048 060 Coil Guards PVC coated steel wire guards to protect outdoor coil Standard equipment on GCS20 single phase units LB 82199CF 47J23 2 guards per order LB 82199CG 47J24 3 guards per order Cold Weather Kit GCS16 Units Canada Only Electric heater automatically controls minimum temperature in gas burner compartment when temperature is below 40 F 4 C CGA certified to allow operation of unit down to 60 F 50 C 65C03 Control Systems See pages 4 5 for complete listing See pages 4 5 Compressor Monitor GCS16 Units Canada Only Non adjustable switch low ambient cut out prevents compressor operation when outdoor tempera ture is below 32 F 0 C T6 1469 45F08 RTD9 6
15. Once the gas valve is energized the non adjust able 45 second indoor blower delay period begins Sparking stops immediately after flame is sensed The control then proceeds to steady state mode where all inputs are monitored to ensure the limit switch rol lout switch and prove switch are closed as well as flame is present When the heat call is satisfied the gas valve is de energized and a 150 second blower off delay begins PLUMBING COMPONENTS 6 516 20 GCS16 024 030 GCS20 024 030 036 GCS16 036 SENSING BULB TXV VALVE a TXV VALVE STRAINER d STRAINER DISCHARGE HIGH PRESSURE LINE SWITCH 54 RECIPROCATING COMPRESSOR COMPRESSOR GCS20 042 GCS16 20 048 GCS16 060 SENSING BULB SENSING BULB SUCTION LINE gt STRAINER lt DISCHARGE LINE DISCHARGE LINE TXV VALVE a a di SCROLL COMPRESSOR TXV VALVE SUCTION LINE RECIPROCATING COMPRESSOR FIGURE 12 Page 25 C Cooling Components Figure 12 A WARNING Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may resultin personal injury or death All units use DX cooling All units use a single slab type en hanced fin evaporator with rifled tubing and a thermal ex pansion valve TXV as the primary
16. To measure temperature rise place thermometers in the supply and re turn air plenums Turn up thermostat to start the unit After plenum thermometers have reached their highest and most steady readings subtract thermometer readings The dif ference should be in the range listed on unit rating plate If this temperature is high wire the blower to a higher speed if resulting temperature is too low wire the blower to a slow er speed Repeat this procedure until desired temperature rise is obtained Cooling Speed Factory blower speeds are listed in a table on the unit wiring diagram Blower performance tables are listed in the first section of this manual Section VIII B Determining Unit CFM shows how to measure discharge static pressure Once discharge static pressure has been determined compare the value to the blower performance tables listed in the first section of this manual If CFM is low wire the blower to a higher speed if CFM is high wire the blower to a lower speed Repeat this procedure until desired CFM is reached CAUTION Potential for personal injury Disconnect power to unit before performing any maintenance or service operation Avoid contact with sharp metallic edges Can cause personal injury or death A CAUTION Potential for personal injury Remember to follow lighting instructions at tached to the unit before putting unit back into eration cau
17. i 208 230v 460v 208 230v 460v 208 230v 460v Line voltage data 60 Hz 3 ph p Recommended maximum fuse size amps 25 15 35 20 45 20 TMinimum Circuit Ampacity 18 10 24 13 29 15 c Rated load amps 10 3 5 1 13 5 7 4 17 3 9 Smpressor Locked rotor amps 77 39 120 495 123 62 Condenser Fan Full load amps 1 1 8 2 1 1 2 1 1 Motor Locked rotor amps 2 3 1 9 42 22 42 22 Evaporator Blower Full load amps 3 9 1 9 4 6 24 4 6 24 Motor 1 phase Locked rotor amps 8 3 42 10 1 5 0 10 1 5 Induced Draft Blower Motor 1 phase Full load amps total 7 p Where current does exceed 100 amps HACR circuit breaker may be used in place of fuse U S only TRefer to National or Canadian Electric Code to determine wire fuse and disconnect size requirements NOTE Extremes of operating range are plus and minus 10 of line volage ELECTRICAL DATA GCS20 Three Phase manufactured April 2002 and later ELECTRICAL DATA GCS20 General Model No GCS20 036 GCS20 048 GCS20 060 Data Line voltage data 60 hz 208 230v 3ph 460v 3ph 208 230v 3ph 460v 3ph 208 230v 3ph 460v 3ph Recommended maximum fuse size amps 25 15 40 20 45 20 TMinimum Circuit Ampacity 19 10 24 13 29 14 Compressor Rated load amps 10 3 5 1 14 7 7 1 17 3 8 2 Locked rotor amps 77 39 91 50 123 62 Condenser Coil Full load amps 2 0 1 1 2 1 1 Fan Motor Locked rotor amps 4 2 2 2 4 2 2 2 Evaporator Motor output hp W 1 3 249 1 3 249 3 4 560 1 2 373 3 4 560 3 4 560 Blower Motor Full load amps 3 9 1
18. tion normally follow these steps 1 Disconnect power to the compressor and the unit 2 Reverse any two field power leads to the unit 3 Reapply power to the compressor and unit Discharge and suction pressures should operate at their normal start up ranges NOTE The compressor noise level will be significantly higher when phasing is incorrect and will not provide cooling when operating backwards C Charging It is not recommended that the system be charged below 60 F 15 C If charging below 60 F 15 C is required or if system is completely void of refrigerant the recommended and most accurate method of charging is to weigh the re frigerant into the unit according to the amount shown on the unit rating plate Approach Method If ambient temperature is above 60 F 15 C read liquid line temperature Approach temperature is the difference between liquid line temperature and ambient temperature Page 31 CAUTION Use the same thermometer for both tem perature readings Approach temperature should be as shown in table 4 5 or 6 Refrigerant must be added to lower approach tempera ture Remove refrigerant from system to increase approach temperature TABLE 4 GCS16 APPROACH TEMPERATURES Gi GCS16 024 5 F 1 2 7 C 0 5 GCS16 030 10 F 1 5 5 C 0 5 GCS16 036 11 F 1 6 C 0 5 GCS16 048 9 F 1 5 C 0 5 GCS16 060 9 F 1 5 C 0 5 TABLE 5 GCS20 APPROACH TEMPERATURES ie sha
19. 1 33 14 3 1 33 14 3 1 33 14 3 1 33 Coil Coil Inner Coil 5 9 0 55 13 7 1 27 13 7 1 27 13 7 1 27 13 7 1 27 Tube diameter in mm 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 Number of rows 1 4 2 2 2 2 Fins per inch m 20 787 20 787 20 787 20 787 20 787 Condenser Motor horsepower W 1 4 187 1 4 187 1 4 187 1 4 187 1 4 187 ran Motor watts 340 360 360 360 360 Diameter in mm 24 610 24 610 24 610 24 610 24 610 Number of blades 4 4 4 4 4 Air volume cfm L s 3880 1830 3770 1780 3770 1780 3770 1780 3770 1780 Evaporator Net face area sq ft m2 5 3 0 49 6 2 0 58 6 2 0 58 6 2 0 58 6 2 0 58 een Tube diameter in mm 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 3 8 9 5 Number of rows 2 3 3 3 3 Fins per inch m 15 590 14 552 14 552 14 552 14 552 Condensate drain coupling size npt in 3 4 3 4 3 4 3 4 3 4 Evaporator Motor horsepower W 1 2 373 3 4 560 3 4 560 3 4 560 3 4 560 Blower Wheel nominal diameter x width 10x8 11 1 2 x 9 11 1 2 x 9 11 1 2 x 9 11 1 2 x 9 in mm 254 X 203 292 x 228 292 x 228 292 x 228 292 x 228 Filters Cleanable polyurethane No amp size 1 20 x 25x 1 1 20 x 25 x 1 1 20 x 25x 1 1 20 x 25 x 1 1 20x 25 x1 in mm 508x635x25 508 x 635 x 25 508 x 635 x 25 508 x 635 x 25 508 x 635 x 25 Shipping Net weight of basic unit Ibs kg 496 225 541 245 541 245 541 245 541 245 Data Ship wt of basic unit
20. 1000 btu s for natural and 2500 btu s for LP Adjust man ifold pressure on gas valve to match time needed TABLE 7 Seconds for Seconds for Natural Propane G High Altitude Derate Unit does not need gas pressure adjustment when operat ing from 0 to 7500 ft 0 to 2248m H Flame Sensing Flame current is an electrical current which passes from the ignition control through the sensor electrode during unit op eration The current passes from the sensor through the flame to ground electrode to complete a safety circuit The minimum flame current necessary to keep the ignitor from lockout is 0 1 microamps The electrodes should be lo cated so the tips are at least 1 2 inside the flame envelope Do not bend electrodes To measure flame current follow the procedure below Page 33 1 Disconnect power to unit 2 Remove lead from sensing electrode and install a microamp meter in series between the sensing electrode and the sensing lead 1 Reconnect power and adjust thermostat for heating demand 4 When flame is established meter reading should be 5 to 1 0 microamps Do not bend electrodes 5 If the meter scale reads 0 the leads are reversed Disconnect power and reconnect leads for proper polarity 6 When finished disconnect power to unit before dis connecting meter Make sure sensor wire is se curely reconnected before reconnecting power to unit Vill INDOOR BLOWER OPERATION ADJUSTMENT A Blo
21. 1015 1885 890 1595 755 130 75 2650 1250 2440 1150 2200 1040 1930 910 1635 770 40 100 2510 1185 2320 1095 2100 990 1835 865 1550 730 40 100 2600 1225 2395 1130 2160 1020 1875 885 1605 760 125 2450 1155 2255 1065 2080 980 E 840 E 50 125 2540 1200 e 2110 995 1805 850 1555 735 60 150 2375 1120 2185 1030 1995 940 1755 830 1440 680 60 150 2480 1170 2265 1070 2025 955 1725 815 1475 695 70 175 2305 1090 2120 1000 1935 915 800 fesses 70 175 2395 1130 2200 1040 1985 935 1630 770 1450 685 180 200 2230 1055 2040 965 1860 880 1645 775 1315 620 180 200 2285 1080 2100 990 1900 895 1540 725 1370 645 90 225 2140 1010 1945 920 1775 840 1585 750 90 225 2155 1015 1985 935 1795 845 1410 665 1 00 250 2030 960 1835 865 1670 790 1 00 250 2000 945 1845 870 1665 785 NOTE All air data is measured external to the unit with dry and without air NOTE All air data is measured external to the unit with dry coil and without air filter For 208v unit operation derate air volume by 7 filter For 208v unit operation derate air volume by 7 GCS 16 20 048 60 75 120 BLOWER PERFORMANCE GCS 16 20 048 60 75 120 BLOWER PERFORMANCE 460 575v Down Flow Air Openings 460 575v Horizontal Air Openings Externa
22. 1615 760 980 1825 860 1580 745 955 1780 840 1540 725 925 1765 835 1450 685 895 1720 810 1415 670 865 1660 785 825 Low External Static Pressure in w g Pa 0 0 05 12 10 25 15 37 20 50 25 62 30 75 40 100 125 60 150 170 175 180 200 90 225 1 00 250 High cfm 2760 2740 2720 2700 2680 2660 2630 2570 2490 2375 2310 2200 2065 1910 Air Volume at Various Blower Speeds Medium High L s cfm Us 1305 2515 1185 1295 2500 1180 1285 2485 1175 1275 2465 1165 1265 2450 1155 1255 2430 1145 1240 2410 1140 1215 2360 1115 1175 2300 1085 1120 2225 1050 1090 2170 1025 1040 2070 975 975 1960 925 900 1820 860 Medium cfm 2020 1970 1900 1820 1710 Lis 955 930 895 860 805 Medium Low Low cfm L s cfm L s 920 1680 795 915 1670 790 910 1660 785 905 1650 780 900 1635 770 895 1620 765 890 1600 755 880 1570 740 860 1525 720 835 1470 695 815 1435 675 790 1380 650 750 1770 1730 1670 1590 NOTE All air data is measured external to the unit with dry and without air filter For 208v unit operation derate air volume by 7 Page 12 NOTE All air data is measured external to the unit with dry coil and without air filter For 208v unit operation derate a
23. 1800 850 0 12 30 SGS20 060 2000 945 0 13 32 2200 1040 0 14 35 Page 16 GCS16 20 PARTS ARRANGEMENT with Scroll Compressor BLOWER ASSEMBLY HEAT EXCHANGER GAS VALVE CONDENSER FAN COMPRESSOR COMBUSTION AIR BLOWER BURNER SECTION FIGURE 1 I APPLICATION GCS 16 20 2 5 ton units are available in two cabinet sizes with GCS20 units built April 2002 and later utilizing one re fer to the Engineering Handbook for more specific applica tion data GCS16 20 2 through 5 ton models are applica ble for single phase installations and GCS16 20 3 through 5 ton models are applicable for three phase installations II UNIT COMPONENTS GCS16 20 unit components are shown in figure 1 A Control Box Components GCS16 20 control box is shown in figure 3 The control box is located in the heating compartment behind the heating compartment access panel Note that the T1 transformer on the 024 030 and 036 model units is located on the mullion adjacent to the compressor compartment access panel The condenser fan can be accessed by removing the fan grill located on top of the unit Page 17 The indoor blower access panel all units is located on the opposite side of the unit from the heating compartment ac cess DANGER All single phase units use single pole contactors One leg of compressor capacitor and condenser fan are connected to line voltage at all times Remove all power to disconnect be
24. 380 15 37 13 32 11 27 41 27 Ep pe 1000 470 19 47 16 40 14 85 14 85 GCS16 036 1200 565 25 62 20 50 17 42 17 42 1400 660 33 82 26 65 20 50 20 50 1600 755 43 107 32 80 20 50 24 60 GCS16 048 1800 850 56 139 40 90 30 75 30 75 GCS16 060 2000 945 73 182 50 124 36 90 36 90 2200 1040 95 236 63 157 44 109 44 109 CEILING DIFFUSER AIR THROW DATA WET INDOOR COIL AIR RESISTANCE Model No RTD9 65 FD9 65 Air Volume Air Resistance Model Number 7 Air Volume Effective Throw Effective Throw cfm Lis w g Pa em E f Hm GCS16 024 1000 30 009 7 1000 470 10 17 3 5 15 20 5 6 1200 EOS 0 08 20 1200 565 11 18 3 5 16 22 5 7 800 380 0 09 22 1400 660 12 19 4 6 17 24 5 7 GCS16 030 1000 470 0 10 25 1200 565 0 11 27 Dmm 80 380 2 2000 945 14 23 47 21 29 6 9 1206 85 XE gt 2200 1040 16 25 5 8 22 30 7 9 1400 660 0 12 30 1 throw based on terminal velocities of 75 ft 22 9 per minute 1600 755 0 11 27 enue 1800 850 0 12 30 WET INDOOR COIL AIR RESISTANCE 2000 915 013 x Modal Number Air Volume Air Resistance 1600 755 0 08 20 cfm Lis in w g Pa ree 1800 850 0 09 22 800 380 0 08 20 2000 945 0 10 25 1000 470 0 09 22 2200 1040 0 11 27 1200 565 0 10 25 800 380 0 07 17 GCS20 036 1000 470 0 08 20 1200 565 0 09 22 1400 660 0 12 30 1600 755 0 13 32 CCS20 048 1800 850 0 14 35 2000 945 0 15 37 2200 1040 0 16 40 1600 755 0 11 27
25. 9 5 0 24 5 0 2 4 Locked rotor amps 8 3 4 2 10 1 5 0 10 1 5 Combustion Air Inducer Motor 1 phase full load amps 0 7 0 7 0 7 0 7 0 7 0 7 TRefer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements NOTE Extremes of operating range are us and minus 10 of line voltage HIGH ALTITUDE GCS16 20 No gas pressure adjustment is needed when operating from 0 to 7500 ft 0 to 2248 m See below for correct manifold pressures for natural gas and LPG propane FUEL Manifold Pressure outlet 0 to 7500 ft 0 to 2248 m above sea level Natural Gas 3 5 in w g 0 87 kPa LPG Propane 9 5 in w g 2 36 kPa Page 8 BLOWER DATA GCS16 20 GC S16 20 024 50 BLOWER PERFORMANCE 230v Down Flow Air Openings GCS16 20 024 50 BLOWER PERFORMANCE 230v Horizontal Air Openings External Static Air Volume at Various Blower Speeds External Static Air Volume at Various Blower Speeds Pressure High ae Medium Low Pressure High pre Medium Low in w g cfm L s cfm 1 6 cfm L s cfm L s in wg Pa cfm L s L s cfm L s cfm L s 0 0 1335 630 1000 470 905 425 665 315 0 0 1315 620 915 430 840 395 615 290 05 12 1330 630 1010 475 915 430 680 320 05 12 1300 615 930 440 855 405 640 300 10 25 1315 620 1015 480
26. 920 435 685 325 10 25 1285 605 945 445 870 410 655 310 15 37 1300 615 1015 480 925 435 690 325 15 37 1265 595 950 450 875 415 670 315 20 50 1280 605 1010 475 920 435 695 Es 20 50 1240 585 950 450 880 415 680 ps 25 62 1255 590 1005 475 915 430 695 330 25 62 1220 575 950 450 880 415 685 325 30 75 1225 580 990 465 900 425 690 325 30 75 1195 565 945 445 875 415 685 325 40 100 1160 550 945 445 865 410 665 315 40 100 1140 540 915 430 850 400 675 320 150 125 1075 505 885 420 815 385 630 pe 50 125 1080 510 870 410 815 385 650 Isis 60 150 975 460 805 380 745 350 585 275 60 150 1010 475 805 380 760 360 610 290 70 175 860 405 705 335 655 310 520 70 175 935 440 725 340 690 325 550 80 200 730 345 590 280 545 255 80 200 845 400 625 295 600 285 920 225 570 270 90 225 735 345 515 245 100 250 1 00 21 2250 esed remm eee xm m NOTE All air data is measured external to the unit with dry and without air filter For 208v unit operation derate air volume by 7 NOTE All air data is measured external to the unit with dry coil and without air filter For 208v uni
27. C 1 7 C on temperature drop and closes at 58 F 4 F 14 4 C 2 2 C on a tem perature rise To prevent coil icing S49 opens during com pressor operation to temporarily disable the compressor until the coil warms sufficiently to melt any accumulate frost If S49 trips frequently due to coil icing check the unit charge air flow and filters before allowing unit back in op eration Make sure to eliminate conditions which might pro mote ice build up 11 Condenser Coil All GCS16 20s have a single condenser coil All models except the GCS16 024 have two rows of copper filled tubes with ripple edged aluminum fins The GCS16 024 units have one row Ill PLACEMENT AND INSTALLATION Make sure that the unit is installed in accordance with the installation instructions and all applicable codes See ac cessories section for conditions requiring use of the option al roof mounting frame RMF16 IV ELECTRICAL CONNECTIONS A Field Wiring Unit and optional thermostat field wiring is shown in the unit diagram section of this manual B Power Supply Refer to start up directions and refer closely to the unit wir ing diagram when servicing Refer to unit nameplate for minimum circuit ampacity and maximum fuse size 230 volt units are factory wired with orange wire connected to con trol transformer primary 208 volt units are field wired with red wire connected to control transformer primary DANGER All SINGLE PHASE uni
28. Flow Air Openings 230v Horizontal Air Openings Air Volume at Various Blower Speeds Air Volume at Various Blower Speeds External Static Medium Medium External Static Medium Medium ressure High High Low Low Pressure High High Low Low in wg cfm L s cfm L s cfm L s cfm L s in wg Pa cfm L s L s cfm L s cfm L s 0 0 1525 720 1350 635 1090 515 870 410 0 0 1435 675 1280 605 1010 475 860 405 05 12 1515 715 1345 635 1090 515 880 415 05 12 1425 675 1265 595 1005 475 860 405 25 1495 705 1335 630 1085 510 885 420 25 1410 665 1250 590 1005 475 865 410 15 37 1480 700 1325 625 1075 505 890 420 15 37 1380 650 1235 585 1000 470 860 405 20 50 1465 690 1310 620 1065 505 885 be 20 50 1365 645 1220 575 990 465 855 P 25 62 1450 685 1285 605 1055 500 875 415 25 62 1345 635 1205 570 975 460 845 400 30 75 1420 670 1270 600 1045 495 870 410 30 75 1315 620 1190 560 970 460 835 395 40 100 1375 650 1230 580 1020 480 855 405 40 100 1270 600 1160 550 945 445 810 380 50 125 1325 625 1190 560 990 465 835 395 50 125 1220 575 1115 525 920 435 790 375 60 150 1280 605 1150 545 965 455 810 380 60 150 1155 545 1070 505 900 425 765 360 70 17
29. GCS20 024 5 F 1 2 7 C 0 5 GCS20 030 10 F 1 5 5 C 0 5 GCS20 036 9 F 1 5 C 0 5 GCS20 042 7 F 1 3 8 C 0 5 GCS20 048 4 F 1 2 2 0 5 GCS20 060 5 F 1 2 7 C 0 5 TABLE 6 GCS20 APPROACH TEMPERATURES manufactured April 2002 and later a 7 uas GCS20 036 8 F 1 4 4 C 0 5 GCS20 048 7 F 1 3 9 0 5 GCS20 060 8 F 1 4 4 C 0 5 VII HEATING SYSTEM SERVICE CHECKS A C S A Applications and Requirements All GCS16 20s are C S A design certified without modifica tion Refer to the GCS16 20 Operation and Installation Instruc tion Manual for more information B Gas Piping Gas supply piping must not allow more than 0 5 W C drop in pressure between gas meter and unit Supply gas pipe must not be smaller than unit gas connection Compounds used on threaded joints of gas piping should be resistant to the action of L P gas C Testing Gas Piping Pressure IMPORTANT In case emergency shutdown is required turn off the main shut off valve and disconnect the main power to unit These controls should be properly labeled by the installer GAS PIPING TEST PROCEDURE MANUAL MAIN SHUT OFF VALVE D WILL NOT HOLD TEST PRESSURE IN EXCESS OF 0 5 PSIG 14 W C L a f as CAP GAS VALVE FIELD PROVIDED LINE PRESSURE TAP FIGURE 19 When pressure testin
30. P 10 8 84 UTDOOR FAN 6 MOTOR COME OWER GEN el CAPAC ITOR OUTDOOR FAN MOTOR cpg IBCUIT BREAKER TRANS 20 PFUSE 5OC LOW AMBIENT KIT 852 W AMD OVI VALVE Bhs T THERMOSTAT 24C OPEN 50 Low Xi KIT ERE HEATER BE EB dr BIENT KIT 574 SWITCH FIRESTAT 35 JACK TEST E75 SNITCH FIRESTAT 2 245 BLOWER MOTOR MEM CONTROL 08 UN RO ON AB COM a 24V COMMON AS t DENOTES OPTIONAL COMPONENTS Y oc EQUIPMENT GROUND I I I pS eo TOR D MOTOR UNITS masa ayam AVAILABLE 208V 2 30V COOL L3 COMMON 1 LINE VOLTAGE FIELD INSTALLED NOTE ALL REMAINING WIRES FACTORY INSTALLED WIRING DIAGRAM 5 04 GCS16 GCS20 036 048 060 5 6 8 Y HEAT COOL SECTION B35 e AW New Form Litho U S A Page 46 TYPICAL GCS16 GCS20 FIELD WIRING DIAGRAM THREE PHASE ECONOMIZER BLOWER G HEAT I WI L3 50 LOW AMBIENT CONTROL CANADIAN UNITS ONLY 12 CONNECTIONS FOR REMOTE MOUNTED SMOKE DETECTOR A17 MAX LOAD 0 1VA 24VAC CLASS II POWER FOR USE ON CGA UNITS ONLY HRI NOT USED ON UNITS WITH SCROLL COMPRESSORS 521 IS USED ON 6 516 036 UNITS COOL DESCRIPTION DESCRIPTION KEY COMPONENT 11 KEY OMPONENT AS CONTROL BURNER SWITCH LIMIT LOW COMP AI7 SEE NOTE 2 COMPRESSOR MONITOR Di ICOMPRESSOR __ 51
31. amps 10 1 12 4 16 21 8 27 6 Somes Locked rotor amps 60 0 69 4 100 131 135 Condenser Coil Full load amps 1 1 2 Fan Motor Locked rotor amps 2 3 4 2 Evaporator Full load amps 2 2 3 0 3 9 4 6 Blower Motor Locked rotor amps 4 2 6 2 8 3 10 1 1 Induced Draft Blower Motor 1 phase 0 7 TRefer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements p Where current does not exceed 100 amps type circuit breaker may be used in place of fuse U S Only NOTE Extremes of operating range are plus and minus 10 of line volage ELECTRICAL DATA GCS16 Three Phase Model No GCS16 036 GCS16 048 GCS16 060 Line voltage data 60 hz 3 phase 208 230v 460v 575v 208 230 460 575v 208 230 460 575v Recommended maximum fuse size amps 25 15 35 15 45 20 15 TMinimum Circuit Ampacity 18 10 8 23 12 10 29 16 12 Rated load amps 10 3 5 1 4 2 12 8 6 4 5 1 17 6 9 5 6 3 Compressor Locked rotor amps 77 39 31 91 46 37 105 55 45 Condenser Coil Full load amps 1 1 80 2 80 2 1 1 211 1 2 1 1 211 1 Locked rotor amps 2 3 1 9 211 9 4 2 2 2 212 2 4 2 2 2 212 2 Evaporator Full load amps 3 9 1 9 211 9 4 6 2 4 212 4 4 6 24 212 4 Blower Motor Locked rotor amps 8 3 4 2 214 2 10 1 5 0 2 5 0 10 1 5 0 2 5 0 1 Induced Draft Blower Motor 1 phase 0 7 Unit Power Factor 86 84 87 86 88 TRefer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements p Where current doe
32. controls in the REMD16M and REMD16 economizers is shown in figures 25 and 26 REMD16M PARTS ARRANGEMENT NOTE Mixed air sensor is shown as it is factory installed in a REMD16M 41 REMD16M 65 is similar CONTROL ACCESS COVER ENTHALPY CONTROL ACCESS COVER REMOTE MIXED AIR SENSOR DAMPER MOTOR FIGURE 25 REMD16 PARTS ARRANGEMENT ACCESS COVER OUTDOOR AIR DAMP 4 Rs MIXED AIR SENSING BULB NOTE Mixed air sensor sensing bulb are shown as 4 7 they are factory installed ina RETURN REMD16 41 AIR a DAMPERS FIGURE 26 ENTHALPY CHART CONTROL POINT 50 RH C 73 70 67 DRY BULB TEMPERATURE F C SOLID STATE ENTHALPY CONTROL FIGURE 27 Page 37 2 Economizer Operation a Enthalpy Control Setpoint Control The key to economizer operation is the enthalpy con trol The enthalpy control senses the total heat con tent of the outside air temperature plus humidity and uses that information to control the amount of outside air brought into the system When the enthal py of outside air is below the control setpoint the con trol actuates a motor which in turn adjusts the outdoor dampers to meet the cooling demands of the build ing When the heat content rises above the control set point the control de activates and the dampers close to the preset minimum position not closed position Two types of adjustment
33. may lock out 8 Flue Vent and Rain Shield Figure 6 A IMPORTANT Vent cap assembly must be installed without modification Any modification to the vent cap assembly or failure to install assembly can re sult in improper operation and will void the AGA CGA certification of the unit CAUTION Do not start or operate unit unless vent cap is in FLUE VENT AND RAIN SHEILD INSTALLATION SLIDE RAIN SHIELD FLANGE UNDER UNIT TOP LIP RAIN SHIELD some units RAIN SHIELD BURNER ACCESS PANEL COMBUSTION AIR INDUCER ORIFIC stationary COMBUSTION AIR LOUVER COVER VENT GASKET VENT CAP ASSEMBLY FIGURE 6 Page 21 9 Gas Valve GV1 Gas valve GV1 figure 7 is a single stage redundant valve manufactured by Honeywell or White Rodgers On a call for heat the valve is energized by the ignition control simul taneously with the spark electrode The valve opens 1 2 to 2 seconds When the valve is de energized it closes in 1 2 to 3 seconds A manual shut off knob is provided on the valve for shut off HONEYWELL VR8205 SERIES GAS VALVE MANIFOLD PRESSURE MANIFOLD PRESSURE OUTLET GAS VALVE SHOWN IN OFF POSITION WHITE RODGERS 36E GAS VALVE MANIFOLD PRESSURE ADJUSTMENT SCREW MANIFOLD PRESSURE OUTLET GAS VALVE SHOWN IN OFF POSITION FIGURE 7 10 Ignitor Ignitor tips are located in the path of the right most burner The spark electrode is connected to the ignition control by a 8m
34. relay K13 Heating demand also passes through high temperature limit S10 to combustion air prove switch 518 Page 44 6 Relay K13 terminals close to energize combustion air blower B6 N O K20 2 terminals 6 9 close to energize the economizer When the combustion air blower nears full speed prove switch S18 closes Heating demand continues through 18 and through flame rollout switch S47 to energize ignition control A3 7 Ignition control then waits 30 to 40 seconds to allow combustion air blower B6 time to draw exhaust gas from combustion chamber and to introduce fresh air Com bustion air blower B6 operates throughout the heating cycle 8 After the ignition control delay A3 activates gas valve GV1 and the spark electrode When flame is sensed by the flame sensor the spark electrode stops If flame is not sensed after the first trial for ignition controller A3 re peats steps 7 and 8 up to two more times depending on controller make before locking out If the control locks out it can be reset by breaking and remaking thermostat demand 9 Once flame is established blower delay relay K25 ener gizes indoor blower relay K20 after a 45 second delay Indoor blower B3 is then energized TYPICAL GCS16 GCS20 FIELD WIRING DIAGRAM SINGLE PHASE 24 POWER NOTE FOR USE WITH COPPER CONDUCTORS ONLY IF ANY WIRE IN THIS APPLIANCE IS REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT REPLACED MUST BE REPLACED WITH AMPAC
35. ressure High High in wg Pa cfm L s cfm L s 0 0 1740 820 05 12 1710 805 10 25 1675 790 15 37 1645 775 20 50 1615 760 25 62 1580 745 30 75 1550 730 40 100 1485 700 150 125 1420 670 60 150 1350 635 1260 595 70 175 1255 590 1165 550 80 200 1180 555 1085 510 90 225 1085 510 985 465 100 250 970 460 870 410 NOTE All air data is measured external to the unit with dry and without air filter For 208v unit operation derate air volume by 7 Page 10 NOTE All air data is measured external to the unit with dry coil and without air filter For 208v unit operation derate air volume by 7 BLOWER DATA GCS16 20 Cont GCS16 20 036 90 BLOWER PERFORMANCE GCS16 20 036 90 BLOWER PERFORMANCE 460 575v Down Flow Air Openings 460 575v Horizontal Air Openings External Static Air Volume at Various Blower Speeds External Static Air Volume at Various Blower Speeds Pressure High Medium Low Pressure High Medium Low in wg Pa Lis cfm Lis cfm Lis in w g Pa cfm Lis cfm Lis cfm Lis 0 0 1570 740 1480 700 1135 535 0 0 1610 760 1515 715 1165 550 05 12 1545 730 1455 685 1135 535 05 12 1585 750 1490 705 1165 550 10 25 1520 715 1430 675 1130 535 10 25 1560 735 1465 690 1160 550 15 37 1490 705 1405 665 1125 530 1
36. steel wire coil guard which is field installed F Low Ambient Kit The optional low ambient kit figure 31 allows for mechani cal cooling operation at low outdoor temperature Low ambient kit field wiring is shown in figure 32 The low ambient pressure switch is wired in series with the con denser fan L1 lead Refer to the low ambient kit installation instruction manual for detailed installation instructions The low ambient pressure switch cycles the condenser fan while allowing normal compressor operation This intermit tent fan operation results in a high evaporating temperature which allows the system to operate without evaporator coil icing and losing capacity LOW AMBIENT KIT TYPICAL INSTALLATION LOW AMBIENT PRESSURE SWTICH COMPRESSOR LIQUID LOOP VALVE DEPRESSOR TEE SUCTION LINE GAUGE PORT SUCTION LINE FIGURE 31 Adjustment The low ambient pressure switch is adjustable but the ad justment knob does not adjust CUT IN or CUT OUT points CUT IN point is fixed and cannot be adjusted The scale on the switch measures the difference in pressure between preset CUT IN and adjustable CUT OUT points Adjust ment knob changes CUT OUT point by adjusting the DIF FERENCE between CUT IN and CUT OUT The low ambient pressure switch is factory set to CUT IN at 285psig with a difference of 145 psig CUT OUT at 140psig Adjustment should not be needed If adjustment is needed adjust the switch a
37. 0 036 048 GCS20 042 048 060 LINE VOLTAGE FIELD INSTALLED NEC CEC CLASS NOTE ALL REMAINING WIRES FACTORY INSTALLED WIRING DIAGRAM COMBINATION UNITS ROOFTOP GCS16 024 030 060 3 5 6 P 042 048 060 030 6CS16 036 048 6 7 P HEA QU ON QU upereedes C7 6 516 060 5 534 333W 534 740W Litho U S A Page 45 TYPICAL GCS16 GCS20 FIELD WIRING DIAGRAM THREE PHASE 24V POWER IF m Tu IN THE APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE M ININUM O AAI T AMPACITY AND OA RATING INSULATION THICKNESS AND TERMINATION MAXIMUM OVERCURRENT PROTECTION SIZE THERMOSTAT HEAT ANTICIPATION SETTING 0 7 AMP USE COPPER CONDUCTORS ONLY C WARNING ELECTRIC SHOCK HAZARD CAUSE INJURY us ELECTRIC SHOCK HAZARD CAN CAUSE IN DISCONNECT ALL POWER BEFORE SERVICING ACCORDANCE WITH NATIONAL AND LOCAL CODES ECONOMIZER BLOWER G HEAT 1 WI 50 C LOW AMBIENT CONTROL CANADIAN UNITS ONLY 3 CONNECTIONS FOR REMOTE MOUNTED SMOKE DETECTOR L2 17 MAX LOAD 0 24VAC CLASS II FOR USE ON CGA UNITS ONLY HRI NOT USED ON UNITS WITH SCROLL COMPRESSORS 521 IS USED ON 6 516 036 UNITS O REFER TO BLOWER SPEED CHART FOR MOTOR CONNECTIONS COOL DESCRIPTION ET EEN OMPONEN COMPONENT l rm m DESCRIPTION KEY COMPONENT Al NOTE 2 5 1 pin TE EN I AS _ CONTROL BURNER MERE E 3 io IMOTOR BLOWER MOY OR BL OVER
38. 10 Ratings EER Btuh Watts 8 70 9 20 Sound Rating Number db 80 Refrigerant C harge HCFC 22 3 Ibs 3 oz 1 45 kg 4 Ibs 3 oz 1 90 kg 4 Ibs 6 oz 1 94 kg Evaporator Blower wheel nominal diameter x width in mm 9x8 229 x 203 10 x 8 254 x 203 Blower Motor horsepower W 1 3 249 1 2 373 Net face area sq ft m2 3 2 0 30 4 10 0 38 EP Tube diameter in mm amp No of rows 3 8 9 5 2 Fins per inch m 15 591 Net face area Outer coil 8 70 0 81 Condenser sq ft m Inner coil 8 40 0 78 Tube diameter in mm amp No of rows 3 8 9 5 1 3 8 9 5 2 Fins per inch m 20 787 Diameter in mm amp No of blades 20 508 4 Condenser Air volume cfm L s 2450 1155 2200 1040 Fan Motor horsepower W 1 6 124 Motor watts 220 240 Gas Supply Connections fpt in mm 1 2 12 7 Recommended Gas Supply Pressure Natural Gas 7 1 7 in w c kPa LPG Propane 11 2 7 Condensate drain size mpt in mm 3 4 19 No amp size of cleanable polyurethane filters in mm 1 16 x 25 x 1 406 x 635 x 25 Net weight of basic unit Ibs kg 350 159 373 169 370 168 Shipping weight of basic unit Ibs kg 1 pkg 432 196 455 206 470 213 Electrical cha racteristics 60hz 208 230v 1 phase 208 230v 1 ph 208 230v 460v or 575v 3 ph Sound Ratin
39. 3 Blower B3 is energized indirectly by thermostat terminal G On a cooling demand thermostat terminal energizes contactor which in turn ener gizes the blower refer to operation sequence on previous page for exact sequence When K3 energizes K3 1 closes to energize the blower and K3 2 closes to energize the economizer see step 2 and open the outdoor air dampers to minimum position Enthalpy Low 1st Stage Cool 4 Initial cooling demand Y1 is sent to enthalpy control A6 and terminal 1 5 Enthalpy control A6 has determined that outside air can be used for cooling and has switched internal relays 1K and 2K 6 Cooling demand is routed through enthalpy control to energize internal relay 1S Internal contacts 151 close to complete a circuit through damper motor terminals T and T1 7 When a voltage is applied across terminals T and T1 of damper motor the damper motor energizes and outdoor air dampers open Supply air sensor R1 varies the voltage across T and T1 and the outdoor air dampers open and adjust accordingly 1st stage cooling is provided by outdoor air Enthalpy Low 2nd Stage Cool 8 Economizer outdoor air dampers remain open 9 Additional cooling demand is routed from thermostat Y2 through enthalpy control terminals 3 and 5 to energize the 1st stage compressors The 1st stage compressors provide all additional cooling Enthalpy High 1st Stage Cool 10 Enthalpy control internal relays 1K and 2K switch Internal relay 15 is
40. 5 1220 575 1110 525 930 440 790 375 70 175 1095 515 1010 475 865 410 740 350 80 200 1130 535 1030 485 885 420 765 360 80 200 1030 485 955 450 820 385 700 330 90 225 1070 505 955 450 820 385 90 225 950 450 865 410 745 350 1 00 250 965 455 860 405 1 00 250 850 400 760 360 NOTE All air data is measured external to the unit with dry and without air filter For 208v unit operation derate air volume by 7 NOTE All air data is measured external to the unit with dry coil and without air filter For 208v unit operation derate air volume by 7 Air Volume at Various Blower Speeds Medium Low cfm L s 1130 1045 955 450 825 390 535 495 GCS16 20 036 90 BLOWER PERFORMANCE 230v Down Flow Air Openings External Static Medium Pressure High High in w g cfm L s cfm L s 0 05 15 20 25 130 40 150 60 150 1300 615 1215 575 70 175 1235 585 1150 545 80 200 1165 550 1075 505 190 225 1090 515 990 465 1 00 250 980 465 885 420 Air Volume at Various Blower Speeds Medium Low cfm L s 1165 1105 1025 485 930 440 550 520 GCS16 20 036 90 BLOWER PERFORMANCE 230v Horizontal Air Openings External Static i Medium
41. 5 67 Ibs 30 kg Diffusers Aluminum grilles large center grille insulated Step Down diffuser box with flanges hanging rings furnished interior double deflec transition even air flow internally sealed prevents recir tion louvers culation adapts to T bar ceiling grids or plaster ceilings Flush fixed Net Weight blade louvers FD9 65 37 Ibs 17 kg podus Gravity Exhaust Dampers 3 Position REMD16 41 48 Ibs 22 kg REMD16 65 66 Ibs 30 kg Down Flow Installs directly in cabinet recir culated air dampers with pressure operated gravi US Fully Modulating REMD16M 41 48 Ibs 22 kg REMD16M 65 66 Ibs 30 kg ty exhaust damper formed gasketed damper Only Indoor Filter 1 16 x 25 x 1 406 x 635 x 25 1 20x25 x 1 508 x 635 x 25 blades nylon bearings 24v damper motor has adjustable minimum position switch electronic Outdoor Filter 1 14 x 25 x 1 356 635 x 25 1 18 x 25 x 1 457 x 635 x 25 discharge air sensor adjustable outdoor air en thalpy control Utilizes filter furnished with unit GCS16 Fully Modulating REMD16M 41S 85 Ibs 39 REMD16M 65S 105 Ibs 48 kg filter rack will accept up to 2 in 51 mm filter units Indoor Filter 1 16 x 25 x 1 406 x 635 x 25 1 20x25x 1 508 x 635 x 25 Removable exhaust air hood and outdoor air in Canada 1 19 718 x 22 3 4 x 1 take hood with cleanabl
42. 5 2650 1250 2425 1145 2210 1045 1880 885 1630 770 15 37 2630 1240 2395 1130 2180 1030 1905 900 1645 775 15 37 2625 1240 2405 1135 2200 1040 1870 885 1620 765 220 50 2580 1220 2360 1115 2150 Feeds fes 765 20 50 2595 1225 2380 1125 2185 1030 1855 875 1610 760 25 62 2540 1200 2320 1095 2120 1000 1860 880 1595 755 25 62 2570 1215 2360 1115 2165 1020 1840 870 1600 755 130 75 2490 1175 2285 1080 2100 990 1840 870 1570 740 130 75 2535 1195 2335 1100 2150 1015 1830 865 1585 750 40 100 2400 1135 2220 1050 2040 965 1795 845 1515 715 40 100 2480 1170 2280 1075 2110 995 1795 845 1550 730 125 2300 1085 2145 1010 1980 935 1740 820 125 2410 1140 2085 985 1750 825 1510 715 60 150 2200 1040 2070 975 1910 900 1680 795 1365 645 60 150 2340 1105 2160 1020 2000 945 1680 795 1455 685 70 175 2130 1005 2000 945 1865 880 Pape 70 175 2255 1065 2080 980 1965 925 1640 775 1410 665 180 200 2050 970 1925 910 1800 850 1550 730 1210 570 180 200 2165 1020 2000 945 1880 885 1565 740 1350 635 90 225 1950 920 1840 870 1715 810 1465 690 90 225 2065 975 1900 895 1785 845 1470 695 100 250 1840 870 1740 820 1610 760 100 250 1940 915 1780
43. 5 37 1525 720 1440 680 1155 545 20 50 1465 690 1375 650 1115 525 20 50 1500 710 1410 665 1145 540 25 62 1435 675 1350 635 1105 520 25 62 1470 695 1385 655 1135 535 130 75 1405 665 1320 625 1090 515 130 75 1440 680 1355 640 1115 525 40 100 1345 635 1265 595 1050 495 40 100 1380 650 1295 610 1085 510 50 125 1285 605 1200 565 1020 480 50 125 1315 620 1230 580 1045 495 60 150 1220 575 1140 540 975 460 60 150 1250 590 1170 550 1000 470 70 175 1155 545 1070 505 920 435 70 175 1185 560 1095 515 945 445 80 200 1085 510 1000 470 850 400 80 200 1110 525 1025 485 845 400 90 225 1000 470 910 430 90 225 1030 485 940 445 1 00 250 905 425 810 380 1 00 250 940 445 845 400 NOTE air data is measured external to the unit with dry and without air filter NOTE All air data is measured external to the unit with dry coil and without air filter GCS16 048 75 GCS20 042 048 75 BLOWER GCS16 048 75 GCS20 042 048 75 BLOWER PERFORMANCE 230v Down Flow Air Openings PERFORMANCE 230v Horizontal Air Openings External Air Volume at Various Blower Speeds External Air Volume at Various Blower Speeds pantie High re oo Medium Medium Low poti High uon Medium Medium in w g Pa cfm L s cfm L s cfm L s cfm 1 6 L s w g Pa cfm L s cfm L s cfm L s cfm L s cfm Lis 0 0 2765 1305 2475 1170 2225 1050 1945 920 1670 790 0 0 2800 1320 2495 1180 925 1680
44. 730 1 00 250 1735 820 1620 765 1475 695 1720 810 1590 750 1470 695 15 ACCESSORY BLOWER DATA GCS16 20 FILTER AND ACCESSORY AIR RESISTANCE Total Air Resistance inches water gauge Pa Unit 1 in 25mm REMD16 Down Flow Economizer EMDH16 Horizontal No iter With Optional With Optional With Furnished cm us Fiter Plested Rolester Fiberglass Titer iem Fier 800 380 15 37 105 12 27 67 13 32 18 45 25 cades 1000 470 18 45 106 15 34 85 18 45 26 65 15 37 26546026 1200 565 21 52 109 22 42 104 24 60 35 87 21 52 1400 660 25 62 15 37 51 127 31 77 46 114 29 72 1600 755 15 37 105 12 40 99 27 67 30 75 17 42 GCS16 048 1800 850 17 42 106 15 48 119 33 82 135 87 19 47 GCS16 060 2000 945 20 50 108 20 56 139 39 97 40 99 22 55 2200 1040 23 57 13 32 66 164 46 114 117 26 65 DIFFUSER AIR RESISTANCE Unit Air Total Air Resistance inches water gauge Pa Model Volume RTD9 65 Diffuser FD9 65 No cfm L s 2 Ends Open 1 Side 2 Ends Open All Ends amp Sides Open Diffuser 800
45. ARK BLOWER IGNITION TRIAL 3 1 42 SEC 122 SEC FIGURE 10 United Technologies Control Figure 11 TABLE 1 The ignition control provides four main functions gas LED STATUS valve control blower control ignition and flame sensing The control has a green LED to show control status table 1 The control is designed to ignite on the first attempt however the ignition attempt sequence provides three trials for ignition before locking out The lockout time for is 1 hour A After lockout the ignition control automatically resets esed and provides three more attempts at ignition Manual reset 4Flashes Flashes Limit Limit switch open Limit switch open after lockout requires breaking and remaking power to the Flashes Flame sensed but gas valve not open ignition control 24 volt thermostat connections P2 and Internal failure in the control heating component connections P1 are made through sep arate jackplugs See table 2 for thermostat terminations and table 3 for heating component terminations Page 23 IGNITION CONTROL UNITED TECHNOLOGIES SHOWN PI 2 YOU 9 FIGURE 11 TABLE 2 P2 TERMINAL DESIGNATIONS Function Y Cool Demand C Common W1 Heat Demand G Indoor Blower R 24 Volts to thermostat TABLE 3 Gas Valve Out Rollout Switch Prove Switch In 6 Limit Switch In Page 24 Flame rectifica
46. COMB AIR BLOWER D 52119 H ONDARY GAS HEA CD CIRCUIT BREAKER TRANS TI S47 SWITCH ROLLOU E20 IFUSE DOC LOW AMBIENT KI 649 ISWITCH FREEZESTAT VALVE GAS 559 THERMOSTAT 35C 50 LOW AMB HEATER COMPRESSOR 560 THERMO 50 LOW AMB HEATER 50C LOW AMBIENT KIT 56 THERMOSTAT 24 50 LOW AMB KIT J35 JACK TEST OC 6574 SWITCH FIRESTAT 143 JACK BLOWER MOTOR 675 ISWITCH FIRESTAT 2 ICON OR COMPRESSOR NSFORMER CONTROI 5 CONTACTOR BLOWER RELAY 52 RIP GROUND 5 2IRELAY COMB AIR BLOWER 20 1 2 25 1 24V COMMON D CHAR ONNI D MOTOR ISPEEDS COOL T HEAT AVAILABLE 08V 230V 208 250 06 5 51 4 L3 COMMON ISPEED 4 TAPS 2 5 4 5 G6 5 LINE VOLTAGE FIELD INSTALLED NOTE ALL REMAINING WIRES FACTORY INSTALLED WIRING DIAGRAM 2 01 OO OMB 0 6 516 056 90 048 75 120 5 6 516 060 75 120 4 Y SEE BLOWER SPEED 6CS20 036 90 048 060 75 120 4 CHART FOR HOOK UP HEAT COOL SECTION B35 048 060 Supersedes Form No New Form No 533 378W 533 689W Lithe U S A Page 42 TYPICAL GCS16 GCS20 FIELD WIRING DIAGRAM THREE PHASE 24V POWER ECONOMIZER BLOVER G HEAT I Wl 50 C LOW AMBIENT CONTROL CGA UNITS ONLY x CONNECTIONS FOR REMOTE MOUNTED SMOKE DETECTOR 17 MAX LOAD 0 1 24VAC CLASS II P FOR USE ON CGA UNITS ONLY HRI N
47. INSULATION THICKNESS REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE THERMOSTAT HEAT ANTICIPATION SETTING 0 7 AMP WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED ACCORDANCE WITH NATIONAL AND LOCAL CODES LINE VOLTAGE FIELD INSTALLED WIRING DIAGRAM COMBINATION UNITS ROOFTOP GCS16 036 90 048 75 120 5 G J GCS16 060 75 120 4 6 J GCS20 036 90 048 060 75 120 4 6 J HEAT COOL SECTION B36 aR Form No New Form No 579W 533 687W Litho U S A STULL gg COOL HEAT HI J38 Page 43 5 516 20 SEQUENCE OF OPERATION Johnson Ignition Control P Y G J Voltage Operation Sequence Cooling 1 Line voltage energizes transformer T1 Transformer T1 provides 24VAC power to all unit controls and thermo stat 2 Cooling demand energizes Y1 and G in the thermostat K1 compressor contactor and K3 blower relay ener gizes 3 K1 1 closes to energize compressor terminal C and con denser fan Compressor B1 and condenser fan B4 im mediately begin operating Single Phase Reciprocat ing Compressor Only Potential Relay K31 remains closed during start up and capacitor C7 remains in cir cuit As compressor gains speed K31 is energized and N C contacts open taking C7 out of the circuit 4 K3 1 contacts close to energize the indoor blower on cooling speed Heating 5 Heating demand initiates at W1 in the thermostat and en ergizes
48. ITY AND MAXIMUM OVERCURRENT PROTECTION SIZE WIRE OF LIKE SIZE RATING lt INSULATION N THERMOSTAT HEAT ANTICIPATION SETTING 0 7 AMP THICKNESS AND TERMINATIO gt WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY gt DISCONNECT ALL POWER BEFORE SERVICING UNIT MUS ACCORDANCE WITH NATIONAL LOCAL CODES ECONOMIZER FOR USE ON CANADIAN UNITS ONLY 521 15 USED ON 024 030 AND 036 UNITS ONLY 50 C LOW AMBIENT CONTROL CGA UNITS ONLY A17 MAX LOAD 0 IVA 24VAC CLASS II A HRI IS NOT USED ON UNITS WITH SCROLL COMPRESSORS A REFER TO BLOWER SPEED CHART FOR MOTOR CONNECTIONS KEY COMPONENT IAS CONTROL BURNER D ICOMPRI vee M AN B6 MOTOR COMB AIR BLOWER 55 ICAPACIIOR DUIDQOR FAN __ ce R 560 RMO THERMOSTAT 3248 OPEN 50C COW AMD KITI 5 4 ISWITCH FIRESTAT 1 R COME F TRANEFORMER CONTAN i SO RANSFORMER CONTROL HRS AE espo LOW AMBIENT KIT TBSATERMINAL STRIP GROUND 243 JACK BLOWER MOTOR J58 CONTROL CONTACTOR COMPRESSOR k3 T IR PS TPR TEST P43 IPLUG BLOWER MOTOR PP _ PLUG BURNER CONTROL amp P66 PLUG NOVAR ETM s DENOTES OPTIONAL COMPONENTS WER HAR SPEEDS OL L HEAT AVAILABLE COBVIZSOVI 206 2507 FS pond H 2 EE reu EP E i2 9 4 5 6 GCS16 024 03
49. L IL JL FIGURE 29 g ThreePositionDamperMotorCheck Honeywell W7459C 1 Disconnect main power to the GCS16 20 2 Remove the control access cover see figures 25 and 26 3 Install jumper across enthalpy control termi nals D and TR1 See figure 30 for location THREE POSITION SOLID STATE ENTHALPY CONTROL 7 FIGURE 30 4 Restore power to unit Outdoor damper should drive to fully open position requires approxi mately 90 seconds for full travel Observe travel for proper damper operation 5 Disconnect power to unit Damper should spring return to closed position 6 Remove jumper installed step 3 Install jumper across enthalpy control terminals X and TR1 See figure 30 for terminal location 7 Restore power to unit Outdoor damper should drive to mid minimum position requires approximately 90 seconds for full travel Ad just minimum position by turning thumb wheel on damper motor 8 Disconnect power to unit and remove jumper Replace all panels Restore power to unit h Warm Up Kit An optional warm up kit may be added to either REMD16 or EMDH16 economizer The warm kit holds the dampers closed during night setback and morning warm up When the first thermostat demand of the day is satisfied the warm up kit opens the out Page 39 door dampers to minimum position The warm up kit mounts to the GCS16 20 in the control mounting area of the blower compartment
50. LED NEC CEC CLASS NOTE ALL REMAINING WIRES FACTORY INSTALLED WIRING DIAGRAN 2 01 COMBINATION UNITS ROOFTOP GCS16 024 50 030 75 060 75 120 4 042 048 060 024 030 036 SEE BLOWER SPEED CHART FOR HOOK UP 6CS20 024 50 030 75 042 75 120 2 P C7 6 516 060 Litho U S A Page 41 TYPICAL GCS16 GCS20 FIELD WIRING DIAGRAM THREE PHASE IF ANY WIRE THE APPLIANCE 15 REPLACED MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING AND INSULATION THICKNESS THERMOSTAT HEAT ANTICIPATION SETTING 0 7 AMP 6 WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY ATH U MUST BE GROUNDEI ACCORDANCE WITH NATIONAL AND LOCAL CODES 24V POWER REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE USE COPPER CONDUCTORS ONLY DISCONNECT ALL POWER BEFORE SERVICING ECONOMIZER BLOWER G HEAT I WI 50 C LOW AMBIENT CONTROL CGA UNITS ONLY CONNECTIONS FOR REMOTE MOUNTED SMOKE DETECTOR A17 MAX LOAD 0 24VAC CLASS II FOR USE ON CGA UNITS ONLY HRI NOT USED ON UNITS WITH SCROLL COMPRESSORS 521 IS NOT USED ON 048 AND 060 UNITS COOL 5 KEY Ss CTC COMPONENT ASC CONTROL BURNER S5 SWITCH LIMIT LOW COMP 1 BI COMPRESSOR COMPRESSOR MONITOR OS IMOTOR BLOWER 1 54 SWITCH LIMIT HI PRESS 84 MOTOR OUTDOOR 510 SW H LIM PRIMARY Bo MOTOR COMB AIR BLOW 511 SWITCH LOW PR OW AMB R ISWITCH
51. MUST BE REPLACED WITH AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE WIRE OF LIKE SIZE RATING AND THERMOSTAT HEAT ANTICIPATION SETTING 0 7 AMP INSULATION THICKNESS 6 WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY DISCONNECT ALL POWER BEFORE SERVICING 20 2 OR DEATH UNIT MUST BE GROUNDED IN OHO ACCORDANCE WITH NATIONAL AND LOCAL CODES ECONOMI ZER BLOWER G HEAT I WI FOR USE ON CGA UNITS ONLY P66 IS USED 8CS16 024 030 NOVAR UNITS ONLY ri 50 C LOW AMBIENT CONTROL CGA UNITS ONLY R VAGA DETECTOR SUPPLY KI cowracron HRI C7 AND K31 ARE NOT USED ON UNITS WITH SCROLL COMPRESSORS 521 IS NOT USED 048 AND 060 UNITS S49 DESCRIPTION 1 KEY COMPONENT ICONTROL BURNER START CAPAC TORDU I 960 THERI CIRCUIT BREAKER TRANS TI EPI TTHERMDETRT BEN oC LOW B KIT F20 FUSE S0C CON AMBIENT KIT 574 SWI TCH F IRESTAT 1 1 1 1 01 S75 SWITCH FTR TTRANSFORWER CONTROL 1 TBS2 TERMINAL STRIP GROUND CSRELAY BLOWER K25 RELAY D LO WER DELAY RELAY POTENTIAL PSS PLUG TES 5 P PLUG BLOWER MOTOR UNITS E EI 024 030 Es EH IS DH 090 l rm L 042 048 060 5151 4 5 BLOWER ee SPEED S SELECTION aig SPEED TAPS gs FACTORY CONNECTED MOTOR AVATL I PABLE c gt w 7 m 024 030 036 048 6 520 042 048 060 LINE VOLTAGE FIELD INSTAL
52. O dif ferential pressure switch used to monitor combustion air in ducer operation A flexible hose connects one side of the switch to the blower housing The other side of the switch is open to the atmosphere The switch is wired in series with ignition control A3 Prove switch S18 closes when combus tion air inducer reaches full speed to allow the ignition con trol to energize This proves that the combustion air inducer is operating and allows the heating cycle to continue Combustion air prove switch S18 is factory set and non ad justable Set point will be on the side of switch 7 Combustion Air Inducer 6 Combustion air inducer B6 provides fresh air to the burner while clearing the combustion chamber of exhaust gases The inducer uses a shaded pole 208 230VAC single phase 1 25 hp motor The blower begins operating imme diately upon receiving a thermostat demand and is de en ergized immediately when thermostat demand is satisfied All combustion air blower motors are sealed and cannot be oiled The tube connecting the switch to the blower flue box must be sloped in a manner that will prevent condensate from collecting in the tube It is normal for a small amount of con densate to form in the tube during unit operation The tube and switch must be allowed to drain accumulated conden sate between thermostat demands If the tube is positioned so that accumulated condensate is trapped in the tube the unit may run improperly or
53. OT USED ON UNITS WITH SCROLL COMPRESSORS S2 IS NOT USED ON 048 AND O60 UNITS COOL I YI DESCRIPTION 1 DESCRIPTION 1 1 KEY COMPONENT IKEY OMPONEN CONTROL BURNER B SWITCH LIMIT LOW COMP AIZ SEE NOTE 2 COMPRESSOR MONITOR ap er eG HI PRESSURE 3 B5 1MOTOR DLOWER p4 jMOTOR OUTDOOR W PR AMD Bo MOTOR COMP B J Ji B BLOW __ICAPACTTOR OUTDOOR_FAN 4 ICAPACTTOR BLOWER_WOTOR CBS DREAKER IRANS T IG49 SWITCH FREEZESTAT F TC Eco ep aoe LOW AMBIENT KIT 559 THERMOSTAT 55 S0C LOW AMD KITI VALVE GAS_ 560 THERMO P B HERM 0 OC LOW AMD R COM 350 66 THERMOSTAT 24C 50C LOW AMB HRG R B S74 SWITCH FIRESTAT 255 5 6575 ISWITCH FIRESTAT 2 5 39 JACK MOTOR SPEED ITRANSF ORMER CONTROL 243 MOTOR RANSFORMER COMBUSTION AIR BLOWER CONTACTOR COMPRESSOR ITRANSF ORMER BLOWER MOTOR 5 2 CONTACTOR BLOWER RELAY TRANSFORMER 50C LOW AMB KIT 24 COMMON 5 2 RELAY COMB AIR BLOWER amp B3 H 45 PLUG BLOWER MOTOR x NOVAR ETM LO RED T4 BROWN Cy K3 2 D OHG E MED MED USE COPPER CONDUCTORS ONLY DISCONNECT ALL POWER BEFORE SERVICING IF IN THE APPLIANCE IS REPLACED IT_MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING AND
54. OVEMENT OF ORBIT IGH PRESURE GAS SUCTION DISCHARGE POCKET FIGURE 16 The scroll compressor is tolerant to the effects of liquid re turn If liquid enters the scrolls the orbiting scroll is allowed to separate from the stationary scroll The liquid is worked toward the center of the scroll and is discharged If the com pressor is replaced conventional Lennox cleanup practic es must be used Due to its efficiency the scroll compressor is capable of drawing a much deeper vacuum than reciprocating com pressors Deep vacuum operation can cause internal fusite arcing resulting in damaged internal parts and compressor failure It is permissible to bump down the system using the compressor but never use a scroll compressor for draw ing a vacuum on the system This type of damage can be detected and will result in denial of warranty claims A CAUTION The head of a scroll compressor may be hot since it is constant contact with discharge gas Contact could result in serious burns For compressor specifications see compressor nameplate or ELECTRICAL DATA section in this manual All compres sors are protected by internal overload protection circuitry 3 Run Capacitor C5 single phase only GCS16 060 single phase units use run capacitor C5 to maximize compressor efficiency See side of capacitor for ratings Three phase models will not use capacitor C5 Page 27 DANGER Shock hazard Compressor m
55. RY INSTALLED 620 OHM 1 WATT 5X RESISTOR REMOVE WHEN SECOND IPs IPLUG LESS ECONOMIZER 1 A7 SENSOR IS INSTALLED TO PROVIDE Ic THERMOSTAT BOOM DIFFERENTIAL ENTHALPY CONTROL AX J9 AND MAY OR MAY NOT BE USED WIRING DIAGRAM 11729 gt DESCRIPTION WIRING DIAGRAM 11 99 DO NOT CONNECT enay COWON KEY I COMPONENT THERMOSTAT HAS TERMINAL COMMON MOST r ACCESSORIES CONTROL ENTHALPY V74594 ACCESSORIES THE C TERMINAL Pon MEME EN a REMD 16 M 16 MACK ECONOMTZER MOTOR TO EXTEND INTO JUNCTION BOX O 2 HEAT 2 COOL MODULATING ECONOMIZER FOR 2 928W THERMOSTAT SECTION Cl pe us ECONOMIZER VALUE LINE UNITS REMOVE P3 WHEN ECONOMIZER IS USED THERMOSTAT SECTION CI E THERMOSTAT SUPPLIED BY USER LARES Eg JPLUG ECONOMIZER MOTOR ECONOMIZER SECTION 05 Supersedes Form No New Form No J3 MAXIMUM LOAD 20VA 24VAC CLASS II RI SENSOR SUPPLY AIR Edw 820 ie ithe U 8 A TERMINAL STRIP 555 505W Litho U S A 09 ELECTROMECHANICAL THERMOSTAT WITH ECONOMIZER Operation Sequence 1 Economizer outdoor air dampers drive full closed anytime blower B3 is not operating switched by K3 2 in the unit 2 Damper motor terminal TR is powered by unit contactor K3 when there is a blower demand or a heating demand When 24VAC is applied between terminals TR and TR1 the damper motor is energized and the outdoor air dampers open to minimum position
56. The kit plugs into the unit wiring harness inline between the unit and the econo mizer For detailed wiring and operation refer to the sequence of operation section of this manual i Night Relay Optional night relay must be added to economizer when night setback functions are desired with elec tromechanical control systems Kit includes a DPDT relay which is hard wired to the economizer harness C OAD16 Outdoor Air Damper OAD16 damper section may be installed any place outside of the building in the return air duct Refer to OAD16 instal lation instruction manual for specific details regarding installation The washable filter supplied with the OAD16 can be cleaned with water and mild detergent It should be sprayed with Filter Handicoater when dry prior to reinstalla tion Filter Handicoater is R P Products coating no 418 and is available as Lennox Part No P 8 5069 D LPG Kit C S A rated GCS16 20s are factory set for use with natu ral gas An optional L P G conversion kit allows change over from natural to L P G supply The kit includes a gas valve changeover kit and new gas orifices See OPTION AL ACCESSORIES section for kit number Refer to the L P G conversion kit installation instruction for specific installation procedures E Condenser Coil Guard Kit Condenser coil guards are standard equipment for GCS20 single phase units only but a kit for all other models is avail able The kit includes PVC coated
57. age Operation Sequence Cooling 1 Line voltage energizes transformer T1 Transformer 1 provides 24VAC power to all unit controls and thermo stat 2 P and Y voltage Cooling demand energizes Y1 and G in the thermostat Compressor contactor K1 is energized G Voltage Compressor contactor K1 and blower relay K3 are energized 3 K1 1 closes to energize compressor terminal C and con denser fan Compressor B1 and condenser fan B4 im mediately begin operating Single Phase Reciprocat ing Compressor Only Potential Relay K31 remains closed during start up and capacitor C7 remains in cir cuit As compressor gains speed K31 is energized and N C contacts open taking C7 out of the circuit 4 P and Y voltage Indoor blower B3 is energized on cool ing speed G voltage K3 1 contacts close to energize indoor blow er B3 on cooling speed Page 48 Heating 5 Heating demand initiates at W1 in the thermostat and A3 checks all safety switches for operation 6 P and Y voltage Combustion air inducer B6 begins op eration 43 1 closes energizing the economizer if ap plicable When the combustion air inducer nears full speed prove switch S18 closes G voltage Relay K13 terminals close to energize com bustion air inducer B6 K43 1 closes energizing the economizer if applicable When the combustion air in ducer nears full speed prove switch 518 closes 7 Ignition control waits 30 seconds to allow the combus tion air in
58. ate air volume by 796 Down Flow Air Openings Horizontal Air Openings External Static z z Pressure Air Volume at Various Blower Speeds Air Volume at Various Blower Speeds High Medium High Medium Low Low High Medium High Medium Low Low in w g Pa cfm L s cfm L s cfm L s cfm Lis cfm L s cfm L s cfm L s cfm L s 00 0 1890 05 10 1870 25 1845 1320 620 1140 540 1325 625 1150 545 1330 625 1160 550 15 35 1820 20 50 1795 25 60 1765 30 75 1740 40 100 1675 50 125 1605 1330 630 1165 550 1330 630 1170 550 1330 625 1170 555 1325 625 1170 550 1305 615 1160 545 1280 605 1135 535 60 150 1530 10 175 1450 80 200 1360 1240 585 1105 520 1195 565 1060 500 1140 535 1010 475 90 225 1270 600 1120 1005 475 1070 505 945 445 1 00 250 1170 550 1020 915 430 995 470 870 410 GCS20 036 75 BLOWER PERFORMANCE 460 VOLTS Down Flow Air Openings Horizontal Air Openings External Static Air Volume at Various Blower Speeds Air Volume at Various Blower Speeds High Medium Low High Medium Low in w g Pa cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s 00 810 1095 515 05 805 1110 525 10 800 1120 530 15 795 1125 530 20 790 1130 535 25 780 1135 535 30 770 1135 535 40 755 1125 530 50 730 1110 525 60 705 1085 510 70 675 1045 495 80 640 1000 470 90 605 945 445 1 00 565 875 415
59. de energized and 151 opens Outdoor air dampers close to minimum position 11 Cooling demand is sent from thermostat terminal Y1 through enthalpy control terminals 1 and 2 and through enthalpy control terminal 5 to energize the 1st stage compressors
60. ducer to draw exhaust gas from the combustion chamber and to introduce fresh air 8 After the ignition control delay A3 activates gas valve GV1 and the spark electrode When flame is sensed by the flame sensor the spark electrode stops If flame is not sensed after the first trial for ignition controller A3 re peats steps 7 and 8 up to two more times depending on controller make before locking out If the control locks out it can be reset by breaking and remaking thermostat demand 9 P and Y voltage After a 45 second delay indoor blower B3 is energized on heating speed G voltage After 45 second delay relay K36 closes ener gizing indoor blower B3 on heating speed ELECTROMECHANICAL THERMOSTAT WITH ECONOMIZER 24V POWER RED A A J3 P3 amp lt 6 Ceo RED 1 10 e Le YELLOW X 2 1 WHITE t HEAT 2 BROWN WHITE 4 ECONOMI ZER PINK BLOWER GREEN HEAT WHITE BLUE Ag Gale COOL 2 BLUE 13 5 WHITE aly COOL YELLOW 2 lt PE 8 lt lt lt lt PURPLE 9 lt lt WHITE 5 lt lt lt A Of amp ct lt lt e 6 24 COMMON GRAY OPTIONAL SECOND A7 INSTALLED IN RETURN AIR PROVIDES DIFFERENTIAL ENTHALPY CONTROL A WHEN 15 RECEIVES POWER ISI CLOSES IKEY T FACTO
61. e aluminum mesh filter Onl Outdoor Filter 1 19 3 8 x 15 3 4 x 1 HOR LEAK Choice of economizer controls 7 9 lt 505 x 578 x 25 Economizer Dampers Horizontal Installs di 3 Position EMDH16 41 110 Ibs 50 kg EMDH16 65 130 Ibs 59 kg rectly in cabinet combination outdoor air and re yg Fully Modulating EMDH16M 41 110 Ibs 50 kg EMDH16M 65 130 Ibs 59 kg circulated air damper formed gasketed damper 1 16 x 25 x 1 406 x 635 x 25 blades nylon bearings 24v damper motor has Indoor Filter 1 20 x 24 x 1 508 x 610 x 25 71 14 25 x1 356 x 635 x 1 adjustable minimum position switch electronic Outdoor Filter 1 8x 24x 1 203 610 25 1 8x 28x 1 203 x 711 x 25 discharge air sensor adjustable outdoor air en thalpy control 1 in 25 mm fiberglass filter fur ccsie Fully Modulating EMDH16M 41S 70 Ibs 32 kg 16 655 86 lbs 39 kg nished filter rack will accept up to 2 in 51 mm Units Indoor Filter 1 20 x 20 x 1 508 x 508 x 25 1 20 x 25 x 1 508 x 635 x 25 filt td ir intake hood with alumi h ilter outdoor air intake hood with aluminum mesh Canada E filter Choice of economizer controls Only Outdoor Filter 1 de Bo 1 1 5152 1 Enthalpy Control Differential Used conjunction with outdoor air enthalpy control Determines and selects which air has the lowest enthalpy Return air enthalpy sensor field installs in economizer dampe
62. eck is complete o 1 3 The CFM can be adjusted by changing the motor speed taps Follow the blower speed change instructions be low C Blower Speed Adjustment 208 230V UNITS Blower speed selection is accomplished by changing the taps in the harness connector at the blower motor see figure 21 See wiring diagram for blower speeds Each motor port in a leadless motor figure 21 is analogous to speed taps pigtails used in previous Lennox units Each motor is capable of four or five different speeds de pending on unit refer to unit wiring diagram Each unit is factory wired to provide a single cooling speed and a single heating speed Speeds be changed by moving the cooling wire or the heating wire to a different port at the har ness connector 460 575V UNITS Blower speed selection is accom plished by changing the J38 blower speed jack in the return air section See unit wiring diagram Page 34 BLOWER SPEED TAP SELECTION 208 230V UNITS IMPORTANT USE J38 TO CHANGE BLOWER SPEED ON 460 575V UNITS FAILURE TO DO SO WILL DAMAGE MOTOR HARNESS CONNECTOR DEPRESS TAB TO RELEASE WIRE TERMINAL SELECT CONNECTOR LOCATION FOR NEW SPEED REFER TO UNIT WIRING DIAGRAM INSERT WIRE UNTIL IT IS SECURELY IN PLACE FIGURE 21 Heating Speed Factory blower speeds are listed in a table on the unit wiring diagram Adjust the blower heating speed for proper air temperature rise listed on unit rating plate
63. electrode flame sensing electrode and gas valve GV1 are directly controlled by ignition control A3 Ignition control A3 is controlled by combustion air blower B6 Combustion air blower B6 is controlled by heating de mand from the thermostat or control system a Burners All units use inshot burners Burners are factory set and do not require adjustment Burner shutters are designed to be fully open only All units have a peep hole with cover in the access panel for flame viewing Always operate unit with access panel in place Burners can be individually removed for service Burner maintenance and service is detailed in the MAINTENANCE section of this manual b Orifice Each burner uses an orifice which is matched to the burner input The orifice is threaded into the manifold The burner is supported by the orifice and will easily slide off for service Each orifice and burner are sized specifically to the unit Refer to unit nameplate or Lennox Repair Parts for correct sizing 3 Primary High Temperature Limit S10 10 is the primary limit for gas heat Units will have either a helical stick type limit or disc type limit Helical type limits are located on the vestbule See figure 4 Disc type limits are located in the blower deck figure 5 on all GCS16 20 model units Primary limit 510 is wired to the ignition control It s N C contacts open to de energize the ignition con trol when excessive heat is reached in the blower com
64. emperature and 80 F 27 C db 67 F 19 5 C wb entering evaporator air Page 4 SPECIFICATIONS GCS20 manufactured April 2002 and later SPECIFICATIONS GCS20 Heating Model No GCS20 036 75 GCS20 048 75 GCS20 048 120 GCS20 060 75 GCS20 060 120 Performance Input Btuh KW 75 000 22 0 75 000 22 0 120 000 35 2 75 000 22 0 120 000 35 2 Output Btuh kW 60 000 17 6 60 000 17 6 96 000 28 1 60 000 17 6 96 000 28 1 X A F U E 80 096 80 096 80 096 80 096 80 096 Gas Supply Connections npt in 1 2 1 2 1 2 1 2 1 2 Recommended Gas Supply Pressure 7 in w c 1 7 kPa 7 in w c 1 7 kPa 7 in w c 1 7 kPa 7 in w c 1 7 kPa 7 in w c 1 7 kPa Natural Gas LPG Propane 11 w c 2 7 kPa 11 w c 2 7 kPa 11 w c 2 7 kPa 11 w c 2 7 kPa 11 w c 2 7 kPa Cooling Nominal Tonnage kW 3 10 6 4 14 1 4 14 1 5 17 6 5 17 6 Performance Cooling Capacity Btuh kW 35 200 10 3 50 000 14 6 50 000 14 6 59 000 17 3 59 000 17 3 Total Unit Watts 3330 4545 4545 5765 5765 SEER Btuh Watts 12 40 12 70 12 70 12 00 12 00 EER Btuh Watts 10 60 11 00 11 00 10 20 10 20 Sound Rating Number dB 82 82 82 82 82 Refrigerant Charge HCFC 22 5 Ibs 2 oz 7 Ibs 14 oz 7 Ibs 14 oz 8 Ibs 8 oz 8 Ibs 8 oz 2 34 kg 3 57 kg 3 57 kg 3 86 kg 3 86 kg Condenser Net face area sq ft m2 Outer 14 3 1 33 14 3
65. ermostat to a setting far enough below room temperature to bring on the compressor 2 Close unit disconnect switch Compressor will start and cycle with demand 3 The cooling circuit is charged with R 22 refrigerant See rating plate for correct amount of charge 4 Refer to the Refrigeration System Service Checks sec tion for the proper method of checking charge C Heating Start Up A WARNING Shock burn hazard This unit is equipped with a direct spark ignition system Do not attempt to light manually BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Gas Valve Operation Figure 18 This unit is equipped with an automatic spark ignition sys tem There is no pilot In case of a safety shutdown move thermostat switch to OFF then return the thermostat switch to HEAT position 1 If using electro mechanical thermostat set to the low est setting 2 Turn off all electrical power to appliance 3 This appliance is equipped with an ignition device which automatically lights burner Do not try to light burner by hand 4 Remove heat access panel
66. expansion device All models use draw through type condenser fans 1 Reciprocating Compressor All GCS16 model units except the 036 and 048 are equipped with a reciprocating compressor All compres sors are protected by internal pressure releif valves for overload and internal crankcase heaters HR1 for proper lu brication Compressor B1 operates during cooling demand and is energized by contactor K1 upon receiving thermosa tat demand For compressor specifications see compres sor nameplate or ELECTRICAL DATA section in this manu al 2 Scroll Compressor All GCS20 model units and GCS16 036 048 uti lize a scroll compressor The scroll compressor DISCHARGE design is simple efficient and requires few moving parts A cutaway diagram of the scroll compressor is shown in figure 13 The scrolls are located in the top of the compressor can and the motor is located in the bottom of the com pressor can The oil level is immediately below the SCROLL COMPRESSOR SUCTION FIGURE 13 motor and oil is pressure fed to the moving parts of the com pressor The lower portion of the compressor shell is ex posed to low side pressure while only the very top of the shell is exposed to high side pressure Page 26 The scroll is a simple compression concept centered around the unique spiral shape of the scroll and its inherent properties Figure 14 shows the basic scroll form Two identical scrolls are mated together formi
67. g Number in accordance with test conditions included in ARI Standard 270 Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations x Certified in accordance with the USE certification program which is based on ARI Standard 210 240 95 F 35 F outdoor air temperature and 80 F 27 C db 67 F 19 C wb entering evaporator coil air Page 2 SPECIFICATIONS GCS16 CONT Model No GCS16 048 75 GCS16X 048 75 GCS16 048 120 GCS16X 048 120 GCS16 060 75 GCS16X 060 75 GCS16 060 120 GCS16X 060 120 Nominal Tonnage kW 4 1 04 5 1 7 6 Heating Input Btuh KW 75 000 22 0 120 000 35 2 75 000 22 0 120 000 35 2 Capacity Output Btuh kW 60 000 17 0 96 000 28 1 60 000 17 0 96 000 28 1 XA F U E 80 096 Cooling capacity Btuh kW 46 500 13 6 58 500 17 1 Total unit watts 4890 6570 Cooling SEER Btuh Watts 10 35 10 00 Ratings EER Btuh Watts 9 5 8 90 Sound Rating Number db 82 Refrigerant Charge HCFC 22 5 Ibs 11 oz 2 58 kg 7 Ibs 0 oz 3 18 kg Blower wheel nominal diameter x width in mm 11 1 2 x 9 292 x 229 Evaporator Blower Motor horsepower W 3 4 560 Net face area sq ft m2 5 30 0 49 6 20 0 58 Tube diameter in mm amp No of rows 3 8 9 5 2 Fins per inch m 15 591
68. g gas lines the gas valve must be dis connected and isolated Gas valves can be damaged if subjected to more than 0 5 psig 14 W C See Figure 19 Page 32 If test pressure is equal to or less than 0 5 psig 14 W C use the main manual shut off valve before testing to isolate unit from gas supply system When checking piping connection for gas leaks use a soap solution or other preferred means Do not use matches candles flame or other source of ignition to check for gas leaks D Testing Gas Supply Pressure When testing gas supply pressure connect test gauge to the inlet pressure tap field provided Test supply gas pres sure with unit firing at maximum rate Make sure the read ing falls within the range of the following values Low pres sure may result in erratic operation or underfire High pressure can result in permanent damage to the gas valve or overfire For natural gas units operating pressure at the unit gas connection must be between 4 5 W C and 10 5 W C For L P gas units operating pressure at the unit gas connection must be between 11 0 W C and 13 0 W C On multiple unit installations each unit should be checked separately with and without the other units operating Sup ply pressure must fall within the range listed in the previous paragraph E Check and Adjust Manifold Pressure After line pressure has been checked and adjusted check manifold pressure Refer to figure 18 for location of man
69. hrough a factory supplied hole in the panel dividing the unit return and supply air The three position economizer sensor switch mounts to pre drilled holes in the unit panel dividing return and supply air e Wiring Installation Maintenance The economizer uses pigtail connectors to connect to the GCS16 20 s harness connector located in the blower compartment For specific details of econo mizer wiring and operation refer to the sequence of operation section of this manual f Modulating Damper Motor Check Honeywell W7459A 1 Disconnect main power to the unit 2 Turn thermostat control to OFF position occu pied mode 3 Install jumper across terminals 6 9 on blower relay K20 in unit control box 4 Install jumper across enthalpy control termi nals T and T1 See figure 29 for location 5 Restore power to unit Outdoor damper should drive to fully open position 60 to 90 sec re quired for full travel Observe travel for proper damper operation 6 Disconnect power to the unit Outdoor damper should spring return to closed position 7 Remove T and T1 jumper then restore power to the unit Outdoor damper should drive to mini mum position Adjust minimum damper posi tion pot located on control See figure 1 8 Disconnect power to unit and remove jumper on blower relay terminals 6 9 Replace all pan els Restore power to unit MODULATING SOLID STATE ENTHALPY CONTROL MINIMUM POSITIONER L JL JE IL I
70. ical power to ORE fae ent thermostat control systems with minimum field wiring nect switch es Unit may have multiple Control options such as economizer warm up kit Honey power supplies well T7300 control or Honeywell T8600 control are applica ble When installed the controls become an integral part of the unit wiring Units are also equipped with a low voltage ELECTROSTATIC DISCHARGE ESD pig tails to facilitate thermostat field wiring Precautions and Procedures Information in this manual is for use by a qualified service technician only All specifications in this manual are subject A CAUTION to change Procedures outlined in this manual are repre PROS ted dati 44 t d Electrostatic discharge affect electronic sentecq as a TecorrneriGauon ONY and Go notsStuperscde or components Take precautions during furnace replace state or local codes installation and service to protect the furnace s electronic controls Precautions will help to A WARNING Refrigerant can be harmful if it is inhaled Refrigerant avoid control exposure to electrostatic discharge by putting the furnace the control and the tech nician at the same electrostatic potential Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface such as the gas valve or blower deck before perform ing any service procedure must be used and recovered responsibly Failure to follow this warning may resultin pers
71. ifold pressure adjustment screw and pressure tap outlet The gas valve is factory set and should not require adjust ment Manifold pressure for gas units is 3 5 0 3 87 074 and for propane units 9 5 0 5 2 36 12 The gas valve should completely and immediately cycle off in the event of gas or power failure The manual shut off knob can be used to immediately shut off gas supply A IMPORTANT For safety connect a shut off valve between the manometer and the gas tap to permit shut off of gas pressure to the manometer Connect test gauge to the outlet pressure tap on the gas valve Start the unit and allow five minutes for the unit to reach steady state N While waiting for the unit to stabilize notice the flame The flame should be stable without flashback and should not lift from the burner head Natural gas should burn blue L P gas should burn mostly blue with some orange streaks After allowing the unit to stabilize for five minutes re cord the manifold pressure 4 Disconnect heating demand as soon as an accurate reading has been obtained 9 1 F Proper Gas Flow Approximate Furnace should operate at least 5 minutes before checking gas flow Determine time in seconds for two revolutions of gas through the meter Two revolutions assures a more ac curate time Divide by two and compare to time in table 7 Seconds in table 7 are based on a 1 cu ft dial and gas value of
72. ir volume by 7 BLOWER DATA GCS16 20 Cont GCS16 20 060 120 BLOWER PERFORMANCE GCS16 20 060 120 BLOWER PERFORMANCE 230v Down Flow Air Openings 230v Horizontal Air Openings External Air Volume at Various Blower Speeds External Air Volume at Various Blower Speeds poc High Man Medium Medium Low paate High gr Medium Medium in w g Pa cfm L s 1 5 cfm L s cfm 1 6 L s w g Pa cfm L s cfm L s cfm L s cfm L s cfm Lis 0 0 2740 1295 2520 1190 2270 1070 2025 955 1710 805 0 0 2760 1305 2545 1200 2295 1085 2015 950 1680 795 05 12 2715 1280 2495 1180 2250 1060 2005 945 1690 800 05 12 2745 1295 2530 1195 2280 1075 2005 945 1675 790 10 25 2685 1265 2470 1165 2230 1055 1980 935 1670 790 10 25 2730 1290 2510 1185 2265 1070 1995 910 1670 790 15 37 2655 1255 2445 1155 2210 1045 1960 925 1650 780 15 37 2710 1280 2495 1180 2250 1060 1985 935 1665 785 20 50 2630 1240 2420 1140 2190 alee 915 fe 770 20 50 2695 1270 2480 1170 2235 1055 1970 930 bed 785 25 62 2600 1225 2395 1130 2170 1025 1910 900 1615 760 25 62 2675 1265 2460 1160 2220 1050 1955 925 1645 775 130 75 2570 1215 2370 1120 2150
73. is any deviation within toler ance of the unit a second or third trial may be nec essary for ignition The control will lock out the heating system if ignition is not obtained within three trials and the indoor blower will not start Reset after lockout requires only breaking and re making thermostat demand See figure 10 for the ignition attempt sequence with retrials nominal timings given for simplicity Loss of flame during a heating cycle is indicated by an absence of flame signal If this happens the control will immediately restart the ignition sequence and then lock out if ignition is not gained within three trials The specific timings for the Johnson ignition control are shown in figure 10 JOHNSON NORMAL IGNITION SEQUENCE TIMINGS NOMINAL 2777 ON CLOSED P TOSSE OFF OPEN 05 30 35 70 END OF DEMAND THERMOSTAT DEMAND combustion air BLOWER combustion air PROVE SWITCH GAS VALVE IGNITION SPARK BLOWER IGNITION TRIAL RETRIALS IGNITION ATTEMPT SEQUENCE TIMINGS NOMINAL LLL ON UP TO 5 SEC J 0 0 35 65 70 100 105 THERMOSTAT DEMAND Mp combustion air PROVE SWITCH GAS VALVE IGNITION SPARK WATCHGUARD BLOWER IGNITION TRIAL LOCKOUT IGNITION CONTROL TIMING 8 SEC TRIAL END OF YILA ON THERMOSTAT DEMAND OFF SECONDSO 30 PEE gt i THERMOSTAT DEMAND bustion air BLOWER GAS VALVE IGNITION SP
74. l Static Air Volume at Various Blower Speeds External Static Air Volume at Various Blower Speeds Pressure High Medium Low Pressure High Medium Low in w g cfm L s cfm L s cfm L s in wg Pa cfm L s Lis cfm L s 0 900 0 0 2655 1255 2350 1110 1920 905 05 890 05 12 2630 1240 2330 1100 1905 900 885 25 2605 1230 2310 1090 1890 890 15 875 15 37 2580 1220 2285 1080 1870 885 20 865 20 50 2555 1205 2260 1065 1850 875 25 855 25 62 2525 1190 2235 1055 1830 865 30 845 30 75 2495 1180 2210 1045 1810 855 40 825 40 100 2465 1165 2155 1015 1765 835 50 800 50 125 2365 1115 2095 990 1720 810 60 150 2250 1060 2000 945 1640 775 60 150 2200 1040 2030 960 1665 785 70 175 2165 1020 1930 910 1580 745 70 175 2205 1040 1965 925 1610 760 80 200 2080 980 1850 875 1510 715 80 200 2115 1000 1890 890 1545 730 90 225 1985 935 1760 830 90 225 2010 950 1800 850 100 250 1860 880 1655 780 100 250 1885 890 1695 800 NOTE All air data is measured external to the unit with dry and without air filter NOTE All air data is measured external to the unit with dry coil and without air filter Page 13 BLOWER DATA GCSC20 manufactured April 2002 and later BLOWER DATA GCS20 All air data is measured external to the unit with dry coil and without air filter GCS20 036 75 BLOWER PERFORMANCE 230 VOLTS For 208V unit operation der
75. ls of proper assembly and mounting Roof mounting frame MUST be squared to roof before mounting Plenum system MUST be installed before unit is set on mounting frame Refer to RMF16 installation instructions for proper plenum construction Many types of roof framing or supports can be used to mount the GCS16 20 unit depending upon different roof structures A typical field fabricated roof mounting frame is shown in figure 23 TYPICAL FIELD FABRICATED MOUNTING FRAME VL 22 MOUNTING FRAME FIGURE 23 B REMD16 Downflow Economizer REMD16M Downflow Economizer 1 Application The economizer opens a set of dampers to allow 0 to 100 percent outdoor air to be used for cooling when outdoor hu midity and temperature are acceptable Additional 2nd stage cooling demand is directed to the compressor while the dampers remain open If outdoor air becomes unac ceptable the outdoor air dampers close to a predetermined minimum position while the compressor cooling circuit cycles as needed Page 36 REMD16 DOWNFLOW ECONOMIZER REMD16M DOWNFLOW ECONOMIZER OUTDOOR AIR DAMES ENTHALPY CONTROL TYPICAL REMD16M shown CONTROL ACCESS hk COVER DAMPER MOTOR gt lt QUTDOOR AIR DAMPER HOOD e RETURN AIR FILTER RETURN AIR DAMPERS FIGURE 24 Refer to the REMD16 41 65 Installation Instruction Manual for specific details regarding installation The physical location of
76. m silicone insulated stranded high voltage wire The wire uses 1 4 female quick connect on the electrode end and female spark plug type terminal on the ignition control end See figure 8 for gap dimension 11 Sensor The sensor tip is located in the left most burner path Flame is sensed by rectification through the flame sensing elec trode IMPORTANT In order to maximize spark energy to the elec trode the high voltage wire should rest the bottom of unit vestibule panel and should touch unit cabinet as little as possible IGNITOR FIGURE 8 12 Ignition Control A DANGER Shock Hazard Spark related components contain Electronic direct spark ignition with flame rectification sens ing is used in GCS16 20 units Flame strength ranges from 0 5 to 1 0 micro amps Ignition controls manufactured by Johnson Johnson Control Figure 9 In GCS16 20 units ignition control A3 is located in the heat ing compartment On a heating demand the ignition con trol is energized after proving combustion air blower opera tion The control allows 30 to 40 seconds for the combus tion air blower to vent exhaust gases from the burner The ignition control then activates gas valve GV1 the spark electrode the flame sensing electrode and blower relay K25 The ignition control is not adjustable high voltage Disconnect power be fore servicing unit The ignition control is not field repairable Can cause un
77. may be made at the control The first is the control setpoint The setpoint deter mines the temperature and humidity conditions at which the outdoor air dampers will open and close The recommended setpoint is A If the economizer is allowing air which is too warm or too humid into the system the control may be changed to a lower set point B C or D Refer to enthalpy chart figure 27 Example If the enthalpy control is set at setpoint A as shown in figure 27 the following situation could occur A cooling demand when the outside air is at 75 and 20 percent humidity would drive the economizer outdoor air damp ers open to utilize outdoor air for cooling The compres sor cooling circuit would be disabled However if the outdoor air should change to 70 F a drop in temperature and 70 percent humidity a dra matic rise in humidity the total heat content of the out door air would rise above the enthalpy control setpoint and de activate the damper motor to the preset mini mum position If cooling demand is still present when the total heat of the outside air rises above the control setpoint cooling demand is routed from the economizer to the compressor cooling circuit b Minimum Positioner The second type of adjustment which may be made at the control is the minimum position of the outdoor damper blades Each economizer has a minimum positioner switch potentiometer which allows the outdoor dampers to be adjusted to a pre
78. motor specifications 8 Evaporator Coil All GCS16 20s have a single slab evaporator coil The coil has two rows of rifled copper tubes fitted with ripple edged aluminum fins A Thermal Expansion Valve TXV feeds multiple parallel circuits through the coil See figure 17 EVAPORATOR PLUMBING GCS16 20 SUCTION LINE ac SENSING BULB p STRAPPED TO SUCTION LINE LIQUID LINE EQUALIZER LINE FEEDER TUBES 2 lt 22 lt gt m COMPRESSOR COMPARTMENT FREEZESTAT FIGURE 17 Page 28 9 High Pressure Switch S4 S4 is a manually reset SPST N C high pressure switch which opens on pressure rise The switch is located on the discharge line and wired in series with compressor contac tor K1 The switches on GCS16 20 036 042 060 dash 6 units ONLY are set at 450 10 psig 3103 kPa 69 kPa For all other GCS16 20 dash number units when discharge pressure rises above 410 10 psig 2827 69 kPa the switch opens and the compressor is de energized the economizer can continue to operate After the problem has been found and corrected the switch can be reset by push ing in the switch button 10 Freezestat Switch S49 All GCS16 20 units are equipped with a low temperature freezestat switch S49 located on the evaporator coil S49 is wired in series with high pressure switch S4 and compres sor contactor K1 S49 is a SPST N C auto reset switch which opens at 29 F 3 F 1 7
79. ng concentric spi ral shapes figure 15 One scroll remains sta tionary while the other is allowed to orbit figure 16 1 Note that the or biting scroll does not ro tate or turn but merely or bits the stationary scroll FIGURE 14 The counterclockwise orbiting scroll draws gas into the out er crescent shaped gas pocket created by the two scrolls figure 16 2 The centrifugal action of the orbiting scroll seals off the flanks of the scrolls figure 16 3 As the orbit ing motion continues the gas is forced toward the center of the scroll and the gas pocket becomes compressed figure 16 4 When compressed gas reaches the center it is discharged vertically into a chamber and discharge port in the top of the compressor figure13 The discharge pressure forcing down on the top scroll helps seal off the upper and lower edges tips of the scrolls figure 15 During a single orbit several pockets of gas are compressed simultaneously providing smooth continuous compression CROSS SECTION OF SCROLLS DISCHARGE STATIONARY SCROLL DISCHARG PRESSURE Sy TIPS SEALED m DISCHARGE PRESSURE ORBITING SCROLL FIGURE 15 SUCTION SN ee Rinna Nea VES UU e SUCTION sy ORBITING SCROLL STATIONARY SCROLL SUCTION INTERMEDIATE PRESSURE GAS 2 CRECENT SHAPED GAS POCKET FLANKS SEALED 7 BY CENTRIFIGUAL FORCE POCKET SUCTION 9 ay M
80. ng on GCS20 042 GCS16 20 048 and GCS16 20 060 units Net Weight NOTE US Only Sound Reduction Plate must be ordered separately for field installation RMF16 41 75 Ibs 35 kg Plate ordered separately 73H80 RMF 16 41 75 Ibs 35 kg Plate ordered separately 73H80 RMF 16 65 86 Ibs 39 kg Plate ordered separately 73H82 Page 6 Indoor filter is not furnished with economizer REMD16 utilizes existing filter furnished with CHA16 unit OPTIONAL ACCESSORIES GCS16 20 CONT Model No 024 030 036 048 060 Outdoor Air Damper Section For down flow ap plications damper assembly replaces blower ac US Onl OAD16 41 12 Ibs 5 kg mle kg cess panel manually adjustable 0 to 25 fixed y 1 5x 17 x 1 in 127 x 432 x 25 mm 203 x 432 x 25 mm outdoor air outdoor air hood with cleanable filter in 203 x lt cluded number and size of filter Net Weight inimum mixed air temperature OAD16 65S 16 lbs 7 Heat mode 45 F 7 C GCS16 Units 16 415 10 lbs 5 kg 1 18 x 6 i 5 7 kg Maximum mixed air temperature Canada Only 1 14 x 6 x 1 in 356 x 152 x 25 mm 457 x 152 x 25 mm Cool mode 90 F 32 C Outdoor Air Pamper Section For horizontal applications installs in return air duct adjacent to unit manually adjustable fixed outdoor air Net Weight OAD3 46 65 8 Ibs 4 kg Timed Off Cont
81. onal injury or death Teennical Page 1 2001 Lennox Industries Inc Publications Litho U S A Table of Contents Introduction 1 2 Optional Accessories 6 Electrical Data 7 High Altitude 8 Blower Data 9 I Application 17 II Unit Components 17 Control Box 17 20 26 Placement and Installation 29 IV Electrical Connections 29 V Stat STER 29 VI Refrgeration System Service Checks 31 VII Heating System Service Checks 32 VIII Indoor Blower Operation 33 IX Maintenance 35 X Accessories 36 XI Wiring and Operation Sequence 41 SPECIFICATIONS GCS16 Model No GCS16 024 50 GCS16X 024 50 GCS16 030 75 GCS16X 030 75 GCS16 036 90 GCS16X 036 90 Nominal Tonnage kW 2 7 0 2 5 8 8 3 10 6 Heating Input Btuh kW 50 000 14 7 75 000 22 0 90 000 26 4 Capacity Output Btuh kW 40 000 11 7 60 000 17 6 72 000 21 1 XA F U E 80 096 m Cooling capacity Btuh kW 23 200 6 8 27 400 8 0 35 400 10 4 Certified Total unit watts 2670 3150 3850 Cooling SEER Btuh Watts 10 00 10
82. ontrol will be locked out Page 35 Under normal operating conditions the combustion air in ducer wheel should be inspected prior to the heating sea son to determine if cleaning is necessary With the power supply disconnected the condition of the blower wheel can be determined by looking through the vent opening Maintenance consists of 1 Checking prove switch Prove switch should close at the factory setting shown on side of switch 2 Check the combustion air pressure switch hose for blockage or deterioration Replace if necessary 3 Position hose so accumulated condensate can drain from the switch into blower housing 4 Clean combustion air inducer assembly To clean combustion air blower 1 Shut off power supply and gas to the unit 2 Remove screws retaining the vent cap and combustion air inducer to the end panel Clean vent cap as neces sary Check gaskets for deterioration Replace if nec essary Pay close attention to the order in which flue orifice and gaskets are installed 3 Remove screws holding blower housing to the flue box cover plate and wires attached to motor 4 Remove combustion air inducer assembly 5 Clean with a wire brush as required 6 Remove burner assembly from unit as described in burner section above 7 Clean heat exchanger tubes with a wire brush as re quired 8 Replace flue box cover and burner assembly Replace combustion air inducer assembly including gaskets CAUTION U
83. part ment At the same time the N O contacts close maintain ing power to blower relay K20 and power to indoor blower B3 Set point is factory set and cannot be adjusted See Lennox Repair Parts handbook for set point Page 20 4 Flame Rollout Switch S47 Flame rollout switch S47 is a high temperature limit located just above the burner on all units See figure 4 The limit is a N C SPST manual reset thermostat connected in series with ignition control A3 When S47 senses flame rollout ignition control immediately stops ignition and closes the gas valve The switch is factory set and cannot be adjusted 5 Secondary Limit S21 GCS16 20 024 030 and 036 090 only size 3 ton units are equipped with a secondary limit located on the blower scroll See figure 5 The limit is an auto reset thermostat which opens on a temperature rise It is electronically con nected in series with the ignition control The limit is used to de energize the ignition control and shut down the burners when temperature in the blower scroll becomes too high The limit is factory preset to open at 170 F 5 F on a tem perature rise and close at 135 F 10 F on a temperature fall It is not adjustable This is a safety shut down function of the unit GCS16 20 HIGH TEMPERATURE LIMIT LOCATIONS 10 all units 024 030 amp 036 090 only FIGURE 5 6 Combustion Air Prove Switch 518 The combustion air prove switch S18 is a SPST N
84. r section 54644 Gravity Exhaust Dampers For use with EMDH16 Pressure operated assem bly field installs in the return air duct adjacent to the economizer assembly In cludes bird screen Net Weight GEDH16 65 4 Ibs 2 kg Horizontal Filter Kit GCS16 Units Canada Only For horizontal applications painted steel cabinet with filter access disposable pleated fiber filter furnished see dimension drawing No and size of filter Net Weight HF16 46 18 Ibs 8 kg 1 20 x 20 x 2 in 508 x 508 x 51 mm HF16 65 21 165 10 kg 1 20 x 25 x 2 in 508 x 635 x 51 mm Low Ambient Control Kit Units operate down to 30 F 1 C outdoor air tem perature in cooling mode without any additional controls Kit can be field installed enables unit to operate properly down to O F 18 C LB 57113BC 24H77 LPG Propane Kits Conversion from Natural Gas to LPG Propane 50L89 50 75 90K input 50L88 120K input Roof Curb Power Entry Kit Allows power entry through roof mounting frame knockouts provided in roof frame kit contains 1 2 in 13 mm x 40 in 1016 mm armored conduit and installation hardware two kits are required one for low voltage and one for high voltage See Dimension Drawing 18H70 Roof Mounting Frame Nailer strip furnished mates to unit U S National Roofing Contractors Approved shipped knocked down RMF 16 41 may be used on all sizes with a slight unit overha
85. rol Prevents compressor short cycling and allows time for suction and discharge pressure to equalize permitting the compres sor to start in an unloaded condition Automatic reset control provides a time delay between compressor shutoff and start up LB 50709BK 47J27 Thermostat Not furnished with unit See Thermostat bulletin in Ther mostats and Controls section and Lennox Price book For commercial control systems see pages 4 5 See Thermostat bulletin in Thermostats and Controls section Lennox Price book and pages 4 5 Transitions Supply and Return Used with diffusers installs in roof mounting frame galvanized steel construction flanges furnished for round duct connection fully insulated Net Weight SRT16 65 20 Ibs 9 kg Unit Stand Off mounting Kit For horizontal applications elevates units above mounting surface Includes six high impact polystyrene 38H18 stand off mounts See dimension drawings ELECTRICAL DATA GCS16 Single Phase Model No GCS16 024 GCS16 030 GCS16 036 GCS16 048 GCS16 060 Line voltage data 60 hz 208 230v 1 phase p Recommended maximum fuse size amps 25 30 40 50 60 TMinimum Circuit Ampacity 16 20 25 34 42 Rated load
86. s follows 1 Loosen knob securing screw to allow knob stop to pass over fixed stop on control see figure 33 Page 40 LOW AMBIENT ADJUSTMENT ROTATE COUNTERCLOCKWISE SET INDICATOR ADJUSTMENT KNOB AT 140 PSIG FIGURE 33 DIFFERENCE set by knob CUT IN POINT fixed minus CUT OUT POINT To find CUT OUT point this equation can be re arranged CUT OUT CUT IN minus the DIFFERENCE 2 Rotate the knob as needed to set the difference indica tor at 145psig 1000kPa 3 Tighten the securing screw after adjusting G SRT 65 Transitions KNOB SECURING Optional supply return transitions are available for use with downflow GCS16 20s utilizing the optional RMF16 roof mounting frame The transition must be installed in the RMF16 mounting frame before mounting the GCS unit to the frame Refer to the manufacturer s instructions in cluded with the transition for detailed installation proce dures H RTD9 65 and FD9 65 Diffusers Optional flush mount diffuser return FD9 65 and extended mount diffuser return RTD9 65 are available for use with the GCS16 unit Refer to the manufacturer s instructions in cluded with the transition for detailed installation proce dures Xl Wiring Diagrams and Operation Sequence TYPICAL GCS16 GCS20 FIELD WIRING DIAGRAM SINGLE PHASE 24 NOTE FOR USE WITH COPPER CONDUCTORS ONLY ANY W APPLIA REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT REPLACED TT
87. s not exceed 100 amps type circuit breaker may be used in place of fuse U S Only 1 Motor is rated at 230 volts Full load amps shown are for step down transformer output 2 Motors are rated at 460 volts Full load amps shown are for step down transformer output NOTE Extremes of operating range are plus and minus 10 of line volage Page 7 ELECTRICAL DATA GCS20 Single Phase Model No GCS20 024 GCS20 030 GCS20 036 GCS20 042 GCS20 048 GCS20 060 Line voltage data 60 Hz 208 230v 1 ph p Recommended maximum fuse size amps 30 30 40 45 60 70 TMinimum Circuit Ampacity 19 21 26 30 37 43 C Rated load amps 12 2 13 5 16 1 17 9 23 7 28 8 ompressor Locked rotor amps 61 73 88 104 129 169 Condenser Fan Full load amps 1 1 2 0 Motor Locked rotor amps 2 3 4 2 Evaporator Blower Full load amps 2 2 3 0 3 9 46 Motor 1 phase Locked rotor amps 46 6 2 8 3 10 1 1 Induced Draft Blower Motor 1 phase Full load amps total 0 7 p Where current does not exceed 100 amps HACR circuit breaker may be used in place of fuse U S only TRefer to National or Canadian Electric Code to determine wire fuse and disconnect size requirements NOTE Extremes of operating range are plus and minus 10 of line volage ELECTRICAL DATA GCS20 Three Phase Model No GCS20 036 GCS20 048 GCS20 060
88. safe operation injury or death The Johnson control is illustrated in figure 9 The unit wires plug directly into the side of the control The spark electrode wire connects to the spark plug type connector on top of the control Page 22 JOHNSON IGNITION CONTROL 5 TRIAL 24V 50 60 Hz NEC CLASS 2 LED CODES CURRENT 0 2 AMBIENT TEMP ON 40 TO 160 DEG F MINUTE RETRY CONTACTS 2 SNR OFF IN RETRY PERIOD G765BCA 12 SPARK GAP 0 125 IN OCT Sc NO DONER OR DIRECT SPARK NOs 4 951 975 DETECTED FAULT IGNITION CONTROL 44L590 B SEC TRIAL NORMAL OPERATION 30 SEC PREPURGE 0 5 SEC 0 2 5 SEC m im FIGURE 9 a The ignition control provides three main functions ion 1 gas valve control ignition and flame sensing It is powered only after the combustion air prove switch has closed and as long as other safety switch cir cuits are closed The ignition attempt sequence provides three trials for ignition before locking out The blower control K25 is energized simulta neously with the gas valve so the blower will ener gize 45 seconds after flame has successfully been established The unit will usually ignite on the first attempt See figure 10 for a normal ignition se quence with nominal timings for simplicity Proper gas air mixture is required for ignition on the first attempt If there
89. se care when cleaning combustion air blower wheel Wheel is made of aluminum and may dis tort if too much pressure is applied 9 Reconnect tubing connecting blower to flue box Ar range tubing so that it can drain accumulated conden sate 10 Clean vestibule panel louvers using a small brush E Flue Make sure the flue is clean and free of debris F Evaporator Coil 1 Clean coil if necessary 2 Check connecting lines and coil for oil leaks 3 Check condensate drain pan and line if necessary G Condenser Coil 1 Clean and inspect condenser coil May be flushed with a water hose 2 Visually inspect connecting lines and coils for evidence of oil leaks H Electrical 1 Check all wiring for loose connections 2 Check for correct voltage at unit unit operating 3 Check amp draw on both condenser fan motor and blower motor X ACCESSORIES A RMF16 Mounting Fram When installing a GCS16 20 unit on a combustible surface for downflow discharge ap plications RMF 16 roof mount ing figure 22 frame is re quired Otherwise the RMF16 is recommended but not required The GCS16 20 FIGURE 22 if not mounted on a flat roof surface MUST be supported under all edges and under the middle of the unit to prevent sagging The GCS16 20 MUST be mounted level within 1 16 per linear foot in any direction The assembled RMF16 mounting frame is shown in figure 22 Refer to the RMF16 installation instructions for detai
90. se property damage unit damage personal injury or death A Lubrication All motor bearings are prelubricated No further lubrication is required B Filters Filters are provided with the GCS16 20 units and installed in the return air duct See Installation Instructions Filters should be checked monthly or more frequently in severe use and cleaned or replaced regularly Take note of the AIR FLOW DIRECTION marking on the filter frame when re installing A IMPORTANT Filters must be U L C certified or equivalent for use in Canada C Burners Clean burner as follows 1 Turn off both electrical power and gas supply to unit 2 Open access panel to burner compartment 3 Remove burner retaining bracket and gas manifold Lift burners from orifices 4 Clean as necessary and replace burners Refit retain ing brackets and gas manifold Make sure that burner heads line up correctly Spark gap on ignition electrode must be properly set Refer to Heating Adjustment sec tion Close access panel 5 Restore electrical power and gas supply Follow light ing instructions attached to unit to restart unit D Combustion Air Inducer All GCS16 20s use combustion air inducers with pre lubri cated sealed stainless steel ball bearings A differential pressure switch combustion air prove switch is used to prove combustion air inducer operation If the in ducer is obstructed the switch will not close and the ignition c
91. service techni cian or gas supplier B To Turn Off Gas To Unit 1 Set thermostat to lowest setting 2 Turn off all electric power to unit if service is to be per formed 3 Remove control access panel 4 Turn knob on Honeywell gas valve clockwise 89 until it stops Depress knob and turn clockwise 499 to OFF Turn knob on White Rodgers 180 either way to off Do not force 5 Replace burner access panel D Safety or Emergency Shutdown Turn off power to the unit Close the manual and or main gas valves E Extended Period Shutdown Turn off the thermostat or set to UNOCCUPIED mode Close all gas valves both internal and external to the unit to prevent gas leakage into the combustion chamber Turn off power to the unit All access panels covers and vent caps must be in place and secured VI REFRIGERATION SYSTEM SERVICE CHECKS A Cooling Start Up 1 Set thermostat system switch in Cool position fan switch in On or Auto position and adjust room ther mostat to a setting below room temperature 2 Close unit disconnect switch 3 Compressor will start and cycle on thermostat de mand B Three Phase Compressor Rotation Three phase scroll compressors must be phased sequen tially to ensure correct compressor rotation and operation At compressor start up a rise in discharge and drop in suc tion pressures indicates proper compressor phasing and operation If discharge and suction pressures do not func
92. set minimum position This allows a preset amount of air ex change at all times during unit operation When unit operation stops the dampers drive fully closed The potentiometer is located on the enthalpy control face modulating economizer or on the damper motor three position economizer c Enthalpy Sensor The enthalpy sensor is located on the outside portion of the outdoor damper blades as shown in figure 28 The sensor monitors the total heat content of the out door air temperature plus humidity and sends the information to the enthalpy control The enthalpy control uses the information to determine if outdoor air can be used for cooling ENTHALPY SENSOR ALL ECONOMIZERS ENTHALPY SENSOR OUTDOOR AIR DAMPERS DAMPER HOOD FIGURE 28 d Mixed Air Sensor The sensor measures the resultant temperature of the mixed air downstream of the evaporator coil The mixed air temperature is used by the enthalpy control when outdoor dampers are open to help determine whether outdoor air dampers should close There are two types of economizers modulating and three position Modulating economizers are equipped with a single mixed air sensor Three position economiz ers are equipped with a separate sensor switch and sensing bulb which are connected by a cap tube Page 38 The mixed air sensor bulb is located in the supply air stream The sensor modulating economizer or sensing bulb three position economizer fits t
93. t operation derate air volume by 7 GCS16 030 75 BLOWER PERFORMANCE 230v Down Flow Air Openings External Static Pressure 200 90 225 1 00 250 High 880 745 590 Air Volume at Various Blower Speeds 415 350 280 790 655 375 preme GCS16 030 75 BLOWER PERFORMANCE 230 Horizontal Air Openings Air Volume at Various Blower Speeds Static I Medium Medium ressure High High low Low in wg Pa cfm L s cfm L s cfm L s cfm L s 0 0 1365 645 05 12 1365 645 25 1360 640 15 37 1350 635 20 50 1335 630 25 62 1320 625 30 75 1300 615 40 100 1250 590 50 125 1185 560 60 150 1105 520 1000 470 855 405 715 335 70 175 1010 475 930 440 780 370 655 310 80 200 905 425 850 400 700 330 580 275 90 225 780 370 730 345 1 00 250 630 295 NOTE All air data is measured external to the unit with dry and without air filter For 208v unit operation derate air volume by 7 Page 9 NOTE All air data is measured external to the unit with dry coil and without air filter For 208v unit operation derate air volume by 7 BLOWER DATA GCS16 20 Cont GCS20 030 75 BLOWER PERFORMANCE GCS20 030 75 BLOWER PERFORMANCE 230v Down
94. ting demand When energized K13 normally open contacts close to energize the combustion air inducer and begin a heating sequence A differential pressure prove switch connected to the combustion air inducer in turn energizes the ignition control and gas valve Page 18 5 Indoor Blower Delay Relay K25 Relay K25 is a printed circuit board located in the control box wired in series with the gas valve K25 is designed to provide an indoor blower delay of 45 seconds on time and 150 seconds off time during a heat demand When there is a demand for heat the gas valve will open and the on time delay will begin When heat demand is satisfied the gas valve will close and the off time will begin If K25 fails re place the entire control 6 Indoor Blower Relay K20 Relay K20 is a DPDT relay also located in the control box Relay K20 is energized after the 45 second on time delay by relay K25 K20 is de energized after the 150 second off time delay by relay K25 after heat demand is satified or when limit S10 resets When relay K20 is de energized contacts K20 1 open to de energize the blower A seperate set of contacts K20 2 close energizing the optional econo mizer 7 Transformer T3 460 G and 575 J voltage units use a line to 230V auto transformer to power the combustion air inducer The auto transformer is connected directly to line voltage and is pow ered at all times It has an output rating of 0 55A 8 Transformer T4
95. tion sensing is used on all GCS16 20 units Loss of flame during a heating cycle is indicated by an absence of flame signal lt 0 5 microamps If this happens the control will immediately restart the ignition sequence and then lock out if ignition is not gained after the third trial See System Service Checks section for flame current mea surement The control shuts off immediately in the event of a power fail ure Upon restoration of power the control will restart the igni tion sequence and continue until flame is established or sys tem locks out Operation On a heating demand the ignition control checks for a closed limit switch and open prove switch Once this check is complete and conditions are correct the igni tion control then allows 30 seconds for the combustion air inducer CAI to vent exhaust gases from the burners When the CAI is purging the exhaust gases the CAI prove switch is closing proving that the CAI is operating before allowing the ignition control to energize If the prove switch does not close within the 300 seconds the control de energizes the CAI for another 300 seconds and then re energizes the CAI again This cycle will con tinue as long as there is a call for heat and the CAI prove switch is open Once the CAI switch is proven closed the control begins a 30 second pre purge period After the pre purge period the ignition control activates gas valve the spark electrode and the flame sensing elec trode
96. ts use single pole contactors One leg of compressor capacitor and con denser fan are connected to line voltage at all times Remove all power to disconnect before servicing W Electrical shock resulting in death or injury may result if power is not disconnected V START UP OPERATION A Preliminary Checks 1 Make sure unit is installed in accordance with the instal lation instructions and applicable codes Make sure fil ter is in place 2 Inspect electrical wiring both field and factory installed for loose connections Tighten as required 3 Check to ensure that refrigerant lines in good condi tion and do not rub against the cabinet or other refriger ant lines 4 Check voltage at the disconnect switch Voltage must be within range listed on the nameplate If not consult the power company and have the voltage condition cor rected before starting the unit 5 Recheck voltage with unit running If power is not with in range listed on unit nameplate stop unit and consult power company Check amperage of unit Refer to nameplate for correct running amps Page 29 B Cooling Start Up A IMPORTANT The following is a generalized procedure and does not apply to all thermostat systems Electronic thermostats may operate differently Refer to the operation sequence section of this manual for more information 1 Setfan switch to AUTO or ON and move the system selection switch to COOL Adjust the th
97. ust be grounded Do not operate with out protective cover over ter minals Capacitors contain high voltage Disconnect pow er before removing cover Dis charge capacitors before ser vicing unit Disconnect power before servicing unit w Can cause unsafe operation injury or death 4 Dual Capacitor C12 single phase only GCS16 20 single phase units except GCS16 060 use a single dual capacitor for both the fan motor and the com pressor The fan side of the capacitor and the compressor side of the capacitor have different mfd ratings The capaci tor is located inside the compressor compartment Ratings will printed on capacitor side 5 Condenser Fan and Motor B4 The specifications section in this manual shows the specifi cations of condenser fans used in GCS16 20s The con denser fan in all units is controlled by cooling contactor K1 6 Condenser Fan Motor Capacitor C1 All GCS16 20 units use single phase PSC condenser fan motors See condenser fan motor nameplate for capacitor ratings 7 Blower Motor B3 and Run Capacitor C4 All GCS16 20 series units use single phase PSC blower motors A single run capacitor is mounted on the blower housing Ratings for capacitor will be on motor nameplate All motors use multiple speed taps Typically the high speed tap is energized during compressor operation and a lower speed tap is energized during heating operation See motor nameplate or ELECTRICAL DATA section for
98. wer Operation The following is a generalized procedure and does not ap ply to all thermostat control systems 1 Blower operation is dependent on the thermostat op tion that has been installed in the GCS16 20 2 Generally blower operation is set at the thermostat subbase fan switch With the fan switch in the ON position the blower operates continuously With the fan switch in the AUTO position the blower cycles with demand or with some control systems runs con tinuously while the heating or cooling circuits cycle 3 In most cases the blower and entire unit will be off when the system switch is in the OFF position The only exception is immediately after a heating demand until blower control switches off B Determining Unit CFM 1 The following measurements must be made with a dry indoor coil Run the blower without the cooling de mand Air filters must be in place when measurements are taken 2 Measure static pressure external to the unit from sup ply to return To Measure Discharge Static Pressure a Measure tap locations as shown in figure 20 hole Insert manometer hose flush with the inside edge of hole or insulation Seal around hole with per magum Connect zero end of manometer to the dis charge supply side of system Connect other end of manometer to return duct as above With only the blower motor running observe the manometer reading Seal around the hole when ch

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