Lennox International Inc. 15GCSX User's Manual
Contents
1. Status LED Description Module has power Status LED Troubleshooting Information 24VAC control power is present at the module terminal Green Power LED OFF Module not powering up Determine verify that both Y and C module terminals are connected and voltage is present at both terminals with a thermostat demand for cooling Y Red Trip LED ON System and compressor check out OK Thermostat demand signal Y1 is present but compres sor not running 1 2 3 Verify Y terminal is connected to 24VAC at contactor coil Verify voltage at contactor coil falls below 0 5VAC when off Verify 24VAC is present across Y and C when thermostat demand signal is present if not present R and C wires are reversed Compressor protector is open Outdoor unit power disconnect is open Compressor circuit breaker or fuse s is open Broken wire or connector is not making contact Low pressure switch open if present in the system Compressor contactor has failed to close Red Trip amp Yellow Alert LEDs Flashing Simultaneous flashing Indicates that the control circuit voltage is too low for operation Yellow Alert Flash Code 1 Long Run Time Compressor is running extremely long run cycles Low refrigerant charge Evaporator blower is not running Evaporator coil is frozen Faulty metering device Condenser coil is dirty Liquid line restriction filter drier blocked if presen2. Cleaning should be performed as often as necessary Use a brush vacuum cleaner attachment or other suitable means If water is used to clean the coil be sure the power to unit is shut off prior to cleaning NOTE Care should be used when cleaning the coil so that the coil fins are not damaged Do not permit the hot condenser air discharge to be obstructed by overhanging structures or shrubs To Clean Burners Light the burners and allow unit to operate for a few minutes to establish normal burning conditions Observe the burner flames Compare this observation to figure 16 to determine if flame is properly adjusted Flame should be predominantly blue in color and strong in appearance Verify that all burners are lit and that the flame does not impinge on the sides of the heat exchanger Burner Flame Heat Exchanger Gas Manifold Burner Flame Blue Only Figure 16 Distorted flame or yellow tipping of the natural gas flame or long yellow tips on LP propane flame may be caused by one or more of the following lint or dirt inside the burner or burner ports lint or dirt at the air inlet between the burner and manifold pipe or an obstruction over the burner orifice Use a soft brush or vacuum to clean the affected areas Vent Outlet Visually inspect vent outlet periodically to make sure that the there is no buildup of soot and dirt If necessary clean to maintain adequate opening to disc
3. The following repair parts are available from your local dealer When ordering parts include the complete model number and serial number which are printed on the unit rating plate All service must be performed by a licensed professional installer or equivalent service agency or gas supplier Controls Blower Components Rollout Switch Blower Housing Assembly Transformer Blower Wheel Limit Control Blower Motor Gas Valve Blower Motor Mount Ignition Control Blower Motor Capacitor if used Electrode Combustion Air Inducer Flame Sensor Fan Blade Auxiliary Limit Fan Motor Pressure Switch Fan Motor Capacitor Blower Control System Operations Monitor Accessories Heating Components Gas Manifold Main Burner Orifices Main Burners Heat Exchanger Cooling Components Compressor Evaporator Coil Drier Expansion Valve Contactor Capacitor Condenser Coil LP Propane Gas Conversion Kit heat sizes 68 and 90 92M52 Number LP Propane Gas Conversion Kit heat sizes 83 110 and 138 92M56 Filter Kit 2 ton to 3 ton capacity units 92M54 Filter Kit 3 1 2 ton to 5 ton capacity units 92M55 PCO20 28 X8787 Installation Hardware Kit for PCO20 28 Y0629 Page 24
4. x nun ids JOULNOD NOILINSI W211A5 80112310804 ELIS HOY 1196 2Jn 10 J9 10J1U02 0J21U 3J2 10j yousazuy 407315 4 uad e jn yi T T vado qopiac jnopjoy HSYIJ 9 HOLIAS paziBsaua jou pasuos oun j HoY1j C vedo pwi HSy1J f IVLSOWYSHL 34055389 01 380565384 91055910 429JJ00U1 SaSUaS 121185 92155924 HS Td Uo ULOFSNS JO OF Palio waysks HSY11 2 02 DUJON HSV1J 15YJ Td SWIIV3H ANANT 9811003 5870 S35VIS 108 ASWHd 3 9N 15 159 ou uot pousdo FOWJON HS TI AOIS 59011135 OZddIHS 1101204 9 0 3OVIS 151 03395 31871 1V3H 29715 ond Eur 30 190300 P Iuris 9NIEL3S NOIIVdIOILNV LV3H 2004 02003 96 941 NYYOVIG NOTIO3NNOO 1081802 NOILIIN9I SIILSONDVIG weibeig edIdAL spun pebeyoed Sed XSOOSL Page 13 Blower Control A54 BLOWER CONTROL A54 ICM P N DIAGNOSTIC E oN DT o LED ARMSTRONG P N T 8 09 45632 001 wi C CFM LED J 100 CFM BLINK 9r o o CI RCom ADJUST SELECTOR PINS Setting affects both heating and cooling modes HEATING SPEED SELECTOR PINS COOLING SPEED SELECTOR PINS NORM o o o TES
5. The ignition control energizes the combustion air inducer on high speed flashes a code 3 on the LED and waits for the pressure switch to close When the pressure switch has closed the LED code 3 flash stops and the control begins the 15 second pre purge period When the pre purge time has expired the control begins the ignition trial The ignition control energizes the gas valve and spark The control ignores the flame sense signal for the first two seconds of the ignition trial If the flame is established within 10 seconds the control de energizes the spark If flame is not established within 10 seconds the gas valve and spark are de energized and the ignition control initiates a 30 second inter purge sequence Approximately 30 seconds after the flame has been established the circulating air blower starts and the combustion air inducer is switched to low speed The ignition control inputs are continuously monitored to ensure that limit switch es roll out switch and pressure switch are all closed and that the flame remains established and heating demand is present First stage gas valve low speed combustion air inducer and Page 18 circulating blower remain energized If the thermostat signals a requirement for second stage heat W2 the ignition control initiates high heat operation When a signal for second stage heat is received by the ignition control the control energizes the second stage gas valve and high speed combustio
6. material suitable for the purpose CAUTION Some soaps used for leak detection are corrosive to certain metals Carefully rinse piping thoroughly af ter leak test has been completed Do not use matches candles flame or other sources of ignition to check for gas leaks 5 The unit and its individual manual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 PSIG 3 48kPa A IMPORTANT The unit must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig See figure 9 The unit and its individual shut off valve must be dis connected from the gas supply piping system during any pressure testing of the system at test pressures greater than 1 2 psig 6 A 1 8 inch N P T plugged tapping accessible for test gage connections must be installed immediately upstream of the gas supply connection to the furnace Page 11 All wiring should be done in accordance with the current National Electric Code ANSI NFPA No 70 in the United States In Canada wiring must be done in accordance with the current CSA C22 2 Part 1 Local codes may take precedence Use wiring with a temperature limitation of 75 C min run the 208 or 230 volt 60 hertz electric power supply through a fused disc
7. right burner If the ignition control does not receive a signal from the flame sensor indicating that the burners have established flame the main gas valve will close after the 10 second ignition trial period built into the ignition control Rollout Switch The switch is located above the main burners In the event of a sustained main burner rollout the main gas valve is closed To reset push the button on top of the switch Auxiliary Limit 42 48 amp 60 units only This control is located in the side of the circulating air blower housing If the circulating air blower fails to operate the temperature rises and opens the auxiliary limit The main gas valve closes This control resets automatically Page 20 System Operation Monitor LSOM The system operation monitor A132 detects the most common fault conditions in the air conditioning system When an abnormal condition is detected the module communicates the specific condition through its ALERT and TRIP lights The module is capable of detecting both mechanical and electrical system problems See figure 15 for the system operation monitor System Operation Monitor A132 POWER LED DATA OUTPUT I DATA OUTPUT Y CONNECTOR M 25 SPADE ALERT LED TRIP LED Figure 15 A IMPORTANT This monitor does not provide safety protection
8. 1 0 inches W C for LP propane gas The maximum inlet gas supply pressure is 10 5 inches W C for natural gas and 13 0 inches W C for LP propane gas Gas input must never exceed the input capacity shown on the rating plate Units fueled by natural gas are rated for manifold pressures of 2 0 inches W C for first stage and 3 5 inches W C for second stage Units fueled by LP propane gas are rated for manifold pressures of 5 6 inches W C for first stage and 10 0 inches W C for second stage Measure manifold pressure Shut off gas supply to the unit Remove plug from pressure tap See figure 13 Connect manometer or gauge to the proper pressure tap then turn on the gas supply The Honeywell VR8205 gas valve has separate adjusting screws for first stage LO and second stage The adjusting screws are positioned on either side of the barbed fitting Turn the adjusting screws clockwise to increase pressure and input turn counterclockwise to decrease pressure and input The pressure regulator adjustment is sensitive One turn of the adjusting screw results in a large change in manifold pressure Final first stage and second stage manifold pressures must be within the allowable rangers for the gas being used For Natural Gas Check the furnace rate by observing gas meter making sure all other gas appliances are turned off The test hand on the meter should be timed for at least one revolution Note the number of seconds for one revolu
9. 48 15GCSX A B V 60 112 117 137 143 HORIZONTAL SUPPLY AIR OPENING HORIZONTAL RETURN AIR OPENINGS 2 BACK VIEW FLUE OUTLET F Model No 15GCSXAV 24 15GCSXAV 30 1661 20 508 15GCSXAV 36 15GCSXAV 42 15GCSX A B V 48 38 1 4 972 75 1905 46 1168 11 1 4 286 19 1 4 489 22 559 15GCSX A B V 60 F G H J K L Model No mm 15GCSXAV 24 15GCSXAV 30 483 15GCSXAV 36 15GCSXAV 42 15GCSX A B V 48 413 15GCSX A B V 60 Parts Arrangement PureAir Air Purification System Optional Gas Valve Evaporator Coil 1 Assembled gas package unit 1 Vent hood assembly with screen and screws As soon as the unit is received it should be inspected for possible damage during transit If you find any damage immediately contact the last carrier These installation instructions are intended as a general guide only for use by an experienced qualified contractor The 15GCSX units are single package air conditioners with two stage gas heat designed for outdoor installation on a rooftop or a slab The unit must be sized based on heat loss and heat gain calculations made according to the methods of the Air Conditioning Contractors of America ACCA The units are shipped assemb
10. 7 Liquid Line Subcooling Liquid Subcooling Values 2 Deg F ARI 82 F OD minus 80 F IDDB Unit Model No 167 F IDWB 5969xs Verify system performance using table 8 as a general guide Table 8 should not be used for charging unit Minor variations in these pressures may be expected due to differences in installations Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system Used carefully this table could serve as a useful service guide Data is based on 80 F dry bulb 67 F wet bulb return air Allow unit operation to stabilize before taking pressure readings Page 16 Table 8 Normal Operating Pressures 80 F db 67 F wb RETURN AIR 4 u TS Heating Start Up Pre Start Check List 1 Check the type of gas being supplied Be sure it is the same as listed on the unit nameplate 2 Make sure the vent hood has been properly installed FOR YOUR SAFETY READ BEFORE LIGHTING BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell around the base of the unit because some gas is heavier than air and will settle down low WARNING Electric shock hazard Can cause injury or death Do not use this unit if any part has been under water Immediately call a qualified service technician to inspect the unit and to replace any part of the con trol system and any gas contro
11. Cements and glues Anti static fabric softeners used in clothes dryers Masonry acid washing materials Chlorinated laundry products Hydrochloric acid Rigging amp Setting Unit Exercise care when moving the unit Do not remove any packaging until the unit is near the place of installation An optional lifting lug kit 92M51 may be purchased separately for use in rigging the unit for lifting The spreader lengths must exceed the width across the top of the unit Recommended spreader lengths for use with 2 2 1 2 and 3 ton units 44 for use with 3 1 2 4 and 5 ton units 54 CAUTION Before lifting a unit make sure that the weight is dis tributed equally the cables so that it will lift evenly Accessory Lift Kit Lifting Bracket Sheet Metal Figure 1 Units may also be moved or lifted with a forklift while still in the factory supplied packaging NOTE Length of forks must be a minimum of 42 inches Clearances All units require certain clearances for proper operation and service Refer to figure 2 for the clearances required for combustible construction servicing and proper unit operation NOTE Do not permit overhanging structures or shrubs to obstruct condenser air discharge outlet or vent outlet Service Clearances Inches Millimeters 48 1219 NOTE Top Clearance 36 in 914 mm NOTE Entire perimeter of unit base requires support when elevated above mounting surface Fig
12. INSTALLATION LENNOX 4 INSTRUCTIONS 15GCSX SERIES UNITS 2010 Lennox Industries Inc Dallas Texas USA 506701 01 38152A086 Litho U S A 06 11 Supersedes 03 11 Table of Contents Unit Dimensions 2 Parts Arrangement 3 Shipping amp Packing 3 General 22 2 ccce wae CR 3 Safety Information 3 Location Selection 4 Rigging amp Setting 5 Clearances 5 Installing Vent Hood 6 Existing Common Vent Systems 6 Condensate Drain 7 RETAIN THESE INSTRUCTIONS UGS RENTES EPUM MO 7 FOR FUTURE REFERENCE Supply amp Return Connections 7 Compressors 8 Gas Supply and 0 8 A WARNING Electrical seinen Gers Eye pes 10 gt Blower Control 12 Improper installation adjustment alteration service or Cooling Start Up n 14 maintenance can cause personal injury loss of life or Heating Start Up 15 damage to property Unit Controls llenar dere m gs 17 Installation and service must be performed
13. REW under cap OUTLET MANIFOLD PRESSURE TAP LOW FIRE ADJUSTING SCRE under cap INLET PRESSURE TAP GAS VALVE SHOWN IN OFF POSITION Figure 13 Page 17 To Shut Down 1 Turn off electric power to unit 2 Turn the gas valve knob to the OFF position Post Start up Check List Gas After the control circuit has been energized and the heating section is operating make the following checks 1 Use soap solution to check for gas leaks in the unit piping as well as the supply piping 2 Check for correct manifold gas pressures See Manifold Gas Pressure Adjustment 3 Check the supply gas pressure It must be within the limits shown on rating nameplate Supply pressure should be checked with all gas appliances in the building at full fire At no time should the supply gas pressure exceed 10 5 inches w c nor drop below 5 0 inches w c for natural gas units For propane gas supply gas pressure should not drop below 11 inches w c gas pressure is outside these limits contact your gas supplier for corrective action 4 Adjust temperature rise to the range specified on the rating plate Checking and Adjusting Gas Input NOTE Units must be converted for use with LP propane gas Conversion kit is ordered separately Conversion must be performed by an approved licensed pipe fitter or technician The minimum permissible gas supply pressure is 5 0 inches W C for natural gas or 1
14. T o o PCB635 1A YI Gs 02 I D3e TI 05 yi o o Figure 12 Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electrical power to unit OFF at disconnect switch es Unit may have multiple power supplies 15GCSX units are equipped with a variable speed motor that is capable of maintaining a specified CFM throughout the external static range A particular CFM can be obtained by positioning jumpers COOL HEAT and ADJUST on the blower control The HEAT and COOL labeled A B C and D Each of the numbers corresponds with an air volume CFM setting The ADJUST jumper is labeled Test and Norm The and pin settings are used to add or subtract a percentage of the CFM selected The Test jumper is used to operate the motor in the test mode See figure 12 Factory settings for the blower speed jumpers are given in the wiring diagram in figure 11 Figure 12 shows the blower control Use tables 4 5 and 6 to determine the correct air volume for operation in heat and cool mode The CFM LED located on the blower control flashes one time per 100 cfm to indicate selected blower speed For example if the unit is operating at 1000 LED will flash 10 times If the CFM is 1150 CFM LED will flash 11 full times plus one fast or half flash At times the light may appear to flicker or glow This takes place wh
15. The monitor is a monitoring device only and cannot con trol or shut down other devices LSOM LED Functions Power LED green Voltage within the range of 19 28VAC is present at the system monitor power connection Alert LED yellow Communicates an abnormal system condition through a unique flash code The alert LED flashes a number of times consecutively then pauses then repeats the process This consecutive flashing corresponds with a particular abnormal condition Trip LED red Indicates a demand signal from the thermostat but detects no current to the compressor Flash code number Corresponds to a number of LED flashes followed by a pause and then repeated Trip amp Alert LEDs flashing simultaneously Indicates that the control circuit voltage is too low for operation The monitor has an automatic reset function which is based on the number of normal run cycles See table 9 LSOM codes are given in table 10 Table 9 Comfort Alert Code Auto Reset Function Normal Run Cycles Required Code Number for Automatic Reset 30 5 6 7 9 1 Condenser Fan Clearances The top of the condenser fan should be 1 1 2 inches from the bottom of the top grille This dimension should be checked and the fan should be adjusted accordingly any time servicing of the outdoor fan system is required Page 21 Table 10 System Operation Monitor LED Troubleshooting Codes Status LED Condition Green Power LED ON
16. ayed for 5 seconds after the compressor starts The blower continues to operate for 90 seconds after the compressor is de energized NOTE With the proper thermostat and subbase continuous blower operation is possible by closing the R to G circuit Cooling blower delay is also functional in this mode System Performance This self contained system has been factory charged for optimal performance If performance is questionable use the following procedure to check the system Ensure that unit has been installed per these instructions and that line voltage and air flow are both correct Check subcooling values by measuring pressure at the liquid line high side service port Measure liquid line temperature within 2 inches of the service port connection to its main tube If subcooling measured deviates from values in table 7 by more than 2 degrees F check internal seals service panels and duct system for air leaks as well as restrictions Also check blower speed settings Make all necessary adjustments If unit performance remains questionable recover unit refrigerant charge evacuate to 500 Microns and weigh in refrigerant to match value given on unit nameplate It is critical that exact required charge is used Failure to follow this instruction will compromise system performance If unit performance is still questionable check for blocked coil or circuits malfunctioning metering devices or other system component problems Table
17. by a 2 licensed professional installer or equivalent Planned Service O O 21 service agency or the gas supplier Repair Parts amp Accessories 22 WARNING FIRE EXPLOSION HAZARD Failure to follow safety warnings ex actly could result in serious injury death property damage LISTED Do not store or use gasoline or other WHAT TO DO IF YOU SMELL GAS flammable vapors and liquids in the Do not try to light any appliance vicinity of this or any other ap Do not touch any electrical switch do not pliance use any phone in your building Leave the building immediately Installation and service must be Immediately call your gas supplier from a performed by a qualified installer neighbor s phone Follow the gas supplier s service agency or the gas supplier instructions If you cannot reach your gas supplier call the fire department 506701 01 06 11 15GCSX Unit Dimensions inches mm E F AA 2 1 2 64 42 2 1 2 64 DOWNFLOW Dee AIR OPENING E BB DOWNFLOW RETURN AIR C OPENING Ce TOP VIEW DD B FRONT VIEW GAS PIPING INLET ELECTRICAL INLET 2 1 2 64 Corner Weights pel Model y Number 15GCSXAV 24 74 94 125 97 15 5 15GCSXAV 36 84 101 126 105 16 177 184 144 151 20 20 15GCSX A B V
18. ck all piping connections factory and field for gas leaks Use soap solution or other preferred means NOTE In case of emergency shutdown shut off main manual gas valve and disconnect main power to unit These devices should be properly labeled by installer The heating value of the gas may differ with locality The value should be checked with the local gas utility NOTE There may be a local gas utility requirement specifying a minimum diameter for gas piping All units require a 1 2 inch pipe connection at the gas valve Gas piping recommendations ACAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction black iron pipe shall be installed at the gas valve and must extend outside the cabinet The flexible connector can then be added between the black iron pipe and the gas supply line 1 A drip leg and a ground joint union must be installed in the gas piping A ground joint union is recommended by the manifold valve 2 When required by local codes a manual shut off valve may have to be installed outside of the unit 3 Use pipe thread sealing compound resistant to propane gas sparingly on male threads 4 The gas supply should be a separate line and installed in accordance with all safety codes After the gas connections have been completed open the main shut off valve admitting normal gas pressure to the mains Check all joints for leaks with soap solution or other
19. ctions Compressor start winding is damaged Yellow Alert Flash Code 7 Open Run Circuit Current only in start circuit Open circuit in compressor start wiring or connections Compressor start winding is damaged Yellow Alert Flash Code 9 Low Voltage Control circuit lt 17VAC Page 22 Control circuit transformer is overloaded Low line voltage contact utility table continued on next page System Operation Monitor LED Troubleshooting Codes Status LED Condition Status LED Description Status LED Troubleshooting Information Flash code number corresponds to a number of LED flashes followed by a pause and then repeated Reset ALERT flash code by removing 24VAC power from monitor last code will display for 1 minute after monitor is powered on NOTE Code 8 is not used Maintenance The GCSX15 unit should be inspected annually by a qualified service technician to ensure proper operation Filters Not supplied Inspect once a month Replace disposable or clean permanent type as necessary DO NOT replace permanent type with disposable Motors Indoor outdoor fan and vent motors are permanently lubricated and require no further lubrication Motors should be cleaned yearly to prevent the accumulation of dust and dirt on the windings or motor exterior Coil Dirt and debris should not be allowed to accumulate on the coil surfaces or other parts in the air conditioning circuit
20. e an external static pressure within the allowable range Refer to the unit rating plate Lennox does not recommend the use of 15GCSX units as a construction heater during any phase of construction Very low return air temperatures harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit 15GCSX units may be used for heating of buildings or structures under construction if the following conditions are met e The vent hood must be installed per these installation instructions e A room thermostat must control the furnace The use of fixed jumpers that will provide continuous heating is not allowed e The return air duct must be provided and sealed to the furnace e Return air temperature range between 60 F 16 C and 80 F 27 C must be maintained e Air filters must be installed in the system and must be maintained during construction e Air filters must be replaced upon construction completion e The input rate and temperature rise must be set per the unit rating plate e One hundred percent 10096 outdoor air must be provided for combustion air requirements during construction Installation of this unit in its intended outdoor location will accomplish this e The heat exchanger components duct system air filters and evaporator coil must be thoroughly cleaned following final construction clean up e The unit operating conditions including ignition input rate temperature ris
21. e and venting must be verified according to these installation instructions NOTE The Commonwealth of Massachusetts stipulates these additional requirements e Gas furnaces shall be installed by a licensed plumber or gas fitter only e The gas cock must be T handle type e When flexible connectors are used the maximum length shall not exceed 36 Location Selection Use the following guidelines to select a suitable location for these units 1 Unit is designed for outdoor installation only Unit must be installed so all electrical components are protected from water 2 Condenser coils must have an unlimited supply of air 3 For ground level installation use a level pre fabricated pad or use a level concrete slab with a minimum thickness of 4 inches The length and width should be at least 6 inches greater than the unit base Do not tie the slab to the building foundation Maintain level within a tolerance of 1 4 inch maximum across the entire length or width of the unit V Page 4 5 Do not locate the unit where the combustion air supply will be exposed to any corrosive substance including the following Permanent wave solutions Chlorinated waxes or cleaners Chlorine based swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents e g perchloroethylene Printing inks paint removers varnishes etc
22. ed as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation If components are to be added to a unit to meet local codes they are to be installed at the dealer s and or customer s expense These units are design listed by UL in both the United States and Canada as follows e For use as a forced air furnace with cooling e For outdoor installation only e For installation on combustible material For use with natural gas or L P propane gas only Use of L P propane gas requires installation of an L P conversion kit which must be ordered separately These units are not suitable for use with conventional venting systems The following safety requirements must also be met when the 15GCSX units are installed 1 Use only with the type of fuel approved for use with this appliance Refer to the unit rating plate 2 Position locate and install the 15GCSX unit only as outlined in these instructions 3 Provide adequate clearance around the vent hood as specified in these instructions 4 Do not use an open flame to check for gas leaks Use commercially available soap solution which has been designed specifically to check for gas leaks Refer to the Gas Supply and Piping section 5 Check the unit operation after start up to make sure that the 15GCSX is operating within the intended temperature rise range The duct system must be designed to provid
23. en the control is communicating with the motor between cycles This is normal operation Read through the jumper settings section before adjusting the jumper to obtain the appropriate blower speed To change jumper positions gently pull the jumper off the pins and place it on the desired set of pins The following section outlines the different jumper selections available and conditions associated with each one Refer to figure 12 After the CFM for each application has been determined the jumper settings must be adjusted to reflect those given in tables 4 5 and 6 From the tables determine which row most closely matches the desired CFM Once a specific row has been chosen NORMAL or CFM volumes from other rows cannot be used Below are descriptions of the jumper selections The variable speed motor slowly ramps up to and down from the selected air flow during both cooling and heating demand This minimizes noise and eliminates the initial blast of air when the blower is initially energized ADJUST The ADJUST pins allow the motor to run at normal speed approximately 15 percent higher or approximately 15 percent lower than normal speed Tables 4 5 and 6 give three rows NORMAL and with their respective CFM volumes Notice that the normal adjustment setting for heat speed position C in table 4 is 900 The adjustment setting for that position is 1035 CFM and for the adjustment setting is 765 CFM After the ad
24. harge flue products Planned Service You should expect a service technician to check the following items during an annual inspection Power to the unit must be shut off for the service technician s safety Fresh air grilles and louvers Must be open and unobstructed to provide combustion air Burners must be inspected for rust dirt or signs of water Exhaust pipe must be inspected for signs of water damaged Rust or disconnected joints Unit appearance must be inspected for rust dirt signs of water burnt or damaged wires or components A good coat of auto wax can extend the appearance Blower access door must be properly in place Return air duct must be properly attached and provide an air seal to the unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications Problems detected during the inspection may make it necessary to temporarily shut down the furnace until the items can be repaired or replaced Pay attention to your unit Situations can arise between annual furnace inspections that may result in unsafe operation For instance items innocently stored next to the unit may obstruct the combustion air supply This could cause incomplete combustion and the production of carbon monoxide gas Page 23 Repair Parts amp Accessories
25. iliary limit switches the roll out switch the pressure switch and the flame sensor LED codes and flash rates are given on page 17 The ignition control is shown in figure 14 Page 19 Ignition Control CONNECTOR LIMIT SWITCH OUTPUT COMMON WITH W TERMINAL GAS VALVE 24 VAC COMMON CHASSIS GROUND LOW GAS VALVE OUTPUT LIMIT SWITCH INPUT PRESSURE SWITCH OUTPUT LOW PRESSURE SWITCH INPUT HIGH GAS VALVE OUTPUT HIGH PRESSURE SWITCH INPUT OPTIONAL FLAME SENSE INPUT CONNECTOR P2 R 24VAC TO THERMOSTAT W THERMOSTAT CALL FOR HEAT W2 THERMOSTAT 2ND STAGE CALL FOR HEAT G THERMOSTAT CALL FOR CONTINUOUS FAN Y THERMOSTAT CALL FOR COOLING QUICK CONNECT TERMINALS INDUCER LOW DRAFT INDUCER MOTOR OUTPUT INDUCER HIGH 2ND STAGE DRAFT INDUCER MOTOR OUTPUT 230 VAC LINE INPUT 230 VAC LINE INPUT 24 VAC SYSTEM COMMON GROUND CONTINUOUS 24VAC FROM TRANSFORMER CIRCULATING AIR BLOWER MOTOR TIMINGS PRE PURGE IGNITION TRIAL INTER PURGE HEAT BLOWER ON DELAY HEAT BLOWER OFF DELAY POST PURGE COOL FAN OFF DELAY SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS Figure 14 Ignition Control LED Codes The ignition control LED flashes codes which indicate normal or abnormal operations Slow Flash Normal operation no call for heat One flash per second Fast Flash Normal operation call for heat Two flashes per second Steady Off Internal failure o
26. justment setting has been determined choose the remaining speed settings from those offered in the table in that row The TEST pin is available to bypass the blower control and run the motor at approximately 70 percent to make sure that the motor is operational This is used mainly in troubleshooting The G terminal must be energized for the motor to run Page 14 COOL The COOL jumper is used to determine the CFM during cooling operation This jumper selection is activated for cooling when Y1 is energized The blower motor runs at 80 percent of the selected air flow for the first 7 1 2 minutes of each cooling demand This feature allows for greater humidity removal and saves energy In the cooling mode the blower control delays blower operation for 5 seconds after the compressor starts The blower continues to operate for 90 seconds after the compressor is de energized HEAT The HEAT jumper is used to determine CFM during gas heat operation only These jumper selections are activated only when W1 is energized In the heating mode the blower control delays blower operation for 30 seconds after the flame is established The blower continues to operate for 90 seconds after the gas valve is de energized CONTINUOUS FAN When the thermostat is set for Continuous Fan operation and there is no demand for heating or cooling the blower control will provide 50 percent of the COOL CFM selected NOTE With the proper thermosta
27. l which has been under water Danger of explosion and fire cause injury or product or property damage You must follow these instructions exactly Danger of explosion Can cause injury or product or property damage If overheating occurs or if gas supply fails to shut off shut off the manual gas valve to the appliance before shutting off electrical supply Air Temperature Entering Outdoor Coil F 90 100 105 148 49 150 161 43 Zi 145 Electric shock hazard Can cause injury or death Before attempting to perform any 7 service or maintenance turn the electrical power to unit OFF at disconnect switch es Unit may have multiple power supplies Use only your hand to turn the gas valve knob Never use tools If the knob will not move by hand do not try to repair the gas valve Call a qualified service technician Force or attempted repair may result in a fire or explosion This furnace is equipped with a direct ignition control Do not attempt to manually light the burners 1 Turn off electrical power to unit 2 Set thermostat to lowest setting 3 Turn the gas valve knob to the ON position Refer to figure 13 4 Turn on electrical power to unit 5 Set room thermostat to desired temperature If thermostat setpoint temperature is above room temperature after the pre purge time expires main burners will light Honeywell VR8205 Series Gas Valve HIGH FIRE ADJUSTING SC
28. led All piping refrigerant charge and electrical wiring are factory installed and Ignition Control Board Condenser Coil condensate drain and duct connections at the point of installation In addition the heating vent hood must be installed before the unit is placed into operation Safety Information A CAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment A IMPORTANT This unit is charged with HFC 410A refrigerant Op erating pressures for units charged with HFC 410A are higher than pressures in units charged with HCFC 22 All service equipment MUST be rated for use with HFC 410A refrigerant Page 3 WARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool dust Breathing this may cause lung cancer Fiberglass wool is known to the State of California to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 These units must be installed in accordance with all applicable national and local safety codes These instructions are intend
29. lls or on overhangs under eaves The vent outlet should not discharge flue products on a sidewalk patio or other walkway where the condensate could cause the surface to become slippery Do not install the unit so that the products of combustion will be allowed to accumulate within a confined space and recirculate Minimum Clearances to Combustible Materials Above and Below Vent Hood Minimum Clearance Above Vent Hood Distance from Top of Vent Hood to Top of Unit m id Minimum Clearance Below Vent Hood Distance from Bottom of Vent Hood to Base of Unit crest Figure 3 Vent Hood Installation The vent hood screen and screws are shipped inside the unit in the plastic bag which contains the installation instructions 1 Insert the vent screen into the vent tube Once inserted the screen should be flush with the end of the tube as shown in figure 4 Vent Hood Installation Front View Top View I Vent Tube yore t Screws should pass through sides of screen to hold screen in place Vent Tube Vent Hood Screen is pre formed Slotted side of vent hood faces condenser coil Figure 4 2 Position the vent hood over the vent tube so that the slotted side of the hood faces the condenser coil Use the four sheet metal screws provided to secure the vent hood to the vent tube The screws should pass through the sides of the screen in o
30. n air inducer until the demand is satisfied If a first stage heat demand continues after the second stage heat demand has been satisfied the ignition control immediately de energizes the second stage gas valve The combustion air inducer is held in high speed operation for an additional 1 second after the second stage gas valve is de energized First stage heat operation first stage gas valve and low speed combustion air inducer continues until heating demand is satisfied When the heating demand is satisfied the control immediately de energizes the gas valve The combustion air inducer remains energized for a 30 second post purge period The circulating air blower operates for 90 seconds after the gas valve is de energized Blower Delay Heating In the heating mode the circulating air blower operation is delayed for 30 seconds after the flame is established The blower continues to operate for 90 seconds after the gas valve is de energized NOTE With the proper thermostat and subbase continuous blower operation is possible by closing the R to G circuit Unit Controls Blower Control A54 15GCSX units are equipped with a variable speed motor which is controlled by a blower control Blower control settings and operation are given on page 12 Ignition Control A3 The 15GCSX unit includes an ignition control which controls the combustion air inducer gas valve and spark electrode It receives signals from the main and aux
31. not carried by drain line connection Seal around drain connection with suitable material to prevent air leakage into return air system Drain piping should not be smaller than drain connection at coil An open vent in drain line will some times be required due to line length friction and static pressure Drains should be constructed in a manner to facilitate future cleaning NOTE The condensate drain line MUST be trapped to provide proper drainage CAUTION Condensate line connection must be hand tight ened Do not use tools Typical Condensate Drain Minimum Pitch 1 in 25 mm per 10 3 m of line MOUNTING Trap must be deep enough to offset maximum FRAME static difference Generally 3 inches minimum Figure 5 Filters are not factory supplied with the unit however optional internally installed filter kits are available Filter kit 92 54 is used with 2 2 1 2 and 3 ton units Filter kit 92M55 is used with 3 1 2 4 and 5 ton units The filter kits accommodate the use of 1 2 or 4 filters If the optional filter kit is not used a filter must be field installed Filters must always be installed ahead of evaporator coil and must be kept clean or replaced Dirty filters will reduce the airflow of the unit Filter sizes are shown in table 1 Page 8 Table 1 Unit Filter Size Unit Modei Fiter Size Fiter Quantity 24 30 36 20 in X 25 in 42 48 60 16 in X 25 in The Healthy Climate P
32. of the gas and length of run In the United States the current National Fuel Gas Code Z223 1 should be followed in all cases unless superseded by local codes or gas company requirements Refer to tables 2 and 3 In Canada refer to the current CSA B 149 installation codes Table 2 Gas Heat Application Data Unit Input Rating Output Rating Gas Capacity Heating Size Btu Btu FT HR Based on 1075 Btu per cubic foot of natural gas Before connecting piping check with gas company or authorities having jurisdiction for local codes or requirements When installing gas supply piping length of run from gas meter must be considered in determining pipe size for 0 5 inch w c maximum pressure drop Do not use supply pipe smaller than unit gas connection For natural gas unit supply pressure at the unit gas connection must be a minimum of 5 inches w c and a maximum of 10 5 w c For LP propane gas units supply pressure at the unit gas connection must be a minimum of 11 inches w c and a maximum of 13 0 inches w c Table 3 Gas T Capacity FT HR Nominal Iron Pipe Size inches Length in Feet The gas supply piping should be routed through the grommet on the side of the unit Refer to figure 7 Gas Line Entry 0 Thermostat __ 9 9 Line Voltage Entry Figure 7 When making piping connections a drip leg should be installed on vertical runs to ser
33. onnect switch to control box of unit and connect as shown in the wiring diagram located on the inside of the control access panel Unit must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electric Code ANSI NFPA No 70 latest edition or CSA C22 2 Part 1 latest edition Power supply to the unit must be N E C Class 1 and must comply with all applicable codes A fused disconnect Switch should be field provided for the unit The switch must be separate from all other circuits If any of the wire supplied with the unit must be replaced replacement wire must be of the type shown on the wiring diagram Electrical wiring must be sized to carry minimum circuit ampacity marked on the unit USE COPPER CONDUCTORS ONLY Each unit must be wired with a separate branch circuit and be properly fused CAUTION When connecting electrical power and control wir ing to the unit waterproof type connectors MUST be used so that water or moisture cannot be drawn into the unit during normal operation See figure 10 for field connection of line voltage wiring See figure 11 for typical wiring diagram 208 230 Line Voltage Wiring contactor fused disconnect switch furnished by installer ground lug NOTE If 208 voltage is supplied transformer connections must be made Figure 10 Thermostat The room thermostat should be located on an inside wall where it will not be s
34. per Setting cfm L s 1380 650 1200 565 1020 480 1000 470 850 400 Jumper Speed Positions cfm L s cfm L s cfm L s cfm L s 920 435 1265 575 1555 735 1265 595 800 380 1100 520 1350 635 1100 520 680 320 935 440 1150 540 935 440 Speed B cfm L s L s L s L s cfm L s 1150 545 1035 490 690 325 575 270 460 215 CONTINUOUS Speed 635 300 1000 470 900 425 600 285 500 235 400 190 850 400 765 360 510 240 425 200 350 165 550 260 470 220 Table 6 15GCSXAV 42 15GCSX A B V 48 15GCSX A B V 60 Blower Performance 0 through 0 80 in w g 0 through 200 Pa External Static Pressure Range Jumper Speed Positions ADJUST COOL Speed Jumper Setting cfm L s HEAT Speed cfm L s cfm L s cfm L s L s L s L s L s L s cfm L s L s CONTINUOUS FAN Speed B D A B D cfm L s 2070 975 NORM 1800 850 1530 720 1840 870 1610 760 1380 650 2015 950 1900 895 1555 735 1325 625 1035 490 920 435 805 380 1600 755 1400 660 1200 565 1750 825 1650 780 1350 635 1150 545 900 425 800 380 700 330 1360 640 1190 560 1020 480 1490 700 1405 660 1150 540 980 460 765 360 680 320 595 280 690 325 600 285 510 240 15 Cooling Start Up The cooling section is a complete factory package utili
35. r no power Micro controller failure self check Steady On Internal control failure Micro controller failure self check Code 2 System lockout Failed to detect or sustain flame Two flashes in 1 second with a 1 second pause Code 3 Pressure switch open with inducer on or closed with inducer off Three flashes in 1 1 2 seconds with a 1 second pause Code 4 High limit or rollout switch open Four flashes in 2 seconds with a 1 second pause Code 5 Flame sensed while gas valve de energized Five flashes in 2 1 2 seconds with a 1 second pause Code 6 Roll out switch is open Six flashes in three seconds with a one second pause Limit Control This control is located inside the heating compartment and is designed to open at abnormally high air temperatures It resets automatically The limit switch operates when a high temperature condition caused by inadequate blower supply airflow occurs The main gas valve is closed The circulating air blower will continue to operate until the blower off delay period has elapsed Pressure Switch If the combustion air inducer motor should fail or if the vent system is blocked the pressure switch prevents the gas valve from being energized Spark Electrode and Flame Sensor Rod The spark electrode and flame sensor rod are part of the burner assembly The spark electrode is typically located on the far left burner The flame sensor rod is typically located on the far
36. rder to hold the screen in place The vent hood must be installed prior to unit start up Existing Common Vent Systems If this packaged outdoor unit is replacing an existing indoor furnace that is being removed from a venting system commonly run with a water heater or other gas appliance the venting system is likely to be too large to properly vent the remaining attached appliance s Conduct the following test while the water heater is operating and the other gas appliances which are not operating remain connected to the common venting system 1 Seal any unused openings in the common venting system 2 Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Follow the lighting instructions Turn on the appliance that is being inspected Adjust the thermostat so that the appliance operates continuously 5 After the burner has operated for 5 minute
37. s test for leaks of flue gases at the draft hood relief opening Use the flame of a match or candle or smoke from a cigarette cigar or pipe 6 After determining that each appliance connected to the common venting system is venting properly step 3 return all doors windows exhaust fans fireplace dampers and any other gas burning appliances to their previous mode of operation 7 f a venting problem is found during any of the preceding tests the common venting system must be modified to correct the problem If necessary you must resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in Appendix G These are in the current standards of the National Fuel Gas Code ANSI Z223 1 NFPA 54 in the USA and the Page 6 appropriate Category 1 Natural Gas and Propane appliances venting sizing tables in the current standards of the CSA B149 Natural Gas and Propane Installation Codes in Canada Page 7 Condensate Drain The 15GCSxX unit is equipped with a 3 4 inch coupling for condensate line connection Plumbing must conform to local codes Use a sealing compound on male pipe threads The drain line must be properly trapped and routed to a suitable drain See figure 5 for proper drain arrangement The drain line must pitch to an open drain or pump a minimum of 1 inch per 10 feet to prevent clogging of the line The drain line must be supported so that weight of drain line is
38. t Thermostat is malfunctioning Yellow Alert Flash Code 2 System Pressure Trip Discharge or suction pressure out of limits or compressor overloaded High head pressure Condenser coil poor air circulation dirty blocked damaged Condenser fan is not running Return air duct has substantial leakage If low pressure switch is present see Flash Code 1 info Yellow Alert Flash Code 3 Short Cycling Compres sor is running only briefly Thermostat demand signal is intermittent Time delay relay or control board is defective If high pressure switch is present see Flash Code 2 info If low pressure switch is present see Flash Code 1 info Yellow Alert Flash Code 4 Locked Rotor Run capacitor has failed Low line voltage contact utility Excessive liquid refrigerant in the compressor Compressor bearings are seized Yellow Alert Flash Code 5 Open Circuit Outdoor unit power disconnect is open Unit circuit breaker or fuse s is open Unit contactor has failed to close High pressure switch is open and requires manual reset Open circuit in compressor supply wiring or connections Unusually long compressor protector reset time due to extreme ambient temperature Compressor windings are damaged Yellow Alert Flash Code 6 Open Start Circuit Current only in run circuit Run capacitor has failed Open circuit in compressor start wiring or conne
39. t and subbase continuous blower operation is possible by closing the R to G circuit Cooling blower delay is also functional in this mode DEHUMIDIFICATION The blower control includes an HUM terminal which provides for connection of a humidistat The JV1 resistor on the blower control must be cut to activate the HUM terminal The humidistat must be wired to open on humidity rise When the dehumidification circuit is used the variable speed motor will reduce the selected air flow rate by 25 percent when humidity levels are high An LED D1 lights when the blower is operating in the dehumidification mode Table 4 15GCSXAV 24 15GCSXAV 30 Blower Performance 0 through 0 80 in w g 0 through 200 Pa External Static Pressure Range ADJUST COOL Speed Jumper Setting cfm L s cfm L s cfm L s 690 325 1035 490 NORM 1000 470 600 285 900 425 510 240 765 360 Jumper Speed Positions cfm L s cfm L s cfm L s 1265 595 1150 545 1035 490 1100 520 1000 470 900 425 935 440 850 400 765 360 HEAT Speed CONTINUOUS FAN Speed cfm L s cfm L s 345 165 520 245 cfm L s cfm L s 575 270 460 215 920 435 800 380 680 320 500 235 400 190 425 200 340 160 300 140 450 210 300 140 385 180 Table 5 15GCSXAV 36 Blower Performance 0 through 0 80 in w g 0 through 200 Pa External Static Pressure Range COOL Speed B L s 1150 545 ADJUST Jum
40. tion BTU HR Cubic Feet Per Revolution X 3600 X Heating Value INPUT No Seconds Per Revolution The heating value of your gas can be obtained from your local utility For LP Propane Gas If a gas meter is available check the input rate as described in the section above Heating value of propane gas is available from propane supplier Otherwise the only check for the output rate is to properly adjust the manifold pressure using a manometer Typical manifold setpoint for installations at altitudes from 0 to 4500 feet above sea level is 10 0 inches W C High Altitude Information Ratings shown on the rating plate for elevations up to 4 500 feet For elevations above 4 500 feet ratings should be reduced at a rate of four percent for each 1 000 feet above sea level See National Fuel Gas Code Z223 1 latest edition or the requirements of the CSA B149 installation codes Heating Sequence of Operation When the thermostat calls for heating W1 is energized NOTE The ignition control ignores a call for second stage heat until first stage heat has been established The ignition control checks high temperature limit and roll out switches to make sure they are closed The control then verifies that the pressure switch is open If the pressure switch is closed the control will flash code 3 on the LED and will wait indefinitely for the pressure switch to open If the pressure switch is open the control proceeds to the 15 second pre purge
41. to cover the side openings The upper return air opening cover must be removed when the PureAir air purification system PCO20 28 is being used In PCO applications both upper and lower return air openings must be covered by the return air plenum to ensure proper PCO operation The upper return air opening is not required in horizontal applications when the PCO is not used Removing Supply and Return Air Opening Covers 4 1 Remove screw and lift 2 Slide cover to free back pin Figure 6 Page 9 Compressors Units are shipped with the compressor mountings factory adjusted and ready for operation CAUTION Do not loosen compressor mounting bolts Gas Supply and Piping Check the unit rating plate to confirm whether unit is equipped for use with natural gas or LP propane If conversion is required use the approved conversion kit NOTE Units are shipped equipped for natural gas but can be converted to LP propane with a conversion kit Conversion must be performed by an approved licensed pipe fitter or technician All LP propane gas equipment must conform to the safety standards of the National Fire Protection Association Complete information regarding tank sizing for vaporization recommended regulator settings and pipe sizing is available from most regulator manufacturers and LP propane gas suppliers Proper sizing of gas piping depends on the cubic feet per hour of gas flow required specific gravity
42. ubject to drafts sun exposure or heat from electrical fixtures appliances Follow manufacturer s instructions enclosed with thermostat for general installation procedure Color coded insulated wires 18 AWG should be used to connect thermostat to unit Four wires are required for cooling Heat Anticipator Setting It is important that the anticipator setpoint be correct Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space Reducing the value below the correct setpoint will give shorter ON cycles and may result in the lowering of the temperature within the conditioned space Heat Anticipator Setting 0 70 AMP Page 12 c00 8808v 3002 1V201 ONY TVNOILYN 631191581 01311 39Y110A 3NI1 2 NI 03080089 38 1508 0350 3D LINN Quv2vH WOOHS 21813313 3818 2 61 NIN AINO HOLIAS ONTNYYA 801204802 834402 350 imr xm 0351 38 150 125 and 3UI 3441 ONY 3715 3HVS AHL d032Y d3U 51 FBIM HOL IAS YOLOVENOD YOLOH TWNESTHO JHL 30 ANY 31 39155399 30553540 33MO18 5300081 310N 5 9 YOLOW NYJ 5830902 21145 Br 1101109 HOLIMS NIVN 1gvH 03345 33S 09 1 A0 2 80 212 Quvog mo U3ngO3SNYUl YOLIYLNOD 0350 31 805534402 024 1 14 TOYLNOD NOILINSI 3503 3 LSON9Y10 P ra Ly
43. ure 2 In the U S units may be installed on combustible flooring made from wood or class A B or C roof covering material In Canada units may be installed on combustible flooring The products of combustion are discharged through a screened vent outlet in the front mullion Install the unit so that the products of combustion will not damage the outer building structure The vent outlet must be at least 4 feet below 4 feet horizontally from and 1 foot above any door window or gravity air inlet into the building In addition install the unit so that the vent outlet is at least 3 feet above any forced air inlet located within 10 feet Clearances to the vent outlet must also be consistent with the requirements of the current National Fuel Gas Code 2223 1 and or the standards of the current CSA 149 codes Figure 3 shows the minimum clearances to combustibles required above and below the vent hood The minimum clearance in front of the vent hood is 24 inches Install the unit so that snow accumulation will not restrict the flow of the flue products Allow a required minimum horizontal clearance of 4 feet from electric meters gas meters regulators and relief equipment In addition to the above requirements ensure that unwanted ice caused by condensate is not allowed to accumulate around the unit Do not locate the unit on the side of the building where the prevailing winter winds could trap moisture causing it to Page 5 freeze on the wa
44. ureAir air purification system PCO20 28 may be used with 15GCSX units installed in horizontal air discharge applications only Installation hardware kit 0629 is required to install the PCO20 28 X8787 in the packaged unit The PCO20 28 is designed for universal voltage and is ready to operate at 208 230V When used the PCO should be installed before the unit is set in place and before the duct connections are made Supply amp Return Duct Connections The duct system should be designed and sized according to the methods in Manual Q of the Air Conditioning Contractors of America ACCA A closed return duct system shall be used This shall not preclude use of economizers or outdoor fresh air intake It is recommended that supply and return duct connections at the unit be made with flexible joints The supply and return air duct systems should be designed for the CFM and static requirements of the job They should NOT be sized by simply matching the dimensions of the duct connections on the unit CAUTION When fastening duct system to side duct flanges on unit insert screws through duct flanges only Do not insert screws through casing Outdoor duct must be insulated and waterproofed The 15GCSX unit is shipped ready for horizontal air discharge side duct connections If bottom air discharge is desired the covers must be removed from the supply and return air openings on the bottom of the unit and re installed
45. ve as a trap for sediment or condensate A 1 8 inch tap accessible for test gauge connection must be provided in field piping upstream from gas supply connection to unit Install a ground joint union between gas control manifold and the manual main shut off valve See figure 8 Compounds used on threaded joints of gas piping shall be resistant to the action of propane LP gases Page 10 Drip Leg Installation field provided 1 8 in pressure tap ground joint union manual main shut off valve gas piping support Figure 8 Pressure Test Gas Piping When pressure testing gas lines the gas valve must be disconnected and isolated Gas valve can be damaged if subjected to more than 0 5 psig 14 inch w c See figure 9 If test pressure is equal to or less than 0 5 psig 14 inch w c shutoff the manual main shut off valve before pressure testing to isolate unit from gas supply system Isolate Gas Valve To Pressure Test Manual Main Shut off Valve Will Not Hold Test Pressures in Excess of 0 5 PSIG 14 in w c gas valve Figure 9 NOTE Codes may require that manual main shut off valve and union furnished by installer be installed in gas line external to unit Union must be of the ground joint type Danger of explosion Can cause injury or product property damage Do not use matches candles flame or other sources of ignition to check for leaks W After gas piping is complete carefully che
46. zing an air cooled condenser The system is factory charged with HFC 410A refrigerant The compressor is hermetically sealed internally sprung and base mounted with rubber insolated hold down bolts Pre Start Check List 1 Make sure refrigerant lines do not rub against the cabinet or each other 2 Inspect all electrical wiring both factory and field installed for loose connections 3 Check voltage at the disconnect switch Voltage must be within the range listed on the unit nameplate If not consult power company and have voltage condition corrected before starting unit 4 Recheck voltage with unit running If power is not within the range listed on the unit nameplate stop the unit and consult the power company Check unit amperage Refer to unit nameplate for correct running amps 5 Make sure filter is in place before unit start up Cooling Sequence of Operation When the thermostat calls for cooling R is closed to G and Y figure 11 This completes the low voltage control circuit energizing the compressor condenser fan motor and blower motor NOTE At the start of the each cooling demand the combustion air blower draft motor will operate for 10 seconds Unit compressors have internal protection If there is an abnormal rise in the compressor temperature the protector will open and the compressor will stop Blower Delay Cooling In the cooling mode the circulating air blower operation is del
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