LENNOX Package Units(both Units Combined) Manual L0806665

User Manual: LENNOX LENNOX Package Units(both units combined) Manual LENNOX Package Units(both units combined) Owner's Manual, LENNOX Package Units(both units combined) installation guides

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Page Count: 17

,t,: 2005 Lennox industries inc.

Dallas, Texas, USA

INSTALLATION

INSTRUCTIONS

13GCSX SERIES UNITS

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

c( )0s

GAS PACKAGED UNITS (2-5 TONS) F_ Technical

505,057M _L.LLPublications

(38152A067)

08/05 Lithe U.S.A.

Supersedes 06/05

Unit Dimensions ............................... 2

Parts Arrangement ............................. 3

Shipping & Packing List ......................... 3

General ....................................... 3

Safety Information .............................. 3

Location Selection .............................. 4

Rigging & Setting Unit .......................... 5

Clearances .................................... 5

Installing Vent Hood ............................ 6

Existing Common Vent Systems .................. 6

Condensate Drain .............................. 7

Filters ......................................... 7

Supply & Return Connections .................... 7

Compressors .................................. 8

Gas Supply and Piping .......................... 8

Electrical ..................................... 10

Blower Speed Settings ......................... 12

Cooling Start-Up .............................. 13

Heating Start-up .............................. 14

Unit Controls ................................. 15

Condenser Fan Clearances ..................... 16

Maintenance .................................. 17

Repair Parts & Accessories ..................... 17

-&WARNING GAS-FIRED

LISTED

Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other ap-

pliance.

Installation and service must be

performed by a qualified installer,

service agency or the gas supplier.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

•Do not touch any electrical switch; do not

use any phone in your building.

•Leave the building immediately.

•Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

•If you cannot reach your gas supplier, call

the fire department.

08/05

IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII

Page 1

505,057M

IIIlllllllllllllllllllllllllllll]lllll]lllllll

L 6S'1G÷

( _ 2-1/2 (64)

AA 4SUPPLY AIR

(70)

--I_ /OP

DOWN-FLOW

RETURN AIR

OPENING

y F

DD

BBfC

_[

u CC

TOP VIEW

Model

Number

13GCSXA-24

13GCSXA-30

13GCSXA-36

13GCSXA-42

13GCSXA-48

13GCSXA-60

74

74

84

108

112

117

Corner Weights

125 97 15.5

125 97 15.5

126 105 16

176 140 20

177 144 20

184 151 20

94

94

101

136

137

143

Center Of

Gravity

FF

in.

28.5

28.5

29.5

33

33.5

33.5

9 B D,

A

FRONT VIEW

--'t

GAS PIPING INLET "'". I

%_ o

'4-4-1/4 (108)

J3-1/4 (83)

I

ELECTRICAL INLET

_.--- L---_

2-I/2(64)_i _ CONDENSATE DRAIN

FLUE

OUTLET

HORIZONTAL HORIZONTAL

SUPPLY AIR RETURN AIR

OPENING OPENING

- '_--- E---_ H

TD_T

2-3/4 _, _, 2-3/4

(70) (70)

--D.K _ j I_D.

BACK VIEW

END VIEW

END VIEW

A B C D E F

Model No. in. mm in. mm in. mm in. mm in. mm in. mm

13GCSXAV-24

13GCSXAV-30 34-1/4 870 65-3/8 1661 36-1/2 927 11-1/4 286 17-1/4 438 20 508

13GCSXAV-36

13GCSXAV-42

13GCSXAV-48 38-1/4 972 75 1905 46 1168 11-1/4 286 19-1/4 489 22 559

13GCSXAV-60

F G H J K L

Model No. in. mm in. mm in. mm in. mm in. mm in. mm

13GCSXAV-24

13GCSXAV-30 20 508 8-1/2 216 3 76 20-1/4 514 4-1/2 114 19 483

13GCSXAV-36

13GCSXAV-42

13GCSXAV-48 22 559 9-1/4 241 3-1/4 83 22-1/4 572 4 102 16-1/4 413

13GCSXAV-60

Page 2

COIL

BLOWER MOTOR

GAS

CONTROL

SECTION

PRESSURE

AIR INDUCER

BURNER

GAS

COIL

FAN

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 13GCSX units are single-package air conditioners

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 assembled. All piping, refrigerant

charge, and electrical wiring are factory-installed and

tested. The units require electric power, gas piping,

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

WARNING

These units must be installed in accordance with all

applicable national and local safety codes.

These instructions are intended 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,

Page 3

A, WARNING

These units are design listed by UL in both the United

States and Canada as follows:

• For use as a forced air furnace with cooling,

• For outdoor installation only.

• For installation on combustible material.

• For use with natural gas or L,P./propane gas only. Use

of LP./propane gas requires installation of an LP, con-

version 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 13GCSX 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 13GCSX 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 a

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 13GCSX is operating within the intended tem-

perature rise range. The duct system must be de-

signed to provide an external static pressure within the

allowable range, Refer to the unit rating plate.

Lennox does not recommend the use of 13GCSX 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,

13GCSX units may be used for heating of buildings or

structures under construction, if the following conditions

are met:

•The vent hood must be installed per these installation in-

structions.

• A room thermostat must control the unit. The use of

fixed jumpers that will provide continuous heating is not

allowed.

• The return air duct must be provided and sealed to the

unit.

• Return air temperature range between 60°F (16°C) and

80°F (27°C) must be maintained.

• Air filters must be installed in the system and must be

maintained during construction.

• Air filters must be replaced upon construction comple-

tion.

• The input rate and temperature rise must be set per the

unit rating plate.

•One hundred percent (100%) outdoor air must be pro-

vided for combustion air requirements during construc-

tion. Installation of this unit in its intended outdoor loca-

tion will accompfish this.

• The heat exchanger, components, duct system, air fil-

ters and evaporator coil must be thoroughly cleaned fol-

lowing final construction clean-up.

• The unit operating conditions (including ignition, input

rate, temperature rise and venting) must be verified ac-

cording to these instaflation instructions.

NOTE -The Commonwealth of Massachusetts stipu-

lates these additional requirements:

•Gas furnaces shall be installed by a licensed plumb-

er or gas fitter only.

•The gas cock must be "T handle" type.

•When flexible connectors are used, the maximum

length shall not exceed 36".

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 thick-

ness 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.

4 - Maintain level within a tolerance of 1/4 inch maximum

across the entire length or width of the unit.

Page 4

5- Donotlocatetheunitwherethecombustionairsupply

willbeexposedtoanycorrosivesubstance,including

thefollowing:

Permanentwavesolutions,

Chlorinatedwaxesorcleaners,

Chlorine-basedswimmingpoolchemicals,

Water-softeningchemicals,

De-icingsaltsorchemicals,

Carbontetrachloride,

Halogen-typerefrigerants,

Cleaningsolvents(e.g.,perchloroethylene),

Printinginks,paintremovers,varnishes,etc.,

Cementsandglues,

Anti-staticfabricsoftenersusedinclothesdryers,

Masonryacid-washingmaterials,

Chlorinatedlaundryproducts,

Hydrochloricacid.

Exercisecarewhenmovingtheunit.Donotremoveany

packaginguntiltheunitisneartheplaceofinstallation.An

optionallifting lug kit (92M51)may be purchased

separatelyforuseinriggingtheunitforlifting.Spreaders

whoselengthexceedsthelargestdimensionacrossthe

unitMUSTbeusedacrossthetopof theunit.

CAUTION

Accessory Lift Kit

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.

Page

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 outleL

Service Clearances

36 (914)

48 (1219)

NOTE - Top Clearance - 36 in. (914 mm)

NOTE - Entire perimeter of unit base requires

support when elevated above mounting surface.

Figure 2

In the U.S. units may be installed on combustible floors

made from wood or class A, B, or C roof covering material.

In Canada, units may be installed on combustible floors.

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

(Z223.1) and/or the standards of the current CSA B149

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 restric 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 addtion 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

freeze on the walls or on overhangs (under eaves). The

vent outletshouldnot dischargeflue productson a

sidewalk,patioor otherwalkwaywherethe condensate

couldcausethesurfacetobecomeslippery.

Do not install the unit so that the products of

combustionwill be allowedto accumulatewithin a

confinedspaceandrecirculate.

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

Minimum Clearance

Below Vent Hood:

Distance from Bottom

of Vent Hood to Base

of Unit

Figure 3

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 in-

serted, the screen should be flush with the end of the

tube as shown in figure 4.

Vent Hood Installation

Front View Top View

_Vent Tube

NOTE -

Screws

Vent Tube '_ should pass

Screen is pre-formed Vent Hood through

sides of

screen to

hold screen

_'_ in place.

i 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 order to hold the

screen in place.

The vent hood must be installed prior to unit start-up.

The 13GCSX packaged unit may replace an existing fur-

nace which is being removed from a venting system com-

monly run with separate gas appliances. In this case, the

existing vent system is likely to be too large to properly

vent the remaining attached appliances.

Conduct the following test while each appliance is operat-

ing and the other appliances (which are not operating) re-

main connected to the common venting system. If the

venting system has been installed improperly, you must

correct the system as indicated in the general venting re-

quirements section.

1 - Seal any unused openings in the common venting sys-

tem.

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 be-

tween the space in which the appliances remaining

connected to the common venting system are located

and other spaces of the building. Turn on clothes dry-

ers 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 oper-

ate at maximum speed. Do not operate a summer ex-

haust 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 main burner has operated for 5 minutes, 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, widows, exhaust fans, fireplace damp-

ers, and any other gas-burning appliances to their pre-

vious mode of operation.

7 - If a venting problem is found during any of the preced-

ing tests, the common venting system must be modi-

fied to correct the problem.

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 stan-

dards of the National Fuel Gas Code

ANSFZ223.1/NFPA 54 in the USA, and the appropri-

ate 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 6

The13GCSXunitisequippedwitha 3/4inchFPTcoupling

forcondensatelineconnection.Plumbingmustconformto

local codes.Use a sealingcompoundon malepipe

threads.

Thedrainlinemustbeproperlytrappedandroutedtoa

suitabledrain.Seefigure5forproperdrainarrangement.

Thedrainlinemustpitchto anopendrainor pumpa

minimumof 1inchper10feetto preventcloggingofthe

line.Sealarounddrainconnectionwithsuitablematerialto

preventairleakageintoreturnairsystem.

Drainpipingshouldnotbesmallerthandrainconnectionat

coil.Anopenventindrainlinewillsometimesberequired

dueto line length,frictionand staticpressure.Drains

shouldbeconstructedinamannertofacilitatefutureclean-

ing.

NOTE -The condensate drain line MUST be trapped to

provide proper drainage.

CAUTION

vent

Trap must be deep enough to offset maximum

static difference (Generally, 3 inches minimum).

Typical Condensate Drain

Minimum Pitch

1 in. (25 ram) per

10' (3 m) of line unit

open

mounting

frame

Figure 5

Filters are not factory-supplied with the unit; however,

optional internally installed filter kits are available. Filter kit

92M54 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.

Table 1

Unit Filter Size

Unit Model Filter Size Filter Quantity

-24, -30, -36 20 in. X 25 in. 1

-42, -48, -60 16 in. X 25 in. 2

The duct system should be designed and sized accordin(

to the methods in Manual Q of the Air Conditionin(

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.

A CAUTION

The 13GCSX 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 to cover the side openings.

Removing Supply and Return

Air Opening Covers

®

®

1. Remove screw and lift. Base-_ I

2. Slide cover to free back pin. U

Figure 6

Page 7

Units are shippedwith the compressormountings

factory-adjustedandreadyforoperation.

CAUTION

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,

NQ TE -Units are shipped equipped for natural gas, but can

be converted to LP/propane with a conversion kit. Conver-

sion 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 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) (FT3/HR)

68 67,500 54,000 63

83 82,500 66,000 77

90 90,000 72,000 84

110 110,000 88,000 102

138 137,500 110,000 128

*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 require-

ments, 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 connec-

tion 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 inch-

esw.c, and a maximum of 13,0 inches w,c,

Table 3

Gas Pipe Capacity-FT 3 /HR

Nominal Iron Pipe Size (inches)

Length in Feet 1/2 in.

10 132

20 92

30 73

40 63

50 56

60 50

70 46

80 43

90 40

1O0 38

3/4in. 1 in. 1-1/4 in.

278 520 1050

190 350 730

152 285 590

130 245 500

115 215 440

105 195 400

96 180 370

90 170 350

84 160 320

79 150 305

The gas supply piping should be routed through the grom-

met on the side of the unit, Refer to figure 7,

Gas Piping and Electrical Conduit Access

Gas

Thermostat _(5/_(_

Entry J o

/

Line Voltage

Entry

Figure 7

When making piping connections, a drip leg should be

installed on vertical runs to serve as a trap for sediment or

condensate, A 1/8 inch N,RT. 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 8

Drip Leg Installation

field provided

1/8 in. !

ground joint

union

manual main

shut-off

unit

I_ leg

gas piping

support

Figure 8

Pressure Test Gas Piping

When pressure testing gas lines, the gas valve must be dis-

connected and isolated. Gas valve can be damaged if sub-

jected 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 pres-

sure 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.)

unit

gas valve cap

Figure 9

NOTE -Codes may require that manual main shut off valve

and union (furnished by installer) be installed in gas line ex-

ternal to unit, Union must be of the ground joint type,

, WARNING

After gas piping is complete, carefully check all piping con-

nections (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 speci-

fying a minimum diameter for gas piping. All units require a

1/2 inch pipe connection at the gas valve,

Gas piping recommendations:

1 - A drip leg and a ground joint union must be installed in

the gas piping.

A ground joint union is recommended by the man-

ifold/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 pro-

pane 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 con-

nections 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

material suitable for the purpose,

CAUTION

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 pres-

sures in excess of 1/2 PSIG (3,48kPa).

AIMPORTANT

6 - A 1/8 inch N.RT. plugged tapping, accessible for test

gage connections, must be installed immediately up-

stream of the gas supply connection to the furnace.

Page 9

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 disconnect 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

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)

T

ground L2

lug

NOTE -ff 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 subject to drafts, sun exposure or heat

from electrical fixtures or 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 10

13GCSX Series Gas Packaged Units

Typical Wiring Diagram

m.Ol[_ SPEED¢_ART

UIItT fKlr_ al_lOD _TTim

¢OGLI_,6iNPUT HEATtN6 INPUT HEAT(BLU) ,COOl.(HI.K)

24 68 WED LOW

30 68 WED I NED

36 68 NED HIGH

36 90 HtGHt HIGH

4E 83 LOW oLOH

42 I I 0 LOWILOW

48 83 LOW WED

48 I I 0 LOW WED

48 138 WED i HEO

60 83 LO!it HIGH

60 I I 0 LQW HIGH

GO t38 NED HIGH

LI

L2

ZOB/ZSOV-l-6O

COMPRESSOR

CONTACTON

_T BLK

DUAL

CAPACITOR CI?

m

COMPRESSOR

MOTOR

uJUMPER REQUIRED

IF THE JUMPER IS HOT USED, CONNECT

BLUE WIRE TO THE HEAT TERMINAL.

iGNiTiON CONTROL I

I I AS ACB ACBI

J

SEE C HAg T----I

_Wi= FOR WIRING

COMUENS

HEAT ANTICIPATION SETTING: 0.70 AMP

HIGH PRESSURE THERMOSTAT

SWITCH (IF USED) YEL BLU

, As,G 5 O C5 I I ]I]

:.VAC :- _ I _ I 1

r-- G=HU G I> | 1 I 1

" _ H254 3 FLAW{ :

WAIN

LINt DIAGNOSTICS IGNITION CONTROL

SWITCH'T_"I II l I_] The following ignition control board LEO codes will

_-I I I I I I=1 indicate normal or abnormal operafionz:

_=1 I JI I I_] SLOW FLASH Normal operation, no call for heat.

.L III I _ FAST FLASH Normol oper_Jfio_, colt for heat.

ROLLOUT_ I I ] [ | g FLASH System IockouE failed to defect or sestain flame.

SWITCH _47 [ I _| t 3 FLASH Pressure switch senses incorrect pressure,

_'" I Il I 4 FLASH Mai_ limit open or rollout switch open.

_I I II I 5FLASH Flame sensed and gas valve nor energized.

'I II STEADY,nter0o,fo. r.*°icro-cootro,lertai,ure;s..c.c.

PN NNOTE:

•EW_T_e_UFI_"_'--"--I Il GVI IF ANY OF THE ORIGINAL

_"'_'/_l -I h_..E_-_.l_v .... WIRE IS REPLACED THE

" -1 J |-- |........ SAME SIZE AND TYPE WIRE

_IMUST BE USED.

PUU_l_ "S_Pl _ USE COPPER CONDUCTOR wer_e_uc

-- ONLY, WIN 75"C WIRE ....... "

AUX. LIMIT ELECTRIC SH_K HAZARD, UNIT

SWITCH(IF USED) MUST BE GROUNDEDIN ACCORDANCE

LINE VOLTAGE FIELD INSTALLED WITH NATIONAL AND LOCAL CODES.

WARNING I

13GCSX units are equipped with an indoor blower that is

controlled by the integrated ignition control board.

Factory settings for the blower speed jumpers are given in

the wiring diagram in figure 11. Use tables 4, 5 and 6 to de-

termine the correct air volume for operation in heat and

cool mode.

To change blower speeds, move blower speed tap wire on

the blower motor. Refer to figure 14.

Table 4

13GCSXA-24, 13GCSXA-30 Blower Performance

0through 0.80 in. w.g. (0 through200 Pa)

ExternalStatic Pressure Range

HorizontalAir Flow

Air Volume at Various Blower Speeds

High

cfm L/s

1470 695

1420 670

1360 640

1290 610

External Static

Pressure

1220 575 950 450 790

1140 540 900 425 740

1050 495 830 390 690

Medium Low

cfm L/s cfm L/s

1070 505 880 415

1060 500 870 410

1020 480 850 400

1000 470 820 385

375

35O

325

in. w.g.

.20 50

.30 75

.40 100

.50 125

.60 150

.70 175

.80 200

NOTE - All air data is measured external to unit without air filters.

1 For down-flow air volume, add 0.05 in. w.g. (12 Pa) to duct static.

Table 5

13GCSXA-36 Blower Performance

0through 0.80 in. w.g. (0 through 200 Pa)

External Static Pressure Range

Horizontal Air Flow

External Static Air Volume at Various Blower Speeds

Pressure High Medium Low

in. w.g.

.20 50

.30 75

.40 100

.50 125

.60 150

.70 175

.80 200

cfm

1510

1460

1400

1330

1250

1180

1100

L/s cfm

715 1060

690 1050

660 1030

630 990

590 950

555 900

520 850

L/s cfm

500 870

495 860

485 840

465 820

450 790

425 750

400 680

NOTE - All air data is measured external to unit without air filters,

1 For down-flow air volume, add 0.05 in. w.g. (12 Pa) to duct static.

L/s

410

4O5

395

385

375

355

32O

Table 6

13GCSXA-42, 13GCSXA-48, 13GCSXA-60

Blower Performance

0 through 0.80 in. w.g. (0 through 200 Pa)

External Static Pressure Range

Horizontal Air Flow

External Static

Pressure

in. w.g.

.20 50

.30 75

.40 100

.50 125

.60 150

.70 175

.80 200

2090 985

2000 945

1930 910

1820 860

1710 805

1590 750

1480 700

1820 860 1520

1780 840 1480

1730 815 1450

1650 780 1440

1570 740 1410

1480 700 1360

1370 645 1260

Air Volume at Various Blower Speeds

High Medium Low

cfm L/s cfm L/s cfm L/s

715

7OO

685

68O

665

64O

595

NOTE - All air data is measured external to unit without air filters,

1 For down-flow air volume, add 0.05 in. w.g. (12 Pa) to duct static.

Page 12

Thecoolingsectionisacompletefactorypackageutilizing

anair-cooledcondenser.Thesystemisfactory-charged

withR-410Arefrigerant.Thecompressoris hermetically

sealed, internallysprung and base-mountedwith

rubber-insolatedhold-downbolts.

Pre-Start Check List:

1 - Make sure refrigerant lines do not rub against the cabi-

net 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 with-

in the range listed on the unit nameplate, stop the unit

and consult the power company. Check unit amper-

age. Refer to unit nameplate for correct running amps.

5 - Make sure filter is in place before unit start-up.

6 - Before placing the unit into full operation, energize the

unit for three false starts. Energize the compressor

just long enough for it to make a few revolutions, wait

five to seven minutes before repeating a second and

third time.

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

delayed 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, continu-

ous blower operation is possible by closing the R to G cir-

cull Cooling blower delay is also functional in this mode.

System Performance

For maximum performance of this cooling system, the

operating temperatures and pressure should be checked

and superheat determined at Standard ARI test conditions

of 82 '_ F outdoor temperature minus ( - ) 80 ° F indoor dry

bulb /67 <_F indoor wet bulb. If superheat measured

deviates from values in table 7, refrigerant charge should

be adjusted accordingly for maximum performance.

Table 7

Suction Superheat Values

Suction Superheat

Unit Model No. 82°F OD minus 80"F IDDB

/67"F IDWB

13GCSX-24

13GCSX-30 16"

13GCSX-36 12 °

13GCSX-42

13GCSX-48 16 °

13GCSX-60

Verify system performance using table 8 as a general guide.

Table 8 should not be used for charging unit. Minor varia-

tions 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 /87°F wet bulb return

air. Allow unit operation to stabilize before taking pressure

readings.

80°F db/ 87°F wb RETURN AIR

UNIT PRESSURE

13GCSX-24

13GCSX-30

13GCSX-36 Suction

13GCSX-42

13GCSX-48

13GCSX-60

13GCSX-24

13GCSX-30

13GCSX-36

13GCSX-42 Liquid

13GCSX-48

13GCSX-60

Table 8

Normal Operating Pressures

Air Temperature Entering Outdoor Coil (°F)

65 70 75 80 82 85 90 95 100 105 110 115

133 136 138 141 142 143 146 149 150 152 155 157

133 135 138 140 141 142 144 147 148 149 151 153

140 142 144 146 147 148 150 152 154 155 157 159

124 127 130 133 134 135 138 142 142 144 147 149

139 140 142 143 144 145 146 148 148 149 150 152

142 143 144 146 146 147 148 149 151 152 154 156

222 245 267 290 299 312 335 358 379 397 429 456

232 255 277 300 309 323 345 368 390 408 440 467

241 265 288 312 321 336 360 382 409 429 461 488

223 247 270 294 303 317 339 364 384 402 434 461

239 261 284 306 315 328 349 373 391 408 440 467

258 281 303 326 335 349 373 394 420 439 471 498

Page 13

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 the unit, smell all around the fur-

nace area for gas. Be sure to smell next to the floor be-

cause some gas is heavier than air and will settle on the

floor,

,WARNING

IkWARNING

,WARNING

WARNING

The gas valve on may be equipped with either a gas con-

trol switch or gas control knob, Use only your hand to

push the switch or turn the gas control knob. Never use

tools. If the the switch will not move or the knob will not

push in or turn by hand, do not try to repair it. Call a quali-

fied service techni clan, Force or attempted repair may

result in a fire or explosion,

This unit 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 - HoneywellVR8205 Gas Valve with ON/OFF Switch -

Set gas valve switch to ON. See figure 12.

Honeywell VR8205 Gas Valve with Knob - Turn knob

on gas valve counterclockwise _1_ to ON, Do not

force. See figure 13.

4 - Turn on electrical power to unit.

5 - Set room thermostat to desired temperature, (If ther-

mostat setpoint temperature is above room tempera-

ture after the pre-purge time expires, main burners will

light),

Honeywell VR8205 Series Gas Valve

Regulator

Adjustment

..........................................

Gas Control Switch

Inlet Pressure Tap

1/8" NPT

Outlet Pressure Tap

1/8" NPT

Figure 12

Honeywell VR8205 Gas Valve with Control Knob

MANIFOLD

PRESSURE _\_

ADJ USTM ENT'_-?,--_ _ 4"

SCREW I)

(under I..=1."_'_

barbed _("1:3"_ ./I" _\

fitting) ' ON

PRESSUREI _ _ /.,4

PORT I -I k_(" OFFj//,

MANIFOLD

GAS VALVE SHOWN IN OFF POSITION

Fiqure 13

To Shut Down:

1 - Turn off electric power to unit.

2 - HoneywellVR8205 Gas Valve with ON/OFF Switch

- Set gas valve switch to OFF,

Honeywell VR8205 Gas Valve with Knob -Turn gas

valve knob clockwise _1_ to OFF. Do not force.

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 pip-

ing as well as the supply piping,

2 - Check for correct manifold gas pressures, See "Man-

ifold 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 build-

ing at full fire, At no time should the supply

Page 14

gaspressureexceed10.5inchesw,c,,nordropbelow

5.0inchesw.c.fornaturalgasunits,Forpropanegas,

supplygaspressureshouldnotdropbelow11inches

w.c.If gaspressureis outsidetheselimits,contact

yourgassupplierforcorrectiveaction,

4 - Adjusttemperaturerisetotherangespecifiedonthe

ratingplate.

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 11,0 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 3,5 inches W,C,

Units fueled by LP/propane gas are rated for manifold

pressures of 10.0 inches W,C,

Measure manifold pressure: Shut off gas supply to the

unit. Remove plug from pressure tap, See figure 12 or 13.

Connect manometer or gauge to the proper pressure tap,

then turn on the gas supply,

The Honeywell VR8205 gas valve has an adjusting screw.

See figure 12 or 13 for adjusting screw location, Remove

the cap and turn the adjusting screw clockwise to increase

pressure and input; turn counterclockwise to decrease

pressure and input. The pressure regulator adjustment is

sensitive. One turn dthe adjusting screw results in a large

change in manifold pressure. Replace the adjusting screw

cap.

Final manifold pressure must be within the allowable range

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 revolution,

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: The only check for the output rate is

to properly adjust the manifold pressure using a manome-

ter, 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, Wl is energized,

The ignition control checks high temperature limit and

rollout 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 30-second pre-purge.

The ignition control energizes the combustion air inducer,

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 30-second pre-purge

period. When the pre-purge time has expired, the control

begins the ignition trial,

The ignition control energizes the gas valve, spark

electrode and flame sensor. 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. The ignition control will initiate

three ignition trials, If the flame sensor does not sense an

established flame at the end of the third ignition trial, the

igntion control will allow a 1-hour Watchguard period to

pass before allowing additional ignition trials.

Approximately 30 seconds after the flame has been

established, the circulating air blower starts, The ignition

control inputs are continuously monitored to ensure that

limit switch(es), rollout switch and pressure switch are all

closed, and that the flame remains established and heating

demand is present.

When the heating demand is satisfied, the control

immediately de-energizes the gas valve and combustion

air inducer, The circulating air blower operates for 120

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 120 seconds after the gas

valve is de-energized,

NOTE -With the proper thermostat and subbase, continu-

ous blower operation is possible by closing the R to G cir-

cull

Integrated Ignition Control Board (A3)

The 13GCSX unit includes an integrated ignition control

board which controls the combustion air inducer, gas valve,

spark electrode and indoor blower. The control board

receives signals from the main and auxiliary limit switches,

the rollout switch, the pressure switch and the flame

sensor. LED codes and flash rates are given on page 16.

The ignition control board is shown in figure 14.

Page 15

Ignition Control Board

ANSl Z2t+20 mUtOrl_++=_: ImmltlOm mVSt[# 2+W*C SO/++Ol++

o @@8 ol3 .......o

@

+sL_ _1 *'

G

K4 K3

.25 MALE QUICK CONNECTS:

TI- SPARK TRANSFORMER

24 VAC HOT

GROUND : 24 VAC RETURN

CMB BLOWER : COMBUSTION BLOWER (LINE VOLTAGE)

LI : LINE VOLTAGE

ACB COOL : AIR CIRCULATING BLOWER COOL

SPEED (LINE VOLTAGE)

ACB HEAT : AIR CIRCULATING BLOWER HEAT

SPEED (LINE VOLTAGE)

UNUSED

,19 MALE QUICK CONNECT:

FLAME z FLAME PROBE

MOLEXIAMP PLUG-IN DESCRIPTION:

I. MAIN LIMIT AND ROLLOUT SWITCH RETURN

2, PRESSURE SWITCH OUT

3. GAS VALVE COMMON

4. GAS VALVE OUT

5. PRESSURE SWITCH RETURN

6, MAIN LIMIT AND ROLLOUT SWITCH OUT

THERMOSTAT INPUT:

R : 24 VAC TO THERMOSTAT (RED)

G : MANUAL FAN INPUT FROM THERMOSTAT (GREEN)

W : HEAT DEMAND INPUT FROM THERMOSTAT (WHITE)

C : COMMON GROUND TO THERMOSTAT

Y : COOL DEMAND INPUT FROM THERMOSTAT (YELLOW)

Figure

Integrated Ignition Control Board LED Codes

The ignition control board LED flashes codes which indi-

cate 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 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 senses incorrect pressure or

is stuck in the closed position,

Three flashes in 1-1/2 seconds with a 1-second pause.

Code 4 -- Main 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,

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 limit

control closes and the blower off delay period has elapsed.

14

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-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 & -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.

The top of the condenser fan should be 1-1/2 inchs from the

bottom of the top grille. This dimension should be checked

and the fan should be adjusted accordingly any time servic-

ing of the outdoor fan system is required.

Page 16

Periodicinspectionandmaintenancenormallyconsistsof

changingorcleaningfiltersand(undersomeconditions)

cleaningthemainburners,

Filters

Notsupplied.Inspectoncea month,Replacedisposableor

cleanpermanenttypeasnecessary,DONOTreplaceper-

manenttypewithdisposable,

Motors

Indoor,outdoorfan and ventmotorsare permanently

lubricatedand requireno furtherlubrication.Motors

shouldbecleanedyearlyto preventtheaccumulationof

dustanddirtonthewindingsormotorexterior,

Coil

Dirtanddebrisshouldnotbeallowedtoaccumulateonthe

coilsurfacesor otherpartsintheairconditioningcircuit.

Cleaningshouldbeperformedasoftenasnecessary.Use

a brush,vacuumcleanerattachment,or othersuitable

means,Ifwaterisusedtocleanthecoil,besurethepower

tounitisshutoffpriortocleaning.

NQ TE -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 ob-

structed by overhanging structures or shrubs,

To Clean Burners

Light the burners and allow unit to operate for a few min-

utes to establish normal burning conditions, Observe the

burner flames. Compare this observation to figure 15 to

determine if flame is properly adjusted. Flame should be

predominantly blue in color and strong in appearance,

Verify that all burnres are lit and that the flame does not

impinge on the sides of the heat exchanger.

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 burn-

er 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,

Burner

Burner Flame Heat

Exchanger

/

Gas Burner Flame

Manifold (Blue Only)

Figure 15

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 discharge flue products,

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,

Controls

Rollout Switch

Transformer

Limit Control

Gas Valve

Ignition Control

Electrode

Flame Sensor

Auxiliary Limit

Pressure Switch

Blower Control

Blower Components

Blower Housing Assembly

Blower Wheel

Blower Motor

Blower Motor Mount

Blower Motor Capacitor (if used)

Combustion Air Inducer

Fan Blade

Fan Motor

Fan Motor Capacitor

Heating Components

Gas Manifold

Main Burner Orifices

Main Burners

Heat Exchanger

Cooling Components

Compressor

Evaporator Coil

Drier

Expansion Valve

Contactor

Capacitor

Condenser Coil

Accessories

LENNOX Cat.

Number

92M57

92M58

92M54

92M55

Description

LP/Propane Gas Conversion Kit (heat sizes 68 and 90)

LP/Propane Gas Conversion Kit (heat sizes 83, 110 and 138)

Filter Kit (2-ton to 3-ton capacity units)

Filter Kit (3-1/2-ton to 5-ton capacity units)

Page 17