SERVICE GCS16 UNIT

1 SERVICEGCS16 UNITINFORMATIONPage 1 Corp. 8911 L7 Litho TON UNITSGCS16 SERIES UNITS2 THROUGH 5 TON UNITSGCS16 series units in the 2-5 ton cooling size wereintroduced in the summer of 1989. The units are packagedcombination gas heat / dx cool units designed for both resi dential and commercial applications. Gas heat sectionsare available with Lennox' helical heat exchanger in50,000 , 75,000 , 100,000 and 125,000 Btuh input are designed for rooftop or side of building installa tion with either bottom or horizontal commercial applications, the GCS16 is designed toaccept any of several different thermostat control systemswith minimum field wiring. Control options such as econo mizer, warm up kit, Honeywell W973 control or HoneywellW7400 control connect to the unit with jack plugs. Whenplugged in the controls become an integral part of the unitwiring. Commercial units are also equipped with a low volt age terminal strip to facilitate thermostat field specifications in this manual are subject to OF CONTENTSI ntroduction Page 1.

2 SpecificationsPages 2-5.. Blower / Air Resistance DataPages 5-9.. Parts ArrangementPages 10-11.. I- APPLICATIONPage 11.. II- unit COMPONENTSPage 11.. Control Box ComponentsPages 11-14.. Heating ComponentsPages 15-22.. Cooling ComponentsPages 23-28.. III- PLACEMENT AND INSTALLATIONPage 28.. IV- ELECTRICAL CONNECTIONSPage 28.. V- START UP - OPERATIONPage 28.. Preliminary ChecksPage 28.. Cooling / Heating Start UpPage 29.. Safety or Emergency Shut DownPage 29.. Extended Period Shut DownPage 29.. VI- REFRIGERATION SYSTEM CHECKSPage 29.. Gauge Manifold AttachmentPage 29.. ChargingPages 29-30.. VII- HEATIING SYSTEM SERVICE CHECKSPage 31.. Applications and RequirementsPage 31.. Gas PipingPage 31.. Testing Gas Piping and Supply PressurePage 31.. Check and Adjust Manifold PressurePage 31.. Proper Gas FlowPage 32.. High Altitude DeratePage 32.. Inshot Burner and Burner ConePages 32-33.. Burner Plate GasketPage 33.

3 Heat ExchangerPage 34.. Ignition ControlPage 34.. Electrode Gap and Flame SensingPage 35.. Combustion Air BlowerPage 35.. Blower / Limit ControlPage 36.. VIII- INDOOR BLOWER OPERATION / ADJUSTMENTPage 36.. Blower OperationPage 36.. Determining unit CFMPage 36.. Blower Speed Adjustment 208/230 VPages 36-37.. Blower Speed Adjustment 460V and 575 VPage 38.. IX- MAINTENANCEPage 38.. Lubrication Page 38.. FiltersPage 39.. Heat Exchanger and BurnerPage 39.. Combustion Air Blower and FluePages 39-40.. Evaporator and Condenser CoilPage 40.. ElectricalPage 40.. X- ELECTRICAL CONNECTIONSPage 40.. Power Supply and Field WiringPage 40.. XI- ACCESSORIESPage 41.. Lifting Lug KitPage 41.. RMF16 Roof Mounting FramePage 42.. EconomizersPages 42-49.. RDE16-41 Duct EnclosurePages 49-51.

4 OAD16 Outdoor Air DamperPage 51.. KitPages 52-53.. Condenser Coil Guard KitPage 53.. High Altitude KitPage 54.. Compressor Crankcase HeaterPage 54.. Downflow Filter KitPage 54.. Timed-Off Control KitPages 54-55.. Compressor MonitorPage 55.. Low Ambient KitPages 55-56.. Roof Curb Power KitPage 56.. FirestatsPage 57.. Transitions and Supply / Return DiffusersPage 58.. Status PanelsPages 58-64.. Commercial Controls HardwarePage 65.. Commercial Controls SystemsPages 65-67.. Controls Mounting Box and BracketPages 67-78.. Clocks / TimersPage 68.. XII- COMMERCIAL CONTROLS INSTALLATIONPage 69.. Night Kit and Night RelayPage 69.. W7400 Control SystemPages 70-71.. Warm-Up KitPage 72.. W973 Control SystemPages 73-74.. XIV- WIRING DIAGRAMS / OPERATION SEQUENCEI ndex and IntroductionPage 75.. Diagrams and Operation SequencePages 76-134.. Page 2 Heating capacity input (Btuh) - Natural GasModel capacity output (Btuh) - Natural GasHeating capacity input (Btuh) - **LPGH eating capacity output (Btuh) - **LPG Natural/** Seasonal Efficiency Natural/** ARI Standard 270 SRN (bels)*ARIS tandard210 RatingsTotal Cooling Capacity (Btuh)Total unit wattsSEER (Btuh/Watts)EER (Btuh/Watts)Refrigerant (R-22) chargeEvaporatorBlowerBlower wheel nominal diameter x width (in.)

5 Motor horsepowerAir volume range (cfm)EvaporatorCoilNet face area (sq. ft.)Tube diameter (in.) & Number of rowsFins per inchCondenserCoilNet face area (sq. ft.)Tube diameter (in.) & Number of rowsFins per inchCondenserFanDiameter (in.) & Number of bladesAir volume (cfm)Motor horsepowerMotor wattsGas SupplyConnections fpt (in.)Natural**LPGR ecommended GasSupply Pressure (wc. in.)Natural**LPGC ondensate drain size mpt (in.)Line voltage dataRecommended max. fuse size (amps)Minimum circuit ampacityElectrical characteristics**Optional LPG Conversion KitOptional Lifting Lug KitOptional Condenser Coil GuardsOptional Duct EnclosureNumber and size of filters (in.)Optional Roof Mounting Frame (used with RDE16-41 only)Optional positionModulatingNumber and sizeof filters (in.)Optional Ceiling Supply andReturn Air DiffusersStep DownFlushTransition50,00075,00038,00050, 00038, , lbs. 3 x 81/3600 - - - 22020 - 419001/43201/21/27113 ,00067,50051, , lbs.

6 3 x 81/3750 - - - 22020 - 419001/43201/21/27113 volts - 60 hz - 1 phaseLB-62090 DBLB-62125 DALB-82199 CARDE16-41(1) 20 x 24 x 1 (fiberglass)RMF16-41 REMD16-41 REMD16M-41(1) 14 x 25 x 1 (polyurethane)RTD9-65FD9-65 SRTH16-65 Optional Outdoor Air Dampers (manual)OAD3-46/65 Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations. Sound Rating Number in accordance with ARI Standard 270.*Rated in accordance with ARI Standard 210 and DOE; 95 F outdoor air temperature and 80 F db/67 F wb entering evaporator air.**For LPG units a field changeover kit is required and must be ordered RESIDENTIAL HORIZONTAL ONLY UNITSI ndoorOutdoor(1) 14 x 25 x 1 (aluminum mesh) Two stage cooling thermostat required with economizer Gravity ExhaustPage 3 Heating capacity input (Btuh) - Natural GasModel capacity output (Btuh) - Natural GasHeating capacity input (Btuh) - **LPGH eating capacity output (Btuh) - **LPG Natural/** Seasonal Efficiency Natural/** ARI Standard 270 SRN (bels)*ARIS tandard210 RatingsTotal Cooling Capacity (Btuh)Total unit wattsSEER (Btuh/Watts)EER (Btuh/Watts)Refrigerant (R-22) chargeEvaporatorBlowerBlower wheel nom.

7 Dia. x width (in.)Motor horsepowerAir volume range (cfm)EvaporatorCoilNet face area (sq. ft.)Tube dia. (in.) & Number of rowsFins per inchCondenserCoilNet face area (sq. ft.)Tube dia. (in.) & Number of rowsFins per inchCondenserFanDiameter (in.) & Number of bladesAir volume (cfm)Motor horsepowerMotor wattsGas SupplyConnections fpt (in.)Natural**LPGR ecommended GasSupply Pressure (wc. in.)Natural**LPGC ondensate drain size mpt (in.)Line voltageRecommended max. fuse size (amps)Minimum circuit ampacityElectrical characteristics**Optional LPG Conversion KitOptional Lifting Lug KitOptional Condenser Coil Guards50,000100,00037,00050,00037, ,00090,00070, , lbs. 12 x 81/2900 - - - 22020 - 422001/62401/21/27113 volts - 60 hz - 1 phaseLB-62090 DBLB-62125 DALB-82199CC-411-100-511-125-651-75125,0 0095,000112,50085, , lbs. 8 x 93/41200 - - - - 438801/43401/21/27113 ,00058,00067,50052, , lbs. 0 x 93/41500 - - - 22024 - 437701/43601/21/27113 ,00095,000112,50085,000 Optional Outdoor Air Dampers (manual)OAD16-65 OAD16-41 Outer coilInner coildataGCS16 RGCS16 RGCS16 RGCS16 RGCS16R Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations.

8 Sound Rating Number in accordance with ARI Standard 270.*Rated in accordance with ARI Standard 210 and DOE; 95 F outdoor air temperature and 80 F db/67 F wb entering evaporator air.**For LPG units a field changeover kit is required and must be ordered RESIDENTIAL UNITSPage 4 Heating capacity input (Btuh) - Natural GasModel capacity output (Btuh) - Natural GasHeating capacity input (Btuh) - **LPGH eating capacity output (Btuh) - **LPG Natural/** Seasonal Efficiency Natural/** ARI Standard 270 SRN (bels)*ARIS tandard210 RatingsTotal Cooling Capacity (Btuh)Total unit wattsSEER (Btuh/Watts)EER (Btuh/Watts)Refrigerant (R-22) chargeEvaporatorBlowerBlower wheel nominal dia. x width (in.)Motor horsepowerAir volume range (cfm)EvaporatorCoilNet face area (sq. ft.)Tube dia. (in.) & No of rows & face area (sq. ft.) outer/innerTube diameter (in.) & Number of rowsFins per inchCondenserFanDiameter (in.) & Number of bladesAir volume (cfm)Motor horsepower & Motor wattsGas Supply Conn.

9 Fpt (in.) - Natural & **LPGR ecommended GasSupply Pressure (wc. in.)Natural**LPGC ondensate drain size mpt (in.)Line voltagefuse size (amps)Minimum circuitElectrical characteristics**Optional LPG Conversion KitOptional Lifting Lug KitOptional Condenser Coil Guards50,000100,00037,00050,00037, ,00090,00067, , lbs. 12 x 81/2900 - - 2 - - 22020 - 422001/6 - 2401/27113/445208/230 volts - 60 hz - 1 or 3 phase 460 or 575 volts - 3 phaseLB-62090 DBGCS16-411-100 GCS16 -511-125 GCS16 -651-75125,00095,000112,50085, , lbs. 8 x 93/41200 - - 2 - - 22024 - 438801/4 - 3401/27113/46075,00058,00067,50052, , lbs. 0 x 93/41500 - - 2 - - 22024 - 437701/4 - 3601/27113/460LB-62090 DCLB-62090 DDLB-62090 DDLB-82199CB125,00095,000112,50085,000 Optional Outdoor Air Dampers (manual)OAD16-65 OAD16-41 GCS16 -413-50 GCS16 -413-100 GCS16 -513-125 GCS16 -653-75 GCS16 -653-125 Data(60hz)Recommended ph3 ph460v - 3 ph208/230v1 ph3 ph460v - 3 Downflow adaptor kit Model no, FiltersOptional Roof Mounting FrameOptionalEconomizerDampersModel positionModulatingNo.

10 & sizeof filters (in.)OptionalEconomizerDampersModel positionModulatingNo. & sizeof filters (in.)HorizontalLB-62125 DALB-82199 CCOptional Ceiling Supply andReturn Air DiffusersStep DownFlushTransitionOptional Controls SelectionElectromechanical Thermostat Honeywell W973 Control System with T7067 ThermostatHoneywell W7400 Control System with T7400 ThermostatFlexstat Thermostat (discontinued as an option after August 1989)Prostat ThermostatT7300 Thermostat Commercial ControlsOptional Control MountsDownflow applicationHorizontal applicationOptional Gravity Exhaust DampersOptional Roof Curb Power Entry KitDF16-65, (1) 20x25x1 (polyurethane)DF16-41, (1) 16x25x1 (polyurethane)RMF16-41 RMF16-41 or RMF16-65 REMD16-41 REMD16-65(1) 14 x 25 x 1 (polyurethane)(1) 18 x 25 x 1 (polyurethane)REMD16M-41 REMD16M-65(1) 14 x 25 x 1 (aluminum mesh)(1) 18 x 25 x 1 (aluminum mesh)EMDH16-41 EMDH16-65(1) 20 x 24 x 1 (fiber glass)(1) 16 x 25 x 1 & (1) 14 x 25 x 1 (fiber glass)EMDH16M-41 EMDH16M-65(1) 8 x 24 x 1 (aluminum mesh)