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Service Manual 2010 - Whaley Food Service

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1. ELECTRICAL DATA 7 5 TON 7 5 TON STANDARD EFFICIENCY R 410A KGA092S4 1 Voltage 60hz 208 230V 3 Ph 460V 3 Ph 575V 3 Ph Compressor 1 Rated Load Amps 13 1 Gal 4 4 Locked Rotor Amps 83 1 41 99 Compressor 2 Rated Load Amps 13 1 6 1 4 4 Locked Rotor Amps 83 1 41 33 Outdoor Fan Full Load Amps 24 1 3 1 Motors 2 total 4 8 2 6 2 Power Exhaust Full Load Amps 24 1 3 1 1 0 33 HP Service Outlet 115V amps 15 15 15 Indoor Blower Horsepower 2 2 2 Motor Full Load Amps 7 5 3 4 2 7 Maximum Unit Only 50 25 15 Overcurrent With 1 0 33 HP 50 25 20 Protection Power Exhaust Minimum Unit Only 42 20 15 Circuit With 1 0 33 HP 45 22 16 Ampacity Power Exhaust 1 Extremes of operating range are plus and minus 10 of line voltage HACR type breaker or fuse 3 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements 8 5 TON STANDARD EFFICIENCY 410 10254 1 Voltage 60hz 208 230V 3 Ph 460V 3 Ph 575V 3 Ph Compressor 1 Rated Load Amps 14 5 6 3 6 Locked Rotor Amps 98 55 41 Compressor 2 Rated Load Amps 14 5 6 3 6 Locked Rotor Amps 98 55 41 Outdoor Fan Full Load Amps 24 1 3 1 Motors 2 total 4 8 2 6 2 Power Exhaust Full Load Amps 24 1 3 1 1 0 33 HP Service Outlet 115V GFI amps 15 15 15 Indoor Blower Horsepower 2 2 Motor Full Load Amps 7 5 3 4 27 2 Maximum Unit Only 50 25 20 Overcurrent Wit
2. FIGURE 2 FIGURE 3 14 I UNIT 5 All 7 5 through 12 5 ton 26 3 through 44 kW units are con figure to order units CTO The KGA unit components are shown in figure 1 All units come standard with removable unit panels All L1 L2 and L3 wiring is color coded L1 is red L2 is yellow and L3 is blue A Control Box Components KGA control box components are shown in figure 2 and 3 The control box is located in the upper portion of the com pressor compartment 1 Disconnect Switch S48 Field Installed for all units All units may be equipped with an optional disconnect switch 548 or circuit breaker CB10 548 and CB10 are toggle switches which can be used by the service technician to dis connect power to the unit 2 Control Transformer T1 all units All use a single line voltage to 24VAC transformer mounted in the control box Transformer supplies power to control circuits in the unit The transformer is rated at 70VA and is protected by a 3 5 amp circuit breaker CB8 The 208 230 Y voltage transformers use two 208 230V TRANSFORMER primary voltage taps as LOW shown figure 4 while 460 G and 575 J voltage transformers use a single primary voltage tap 208 VOLTS PRIMARY ai ack FIGURE 4 ORANGE 3 A Transformers T3 575V units All 575 J voltage units use transformer mounted in the co
3. Air Vol Wet Indoor Coil Gas Heat Exchanger Filters Return Air cin 092 102 120 150 Standard Medium High 13 Adaptor Heat heat Heat Plate 2250 0 07 0 10 0 13 0 07 0 07 0 08 0 08 0 01 0 04 0 00 2500 0 09 0 12 0 15 0 09 0 10 0 11 0 11 0 01 0 05 0 00 2750 0 09 0 12 utl 0 09 0 11 0 12 RIA 0 02 0 05 0 00 3000 0 11 0 15 0 19 0 11 0 12 0 13 0 13 0 02 0 06 0 02 3250 0 13 010 O28 0 12 0 15 0 16 0 15 0 02 0 06 0 02 3500 0 14 0 21 0 26 0 12 0 16 0 17 0 15 0 03 0 07 0 04 3750 0 16 02238 O29 0 14 0 19 0 20 0 15 0 03 0 08 0 07 4000 0 17 0 25 0 31 0 14 0 21 0 22 0 19 0 04 0 08 0 09 4250 0 20 O27 025 0 14 0 24 0 28 0 19 0 04 0 09 0 11 4500 0 21 0 30 0 37 0 15 0 26 0 32 0 22 0 04 0 09 0 12 4750 0 23 0 32 0 40 0 16 0 29 0 37 0 25 0 05 0 10 0 16 5000 0 26 0 35 0 43 0 16 0 34 0 43 0 29 0 06 0 10 0 18 5250 05277 0 36 0 46 0 16 0 37 0 47 0 32 0 06 0 11 0 19 5500 0 29 0 40 0 50 0 18 0 44 0 54 0 34 0 07 0 12 0 22 5750 0 32 0 43 0 56 0 19 0 49 0 59 0 45 0 07 0 112 0 25 6000 0 33 0 46 0 59 0 20 0 54 0 64 0 52 0 08 0 13 0 27 10 BLOWER DATA CEILING DIFFUSERS AIR RESISTANCE in w g RTD11 Step Down Diffuser _ FD11 Flush Unit Size Air Volume 2 Ends Open 1 Side 2 Ends Ends amp Sides Diffuser cfm Open
4. Vertical Vent Extension C1EXTN20FF1 42W16 X X X X BLOWER SUPPLY AIR Motors Belt Drive 2 Factory Belt Drive 3hp Factory 5 Factory O O Drive Kits Kit 1 590 890 rpm Factory See Data Tables for selection 2 800 1105 Factory Kit 3 795 1195 Factory O Kit 4 730 970 Factory 5 940 1200 rpm Factory Kit 6 1015 1300 rpm Factory O O Kit 10 900 1135 rpm Factory Kit 11 1040 1315 Factory O Kit 12 1125 1425 rpm Factory O NOTE Catalog and model numbers shown for ordering field installed accessories OX Configure To Order Factory Installed or Field Installed O Configure To Order Factory Installed X Field Installed Page 2 OPTIONS ACCESSORIES Item Description Model Catalog ss Number Number 092 402 120 150 CABINET Coil Guards K1GARD20B 1 55 08 X X X X Hail Guards K1GARD10B1 55W11 X X X X Hinged Access Panels Factory Horizontal Discharge Kit K1HECKOOB 1 51W25 X X X X Return Air Adaptor Plate for L Series and T Class replacement C1CONV10B 1 54W96 X X X X CONTROLS Commercial Controls L Connection Building Automation System X X X X Smoke Detector Supply or Return Power board and one sensor C1SNSR44B 1 5
5. Total 2 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 em RPM BHP RPM BHP BHP BHP BHP RPM RPM BHP RPM BHP 2250 707 0 14 753 0 50 800 10 84 847 1 15 892 1 38 934 1 53 979 1 65 1051 1 86 1126 2 12 1183 2 36 1238 2 62 2500 714 0 29 758 0 64 803 0 97 849 1 26 893 1 48 936 1 63 983 1 75 1052 1 96 1124 2 22 1184 2 49 1241 2 77 2750 680 0 11 721 0 45 763 0 78 807 1 09 852 1 37 896 1 58 940 1 74 989 1 88 1053 2 08 1121 2 34 1185 2 63 1244 2 93 3000 689 0 29 728 0 61 770 0 93 812 1 23 856 1 49 901 1 70 947 1 87 996 2 02 1055 2 21 1120 2 47 1186 2 78 1248 3 10 3250 661 0 17 698 0 46 737 0 78 777 1 09 819 1 38 862 1 63 908 1 84 955 2 01 1004 2 17 1059 2 36 1122 2 62 1189 2 94 1252 3 28 3500 672 0 36 708 0 65 746 0 95 786 1 25 827 1 53 870 1 78 916 1 99 965 2 17 1013 2 33 1065 2 52 1126 2 79 1193 3 12 1257 3 47 3750 684 0 56 719 0 85 756 1 14 795 1 43 836 1 70 880 1 95 927 2 16 976 2 34 1023 2 51 1073 2 71 1133 2 98 1198 3 32 1263 3 67 4000 697 0 78 731 1 05 768 1 34 807 1 62 848 1 89 892 2 13 940 2 34 988 2 53 1034 2 71 1083 2 91 1141 3 19 1205 3 53 1270 3 89
6. LENNOX Service Literature UNIT INFORMATION Corp 1010 L8 KGA SERIES 7 5 to 12 5 ton 26 3 to 42 kW KGAO092 through 150 The KGA 7 5 8 5 10 and 12 5 ton 092 102 120 150 packaged gas units are available in standard cooling effi ciency Units are available in 130 000 180 000 or 240 000Btuh 38 1 52 7 or 70 3 kW heating inputs Gas heat sections are designed with Lennox aluminized steel tube heat exchangers units are designed to accept any of several different energy management thermostat control systems with mini mum field wiring Factory or field provided control options connect to the unit with jack plugs When plugged in the controls become an integral part of the unit wiring Information contained in this manual is intended for use by qualified service technicians only All specifications are sub ject to change Procedures outlined in this manual are pre sented as a recommendation only and do not supersede or replace local or state codes If the unit must be lifted for service rig unit by attaching four cables to the holes located in the unit base rail two holes at each corner Refer to the installation instructions for the proper rigging technique AWARNING Improper installation adjustment alteration service or maintenance can cause property damage person Options Accessories Page 2 al injury or loss of life Installation and service mu
7. 4 Measure return air temperature Mark that point on the top line of chart 1 and label the point 74 F 23 shown 5 Measure mixed air outdoor and return air tempera ture Mark that point on the top line of chart 1 and label point 70 F 21 C shown 6 Draw a straight line between points A and B 7 Draw a vertical line through point C 8 Draw a horizontal line where the two lines meet Read the percent of fresh air intake on the side 9 If fresh air percentage is less than desired adjust MIN POS SET potentiometer higher If fresh air percentage is more than desired adjust MIN POS SET potentiom eter lower Repeat steps 3 through 8 until calculation reads desired fresh air percentage Page 34 1 CALCULATE FRESH AIR MIXED AND RETURN AIR TEMPERATURE 20 29 0 10 0 10 20 30 40 23 18 42 7 1 4 F C 50 10 60 70 16 1 C B 80 27 90 32 100 F 38 C 10 20 30 30 40 40 50 50 60 lt o z PERCENT FRESH AIR 60 70 70 80 80 90 100 F 20 C 29 10 0 10 20 30 40 23 18 12 7 4 50 10 90 100 F C 60 70 16 21 80 27 90 32 100 38 OUTDOOR AIR TEMPERATURE DCV Set and Max Settings Adjust settings when an optional IAQ sensor is i
8. 4250 710 1 00 745 1 27 781 1 55 819 1 83 861 2 09 906 2 33 954 2 55 1001 2 74 1046 2 93 1094 3 14 1151 3 42 1214 3 76 1278 4 12 7 BLOWER DATA 120 BELT DRIVE BLOWER BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY NO HEAT SECTION WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE FOR ALL UNITS ADD 1 Wet indoor coil air resistance of selected unit 2 Any factory installed options air resistance heat section economizer etc 3 Any field installed accessories air resistance duct resistance diffuser etc Then determine from blower table blower motor output required See page 10 for blower motors and drives See page 10 for wet coil and option accessory air resistance data MAXIMUM STATIC PRESSURE WITH GAS HEAT 2 0 in w g Total Total Static Pressure in w g Air Volume 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 3000 677 0 24 719 0 55 764 0 87 813 1 18 866 1 45 920 1 67 975 1 82 1026 1 96 1076 2 13 1126 2 35 1176 2 63 1225 2 92 3250 650 0 14 688 0 43 730 0 73 775 1 04 823 1 34 875 1 60 930 1 81 985
9. GAS PIPING SUPPORT FIGURE 20 1 Gas Piping Gas supply piping must not allow more than 0 5 W C 124 3 Pa drop in pressure between the gas meter and the unit Supply gas pipe must not be smaller than the unit gas connection Refer to installation instructions for de tails 2 Testing Gas Piping NOTE In case emergency shutdown is required turn off the main manual shut off valve and disconnect the main power to the unit These controls should be properly la beled by the installer When pressure testing gas lines the gas valve must be dis connected and isolated Gas valves can be damaged if subjected to more than 0 5 psig 14 W C 3481 Pa See figure 20 When checking piping connection for gas leaks use the preferred means Common kitchen detergents can cause harmful corrosion on various metals used in gas piping The use of specialty Gas Leak Detector is strong ly recommended It is available through Lennox under part number 31B2001 See CORP 8411 L10 for further details Do not use matches candles flame or any other source of ignition to check for gas leaks 3 Testing Gas Supply Pressure When testing gas supply pressure connect test gauge to the inlet pressure tap located on unit gas valve GV1 Test sup ply gas pressure with unit firing at maximum rate both stages energized Make sure the reading falls within the range of the following values Low pressure may result in erratic operation or underfire
10. WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURDEONH UNIT MUST BE GROUNDEDIN ACCORDANCBWITH NATIONAL AND LOCAL CODES DISCONNECT ALL POWER BEFORE SERVICING R Desa e we eum ee L P h S48 9 EQUIPMENT x GROUND 2 999 J11 H 120 60 1 GROUND PLUG OUTDOOR FANS 1 PLUG EXHAUST FAN MOTOR 1 JACK SMOKE DETECTOR ONE JACK SMOKE DETECTOR ONE JACK SMOKE DETECTOR TWO JACK SMOKE DETECTOR TWO 255 MODULE CONTROL SMOKE DETECTION p DENOTES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED SWITCH LIMIT LOW COMPRESSOR 1 39 24V POWER NOTE FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE P2 IS USED ON KCA UNITS ONLY IMPORTANT TO PREVENTMOTOR BURNOUT NEVER CONNECTMORETHAN ONEMOTORLEADTO ANY ONE CONNECTION TAPE UNUSED MOTOR LEADS 542 USEDON M VOLTAGEUNITS AND UNITS WITH HIGH EFFICIENCY MOTORS CONNECT A172 SENSOR TO J261 ON SUPPLY AIR SMOKE DETECTOR ONLY 548 OR CB10 MAY BE USED JUMPER WHEN 11 AND S84 ARE NOT USED ECONOMIZER BLOWER G HEAT 1 W1 bP HEAT 2 W2 DESCRIPTION COMPONENT MONITOR PHASE PROTECTION MODULE VOLTAGE REDUCTION gt A m lt A144 COOL 1 Y1 COOL 2 Y2 SENSOR ONE SMOKE RETURN AIR SENSOR TWO SMOKE SUPPLY AIR MODULE CONTROL SMOKE DETECTION COMPRESSOR
11. Do not force 8 9 Close or replace the heat section access panel Turn on all electrical power to appliance 10 Set thermostat to desired setting 11 The combustion air inducer will start The burners will light within 40 seconds 12 If the appliance does not light the first time gas line not fully purged it will attempt up to two more ignitions before locking out 13 If lockout occurs repeat steps 1 through 10 14 If the appliance will not operate follow the instructions Turning Off Gas to Appliance and call your service technician or gas supplier Turning Off Gas to Unit 1 If using an electromechanical thermostat set to the lowest setting 2 Before performing any service turn off all electrical power to the appliance 3 Open or remove the heat section access panel 4 Turn the knob on the gas valve clockwise 499 to OFF Depress 36C knob slightly Do not force 5 Close or replace the heat section access panel C Cooling Startup 1 Initiate first and second stage cooling demands ac cording to instructions provided with thermostat 2 First stage thermostat demand will energize compres sor 1 Second stage thermostat demand will energize compressor 2 On units with an economizer when out door air is acceptable a first stage demand will ener gize the economizer a second stage demand will en ergize compressor 1 3 Units contain two refrigerant circuits or stages See fig ure 19
12. 4 Each refrigerant circuit is separately charged with re frigerant See unit rating plate for correct amount of charge NOTE Refer to IV CHARGING for proper method to check refrigerant charge Three Phase Scroll Compressor Voltage Phasing Three phase power supplied to the unit disconnect switch must be phased sequentially to ensure the scroll com pressor and indoor blower rotate in the correct direction Compressor and blower are wired in phase at the factory Power wires are color coded as follows line 1 red line 2 yellow line 3 blue 1 Observe suction and discharge pressures and blower rotation on unit start up 2 Suction pressure must drop discharge pressure must rise and blower rotation must match rotation marking If pressure differential is not observed or blower rotation is not correct 3 Disconnect all remote electrical power supplies 4 Reverse any two field installed wires connected to the line side of K2 contactor or disconnect switch if installed Do not reverse wires at blower contactor Page 25 5 sure the connections tight Discharge and suction pressures should operate at their normal start up ranges REFRIGERANT CIRCUITS 092 150 CONDENSER COIL STAGE 2 CONDENSER COIL STAGE 1 EVAPORATOR COIL STAGE 2 BOTH FANS ARE ENERGIZED WITH A Y1 DEMAND CONDENSER FAN 1 CONDENSER FAN 2 EVAPORATOR COIL STAGE 1 FIGURE 19 D Safety or Emergency Shutdown Turn of
13. 05 CROMER Ee ENTHALPY DESIGNATES OPTIONAL WIRING PLUG ECONOMIZER CLASS II FIELD WIRING P104 PLUG SENSOR OUTDOOR ENTHALPY PLUG SENSOR RETURN AIR ENTHALPY WIRING DIAGRAM RESISTOR SENSIBLE 820 OHM IRT26 SENSOR OUTDOOR AIR TEMP RT27 SENSOR INDOOR AIR TEMP ACCESSORIES THERMOSTAT SENSIBLE TEMP 55 70F SWITCH EXHAUST DAMPER ECONOMIZER TERMINAL STRIP CLASS Il VOLT ECONOMIZER SECTION D1 Supersedes Form No New Form No 537080 01 2009 Litho U S A SEQUENCE OF OPERATION POWER 1 Terminal strip TB1 energizes the economizer components with 24VAC OPERATION 2 Enthalpy sensor A7 and A62 if differential enthalpy is used communicates to economizer control module A6 when to power the damper motor B7 3 Economizer control module A6 supplies B7 with O 10 VDC to control the positioning of economizer 4 The damper actuator provides 2 to 10 VDC position feedback Page 44
14. 1 COMPRESSOR 2 MOTOR BLOWER MOTOR OUTDOOR FAN 1 MOTOR OUTDOOR FAN 2 MOTOR EXHAUST FAN 1 CAPACITOR OUTDOOR FAN 1 2 CAPACITOR OUTDOOR 2 6 CAPACITOR EXHAUST FAN 1 B8 CIRCUIT BREAKER T1 A171 1 3 lt 2 DELAY OVERFLOW SWITCH HEATER COMPRESSOR 1 HEATER COMPRESSOR 2 R R2 2 JACK GFI RECEPTICLE JACK EXHAUST FAN COMPT 24 JACK EXHAUST FAN 35 JACK TEST JACK TEST COOL JACK OUTDOOR FANS 1 JACK BLOWER EXHAUST FAN MOTOR 1 JACK SMOKE DETECTOR ONE JACK SMOKE DETECTOR ONE JACK SMOKE DETECTOR TWO JACK SMOKE DETECTOR TWO JACK MODULE CONTROL SMOKE DETECTION lt lt gt o I 5 3 RELAY EXHAUST FAN K220 RELAY OVERFLOW DELAY pis EXHAUST FAN COMPT PLUG EXHAUST JACK TEST PLUG TEST COOL WIRING DIAGRAM 03 10 COOLING KCA KGA 092 102 120 150 G J M Y Supersedes New Form No 2009 Lennox Commercial KGA092 150 Sequence of Operation Power 1 Line voltage from unit disconnect energizes transform er T1 T1 provides 24VAC power to terminal strip TB1 TB1 provides 24VAC to the unit cooling heating and blower controls Blower Operation 2 Indoor thermostat terminal G energizes blower contac tor K3 with 24VAC N O K3 closes energizing blower B3 Economizer Operation 3 The economizer control module receives a demand and energizes exhaust fan
15. High pressure can result in permanent damage to the gas valve or overfire For nat ural gas units operating pressure at the unit gas connec Page 27 tion must be between 4 7 W C 10 5 W C 1168 Pa and 2610 Pa For L P gas units operating pressure at the unit gas connection must be between 10 8 W C and 13 5 W C 2685 3 Pa and 3356 7 Pa On multiple unit installations each unit should be checked separately while operating at maximum rate beginning with the one closest to the supply gas main and progressing to the one furthest from the main Multiple units should also be tested with and without the other units operating Supply pressure must fall within the range listed in the previous paragraph 4 Check and Adjust Manifold Pressure After line pressure has been checked and adjusted check manifold pressure Move test gauge to the outlet pressure tap located on unit gas valve GV1 See figure 17 for location of pressure tap on the gas valve The manifold pressure is factory set and should not re quire adjustment See table 12 If manifold pressure is incor rect and no other source of improper manifold pressure can be found the valve must be replaced See figure 17 or 18 for location of gas valve manifold pressure adjustment screw All gas valves are factory regulated The gas valve should completely and immediately cycle off in the event of gas or power failure The manual shut off knob can be used to imme di
16. Open 2400 0 21 0 18 0 15 0 14 2600 0 24 0 21 0 18 0 17 2800 0 27 0 24 0 21 0 20 092 Models 3000 0 32 0 29 0 25 0 25 3200 0 41 0 37 0 32 0 31 3400 0 50 0 45 0 39 0 37 3600 0 61 0 54 0 48 0 44 3800 0 73 0 63 ORO 0 51 3600 0 36 0 28 0 23 0 15 3800 0 40 0 32 0 26 0 18 4000 0 44 0 36 0 29 0 21 4200 0 49 0 40 0 33 0 24 102 amp 120 Models 4400 0 54 0 44 0 37 0 27 4600 0 60 0 49 0 42 0 31 4800 0 65 0 53 0 46 0 35 5000 0 69 0 58 0 50 0 39 5200 0 75 0 62 0 54 0 43 4200 0 22 0 19 0 16 0 10 4400 0 28 0 24 0 20 0 12 4600 0 34 0 29 0 24 0 15 4800 0 40 0 34 0 29 0 19 150 Models 5000 0 46 0 39 0 34 0 23 5200 0 52 0 44 0 39 0 27 5400 0 58 0 49 0 43 0 31 5600 0 64 0 54 0 47 0 35 5800 0 70 0 59 0 51 0 39 CEILING DIFFUSER AIR THROW DATA 1 Effective Throw Range Air Volume Model No RTD11 Step Down FD11 Flush cfm ft ft 2600 24 29 19 24 2800 25 30 20 28 092 Models 3000 27 33 21 29 3200 28 35 22 29 3400 30 37 22 30 3600 25 33 22 29 3800 27 35 22 30 1 4000 29 37 24 33 4200 32 40 26 35 4400 34 42 28 37 5600 39 49 28 37 5800 42 51 29 38 6000 44 54 40 50 6200 45 55 42 51 6400 46 55 43 52 6600 47 56 45 56 1 Throw is the horizontal vertical distance air stream travels leaving the outlet diffuser before the maximum velocity is reduced to 50 ft per minute Four sides open Page 11
17. See section IV CHARGING NOTE When unit is properly charged discharge line pres sures should approximate those in tables 7 through 10 VI MAINTENANCE The unit should be inspected once a year by a qualified ser vice technician Electric shock hazard cause injury or death Before attempting to perform any service or maintenance g turn the electrical power to unit OFF at disconnect switch es Unit may have multiple power supplies ACAUTION Label all wires prior to disconnection when servicing controls Wiring errors cause improper and dan gerous operation Verify proper operation after ser vicing AWARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool Breathing this may cause lung cancer Fiberglass wool is known to the State of Cali fornia 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 on unit nameplate or contact your supervisor AIMPORTANT The Clean Air Act of 1990 bans the intentional vent ing of refrigerant CFC s and HCFC s as of July 1 1992 Approved methods of recovery recycling or re claiming must followed Fines and or tion may be levied for non compliance A Filters Un
18. Setting A is recommended See figure 28 At set ting A free cooling will be energized when outdoor air is approximately 73 F 23 C and 50 relative humidity If in door air is too warm or humid lower the setpoint to B At set ting B free cooling will be energized at 70 F 21 C and 50 relative humidity When an optional A62 differential sensor is installed turn A6 enthalpy control free cooling setpoint potentiometer completely clockwise to position D TABLE 15 ENTHALPY CONTROL SETPOINTS 881 67 19 63 17 Damper Minimum Position NOTE A jumper is factory installed between TB1 R and OC terminals to maintain occupied status allowing mini mum fresh air When using an electronic thermostat or energy management system with an occupied unoccu pied feature remove jumper 1 Set thermostat to occupied mode if the feature is avail able Make sure jumper is in place between TB1 termi nals R and OC if using a thermostat which does not have the feature 2 Rotate MIN POS SET potentiometer to approximate desired fresh air percentage Note Damper minimum position can be set lower than traditional minimum air requirements when an IAQ sensor is specified Dampers will open to DCV MAX setting if CO2 is above setpoint to meet traditional ventilation require ments 3 Measure outdoor air temperature Mark the point on the bottom line of chart 1 and label the point A 40 F 4 C shown
19. see figure 31 air discharge applications Horizontal gravity exhaust dampers are installed in the return air duct The dampers must be used any time an economizer and a power exhaust fan is applied to KGA series units Gravity exhaust dampers allow exhaust air to be dis charged from the system when an economizer and or pow er exhaust is operating Gravity exhaust dampers also pre vent outdoor air infiltration during unit off cycle See installation instructions for more detail NOTE GED is optional except required with power ex haust dampers GRAVITY EXHAUST DAMPERS DOWNFLOW HOOD TOP SUPPORT FIGURE 30 FIGURE 31 Page 36 G Power Exhaust Fan The power exhaust fan PEF requires an optional gravity exhaust damper and economizer and is used in downflow applications only See figure 32 The PEF provides exhaust air pressure relief and also runs when return air dampers are closed and the supply air blower is operating See installation instructions for more detail GED AND PEF INSTALLATION GED GRAVITY EXHAUST DAMPERS PEF POWER EXHAUST FAN ASSEMBLY ORDERED SEPARATELY FIGURE 32 Power Exhaust Setpoint Adjustment Locate the A6 enthalpy control in the control area The EXH SET potentiometer is factory set at approximately 50 of the dial range See figure 33 Power exhaust fans will be en ergized 30 seconds after dampers are 50 open Adjust the EXH SET potentiometer higher clockwise toward 10V to ener
20. sion valve as the primary refrigerant metering device Each evaporator is also equipped with enhanced fins and rifled tubing In all units each compressor is protected by 549 and S50 free zestats and S4 and S7 high pressure switches on each evaporator Low ambient switches S11 S84 are available as an option for additional compressor protection On 150 units each compressor is protected by a crankcase heater 1 Compressors B1 and B2 All KGA092 150 units use two scroll compressors Com pressor capacity may vary from stage to stage In all cases the capacity of each compressor is added to reach the total capacity of the unit See SPECIFICATIONS and ELEC TRICAL DATA table of contents or compressor nameplate for compressor specifications A WARNING Electrical shock hazard Compressor must be grounded Do not operate without protective cover over terminals Disconnect power before removing protective cover Discharge capacitors before ser vicing unit Failure to follow these precautions could cause electrical shock resulting in injury or death Each compressor is energized by a corresponding com pressor contactor NOTE Refer to the wiring diagram section for specific unit operation If Interlink compressor replacement is necessary call 1 800 4 LENNOX 1 800 453 6669 AIMPORTANT Some scroll compressors have an internal vacuum protector that will unload scrolls when suction pressure goes below 20 p
21. 0 ft 2400m A IMPORTANT Disconnect heating demand as soon as an accurate reading has been obtained 6 Proper Gas Flow Furnace should operate at least 5 minutes before checking gas flow Determine time in seconds for two revolutions of gas through the meter Two revolutions assures a more ac curate time Divide by two and compare to time in table 13 Seconds in table 13 are based on a 1 cu ft dial and gas val ue of 1000 btu s for natural and 2500 btu s for LP Adjust manifold pressure on gas valve to match time needed NOTE To obtain accurate reading shut off all other gas appliances connected to meter TABLE 13 untinsw s Pirat Propane Natural Propane momo 25 e 7 Heat Exchanger To Access or Remove Heat Exchanger From Unit 1 Turn off gas and electric power 2 Remove access panel s and unit center mullion 3 Remove gas valve manifold assembly and burn ers 4 Remove combustion air inducer and flue box cover Pay careful attention to the order in which gaskets and orifice are removed 5 Support heat exchanger to prevent it from falling when final screws are removed 6 Remove screws supporting heat exchanger 7 To install heat exchanger reverse procedure Be sure to secure all wires and check plumbing and burner plate for airtight seal Screws must be torqued to 35 in Ibs to ensure proper operation Page 28 8 Flame Sensing Flame current electrical current which
22. 1 97 1036 2 12 1086 2 31 1136 2 54 1186 2 83 1235 3 13 3500 663 0 35 700 0 63 741 0 92 786 1 22 834 1 5 886 1 76 942 1 96 997 2 14 1048 2 31 1097 2 51 1147 2 75 1196 3 04 1245 3 35 3750 676 0 57 714 0 84 754 1 12 798 1 41 846 1 68 899 1 93 956 2 14 1010 2 32 1060 2 51 1109 2 72 1158 2 98 1207 3 27 1255 3 58 4000 691 0 79 728 1 05 768 1 33 812 1 61 860 1 88 914 2 12 971 2 34 1023 2 53 1072 2 73 1121 2 95 1169 3 22 1218 3 51 1266 3 83 4250 706 1 03 743 1 28 783 1 55 827 1 82 876 2 09 931 2 33 987 2 55 1037 2 76 1085 2 97 1133 3 20 1181 3 47 1229 3 76 1277 4 08 4500 722 1 27 759 1 52 799 1 78 844 2 05 894 2 31 949 2 56 1003 2 79 1052 3 00 1098 3 22 1145 3 46 1193 3 73 1241 4 03 1289 4 34 4750 739 1 53 776 1 77 817 2 03 862 2 30 913 2 56 968 2 81 1020 3 04 1066 3 27 1112 3 49 1158 3 74 1205 14 01 1253 4 30 1301 4 61 5000 757 1 79 794 2 04 835 2 30 882 2 56 934 2 83 988 3 08 1036 3 32 1081 3 55 1125 3 78 1171 4 02 1218 4 29 1265 4 59 1312 4 89 8 BLOWER DATA 150 BELT DRIVE BLOWER BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY NO HEAT SECTION WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE FOR ALL UNITS ADD 1 Wet indoor coil air resista
23. 1 Rated Load Amps 19 e 7 4 Locked Rotor Amps 123 62 50 Compressor 2 Rated Load Amps 19 9 7 7 4 Locked Rotor Amps 123 62 50 Outdoor Fan Full Load Amps 3 1145 1 2 Motors 2 total 6 3 2 4 Power Exhaust Full Load Amps 2 4 1 3 1 1 0 33 Service Outlet 115V GFI amps 15 15 15 Indoor Blower Horsepower 5 Motor Full Load Amps 16 7 7 6 6 1 Maximum Unit Only 70 35 25 Overcurrent With 1 0 33 HP 70 35 25 Protection Power Exhaust 3 Minimum Unit Only 53 27 22 Circuit With 1 0 33 HP 56 29 23 Ampacity Power Exhaust 1 Extremes of operating range are plus and minus 10 of line voltage 2 HACR type breaker or fuse 3 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Page 13 PARTS DISCONNECT CIRCUIT BREAKER EVAPORATOR BLOWER CONDENSER ECONOMIZER FACTORY OR FIELD COIL MOTOR FANS OPTIONAL INSTALLED OPTION CONDENSER COMBUSTION AIR INDUCER COMPRESSORS GAS VALVE FILTERS CONDENSATE BURNERS FOUR 20 X 25 X 2 DRAIN FIGURE 1 KGA CONTROL BOX Y G J VOLT UNITS KGA CONTROL BOX M VOLT CE UNITS o 5176 5177 542
24. 3W80 X X X X Smoke Detector Supply and Return Power board and two sensors C1SNSR43B 1 53W81 X X X X INDOOR AIR QUALITY Air Filters Healthy Climate High Efficiency Air Filters MERV 8 CTFLTR15B 1 50W61 X 20 x 25 x 2 Order 4 unit MERV 13 C1FLTR40B 1 52W41 X X X X Replacement Media Filter With Metal Mesh C1FLTR30B 1 Y3063 X x X X Frame includes non pleated filter media Indoor Air Quality CO Sensors Sensor Wall mount off white plastic cover with LCD display COSNSR50AE1L 77N39 X X X X Sensor Wall mount off white plastic cover no display COSNSR52AE1L 87N53 X X X X Sensor Black plastic case with LCD display rated for plenum COSNSR51AE1L 87 52 X X X X mounting Sensor Wall mount black plastic case no display rated for COMISC19AE1 87N54 X X X X plenum mounting CO Sensor Duct Mounting Kit for downflow applications COMISC19AE1 85L43 X X X X euler duct mounting non plenum rated sensors COMISC16AE1 90 43 X X X X UVC Germicidal Lamps Healthy Climate UVC Light Kit 208 230v 1ph C1UVCL10B 1 54W62 X X X X ELECTRICAL Voltage 60 hz 208 230V 3 phase Factory 460V 3phase Factory 575V 3 phase Factory O O Disconnect Switch 80 C1DISCO80B 1 54W56 GFI Service Outlets LTAGFIK10 15 74M70 OX Lamps operate on 110 230V single phase power supply Step
25. 54W47 X X X X 18 in height C1CURB21B 1 54W48 X X X X 24 in height C1CURB22B 1 54W49 X X X X Standard 8 in height C1CURB12B 1 54W44 X X X X 14 in height C1CURB10B 1 54W43 X X X X 24 in height C1CURB11B 1 54W45 X X X X Adjustable Pitched Curb 14 in height C1CURB55B 1 54W50 X X X X CEILING DIFFUSERS Step Down Order one RTD11 95 29604 X RTD11 135 29605 X X RTD11 185 29606 X Flush Order one FD11 95 29G08 X FD11 135 29609 X X FD11 185 29610 X Transitions Supply and Return Order one LASRT08 10 24114 X LASRT10 12 49 55 X X LASRT15 49K56 X NOTE Catalog and model numbers shown are for ordering field installed accessories OX Configure To Order Factory Installed or Field Installed O Configure To Order Factory Installed X Field Installed Page 4 SPECIFICATIONS General Data Nominal Tonnage 7 5 Ton 8 5 Ton 10 Ton 12 5 Ton Model Number KGA092S4B KGA102S4B KGA120S4B KGA150S4B Efficiency Type Standard Standard Standard Standard Blower Type Constant Air Constant Air Constant Air Constant Air Volume CAV Volume CAV Volume CAV Volume CAV Cooling Gross Cooling Capacity Btuh 88 900 100 500 119 600 144 800 Performance Net Cooling Capacity Btuh 86 000 97 000 115 000 138 000 AHRI Rated Air Flow cfm 3 000 3 400 3 800 4 300 Total Unit Power kW 7 8 8 8 10 4 12 8 1 EER Btuh Watt 11 11 11 10 8 2 IEER Btuh Watt 11 2 11 2 11 2 11 Refrigerant R 410A R 410A R 410A R 410A Ref
26. 7 1227 4 44 1278 4 74 1330 5 05 5250 807 2 33 850 2 61 893 2 87 937 3 11 979 3 33 1021 3 55 1064 3 80 1107 4 03 1151 4 27 1197 4 51 1245 4 78 1295 5 08 1347 5 38 5500 831 2 66 874 2 94 917 3 2 960 3 43 100213 67 1043 3 91 108514 16 1127 4 39 1171 4 63 1216 4 87 1264 5 14 1313 5 42 1364 5 72 5750 856 3 00 899 3 29 943 3 55 985 3 79 1026 4 04 1066 4 30 1107 4 55 1149 4 78 1192 5 00 1237 5 24 1284 5 50 6000 883 3 38 927 3 66 970 3 93 1010 4 19 1050 4 46 1089 4 72 1129 4 95 1171 5 17 12135 40 12575 63 6250 912 3 78 956 4 07 997 4 35 1036 4 63 1074 4 90 1113 5 15 1152 5 37 1193 5 58 Page 9 BLOWER DATA FACTORY INSTALLED BELT DRIVE KIT SPECIFICATIONS Nominal Maximum Drive Kit Number RPM Range hp hp 2 23 1 590 890 2 23 2 800 1105 2 23 3 795 1195 3 3 45 4 730 970 3 3 45 5 940 1200 3 3 45 6 1015 1300 5 SI 10 900 1135 5 DAS 11 1040 1315 5 OS 12 1125 1425 POWER EXHAUST FAN PERFORMANCE Return Air System Static Pressure Air Volume Exhausted in w g cfm 0 3175 0 05 2955 0 10 2685 015 2410 0 20 2165 0 25 1920 0 30 1420 0 35 1200 FACTORY INSTALLED OPTIONS FIELD INSTALLED ACCESSORY AIR RESISTANCE in w g
27. 9 li AA PLUG HEAT PLUG COMBUSTION AIR BLOWER P19 P229 PLUG VESTIBULE HEATER CONTROL 1 SWITCH LIMIT PRIMARY GAS SWITCH COMB AIR BLOWER PROVE SWITCH FLAME ROLLOUT BURNER 1 THERMOSTAT OPEN 20F CLOSE 10F e gt 9 18 559 560 THERMOSTAT OPEN 20 CLOSE 10 561 THERMOSTAT OPEN 50F CLOSE 20F 3 TRANSFORMER COMB AIR BLOWER 1 EM Nilo K1 1 E O OHO W2 OUT CSA 50C LOW AMBIENT KIT OPTIONAL A T3 USED ON 480V AND 600V UNITS INDICATES MICRO PROCESSER DENOTES OPTIONAL COMPONENTS WIRING DIAGRAM COMBINATION UNIT ROOFTOP GAS HEAT FOR TGA UNITS 130 TURY 240 UNITS B BOX HEATING SECTION A1 Supersedes Form No New Form No 535334w 537063 01 Page 41 Litho U S A GAS HEAT SEQUENCE OF OPERATION First Stage Heat 1 The thermostat initiates W1 heating demand 2 24 is routed from TB1 to ignition control through P2 proves N C primary limit S10 and rollout switch S47 3 Combustion air inducer blower B6 is energized 4 After the combustion air inducer B6 has reached full speed the combustion air proving switch S18 con tacts close 5 After a 30 second delay A3 energizes the ignitor and LO terminal low fire of gas valve GV1 Second Stage Heat 6 With first stage heat operating an additional heating demand from the thermostat initiates W2 7 A second stage heating demand is received by 1 The second stage
28. 9 The Honeywell T7300 thermostat is a programmable in ternal or optional remote temperature sensing thermo stat The T7300 provides occupied and unoccupied changeover control J Smoke Detectors A171 and A172 Photoelectric smoke detectors are a field installed option The smoke detectors can be installed in the supply air sec tion A172 return air section A171 or in both the supply and return air section K LP Propane Kit 5 092 150 units require a natural to LP propane kit The kit includes one LP spring conversion kit up to eleven burner orifices and three stickers For more detail refer to the natural to LP gas changeover kit installation instructions L Drain Pan Overflow Switch 5149 optional The overflow switch is used to interrupt cooling operation when excessive condensate collects in the drain pan The overflow switch is controlled by K220 and DL46 re lays located in the unit control panel When the overflow Switch closes 24VAC power is interrupted and after a five second delay unit compressors are de energized Once the condensate level drops below the set level the switch will open After a five minute delay the compressor will be energized Page 38 VIII Wiring Diagrams and Sequence of Operation KGA092 150 UNIT DIAGRAM A173 SENSOR 1 220 240V NOTE IF ANY WIRE IN THIS APPLIANCHS MUST REPLACEDWITH WIRE OF LIKE SIZE RATING TERMINATION AND INSULATION THICKNESS
29. AIR FIGURE 23 TYPICAL FLASHING DETAIL UNIT BASE BOTTOM UNIT BASE RAIL FIBERGLASS INSULATION Furnished COUNTER FLASHING NAILER STRIP Field Supplied Furnished CANT STRIP Field Supplied RIGID INSULATION Field Supplied MOUNTING FRAME Extends around entire perimeter of unit FIGURE 24 ROOFING MATERIAL B Transitions Optional supply return transitions LASRT08 10 is available for use with the KGA 7 5 ton units and LASRT10 12 is avail able for the 8 5 and 10 ton units utilizing optional C1CURB roof mounting frames KGA 12 5 ton units will use LASRT15 with C1CURB roof mounting frame Transition must be installed in the C1CURB mounting frame before mounting the unit to the frame Refer to the manufacturer s instructions included with the transition for detailed installa tion procedures C Supply and Return Diffusers Optional flush mount diffuser retum FD11 and extended mount diffuser return RTD11 are available for use with all KGA units Refer to manufacturers instructions included with transi tion for detailed installation procedures D LAOAD M Outdoor Air Dampers Field or Factory Installed Optional manual and motorized outdoor air dampers pro vide up to 25 percent fresh air for return Motorized damper opens to minimum position simultaneously with the blower during the occupied period and remains closed during the unoccupied period Manual damper assembly is manually
30. B5 9 Power Exhaust Relay K65 PED units Power exhaust relay K65 is a DPDT relay with a 24VAC coil K65 is used in all KGA units equipped with the op tional power exhaust dampers K65 is energized by the economizer enthalpy control A6 after the economizer dampers reach 50 open adjustable When K65 closes exhaust fan B10 is energized Page 15 KGA092 102 120 150 PLUMBING AND COMPRESSOR CIRCUITS DETAIL INDOOR COIL STAGE 2 INDOOR COIL STAGE 1 COMPRESSOR 2 COMPRESSOR 1 COMPRESSOR 2 S8 THERMAL PROTECTOR SUCTION LINE DISCHARGE LINE S7 HIGH PRESSURE SWITCH PRESSURE TAP OUTDOOR COIL STAGE 2 STATA Si YES EYE a WATAT Cm m Tm NYC NINE ao PEE io To TN DRIERS OUTDOOR COIL STAGE 1 COMPRESSOR 1 55 THERMAL PROTECTOR SUCTION LINE DISCHARGE LINE S4 HIGH PRESSURE SWITCH PRESSURE TAP FIGURE 6 Page 16 B Cooling Components All units use independent cooling circuits consisting of sepa rate compressors condenser coils and evaporator coils See figure 6 Two draw through type condenser fans are used in KGA092 150 units All units are equipped with belt drive blowers which draw air across the evaporator during unit operation Cooling may be supplemented by factory or field installed economizer The evaporators are slab type and are stacked Each evaporator uses a thermostatic expan
31. In case of a safety shutdown move thermostat switch to OFF and return the thermostat switch to HEAT to reset ignition control Placing Unit In Operation AWARNING Danger of explosion and fire Can cause injury or product or property damage You must follow these instructions exactly W Gas Valve Operation for White Rodgers 36C figure 17 and Honeywell VR8205Q VR83059 figure 18 1 Setthermostat to lowest setting 2 Turn off all electrical power to appliance Page 24 WHITE RODGERS 36 76 GAS VALVE HIGH FIRE MANIFOLD PRESSURE INLET ADJUSTMENT SCREW UNDER CAP MANIFOLD PRESSURE PRESSURE TAP SIDE TAP SIDE GAS VALVE SHOWN IN OFF POSITION FIGURE 17 HONEYWELL VR8205Q VR8305Q SERIES GAS VALVE HIGH FIRE ADJUSTMENT LOW FIRE PRESSURE TAP Gas valve knob is shown in OFF position FIGURE 18 3 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 4 Open or remove the heat section access panel 5 Turn the knob on the gas valve clockwise 499 to OFF Depress 36C knob slightly Do not force O 1 Wait five 5 minutes to clear out any gas If you then smell gas STOP Immediately call your gas suppli er from a neighbor s phone Follow the gas supplier s instructions If you do not smell gas go to the next step 7 Turn the knob on the gas valve counterclockwise to
32. SE IN PLACE REMOVE TWO SCREWS EN TO COMPLETELY SLIDE BLOWER OUT OF UNIT tions provided with thermostat Unit will cycle on thermostat demand The following steps apply to applications using a typical electro mechanical thermostat 1 Blower operation is manually set at the thermostat sub base fan switch With fan switch in ON position blow ers will operate continuously 2 With fan switch in AUTO position the blowers will cycle with demand Blowers and entire unit will be off when system switch is in OFF position Determining Unit CFM 1 The following measurements must be made with a dry indoor coil Run blower without a cooling demand Measure the indoor blower shaft RPM Air filters must be in place when measurements are taken 2 With all access panels in place measure static pres sure external to unit from supply to return Measure static below roof curb if roof curb is used 3 Refer to blower tables in BLOWER DATA table of con tents in the front of this manual Use static pressure and RPM readings to determine unit air volume BLOWER ASSEMBLY SIDE VIEW ALLEN SCREW PULLEY BLOWER HOUSING BLOWER FRAME LOOSEN BEFORE ADJUSTING BELT TENSION TWO EACH SIDE REMOVE TWO SCREWS ON EACH SIDE TO SLIDE FRAME PARTIALLY OUT OF UNIT FOR SERVICE ACCESS FIGURE 7 Page 18 4 The blower RPM be adjusted at the motor pulley Loosen Allen screw and turn adjustable pulley cloc
33. TS J3 MAXIMUM LOAD 20VA 24VAC CLASS II CONNECTION SCHEME FOR KCA KGA AND KHA 092 THROUGH 150 UNITS WITHOUT ECONOMIZER ONLY TIME CLOCK CONTACTS OPT CLOSED OCCUPIED ACCESSORIES TOUCHSCREEN THERMOSTAT ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT 13 AND ARE NOT USED ON KCA KGA AND KHA SECTION C 092 THROUGH 150 UNITS WITHOUT ECONOMIZER Supersedes New Form No REMOVE JUMPER BETWEEN TB1 R AND TB1 OCP ee 573 537077 01 WHEN USING A NITE SETBACK THERMOSTAT Lennox Commercial P P P P P P P POWER 1 Terminal strip TB1 energizes thermostat components with 24VAC OPERATION 2 TB1 receives data from the electronic thermostat A2 Y1 Y2 W1 W2 G OCP The 24VAC signal from TB1 ener gizes the appropriate components for heat or cool demand Page 43 ECONOMIZER B7 MS7110K RANGE 2 10 VDC OPTIONAL OUTDOOR THERMOSTAT REPLACE N USED ON C BOX UNITS DESCRIPTION RT26 SENSIBLE SENSOR ZX A62 ENTHALPY SENSOR OR RT27 USED COMPONENT A OPTIONAL EXHAUST DAMPER TO HOLD EXHAUST FOR DIFFERENTIAL SENSING CONTROL SOLID STATE ENTHALPY DAMPER CLOSED WHEN OUTSIDE AIR DAMPER IS N RT26 AND RT27 TEMPERATURE SENSORS MAY SENSOR SOLID STATE ENTHALPY CLOSED BE USED INSTEAD OF A7 AND A62 ENTHALPY SENSORS A62 SENSOR 11 USED ON C BOX ONLY WITH MOTOR M7215A MOTOR EXHAUST DAMPER ZX REPLACE A7 OR RT26 WITH 620 OHM RESISTOR JACK ECONOMIZER FOR CONTROLS WITH GLOBAL ECON J104__ JACK SENSOR OUTDOOR ENTHALPY
34. a SPST switch located to the right of the induced draft assembly 518 monitors combustion air inducer operation Switch 518 is wired to the ignition control A3 The switch closes on a negative pressure fall This neg ative pressure fall and switch actuation allows the ignition sequence to continue proves by closing that the combus tion air inducer is operating before allowing the gas valve to open The combustion air prove switch is factory set and not adjustable The switch will automatically open on a pressure rise less negative pressure Table 2 shows prove switch settings TABLE 2 18 Prove Switch Settings Close w c Pa Open w c Pa 0 10 5 24 8 12 4 0 25 5 62 3 12 4 6 Combustion Air Inducer B6 Combustion air inducers KGA092 150 units provide air to the corresponding burners while clearing the combustion chamber of exhaust gases The inducer begins operating immediately upon receiving a thermostat demand and is de energized when thermostat demand is satisfied The inducer uses a 208 230V single phase PSC motor and a 4 81in x 1 25in 122mm x 32mm blower wheel All motors operate at 3200RPM and are equipped with auto reset overload protection Inducers are supplied by vari ous manufacturers Ratings may vary by manufacturer Specific inducer electrical ratings can be found on the unit rating plate On a heating demand W1 the ignition control A3 initiates the heating cycle A3 th
35. alified service technician to inspect the unit and to replace any part of the control system and any gas control which has been under water AWARNING Danger of explosion Can cause injury or product or property damage lf over heating occurs or if gas supply fails to shut off shut off the manual gas valve to the appliance before shutting off electrical supply AWARNING 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 AWARNING SMOKE POTENTIAL The heat exchanger in this unit could be a source of smoke on initial firing Take precautions with respect to building occupants and property Vent initial sup ply air outside when possible BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion AWARNING W Danger of explosion Can cause injury or death Do not attempt to light manually Unit has a direct spark ignition system This unit is equipped with an automatic spark ignition sys tem There is no pilot
36. ange F 15 45 30 60 40 70 Thermal Efficiency 8096 80 80 Gas Supply Connections 3 4 3 4 3 4 Recommended Gas Supply Natural 7 7 Pressure in w g LPG Propane 11 11 11 HIGH ALTITUDE DERATE Units may be installed at altitudes up to 2000 feet above sea level without any modification At altitudes above 2000 feet units must be derated to match gas manifold pressures shown in table below NOTE This is the only permissible derate for these units Gas Heat Altitude Ga Manifold pressure Natural Poe po Type Natural Gas LPG Propane Gas First Stage Second Stage ft In w g In w g Btuh Btuh Standard 2001 4500 3 4 9 6 84 500 124 000 Medium 2001 4500 3 4 9 6 117 000 172 000 High 2001 4500 3 4 9 6 156 000 230 000 Page 6 BLOWER DATA 092 AND 102 BELT DRIVE BLOWER BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY NO HEAT SECTION WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE FOR ALL UNITS ADD 1 Wet indoor coil air resistance of selected unit 2 Any factory installed options air resistance heat section economizer etc 3 Any field installed accessories air resistance duct resistance diffuser etc Then determine from blower table blower motor output required See page 10 for blower motors and drives See page 10 for wet coil and option accessory air resistance data MAXIMUM STATIC PRESSURE WITH GAS HEAT 2 0 in w g Total Static Pressure in w g
37. ant differences could mean that the system is not properly charged or that a problem exists with some component in the system Correct any system problems before proceeding 6 If discharge pressure is high remove refrigerant from the system If discharge pressure is low add refrigerant to the system Add or remove charge in increments Allow the system to stabilize each time refrigerant is added or removed 7 Use the following approach method along with the nor mal operating pressures to confirm readings TABLE 7 KGA092 NORMAL OPERATING PRESSURES Outdoor CIRCUIT 1 CIRCUIT 2 Coil Dis Dis Entering charge Suction charge i 10 psig 5 psig 10 psig Suction 5 psig Outdoor CIRCUIT 1 CIRCUIT 2 Coil Dis Dis Entering charge Suction charge i 10 psig 5psig 10 psig Suction 5 psig TABLE 9 KGA120 NORMAL OPERATING PRESSURES Outdoor CIRCUIT 1 CIRCUIT 2 Coil Dis Dis Entering charge Suction charge Suction Air Temp 10 psig 5psig 10 psig 5 psig 2 rr SE 355 40 366 4 40 2 44 f Cose 45 464 5 4e WB S7 T m j Page 26 TABLE 10 KGA150 NORMAL OPERATING PRESSURES Outdoor CIRCUIT 1 CIRCUIT 2 Coil Dis Dis Entering charge Suction charge Suction Air Temp 10 psig 5psig 10 psig 5 psig 5 136 zu 138 85 F 139 95 F 140 105 F 142 115 F 508 145 Charge Ver
38. ately shut off gas supply CAUTION For safety connect a shut off valve between the manometer and the gas tap to permit shut off of gas pressure to the manometer Manifold Adjustment Procedure 1 Connecttest gauge to the outlet pressure tap on the gas valve Start the unit call for second stage heat and allow five minutes for the unit to reach steady state 2 While waiting for the unit to stabilize notice the flame The flame should be stable without flashback and should not lift from the burner heads Natural gas should burn basically blue with some clear streaks L P gas should burn mostly blue with some clear yellow streaks 3 After allowing the unit to stabilize for five minutes re cord the manifold pressure and compare to the values given in table 3 5 High Altitude Units may be installed at altitudes up to 2000 feet 610 m above sea level without any modification At altitudes above 2000 feet 610 m units must be derated to match the gas manifold pressures shown in table 12 NOTE This is the only permissible derate for these units TABLE 12 Gas Manifold Pressure in w g kPa LP Propane 10 5 2 61 10 2 2 54 Altitude ft m Natural 0 2000 610 2001 3000 610 915 4001 5000 1220 1525 5001 6000 1525 1830 6001 7000 1830 2135 7001 8000 2135 2440 3 1 0 77 8 8 2 19 Contact Technical Support for altitudes higher than 800
39. both stages without delay On both valves first stage low fire is quick opening on and off in less than 3 seconds On the White Rodgers valve second stage is slow opening on to high fire pressure in 40 seconds and off to low fire pressure in 30 seconds The White Rodgers valve is adjustable for high fire only Low fire is not adjustable On the Honeywell valve second stage is quick opening The Honeywell valve is ad justable for both low fire and high fire Figures 17 and 18 show gas valve components Table 3 shows factory gas valve regulation for KGA series units TABLE 3 GAS VALVE REGULATION Operating Manifold Pressure Inlet Pressure Natural L P V 1 6 0 2 3 7 0 3 65 03 10 5 0 5 W C C W W C Page 21 9 Spark Electrode Figure 13 An electrode assembly is used for ignition spark The elec trode is mounted through holes under the left most burner location The electrode tip protrudes into the flame enve lope of the adjacent burner The electrode assembly is fas tened to burner supports and can be removed for service without removing any part of the burners During ignition spark travels through the spark electrode figure 13 and ignites the left burner Flame travels from burner to burner until all are lit The spark electrode is connected to the ignition control by a 8 mm silicone insulated stranded high voltage wire The wire uses 1 4 6 35 mm female quick connect on bot
40. ction The blower assembly is accessed by disconnecting the blow er motor See Blower Access in the Operation Adjustment section The blower pulls out as shown in figure 7 1 Blower Wheels All KGA092 150 units have one 15 in x 15 in 381 mm x 381 mm blower wheel 2 Indoor Blower Motor B3 All units use three phase single speed blower motors CFM adjustments are made by adjusting the motor pulley sheave Motors are equipped with sealed ball bearings All motor speci fications are listed in the SPECIFICATIONS table of contents in the front of this manual Units may be equipped with motors manufactured by various manufacturers therefore electrical FLA and LRA specifications will vary See unit rating plate for information specific to your unit OPERATION ADJUSTMENT Blower Operation Initiate blower demand at thermostat according to instruc TO INCREASE BELT TENSION 1 Loosen four bolts securing motor mounting base to frame 2 Turn adjusting bolt to the right or clockwise to move the motor away from the blower housing IMPORTANT Gap between end of frame and motor mounting base should be equal at both ends i e par allel along gap 3 Tighten four bolts securing motor mounting base to frame 4 Relieve tension on two adjusting bolts MOTOR MOUNTING BASE BELT ADJUSTING BOLTS TURN CLOCKWISE TO TIGHTEN BELT GAP BETWEEN EDGES SHOULD BE PARALLEL ON BOTH ENDS BEFORE TIGHTENING MOTOR MOUNTING BA
41. ctrode The igni tion control allows the gas valve to stay open as long as a flame signal current passed through the flame is sensed SIDE VIEW SENSOR Gas Flow gt FIGURE 14 INTEGRATED CONTROL BOARD A3 11 Burner Control A3 AWARNING Shock hazard Spark related compo nents contain high voltage which can cause personal injury or death Discon nect power before servicing Control is not field repairable Unsafe operation will result If control is inoperable sim ply replace the entire control The burner control A3 is located in the gas heat section See figures 16 and 15 The ignition control provides four main functions gas valve control blower control ignition and flame sensing The control has a green LED to show control status table 4 The unit will usually ignite on the first trial and A3 allows three trials for ignition before locking out The lockout time is 1 hour After lockout the ignition control automatically resets and provides three more attempts at ignition Manual reset after lockout requires removing power from the control for more than 1 second or removing the thermostat call for heat for more than 1 second but no more than 20 seconds 24 volt thermostat connections P2 and heating component con nections J1 are made through separate jackplugs See table 5 for thermostat terminations and table 6 for heating compo
42. down transformer may be ordered separately for 460V and 575V units Alternately 110V power supply may be used to directly power the UVC ballast s NOTE Catalog and model numbers shown are for ordering field installed accessories OX Configure To Order Factory Installed or Field Installed O Configure To Order Factory Installed X Field Installed Page 3 OPTIONS ACCESSORIES Item Description Model Catalog Number Number 092 102 120 150 ECONOMIZER Economizer Economizer with Single Temperature Control Downflow or K1ECON20B 1 54W55 OX OX OX OX Horizontal With Barometric Relief Dampers downflow and Air Hoods Economizer Controls Single Enthalpy Control C1SNSR64FF1 53W64 OX OX Differential Enthalpy Control order 2 C1SNSR64FF1 53W64 X X X X Horizontal Barometric Relief Dampers With Exhaust Hood Horizontal Barometric Relief Dampers Exhaust Hood Furnished LAGEDH03 15 53K04 X X X X OUTDOOR AIR Outdoor Air Dampers Motorized Dampers with outdoor air hood C1DAMP20B 1 53W49 OX OX OX OX Manual Dampers with outdoor air hood C1DAMP10B 1 53W48 OX OX OX OX POWER EXHAUST Standard Static 208 230V 3ph KIPWRE10B 1Y 53W44 X X X X 460V 3ph KIPWRE10B 1G 53W45 X X X X 575V 3ph K1PWRE10B 1J 53W46 X X X X ROOF CURBS DOWNFLOW Clip Curb 8 in height C1CURB23B 1 54W46 X X X X 14 in height C1CURB20B 1
43. e clips connecting coils slabs and separate slabs 3 4 76 102mm Clean coils with detergent or commercial coil cleaner Rinse thoroughly with water and reassemble FIGURE 22 Page 30 VII ACCESSORIES The accessories section describes the application of most of the optional accessories which can be factory or field installed to the KGA units OPTIONAL ACCESSORIES section see table of contents show specific size per unit A LARMF Mounting Frames When installing units on a combustible surface for downflow discharge applications the Lennox C1CURB roof mounting frame is used The roof mounting frames are recommended in all other applications but not required If the KGA units are not mounted on a flat roof surface they MUST be sup ported under all edges and under the middle of the unit to prevent sagging The units MUST be mounted level within 1 16 per linear foot or 5mm per meter in any direction The assembled C1CURB mounting frame is shown in fig ure 23 Refer to the roof mounting frame installation instruc tions for details of proper assembly and mounting The roof mounting frame MUST be squared to the roof and level be fore mounting Plenum system MUST be installed before the unit is set on the mounting frame Typical roof curbing and flashing is shown in figure 24 Refer to the roof mount ing frame installation instructions for proper plenum construction and attachment ASSEMBLED ROOF MOUNTING FRAME SUPPLY
44. en allows 30 to seconds for the com bustion air inducer to vent exhaust gases from the burners When the combustion air inducer is purging the exhaust gases the combustion air prove switch closes proving that the combustion air inducer is operating before allowing the ignition sequence to continue When the combustion air prove switch is closed and the delay is over the ignition control activates the first stage operator of the gas valve low fire the spark and the flame sensing electrode Spark ing stops immediately after flame is sensed or at the end of the eight second trial for ignition All combustion air inducer motors are sealed and cannot be oiled The inducer cannot be adjusted but can be dis assembled for cleaning 7 Combustion Air Motor Capacitor C3 The combustion air inducer motors in all KGA units re quire run capacitors Capacitor C3 is connected to com bustion air inducer B6 Ratings will be on side of capaci tor or combustion air motor nameplate 8 Gas Valves GV1 Gas valve GV1 is a two stage redundant valve Units are equipped with valves manufactured by White Rodgers or Honeywell On a call for first stage heat low fire the valve is energized by the ignition control simultaneously with the spark electrode On a call for second stage heat high fire the sec ond stage operator is energized directly from A3 A manual shut off knob is provided on the valve for shut off Manual shut off knob immediately closes
45. f power to unit Close manual and main ga valves IV CHARGING A WARNING Refrigerant can be harmful if it is inhaled Refrigerant must be used and recovered responsibly Failure to follow this warning may result in person al injury or death WARNING Do not exceed nameplate charge under any condition This unit is factory charged and should require no further adjustment If the system requires additional refrigerant re claim the charge evacuate the system and add required nameplate charge NOTE System charging is not recommended below 60 F 15 C In temperatures below 60 F 15 C the charge must be weighed into the system If weighing facilities are not available or to check the charge use the following procedure 1 Attach gauge manifolds and operate unit in cooling mode with economizer disabled until system stabilizes approximately five minutes Make sure outdoor air dampers are closed 2 Check each system separately with all stages operating 3 Use a thermometer to accurately measure the outdoor ambient temperature 4 Apply the outdoor temperature to tables 7 through 10 to determine normal operating pressures Pressures are listed for sea level applications at 80 F dry bulb and 67 F wet bulb return air 5 Compare the normal operating pressures to the pres sures obtained from the gauges Minor variations in these pressures may be expected due to differences in installations Signific
46. gas mixture is drawn in at the bottom Heat is transferred to the air stream from all surfaces of the heat exchanger tubes The supply air blower forces air across the tubes to extract the heat of combustion The shape of the tubes ensures maximum heat exchange The gas valves accomplish staging by allowing more or less gas to the burners as called for by heating demand HEAT EXCHANGER ASSEMBLY HEAT COMBUSTION AIR INDUCER CONNECTOR m P Rd Sy FIGURE 10 2 Burner Box Assembly Figure 11 The burner assembly consists of a spark electrode flame sensing electrode and gas valve Ignition board A3 controls all functions of the assembly Burners All units use inshot burners Burners are factory set and do not require adjustment A peep hole with cover is fur nished in the heating access panel for flame viewing Always operate the unit with the access panel in place Burners can be removed individually for service Burner maintenance and service is detailed in the SERVICE CHECKS section of this manual GAS VALVE BURNER Orifice Each burner uses an orifice which is matched to the burn er input The orifice is threaded into the burner manifold The burner is supported by the orifice and will easily slide off for service once the mounting screws are removed from the burners NOTE Do not use thread sealing compound on the orifices Using thread sealing compound may plug the orifices Each orifice a
47. gize fans when dampers are further open Adjust the EXH SET potentiometer lower counterclockwise toward 2V to energize fans when dampers are further closed Thirty second delay allows dampers to partially open be fore exhaust fan starts H Optional Cold Weather Kit Canada only Electric heater is available to automatically control the minimum temperature in the gas burner compartment Heater is ETL CSA certified to allow cold weather opera tion of unit down to 60 F 50 C The kit includes the following parts 1 Transformer T20 is a 600V to 120 240V step down trans former mounted in the blower compartment 2 T20 has two in line fuses F20 one on each leg of the trans former Both are rated at 15 amps 3 The strip heater HR6 is located as close as possible to the gas valve It is wired in series with T20 The strip heater is rated at 500 Watts 4 Athermostat mounting box is installed on the vesti bule of the heating compartment Included in the box are the following thermostat switches A6 ENTHALPY CONTROLLER ADJUST POWER EXHAUST FAN SETPOINT ENERGIZED WHEN DAMPER POSITION IS HIGHER THAN EXHAUST FAN SETPOINT FIGURE 33 a Thermostat switch 559 is an auto reset SPST switch which opens on a temperature drop The Switch is wired in series with 24v power and the com bustion air blower switch When the temperature drops below 30 F 35 C the switch opens and the gas heat section i
48. h 1 0 33 HP 60 25 25 Protection Power Exhaust 3 Minimum Unit Only 45 21 19 Circuit With 1 0 33 HP 48 22 20 Ampacity Power Exhaust 1 Extremes of operating range are plus and minus 10 of line voltage 2 HACR type breaker or fuse 3 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements Page 12 ELECTRICAL DATA 10 TON 10 TON STANDARD EFFICIENCY R 410A KGA120S4 Voltage 60hz 208 230V 3 Ph 460V 3 Ph 575V 3 Ph Compressor 1 Rated Load Amps 16 7 8 51 Locked Rotor Amps 110 52 38 9 Compressor 2 Rated Load Amps 16 7 8 5 7 Locked Rotor Amps 110 52 38 9 Outdoor Fan Full Load Amps 24 1 3 1 Motors 2 total 4 8 2 6 2 Power Exhaust Full Load Amps 2 4 1 3 1 1 0 33 HP Service Outlet 115V GFI amps 15 15 15 Indoor Blower Horsepower 3 Motor Full Load Amps 10 6 4 8 3 9 2 Maximum Unit Only 60 30 20 Overcurrent With 1 0 33 HP 60 30 25 Protection Power Exhaust 3 Minimum Unit Only 52 25 19 Circuit With 1 0 33 HP 54 27 20 Ampacity Power Exhaust 1 Extremes of operating range are plus and minus 10 of line voltage 2 HACR type breaker or fuse 3 Refer to National or Canadian Electrical Code manual to determine wire fuse and disconnect size requirements 12 5 TON STANDARD EFFICIENCY R 410A KGA150S4 1 Voltage 60hz 208 230V 3 Ph 460V 3 Ph 575 3 Ph Compressor
49. h ends of the wire NOTE If electrode wire is replace wire and suppres sion must be same type cable See Lennox Repair Part Handbook for replacement The spark electrode assembly can be removed for inspec tion by removing the screw securing the electrode assem bly and sliding it out of unit For proper unit operation electrodes must be positioned and gapped correctly Spark gap may be checked with appropriately sized twist drills or feeler gauges Disconnect power to the unit and re move electrode assembly The gap should be between 0 125 0 015 3 2 mm 4 mm See figure 13 NOTE IN ORDER TO MAXIMIZE SPARK ENERGY TO ELECTRODE HIGH VOLTAGE WIRE SHOULD TOUCH UNIT CABINET AS LITTLE AS POSSIBLE IGNITOR SPARK GAP SHOULD BE 1 8 3mm FIGURE 13 10 Flame Sensor Figure 14 A flame sensor is located under the right most side burner The sensor is mounted through a hole in the burner support and the tip protrudes into the flame envelope of the right most burner The sensor assembly is fastened to burner supports and can be removed for service without removing any part of the burners When flame is sensed by the flame sensor indicated by microamp signal through the flame sparking stops imme diately or after the eight second trial for ignition During op eration flame is sensed by current passed along the ground electrode located on the spark electrode through the flame and into the sensing ele
50. h sharp edges AWARNING Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electrical power to unit OFF at discon nect switch es Unit may have multiple power supplies OPTIONS ACCESSORIES Item Description Model Catalog A q Number Number 092 102 120 150 COOLING SYSTEM Compressor Crankcase Heater 208 230V 3ph KICCHTO2B 1Y 54W17 X X X 460V 3ph K1CCHT02B 1G 54W18 X X X 575V 3ph KICCHTO2B 1J 54W19 X X X Condensate Drain Trap PVC LTACDKP09 36 76M18 X X X X Copper LTACDKC09 36 76M19 X X X X Corrosion Protection Factory Drain Pan Overflow Switch K1SNSR71AB1 74W42 X X X X Efficiency Standard O Low Ambient Kit K1SNSR33B 1 54W16 X X X X Refrigerant Type R 410A O SYSTEM Bottom Gas Piping Kit C1GPKTO1B 01 54W95 X X X X Combustion Air Intake Extensions T1EXTN10AN1 19W51 X X X X Gas Heat Input 130 000 Btuh Factory 180 000 Btuh O O O 240 000 Factory O O O Low Temperature Vestibule Heater 208 230V 3ph CILTVH10B 1Y 55W91 X X X X 460V C1LTVH10B 1G 55 92 X X X X 575V C1LTVH10B 1J 55W93 X X X X LPG Propane Conversion Kits Standard Heat E1LPCO10B 1 53W07 X X X X Medium Heat 20 1 53W08 X X X X High Heat 1 53W09 X X X X Stainless Steel Heat Exchanger Factory
51. heat signal passes from TB1 to A3 8 A3 energizes HI terminal high fire of gas valve GV1 Page 42 End of Second Stage Heat 9 Heating demand is satisfied Terminal W2 high fire is de energized 10 Terminal HI of GV1 is de energized by A3 control module End of First Stage Heat 11 Heating demand is satisfied Terminal W1 low fire is de energized 12 Ignition A3 is de energized in turn de ener gizing terminal LO of GV1 Optional Low Ambient Kit ETL CSA 50 C Low Ambient Kit 13 Line voltage is routed through the N C low ambient kit thermostats S60 and S61 K125 relay is energized closing N O K125 1 contacts and energizing the low ambient kit heater HR6 ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT 24V POWER fae A A ECONOMIZER Euge BLOWER G HEAT 1 W1 m W HEAT 2 W2 COOL 1 1 COOL 2 Y2 24V COMMON DESCRIPTION COMPONENT SENSOR ELECTRONIC THERMOSTAT SENSOR 2 CLOCK TIME JACK UNIT ECONOMIZER RELAY EXHAUST FAN PLUG ECONOMIZER BYPASS SENSOR MIXED AIR OR SUPPLY AIR SENSOR REMOTE THERMOSTAT TERMINAL STRIP CLASS VOLTAGE lt 2 63 COOL 1 Y1 65 3 T2 TB1 22 ne A m COOL 2 2 DENOTES OPTIONAL COMPONENTS QLASS II FIELD WIRING a THERMOSTAT SUPPLIED BY USER 24V COMMON WIRING DIAGRAM 12 09 REMOVEP3 WHEN ECONOMIZERS USED ONLY ON KCA KGA AND KHA 180 THROUGH 300 UNI
52. ification Approach Method AHRI Testing 1 Using the same thermometer compare liquid tempera ture at condenser outlet to outdoor ambient tempera ture Approach Temperature Liquid temperature minus ambient temperature N Approach temperature should match values shown in table 11 An approach temperature greater than this val ue indicates an undercharge An approach tempera ture less than this value indicates an overcharge 3 The approach method is not valid for grossly over or undercharged systems Use tables 7 through 10 as a guide for typical operating pressures TABLE 11 APPROACH TEMPERATURE Liquid Temp Minus Ambient Temp 1st Stage 2nd Stage 092 9 F 1 5 0 C 0 5 8 F 1 4 4 C 0 5 102 7 1 3 9 C 0 5 6 F 1 9 3 C 0 5 120 8 F 1 4 4 C 0 5 6 F 1 3 3 0 5 150 6 F 1 3 3 0 5 6 F 1 3 3 0 5 V SYSTEMS SERVICE CHECKS A Heating System Service Checks All KGA units are ETL CSA design certified without modification Before checking piping check with gas company or au thorities having jurisdiction for local code requirements Refer to the KGA Installation instruction for more infor mation GAS PIPING COMPONENTS REFER TO INSTALLATION INSTRUCTIONS GROUND JOINT UNION MANUAL MAIN SHUT OFF VALVE REFER TO LOCAL CODES CAP HERE TO ISOLATE VALVE WHEN PRESSURE TESTING LINE ROOF MOUNTING FRAME DRIP LEG
53. ion as follows 1 Measure span length X See figure 9 2 Apply perpendicular force to center of span X with enough pressure to deflect belt 1 64 for every inch of span length or 1 5mm per 100mm of span length Example Deflection distance of a 40 span would be 40 64 or 5 8 Example Deflection distance of a 400mm span would be 6mm 3 Measure belt deflection force For a used belt the deflection force should be 5 Ibs 35kPa A new belt deflection force should be 7 Ibs 48kPa A force below these values indicates an underten sioned belt A force above these values indicates an overtensioned belt MEASURE BELT TENSION DEFLECTION 1 64 PER INCH OF SPAN OR 1 5mm PER 100mm OF SPAN FIGURE 9 Page 19 D GAS HEAT COMPONENTS KGA092 150 units are available in 130 000 BTUH 38 1 kW 180 000 BTUH 52 7 Kw or 240 000 BTUH 70 3 kW heat sizes 1 Heat Exchanger Figure 10 The KGA units use aluminized steel inshot burners with tubular aluminized steel heat exchangers and two stage redundant gas valves KGA092 150 units use one eleven tube burner for high heat one eight tube burner for me dium heat and one six tube burner for standard heat Burn ers in all units use a burner venturi to mix gas and air for proper combustion Combustion takes place at each tube entrance As hot combustion gases are drawn upward through each tube by the combustion air inducer exhaust gases are drawn out the top and fresh air
54. ir inducer gas ket be replaced during reassembly 6 Clean combustion air inlet louvers on heat access pan el using a small brush F Flue Passageway and Flue Box 1 Remove combustion air inducer assembly as de scribed in section D 2 Remove flue box cover Clean with a wire brush as re quired 3 Clean tubes with wire brush 4 Reassemble the unit The flue box cover gasket and combustion air inducer gasket should also be replaced during reassembly G Condenser Coil Clean condenser coil annually with detergent or commercial coil cleaner and inspect monthly during the cooling season Condenser coils are made of one two and three formed slabs Dirt and debris may become trapped between the slabs To clean between slabs carefully separate coil slabs and wash them thoroughly See figure 22 Flush coils with water following cleaning Note Remove all screws and gaskets prior to cleaning pro cedure and replace upon completion H Supply Blower Wheel Annually inspect supply air blower wheel for accumulated dirt or dust Turn off power before attempting to remove ac cess panel or to clean blower wheel CLEAN CONDENSER COIL ENDPLATE IS SECURED TOP VIEW LLI EVAPORATOR COILI 4 BLOWER CONDENSER ACCESS PANEL CONDENSER COILS Remove unit top panel and condenser section access panel Remove screws securing coil end plate to mullion Remov
55. its are equipped with four 20 X 25 X 2 filters Filters should be checked and replaced when necessary with fil ters of like kind and size Take note of air flow direction marking on filter frame when reinstalling filters See figure 21 Filters must be U L C certified or equivalent for use in Canada B Lubrication All motors are lubricated at the factory No further lubrica tion is required REMOVE FILTERS _ CON SASS PULL TO REMOVE FILTERS FIGURE 21 C Evaporator Coil Inspect and clean coil at beginning of each cooling season Clean using mild detergent or commercial coil cleanser Flush coil and condensate drain with water taking care not to get insulation filters and return air ducts wet Page 29 D Burners Periodically examine burner flames for proper appearance during the heating season Before each heating season ex amine the burners for any deposits or blockage which may have occurred Clean burners as follows 1 Turn off both electrical power and gas supply to unit 2 Remove burner compartment access panel 3 Remove two screws securing burners to burner sup port and lift the burners from the orifices See figure 11 Clean as necessary 4 Locate the ignitor under the left burners Check ignitor spark gap with appropriately sized twist drills or feeler gauges See figure 13 5 Replace burners and screws securing gas manifold AWARNING Danger of explosion Can cau
56. k wise to increase CFM Turn counterclockwise to de crease CFM See figure 7 Do not exceed minimum and maximum number of pulley turns as shown in table 1 TABLE 1 MINIMUM AND MAXIMUM PULLEY ADJUSTMENT Belt Minimum Maximum Turns Open Tums Open eec No minimum number of turns open when B belt is used on pulleys 6 O D or larger Blower Belt Adjustment Maximum life and wear can be obtained from belts only if proper pulley alignment and belt tension are main tained Tension new belts after a 24 48 hour period of op eration This will allow belt to stretch and seat grooves Make sure blower and motor pulley are aligned as shown in figure 8 PULLEY ALIGNMENT ALIGNED BLOWER PULLEY PULLEY NOT ALIGNED FIGURE 8 1 Loosen four bolts securing motor base to mounting frame See figure 7 2 To increase belt tension Turn adjusting bolt to the right or clockwise to move the motor outward and tighten the belt This increases the distance between the blower motor and the blower housing To loosen belt tension Turn the adjusting bolt to the left or counterclockwise to loosen belt tension IMPORTANT Align top edges of blower motor base and mounting frame base parallel before tightening two bolts on the other side of base Motor shaft and blower shaft must be parallel 3 Tighten bolts on side of base Check Belt Tension Overtensioning belts shortens belt and bearing life Check belt tens
57. n for flame current measurement The control shuts off gas flow immediately in the event of a power failure Upon restoration of gas and power the control will restart the ignition sequence and continue until flame is established or system locks out Operation On a heating demand the ignition control checks for a closed limit switch and open combustion air prove switch Once this check is complete and conditions are correct the ignition control then allows 30 seconds for the combustion air inducer to vent exhaust gases from the burners When the combustion air inducer is purging the exhaust gases the combustion air prove switch closes proving that the combustion air inducer is operat ing before allowing the ignition control to energize When the combustion air prove switch is closed and the delay is over the ignition control activates the gas valve the spark electrode and the flame sensing electrode Once the gas valve is energized the non adjustable 40 second indoor blower delay period begins Sparking stops immediately after flame is sensed or at the end of the 8 second trial for ignition The control then proceeds to steady state mode where all inputs are monitored to ensure the limit switch rol lout switch and prove switch are closed as well as flame is present When the heat call is satisfied and the gas valve is de energized a combustion air inducer post purge period of 5 seconds begins along with a 120 sec ond blower off dela
58. nce of selected unit 2 Any factory installed options air resistance heat section economizer etc 3 Any field installed accessories air resistance duct resistance diffuser etc Then determine from blower table blower motor output required See page 10 for blower motors and drives See page 10 for wet coil and option accessory air resistance data MAXIMUM STATIC PRESSURE WITH GAS HEAT 2 0 in w g Total Total Static Pressure in w g Air Volume cfm 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 RPM BHP RPM BHP RPM BHP RPMIBHPIRPMIBHP RPMIBHPIRPMIBHPI RPMIBHP RPM BHPI RPM 3750 1689 0 68 731 10 97 775 1 27 820 1 56 865 1 81 911 2 02 957 2 19 1004 2 35 1051 2 53 1100 2 74 11512 9911204 3 29 1258 3 61 4000 706 0 921 748 1 22 792 1 51 836 1 78 881 12 02 926 12 22 972 2 39 10182 57 1065 2 76 1113 2 98 1163 3 25 1217 3 55 1271 3 87 4250 725 1 18 766 1 47 810 1 75 854 2 02 899 12 25 943 2 44 988 2 61 10332 81 10793 0111273 25 11783 52 123013 82 1284 4 14 4500 744 1 45 786 1 73 829 2 01 873 2 27 917 2 49 961 2 67 100512 87 1050 3 07 1096 3 29 114313 53119313 81124514 11 1298 4 43 4750 764 1 73 806 2 01 849 2 28 893 2 53 936 2 74 980 12 94 10233 15 1068 3 37 1113 3 60 1160 3 84 1210 4 12 1261 4 42 1314 4 74 5000 785 2 02 1827 2 30 870 2 57 914 2 81 957 3 0210001 3 23 1043 3 46 1087 3 69 1131 3 92 1178 4 1
59. nd burner are sized specifically to the unit Refer to Lennox Repair Parts Listing for correct sizing infor mation BURNER BOX ASSEMBLY FLAME ROLLOUT LIMIT SWITCH IGNITOR not shown GAS MANIFOLD SENSOR FIGURE 11 3 Primary High Temperature Limit S10 10 is a SPST N C high temperature primary limit for gas heat KGA092 150 units On KGA092 150 S10 is located on the blower See figure 12 FIGURE 12 Page 20 Primary limit S10 is wired to the ignition control A3 Its N C contacts open to de energize the ignition control when ex cessive temperature is reached in the blower compart ment If the limit trips the blower relay coil K3 will be ener gized by ignition control A3 Three limits with different actuating temperatures are used for limits 510 See Lennox Repair Parts Handbook for replacement 4 Flame Rollout Limit Switch S47 Flame rollout limit switch S47 is a SPST N C high temper ature limit located just above the burner air intake opening in the burner enclosures see figure 11 S47 is wired to the igni tion control A3 When S47 senses flame rollout indicating a blockage in the combustion air passages the flame rollout limit trips and the ignition control immediately closes the gas valve Limit S47 is factory preset to open at 290 F 12 F 143 C 6 7 C on a temperature rise on all units All flame rollout limits are manual reset 5 Combustion Air Prove Switch S18 Prove switch 518 is
60. nent terminations TABLE 4 Slow Flash Normal operation No call for heat Fast Flash Normal operation Call for heat Steadv Off Internal Control Fault No Power To Board y or Gas Valve Relay Fault Steady On Control Internal Failure 2 Flashes Lockout Failed to detect or sustain flame Page 22 Rollout switch open switch open 4 Flashes Primary High Limit switch open 5 Flashes Flame sensed but gas valve not open 6 Flashes On Board Microprocessors Disagree TABLE 5 P2 TERMINAL DESIGNATIONS Function W1 Heat Demand Y Cool Demand C Common G Indoor Blower BL OUT Indoor Blower Relay 7 W2 Second Stage Heat TABLE 6 Gas Valve Rollout Switch Prove Switch In Limit Switch In IGNITION CONTROL A3 2 J s l2 6000 DAD KI RELAY Hine a 54 c O QUT FLAME 1 w W2 OUT SPARK OUTPUT t CD 6 CAI Line Line voltage FIGURE 15 IGNITION CONTROL A3 AIR PROVING SWITCH A3 IGNITION CONTROL FIGURE 16 Flame rectification sensing is used on all KGA units Loss of flame during a heating cycle is indicated by an ab sence of flame signal 0 microamps If this happens the con trol will immediately restart the ignition sequence and then lock out if ignition is not gained after the third trial See System Service Checks sectio
61. nominal 1 15 X 15 1 1092 15 15 1 15 X 15 diameter x width in Filters Type of filter Disposable Number and size in 4 20 x 25 x 2 Electrical characteristics 208 230V 460V or 575V 60 hertz 3 phase NOTE Net capacity includes evaporator blower motor heat deduction Gross capacity does not include evaporator blower motor heat deduction 1 Certified in accordance with the ULE certification program which is based Standard 340 360 95 F outdoor air temperature and 80 F db 67 F wb entering evaporator air minimum external duct static pressure Integrated Energy Efficiency Ratio certified and tested according to AHRI Standard 340 360 3 Using total air volume and system static pressure requirements determine from blower performance tables rpm and motor output required Maximum usable output of motors furnished are shown In Canada nominal motor output is also maximum usable motor output If motors of comparable output are used be sure to keep within the service factor limitations outlined on the motor nameplate Standard motor and drive kit furnished with unit Page 5 SPECIFICATIONS GAS HEAT Heat Input Type Standard Medium High Number of Gas Heat Stages 2 2 2 Gas Heating Input Btuh First Stage 84 500 117 000 156 000 Performance Second Stage 130 000 180 000 240 000 Output Btuh Second Stage 104 000 144 000 192000 Temperature Rise R
62. nstalled The DCV SET potentiometer is factory set at approxi mately 50 of the potentiometer range Using a standard 1 2000ppm CO sensor dampers will start to open when the IAQ sensor reads approximately 1000ppm Adjust the DCV SET potentiometer to the approximate setting specified by the controls contractor Refer to figure 28 The DCV MAX potentiometer is factory set at approxi mately 50 of the potentiometer range or GVDC Damp ers will open approximately half way when CO rises above setpoint Adjust the DCV MAX potentiometer to the approximate setting specified by the controls con tractor Refer to figure 28 Note DCV Max must be set higher than economizer mini mum position setting for proper demand control ventilation Economizer Operation The occupied time period is determined by the thermostat or energy management system Outdoor Air Not Suitable During the unoccupied time period dampers are closed During the occupied time period a cooling demand will open dampers to minimum position and mechanical cooling functions normally During the occupied time period dampers will open to DCV MAX when IAQ reading is above setpoint regardless of thermostat demand or outdoor air suitability Outdoor Air Suitable See table 16 for economizer operation with a standard two stage thermostat During the occupied period dampers will open to DCV MAX when IAQ reading is above setpoint regardless of thermostat demand or o
63. ntrol box The transformers have an output rating of 0 5A T3 transformer supplies 230 VAC power to the combus tion air inducer motor B6 4 Terminal Strip TB1 All indoor thermostat connections will be to TB1 located in the control area For thermostats without occupied unoccupied modes a factory installed jumper across ter minals R and OC should be in place 5 Condenser Fan Capacitors C1 amp C2 Fan capacitors C1 and C2 are used to assist in the start up of condenser fans B4 and B5 Ratings will be on side of capaci tor or outdoor fan motor nameplate 6 Compressor Contactor K1 amp K2 All compressor contactors are three pole double break contactors with 24VAC coils In all KGA units K1 and K2 energize compressors B1 and B2 in response to thermostat demand On CE M volt units contactor is CE approved by manufacturer Siemens See figure 5 CONTACTOR KEY H H H FIGURE 5 7 Blower Contactor Blower contactor K3 used in all units is a three pole double break contactor with a 24VAC coil used to energize the indoor blower motor B3 in response to blower demand K3 is energized by a thermostat cooling demand On M volt CE units the contactor is CE approved by manufacturer Siemens See figure 5 8 Condenser Fan Relay K10 Outdoor fan relay K10 is a DPDT relay with a 24VAC coil K10 energizes condenser fans B4
64. ntrol ventilation DCV is specified Damper minimum position can be set lower than traditional minimum air requirements resulting in cost savings The IAQ sensor allows the A6 to open damp ers to traditional ventilation requirements as room occu CO2 increases TABLE 14 Dampers will modulate to 55 F discharge air RT6 when Single OA Sensible OA temperature S175 is lower than free cooling setpoint OA Sensible temperature humidity 7 FIGURE 27 is lower than free cooling setpoint OA temperature and humidity A7 5 is lower than RA temperature and in OA and 1 in RA humidity A62 Differential Enthalpy 1 sensed A63 is higher than IAQ Sensor CO2 setpoint Page 33 A6 Enthalpy Control LED S A steady green Free Cool LED indicates that outdoor air is suitable for free cooling When an optional IAQ sensor is installed a steady green DCV LED indicates that the IAQ reading is higher than set point requiring more fresh air See figure 28 A6 ENTHALPY CONTROLLER DAMPER MINI MUM POSITION IAQ MAXIMUM POSITION set higher than minimum position IAQ READING IS ABOVE SETPOINT IAQ SETPOINT OUTDOOR AIR SUITABLE LED FREE COOLING SETPOINT A Completely counterclockwise D Completely clockwise FIGURE 28 Free Cooling Setpoint Outdoor air is considered suitable when temperature and humidity are less than the free cooling setpoints shown in table 15
65. ompressor discharge line and wired in series with the re spective compressor contactor coils When discharge pressure rises to 640 10 psig 4413 69 kPa indicating a problem in the system the switch opens and the respective compressor is de energized the economizer can continue to operate 5 Low Ambient Switches S11 amp S84 optional The low ambient switch is an auto reset SPST N O pres sure switch which allows for mechanical cooling operation at low outdoor temperatures In all models a switch is lo cated in each liquid line prior to the indoor coil section In the KGA092 150 511 and S84 are wired in parallel with outdoor fan relay K10 When liquid pressure rises to 450 10 psig 3102 69 kPa the switch closes and the condenser fans are ener gized When liquid pressure in both refrigerant circuits drops to 240 10 psig 1655 69 kPa the switches open and the condenser fans are de energized This intermittent fan operation results in higher evaporating temperature al lowing the system to operate without icing the evaporator coil and losing capacity 6 Crankcase Heaters HR1 HR2 1505 units use insertion type heaters Heater HR1 is installed around compressor B1 and heater HR2 is installed around compressor B2 Crankcase heater wattage varies by compressor manufacturer Page 17 C Blower Compartment The blower compartment in all KGA092 150S units is located between the evaporator coil and the condenser coil se
66. operated damper position is manually set at installation and remains in that position Page 31 LAOAD M MOTORIZED OUTDOOR AIR DAMPER MOTORIZED DAMPER COVER PANEL SUPPLY AIR OPENING HORIZONTAL lt p wi COMPRESSOR RETURN AIR p SECTION OPENING 7 LOWER PANEL MANUAL OUTDOOR AIR DAMPER COVER PANEL HORIZONTAL SUPPLY AIR OPENING RETURN AIR SECTION OPENING LOWER PANEL HORIZONTAL COMPRESSOR FIGURE 25 Page 32 ECONOMIZER ECONOMIZER ACCESSORY PANEL MULLION DIVIDER PANEL Attach with two provided screws BOTTOM OF COMPRESSOR SECTION FLANGED RETURN AIR OPENING FIGURE 26 E K1ECON20B Economizer Field or Factory Installed MIXED AIR SENSOR R1 LOCATION Economizers use outdoor air for free cooling when temper ature and or humidity is suitable See figure 26 The mixed air temperature sensor R1 measures the sup ply air sensible temperature See figure 27 The outdoor air sensible control is the default economizer control An out door air single sensible sensor S175 is also provided See table 14 for outdoor and return air OA and RA sensor op tions Refer to instructions provided with sensors for instal lation R1 MIXED AIR SENSOR An IAQ sensor is used when demand co
67. passes from the ignition control through the sensor electrode during unit op eration The current passes from the sensor through the flame to the ground electrode located on the flame elec trode to complete a safety circuit The electrodes should be located so the tips are at least 1 2 12 7 mm inside the flame envelope Do not bend electrodes To measure flame current follow the procedure on the following page NOTE Electrodes are not field adjustable Any alter ations to the electrode may create a hazardous con dition that can cause property or personal injury 1 Disconnect power to unit 2 Remove lead from sensing electrode and install a 0 50DC microamp meter in series between the sens ing electrode and the sensing lead 3 Reconnect power and adjust thermostat for heating demand 4 When flame is established microamp reading should be 0 5 to 1 0 Do not bend electrodes Drop out signal is 09 or less 5 Disconnect power to unit before disconnecting meter Make sure sensor wire is securely reconnected before reconnecting power to unit NOTE If the meter scale reads 0 the leads re versed Disconnect power and reconnect leads for proper polarity B Cooling System Service Checks KGA units are factory charged and require no further adjust ment however charge should be checked periodically using the approach method The approach method compares actual liquid temperature with the outdoor ambient temperature
68. relay K65 with 24VAC at 50 outside air damper open adjustable 4 N O K65 1 and N O K65 2 both close energizing ex haust fan motor B10 1st Stage Cooling compressor B1 5 First stage cooling demand Y1 and G are energized by the thermostat G energizes blower 24VAC is routed through 1 passing N C freezestat 549 and optional N C high pressure switch S4 Compressor contactor K1 is energized N O contacts K1 close energizing compressor B1 6 Optional N O low ambient switch S11 closes to ener gize condenser fan relay K10 N O contacts K10 1 and K10 2 close energizing condenser fans B4 and B5 N C contacts K10 1 open de energizing crankcase heaters HR1 and HR2 2nd Stage Cooling compressor B2 is energized 7 24VAC is routed through TB1 and proves N C freezes tat S50 and optional N C high pressure switch S7 Compressor contactor K2 is energized N O K2 con tacts close energizing compressor B2 8 Optional N O low ambient switch S84 closes to ener gizing condenser fan relay K10 N O contacts K10 1 and K10 2 close energizing condenser fans B4 and B5 N C contacts K10 1 open de energizing crankcase heaters HR1 and HR2 Page 40 GAS HEAT FOR KGA092 150 UNITS P1 J4 810 2 6 547 2 518 2 gt 6 3 4 GV1 GV1 2STG 8 1STG 2 3 1 a PL IS O N 1 1 3 70 1 51 GV1 VALVE GAS 1 R6 9 T RELAY HEAT SHUTOFF PLUG GAS LIMIT J1 1 J2 J22
69. rigerant Circuit 1 165 8 oz 8 Ibs 8 oz 10 Ibs 0 oz 14 Ibs 0 oz Charge Circuit 2 lbs 0 oz 8 Ibs 8 oz 10 Ibs 0 oz 12 165 0 oz Furnished Gas Heating Options Available See page 6 Standard 2 stage Medium 2 Stage High 2 Stage Compressor Type number Scroll 2 Scroll 2 Scroll 2 Scroll 2 Outdoor Net face area total sq ft 20 42 24 5 28 0 28 0 Coils Tube diameter in 3 8 3 8 3 8 3 8 Number of rows 2 2 2 3 Fins per inch 20 20 20 20 Outdoor Motor No hp 2 1 3 2 1 3 2 1 3 2 1 2 Coil Fans Motor rpm 1075 1075 1075 1075 Total Motor watts 670 670 670 830 Diameter No in 2 24 2 24 2 24 2 24 Number of blades 3 3 3 Total Air volume cfm 7200 7400 7800 8 800 Indoor Net face area total sq ft 12 78 12 78 12 78 13 54 Coils Tube diameter in 3 8 3 8 3 8 3 8 Number of rows 2 2 3 4 Fins per inch 14 14 14 14 Drain connection Number 1 1 in coupling and size Expansion device type Balance port TXV removable head 3 Indoor Nominal motor output 2 hp 3 hp 5 hp Blower and Maximum usable motor output 2 3 hp 3 45 hp 5 75 hp Drive US Only Selection Motor Drive kit number 2 hp Kit 1 590 890 rpm Kit 2 800 1105 rpm Kit 3 795 1195 rpm 3hp Kit 4 730 970 rpm Kit 5 940 1200 rpm Kit 6 1015 1300 rpm 5hp Kit 10 900 1135 rpm Kit 11 1040 1315 rpm Kit 12 1125 1425 rpm Blower wheel
70. s de energized The switch automati cally resets when the heating compartment tempera ture reaches 10 F 12 C b Thermostat switch S60 is an auto reset SPST N C switch which opens on a temperature rise The switch is wired in series with HR6 and T20 When the temperature rises above 20 F 7 C the switch opens and the electric heater is de energized The switch automatically resets when the heating compartment temperature reaches 10 F 23 3 C c Thermostat switch 561 is an auto reset SPST N O switch which closes on a temperature drop The switch is wired in series with HR6 and T20 When temperature drops below 20 F 7 C the switch closes and electric heater is energized The switch automatically opens when heating compartment temperature reaches 76 F 24 C I Control Systems Three different types of control systems may be used with the KGA series units All thermostat wiring is connected to TB1 located in the control area Each thermostat has addi tional control options available See thermostat installation instructions for more detail 1 Electro mechanical thermostat 13F06 The electro mechanical thermostat is a two stage heat two stage cool thermostat with dual temperature levers A non switching or manual system switch subbase may be used 2 Electronic thermostat see price book Page 37 Any two stage heat two stage cool electronic ther mostat may be used 3 Honeywell T7300 thermostat 601 5
71. se injury or death Do not overtighten main burner mounting screws Snug tighten only 7 Replace access panel 8 Restore electrical power and gas supply Follow light ing instructions attached to unit and use inspection port in access panel to check flame E Combustion Air Inducer A combustion air proving switch checks combustion air in ducer operation before allowing heating sequence to con tinue The sequence will not be allowed to continue if induc er is obstructed The combustion air inducer wheel should be checked and cleaned prior to the heating season It should be examined periodically during the heating season to establish an ideal cleaning schedule With power supply disconnected the condition of the inducer wheel can be determined by re moving the vent pipe and inspecting the wheel through the outlet opening Clean combustion air inducer as follows 1 Shut off power supply and gas to unit 2 Disconnect pressure switch air tubing from combustion air inducer port 3 Remove and retain screws securing combustion air in ducer to flue box Remove and retain two screws from bracket supporting vent connector See figure 10 4 Clean inducer wheel blades with a small brush and wipe off any dust from housing Clean accumulated dust from front of flue box cover 5 Return combustion air inducer motor and vent connec tor to original location and secure with retained screws It is recommended that the combustion a
72. sig A hissing sound will be heard when the compressor is running un loaded Protector will reset when low pressure in system rises above 40 psig DO NOT REPLACE COMPRESSOR 2 Thermal Protectors S5 S8 Some compressors have thermal protectors located on top of the compressor The protectors open at 248 F 9 F 120 5 and close at 169 F 18 F 76 10 3 Freezestats S49 and S50 Each unit is equipped with a low temperature switch freezes tat located on a return bend of each evaporator coil S49 first circuit and S50 second circuit are located on the corresponding evaporator coils Freezestats are wired in series with compressor contactors Each freezestat is a SPST N C auto reset switch which opens at 29 F 3 F 1 7 C 1 7 C on a temperature drop and closes at 58 F 4 F 14 4 C 2 2 on a tempera ture rise To prevent coil icing freezestats open during compressor operation to temporarily disable the re spective compressor until the coil temperature rises If the freezestats are tripping frequently due to coil icing check the airflow filters economizer position and unit charge before allowing unit back in operation Make sure to eliminate conditions which might promote evaporator ice buildup 4 High Pressure Switches S4 and S7 The high pressure switch is a manual reset SPST N C switch which opens on a pressure rise S4 first circuit and S7 second circuit are located in the c
73. st be performed by a qualified installer or service Specifications Page 5 Blower Data Page 7 pee olen DISCHARGE FSD Electrical Data Page 12 Precautions and Procedures A CAUTION Parts Arrangement Page 14 l Unit Components Page 15 Electrostatic discharge affect electronic components Take precautions during unit instal II Placement and Installation Page 24 lation and service to protect the unit s electronic i controls Precautions will help to avoid control Start Up 24 exposure to electrostatic discharge putting IV Charging Page 26 the furnace the control and the technician at the same electrostatic potential Neutralize electro V System Service Checks Page 27 static charge by touching and all tools on an unpainted unit surface such as the gas valve or VI Maintenance Page 29 blower deck before performing any service pro cedure P 9 VII Accessories Page 31 Vill Wiring Diagrams Page 39 Publications Page 1 2010 Lennox Industries Inc A CAUTION Danger of sharp metallic edges Can cause injury Take care when servicing unit to avoid accidental contact wit
74. utdoor air suitability DCV MAX will NOT override damper full open position When an R1 mixed air sensor for modulating dampers is installed DCV MAX may override damper free cooling position when oc cupancy is high and outdoor air temperatures are low If R1 senses discharge air temperature below 45 F 7 C dampers will move to minimum position until discharge air temperature rises to 48 F 9 C TABLE 16 ECONOMIZER OPERATION OUTDOOR AIR IS SUITABLE FOR FREE COOLING FREE COOL LED ON DAMPER POSITION THERMOSTAT DEMAND UNOCCUPIED MECHANICAL COOLING OCCUPIED Y1 OPEN Y2 OPEN OPEN NO STAGE 1 OPEN Dampers will open to maintain 55 F 13 C supply air when R11 mixed air sensor 15 installed Page 35 B Outdoor Air Dampers Optional manual and motorized outdoor air dampers pro vide fresh outdoor air The motorized damper assembly opens to minimum position during the occupied time peri od and remains closed during the unoccupied period Manual damper assembly is set at installation and re mains in that position Set damper minimum position in the same manner as economizer minimum position Adjust motorized damper position using the thumbwheel on the damper motor See figure 29 Manual damper fresh air intake percentage can be determined in the same manner DAMPER MOTOR THUMBWHEEL FIGURE 29 F Gravity Exhaust Dampers Dampers used in downflow see figure 30 and horizon tal
75. y Page 23 AND INSTALLATION sure the unit is installed accordance with the installation instructions and all applicable codes See accessories section for conditions requiring use of the optional roof mounting frame LARMF18 36 or LARMFH18 24 lil STARTUP OPERATION A Preliminary and Seasonal Checks 1 Make sure the unit is installed in accordance with the installation instructions and applicable codes 2 Inspect all electrical wiring both field and factory installed for loose connections Tighten as required Refer to unit diagram located on inside of unit compressor access pan el 3 Check to ensure that refrigerant lines are in good condition and do not rub against the cabinet or other refrigerant lines 4 Check voltage at the disconnect switch Voltage must be within the range listed on the nameplate If not con sult the power company and have the voltage cor rected before starting the unit 5 Recheck voltage and amp draw with unit running If voltage is not within range listed on unit nameplate stop unit and consult power company Refer to unit nameplate for maximum rated load amps 6 Inspect and adjust blower belt see section on Blower Compartment Blower Belt Adjustment B Heating Startup FOR YOUR SAFETY READ BEFORE LIGHTING AWARNING Electric shock hazard Can cause injury or death Do not use this unit if any part has been under water Immediately call a qu

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