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KCA SERIES WARNING CAUTION WARNING

1. oll FUSE 4 F4 1 FUSE FIRST STAGE ELECTRIC SECOND STAGE ELECTRIC F3 1 HEAT CONTACTOR K15 HEAT CONTACTOR K16 FIGURE 15 Page 25 II PLACEMENT AND INSTALLATION Make sure the unit is installed in 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 un
2. meves Co Ce Co 208 230V 60 Amp 250V 60 Amp 250V 60 Amp 250V 60 Amp 250V EHA150 60 Page 24 7 5 15 22 5 30 45 60KW ELECTRIC HEAT SECTION PARTS ARRANGEMENT a HEATING ELEMENTS HE1 LIMIT S20 SECONDARY 0 ig 48 g N F P SN ER TEEN LIMIT S20 ELECTRIC HEAT VESTIBULE SECONDARY LIMIT S20 SECONDARY LIMIT S20 ELECTRIC HEAT THERMOSTAT 19 PRIMARY ELECTRIC HEAT LIMIT 15 CONTROL WIRE _ HARNESS FIGURE 14 ELECTRIC HEAT VESTIBULE PARTS ARRANGEMENT FUSE F4 TERMINAL STRIP FUSE F3 4 2 TB3 F3 2 o88 088 EE
3. E ALALA INDOOR COIL STAGE 1 p DRIERS OUTDOOR COIL STAGE 1 COMPRESSOR 2 COMPRESSOR 1 COMPRESSOR 2 COMPRESSOR 1 S8 THERMAL S5 THERMAL PROTECTOR SUCTION PROTECTOR UE a 2 a SUCTION LINE m di DISCHARGE LINE S7 HIGH PRESSURE SWITCH S4 HIGH PRESSURE SWITCH PRESSURE PRESSURE TAP FIGURE 9 Page 19 B Cooling Components All units use independent cooling circuits consisting of sepa rate compressors condenser coils and evaporator coils See figure 9 Two draw through type condenser fans are used in KCA092 150 units All units are equipped with belt drive blowers which draw air across the evaporator during unit operation Cooling may be supplemented by a factory or field installed economizer The evaporators are slab type and are stacked Each evaporator uses a thermostatic expan 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 S49 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 KCA092 150 units use two scroll compressors Com pressor capa
4. 1 Extremes of operating range are plus and minus 1096 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 Page 11 ELECTRICAL ELECTRIC HEAT DATA 8 5 TON 8 5 TON STANDARD EFFICIENCY R 410A 10254 Voltage 60hz 208 230V 3 Ph 460V 3 Ph 575V 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 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 2 Motor Full Load Amps 7 5 34 2 7 Makimum Unit Only 50 25 20 Overcurrent With 1 0 33 HP 60 25 25 Protection Power Exhaust Minimum Unit Only 45 21 19 Circuit With 1 0 33 HP 48 22 20 Ampacity Power Exhaust ELECTRIC HEAT DATA Electric Heat Voltage 208V 240V 480V 600V Maximum Unitt 7 5 kW 50 50 25 20 Overcurrent Electric Heat 15 kW 50 60 30 25 Protection 22 5 kW 70 80 40 35 30 kW 90 100 50 40 45 kW 150 150 80 60 3 Minimum Unitt 7 5 kW 45 45 21 19 Circuit Electric Heat 15 kW 49 55 27 22 Ampacity 22 5 kW 69 78 39 31 30 kW 88 100 50 40 45 kW 127 145 72 58 Maximum 17 5 kW 60 60 25 25 Overcurrent Electric Heat 15 kW 60 60 30 25
5. LENNOX Service Literature UNIT INFORMATION Corp 1011 L9 KCA SERIES 7 5 to 12 5 ton 26 3 to 42 kW KCA092 through 150 The KCA 7 5 8 5 10 and 12 5 ton 092 102 120 150 packaged cooling units are available in standard cooling efficiency Optional auxiliary electric heat is factory or field installed in KCA units Electric heat operates in single or multiple stages depending on the kW input size 7 5kW through 60kW heat sections are available for the KCA heat pump All KCA units are designed to accept any of several differ ent energy management thermostat control systems with minimum field wiring Factory or field provided control op tions 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 Options Accessories Page 2 maintenance can cause property damage person Spe
6. 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 the 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 39 7 5 15 22 5 30 45 amp 60 VOLTAGE SERIES UNITS 4 F42 FUSE FUSE ELECTRIC HEAT 3 E 3 F42 44 HET HE2 ELEMENT ELECT HEAT 6 JACK ELECT HT SUB BASE KIT RELAY HEAT CONTACTOR ELECTRIC HT 1 CONTACTOR ELECTRIC HT 2 PLUG UNIT HEAT PLUG ELECT HT SUB BASE KIT SWITCH LIMIT PRIMARY ELECT HT THERMOSTAT ELECTRIC HEAT LIMIT SWITCH LIMIT SECONDARY ELECT HT 5157 SWITCH LIMIT SECONDARY ELECT 2 SWITCH LIMIT SECONDARY ELECT HT 3 SWITCH LIMIT SECONDARY ELECT HT 4 SWITCH LIMIT SECONDARY ELECT HT 5 SWITCH LIMIT SECONDARY ELECT HT 6 TERMINAL STRIP UNIT F44 HE1 HE2 22 5 amp 30KW Q SN po F43 AN ya C HE1 HE2 HE4 HES 7 5 15 15 7 5 15 15 r3 15 5161 HE4 F44 7 5 OT 2 O F42 F43 OA NOT USED ON 7 5 15 AND 30KW UNITS ZX 15 USED ON SOME UNITS TB2 848 OR CB10 MAY BE USED WIRING DIAGRAM HEATING ELECTRIC E
7. 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 2 24 26 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 2250 2500 2750 3000 3250 3500 3750 4000 4250 661 672 684 697 710 0 17 0 36 0 56 0 78 1 00 680 0 11 689 0 29 698 0 46 708 0 65 719 0 85 731 1 05 745 1 27 707 714 721 728 737 746 756 768 781 0 14 0 29 0 45 0 61 0 78 0 95 1 14 1 34 1 55 753 758 763 770 786 795 807 819 0 50 0 64 0 78 0 93 1 09 1 25 1 43 1 62 1 83 800 803 807 812 819 827 836 848 861 0 84 0 97 1 09 1 23 1 38 1 53 1 70 1 89 2 09 847 849 852 856 862 870 880 892 906 1 15 1 26 1 37 1 49 1 63 1 78 1 95 2 13 2 33 892 1 38 893 1 48 896 1 58 901 1 70 908 1 84 916 1 99 927 2 16 940 2 34 954 2 55 6 934 936 940 947 955 965 976 988 1001 1 53 1 63 1 74 1 87 2 01 2 17 2 34 2 53 2 74 979 983 989 996 1004 1013 1023 1034 1046 1 65 1 75 1 88 2 02 2 17 2 33 2 51 2 71 2 93 1051 1052
8. 1053 1055 1059 1065 1073 1083 1094 1 86 1 96 2 08 2 21 2 36 2 52 DAT 2 91 3 14 112612 12 112412 22 11212 34 1120 2 47 1122 2 62 1126 2 79 1133 2 98 1141 3 19 1151 3 42 1183 2 36 1184 2 49 1185 2 63 1186 2 78 1189 2 94 1193 3 12 1198 3 32 1205 3 53 1214 3 76 1238 1241 1244 1248 1252 1257 1263 1270 1278 2 62 2 77 2 93 3 10 3 28 3 47 3 67 3 89 4 12 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 9 for blower motors and drives See page 9 for wet coil and option accessory air resistance data MINIMUM AIR VOLUME REQUIRED FOR USE WITH OPTIONAL ELECTRIC HEAT Maximum Static Pressure 2 0 in w g 15 kW 22 5 kW 30 kW and 45 kW 2800 cfm 60 kW 4000 cfm 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 2 2 2 4 2 6 RPM BHP RPMIBHPIRPMI BHP RPMIBHPIRPMIBH
9. 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 with 24VAC closes energizing blower B3 Economizer Operation 3 The economizer control module receives a demand and energizes exhaust fan 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 TB1 passing N C freezestat S49 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 50 and optional 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
10. Protection and 1 0 33 22 5 kW 80 90 40 35 HP 30 kW 100 110 60 45 PowerExhaust 45 kW 150 150 80 60 Minimum Unitt 7 5 kW 48 48 22 20 Circuit Electric Heat 15 kW 52 58 29 23 Ampacity 1 0 33 22 5 kW 72 81 40 32 HP 30 kW 91 103 51 41 Power Exhaust 45 kW 130 148 74 59 ELECTRICAL ACCESSORIES Disconnect 7 5 kW 54W56 54W56 54W56 54W56 15 kW 54W56 54W56 54W56 54W56 22 5 kW 54W56 54W56 54W56 54W56 30 54W57 54W57 54W56 54W56 45 kw 54W57 57W57 54W56 54W56 1 Extremes of operating range are plus and minus 10 2 HACR type breaker or fuse 3 Refer to National or Canadian Electrical Code manua of line voltage to determine wire fuse and disconnect size requirements Page 12 ELECTRICAL ELECTRIC HEAT DATA 10 TON 10 TON STANDARD EFFICIENCY R 410A 12054 Voltage 60hz 208 230V 3 Ph 460V 3 Ph 575V 3 Ph Compressor 1 Rated Load Amps 16 7 8 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 11 8 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 3 3 Motor Full Load Amps 10 6 4 8 3 9 Maximum Unit Only 60 30 20 Overcurrent With 1 0 33 HP 60 30 25 Protection Power Exhaust Minimum Unit Only 52 25 19 Circuit With 1 0 33 HP 5
11. system switch is in OFF position Determining Unit CFM 1 The following measurements must be made with a dry indoor Run blower without 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 to unit from supply to return 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 10 Page 21 4 The blower can be adjusted at the motor pulley Loosen Allen screw and turn adjustable pulley clockwise to increase Turn counterclockwise to decrease CFM See figure 10 Do not exceed minimum and maxi mum number of pulley turns as shown in table 1 TABLE 1 MINIMUM AND MAXIMUM PULLEY ADJUSTMENT Minimum Maximum Tums Open Turns Open B Section 1 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 mai
12. 000 1 18 9 64 500 2 25 2 86 000 2 37 8 129 000 2 50 4 172 000 2 575 6 9 23 600 1 13 8 47 100 1 20 7 70 700 2 27 5 93 900 2 41 3 141 000 2 55 1 188 000 2 600 7 5 25 600 1 15 0 51 200 1 22 5 76 800 2 30 0 102 400 2 45 0 153 600 2 60 0 204 800 2 15 PARTS DISCONNECT CIRCUIT BREAKER EVAPORATOR BLOWER CONDENSER ECONOMIZER FACTORY OR FIELD MOTOR FANS OPTIONAL INSTALLED OPTION CONDENSER ELECTRIC HEAT CONDENSATE FILTERS DRAIN FOUR 20 X 25 X 2 FIGURE 1 KCA CONTROL BOX Y G J VOLT UNITS KCA CONTROL BOX M VOLT CE UNITS FIGURE 2 FIGURE 3 16 I UNIT COMPONENTS All 7 5 through 12 5 ton 26 3 through 44 kW units are con figure to order units CTO The KCA 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 KCA control box components are shown in figure 2 and 3 The control box is located in the upper portion of the
13. 1 15 X 95 Cover must also be lifted to adjust control mode from automatic reset to manual reset see detail above and to test the control Control must be in the manual reset mode to perform a test Use a pointed object to press the small red test button A yellow marker should appear in the trip indication window to the right of the amp setting control Press the blue reset screw to reset the relay The red STOP button opens the normally closed contacts which power the blower motor This button stops blower motor operation as long as it is pressed in FIGURE 7 SIEMENS OVERLOAD RELAY BLUE RESET BUTTON IN FACTORY SET AUTO MODE Turn clockwise to H for manual reset GREEN TRIP INDICATOR Flush with surface not tripped Above surface tripped RED TEST BUTTON AMP ADJUSTMENT DIAL Adjust relay amp setting according to value given on the blower motor nameplate Proper relay amp setting equals motor nameplate FLA X service factor of 1 15 X 95 Use small slotted screwdriver to adjust control mode from automatic reset A to manual reset H Control must be in the manual reset mode H to perform a test Press the red test button Green trip indicator should pop out Press the blue reset screw to reset the relay FIGURE 8 Page 18 KCA092 102 120 150 PLUMBING AND COMPRESSOR CIRCUITS DETAIL OUTDOOR COIL STAGE 2 OUR Sa inen o n SES NT NT INDOOR COIL STAGE 2
14. 7 or Siemens figure 8 M volt CE units will be equipped with a relay manufac tured by Siemens See figure 6 10 Compressor Overload Relays S176 S177 M volt CE units Relays are wired in series with the appropriate compres sor contactor and monitor the current flow to the compres sor motor When the relay senses an overload condition N C contacts open to de energize the compressor Re lays are manufactured by Siemens see figure 6 H COMPRESSOR OVERLOAD RELAYS 111 OVERLOAD O SETTING SET RELAYS TO MAXIMUM FIGURE 6 Page 17 LINE VOLTAGE IN N TELEMECANIQUE OVERLOAD RELAY TRIP INDICATION CLEAR WINDOW SHOWR DETAIL SHOWING RESET BUTTON 22 SHOWN ADJUSTED TO MANUAL POSITION CLOSED STOP Lift clear cover and turn adjustment screw BUTTON counterclockwise Reset screw will pop out RED when pointer is in M manual position Close cover to lock reset screw into position AMP SETTING CONTROL BLUE DIAL RED TEST BUTTON Push Test BLUE RESET SCREW Shown in AUTO position as LOAD VOLTAGE OUT shipped from the factory Lift clear cover to adjust relay amp setting according to value given on the blower motor nameplate Proper relay amp setting equals motor nameplate FLA X service factor of
15. Electric Heat Relay K9 All KCA series units with electric heat use an electric heat relay K9 K9 is a N O DPDT pilot relay intended to electri cally isolate the unit s 24V circuit from the electric heat 24V circuit K9 is energized by K9 1 closes energizing timer DL2 K9 is located in the electric heat control assem bly See figure 13 2 Time Delay DL2 DL2 is a factory installed solid state timer used in 22 5 to 60 kW electric heat units DL2 allows staging by providing a timed interval between the first and second heating ele ments When the timer is energized the contacts are delayed for 30 seconds before closing When the timer is de energized the contacts are delayed 1 second before opening DL2 is located in the electric heat control assem bly See figure 13 ELECTRIC HEAT CONTROL ASSEMBLY ELECTRIC HEAT CONTROL ASSEMBLY ELECTRIC HEAT SECTION FIGURE 13 Page 23 2 ELECTRIC HEAT SECTION FUSE RATING voumses pop Size a Ca rme mem Co mas T mew Co wave Co rr sean mas mmm ew eee Ca me L T Ce L Ca ms L T WEZI ZI Co
16. Ends Open 1 Side 2 Ends All Ends amp Sides Diffuser cfm Open 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 3000 0 32 0 29 0 25 0 25 092 Models 102 amp 120 Models 4600 0 34 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 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 15 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 Throw is the horizontal or vertical distance an air stream travels on leaving the outlet or diffuser before the maximum velocity is reduced to 50 ft per minute Four sides open Page 10 ELECTRICAL ELECTRIC HEAT DATA 7 5 TON STANDARD EFFICIENCY R 410A 7 5 TON KCA092S4 Voltage 60hz 208 230V 3 Ph 460V 3 Ph 575V 3 Ph Compre
17. PEF requires an optional gravity exhaust damper and economizer and is used in downflow applications only See figure 28 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 28 Power Exhaust Setpoint Adjustment Locate the A6 enthalpy control in the control area The EXH SET potentiometer is factory set at approximately 5096 of the dial range See figure 29 Power exhaust fans will be en ergized 30 seconds after dampers are 5096 open Adjust the EXH SET potentiometer higher clockwise toward 10V to energize fans when dampers are further open Adjust the EXH SET potentiometer lower counterclockwise toward 2 to energize fans when dampers are further closed Thirty second delay allows dampers to partially open be fore exhaust fan starts A6 ENTHALPY CONTROLLER ADJUST POWER EXHAUST FAN SETPOINT ENERGIZED WHEN DAMPER POSITION IS HIGHER THAN EXHAUST FAN SETPOINT FIGURE 29 H Control Systems Three different types of control systems may be used with the 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 me
18. 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 to this substance or for further information consult material safety data sheets available from address shown on unit nameplate or contact your supervisor A Filters Units eguipped with four 20 25 2 filters Filters should be checked and replaced when necessary with filters of like kind and size Take note of air flow direction marking on filter frame when reinstalling filters See figure 17 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 PULL FILTERS ZO FIGURE 17 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 D 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
19. in RA R1 MIXED AIR SENSOR FIGURE 23 Page 31 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 IAA reading is higher than set point requiring more fresh air See figure 24 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 24 Free Cooling Setpoint Outdoor air is considered suitable when temperature and humidity are less than the free cooling setpoints shown in table 9 Setting A is recommended See figure 24 At set ting A free cooling will be energized when outdoor air is approximately 73 F 23 C and 50 relative humidity If indoor air is too warm or humid lower the setpoint to B At setting 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 TABLE 9 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
20. outdoor air temperature and 80 F db 67 F wb entering evaporator air minimum external duct static pressure 2 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 4 Standard motor and drive kit furnished with unit Page 5 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 9 for blower motors and drives See page 9 for wet coil and option accessory air resistance data MINIMUM AIR VOLUME REQUIRED FOR USE WITH OPTIONAL ELECTRIC HEAT Maximum Static Pressure 2 0 in w g 7 5 kW 15 kW 22 5 kW 30 kW and 45 kW 2800 cfm Total Air Volume cfm Total Static Pressure in w g
21. return RTD11 are available for use with all KCA units Refer to manufacturers instructions included with transi tion for detailed installation procedures E K1ECON20B Economizer Field or Factory Installed Economizers use outdoor air for free cooling when temper ature and or humidity is suitable See figure 22 The mixed air temperature sensor R1 measures the supply air sensible temperature See figure 23 The outdoor air sen sible control is the default economizer control An outdoor air single sensible sensor 5175 is also provided See table 8 for outdoor and return air OA and RA sensor options Refer to instructions provided with sensors for installation An IAQ sensor is used when demand control ventilation DCV is specified Damper minimum position can be set lower than traditional minimum air requirements resulting in cost savings The IAA sensor allows the A6 to open damp ers to traditional ventilation requirements as room occu increases 8 Dampers will modulate to 55 F discharge air RT6 when Single OA Sensible OA temperature S175 is lower than free cooling setpoint Single OA Sensible OA temperature and humidity A7 is lower than free cooling setpoint OA temperature and humidity A7 is lower than RA temperature and humidity A62 sensed A63 is higher than lAGQ Sensor setpoint MIXED AIR SENSOR R1 LOCATION Differential Enthalpy 1 in OA and 1
22. slabs Dirt and debris may become trapped between the slabs To clean between slabs carefully separate coil slabs and wash them thoroughly See figure 18 Flush coils with water following cleaning Note Remove all screws and gaskets prior to cleaning pro cedure and replace upon completion E 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 Page 28 CLEAN CONDENSER COIL ENDPLATE IS SECURED TOP VIEW EVAPORATOR 4 J BLOWER CONDENSER ACCESS PANEL FIGURE 18 VII ACCESSORIES The accessories section describes the application of most of the optional accessories which can be factory or field installed to the KCA 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 KCA 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 19
23. switch is lo cated in each liquid line prior to the indoor coil section In the KCA092 150 S11 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 discharge 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 150 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 20 C Blower Compartment The blower compartment in all KCA092 150S units is located between the evaporator coil and the condenser coil section 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 10 1 Blower Wheels All KCA092 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 specifications are listed in
24. 092 9 1 5 0 0 5 8 F 1 4 4 C 0 5 102 7 1 3 9 0 5 6 1 3 3 0 5 120 1 4 4 0 5 6 1 3 3 0 5 150 6 F 1 3 3 0 5 6 F 1 3 3 0 5 27 V SYSTEMS SERVICE CHECKS A Cooling System Service Checks KGA units are factory charged and reguire no further adjust ment however charge should be checked periodically using the approach method The approach method compares actual liguid temperature with the outdoor ambient temperature See section IV CHARGING NOTE When unit is properly charged discharge line pres sures should approximate those in tables 3 through 6 AIMPORTANT The Clean Air Act of 1990 bans the intentional vent ing of refrigerant as of July 1 1992 Approved methods of recovery recycling or re claiming must be followed Fines and or incarcera tion may be levied for non compliance VI MAINTENANCE The unit should be inspected once a year by a qualified ser vice technician turn the electrical power to unit OFF controls Wiring errors can cause improper and dan at disconnect switch es Unit gerous operation Verify proper operation after ser Electric shock hazard Can cause have multiple power supplies injury or death Before attempting to A CAUTION perform any service or maintenance Label all wires prior to disconnection when servicing vicing A WARNING Product
25. 1 142 497 144 TABLE 4 KCA102 NORMAL OPERATING PRESSURES Outdoor CIRCUIT1 1 CIRCUIT 2 Coil Suction Entering 5 psig Air Temp Dis Prem Dis charge Suction charge 10 psig 5psig 10 psig 487 143 501 75 F 131 TABLE 5 KCA120 NORMAL OPERATING PRESSURES CIRCUIT1 1 CIRCUIT 2 Outdoor Coil ____ Dis Entering charge Suction charge Suction Air Temp 10 psig 5psig 10 psig 5 psig 145 75 F 138 TABLE 6 KCA150 NORMAL OPERATING PRESSURES Outdoor CIRCUIT1 1 CIRCUIT 2 Coil Suction Entering 5 psig Air Temp Dis charge Suction charge 10 psig 5psig 10 psig pom px 456 75 F 138 Charge Verification Approach Method AHRI Testing 1 Using the same thermometer compare liquid tempera ture at condenser outlet to outdoor ambient temperature Approach Temperature Liquid temperature minus ambient temperature 2 Approach temperature should match values shown in table 7 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 3 through 6 as a guide for typical operating pressures TABLE 7 APPROACH TEMPERATURE Liquid Temp Minus Ambient Temp gni 1st Stage 2nd Stage
26. 1273 25 1178 3 52 1230 3 821284 4 14 4500 744 11 45 786 1 73 829 12 01 873 2 27 917 2 49 961 2 67 100512 87 1050 3 07 1096 3 29 1143 3 53 1193 3 81 1245 4 11 1298 4 43 4750 764 11 73 806 2 01 849 2 28 893 2 53 936 12 74 980 2 94 10233 15 1068 3 37 1113 3 60 11603 84 121014 1212614 4213144 74 5000 785 2 02 827 2 30 870 2 57 914 2 81 957 13 02 1000 3 23 1043 3 46 1087 3 69 1131 3 92 11784 17 1227 4 44 1278 4 74 133015 05 5250 1807 2 33 850 12 61 893 2 87 937 3 11 979 3 33 1021 3 55 106413 80 1107 4 03 1151 4 27 1197 4 51 1245 4 78 1295 5 08 1347 5 38 5500 831 12 66 874 2 94 917 3 2 960 13 43 1002 3 67 1043 3 91 1085 4 16 1127 4 39 1171 4 63 1216 4 87 126415 14 13135 42 136415 72 5750 1856 3 00 899 13 29 943 3 55 985 3 79 102614 04 106614 30 1107 4 55 114914 78 1192 5 00 1237 5 24 1284 5 50 6000 883 3 381927 3 66 970 3 93 1010 4 19 105014 46 108914 72 112914 95 1171 5 17 12135 40 1257 5 63 6250 1912 3 78 956 4 07 997 4 35 1036 4 63 107414 90 111315 15 1152 5 37 11935 58 8 BLOWER DATA FACTORY INSTALLED BELT DRIVE KIT SPECIFICATIONS Nominal Drive Number RPM Range hp hp 2 23 1 590 890 2 23 2 800 1105 2 29 3 795 1195 3 3 45 4 730 970 3 3 45 5 940 1200 3 3 45 6 10
27. 15 1300 5 5 75 10 900 1135 5 DS 11 1040 1315 5 55 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 0 15 2410 0 20 2165 05255 1920 0 30 1420 0 35 1200 FACTORY INSTALLED OPTIONS FIELD INSTALLED ACCESSORY AIR RESISTANCE in w g As Volume Wet Indoor Coil Electric Filters Return Air Economizer Adaptor cfm 092 102 120 150 Heat MERV 8 MERV 13 Plate 2250 0 07 0 10 0 13 0 04 0 08 0 01 0 04 0 00 2500 0 09 0 12 0 15 0 04 0 11 0 01 0 05 0 00 2750 0 09 0 12 0 17 0 05 9 12 0 02 0 05 0 00 3000 0 11 0 15 0 19 0 06 0 13 0 02 0 06 0 02 3250 0 13 0 18 0 23 0 06 0 15 0 02 0 06 0 02 3500 0 14 0 21 0 26 0 09 0 15 0 03 0 07 0 04 3750 0 16 0 23 0 29 0 09 0 15 0 03 0 08 0 07 4000 0 17 0 25 0 31 0 09 0 19 0 04 0 08 0 09 4250 0 20 0 27 0 34 0 13 0 19 0 04 0 09 0 11 4500 0 21 0 30 0 37 0 14 0 22 0 04 0 09 0 12 4750 0 23 0 32 0 40 0 17 0 25 0 05 0 10 0 16 5000 0 26 0 35 0 43 0 20 0 29 0 06 0 10 0 18 5250 0 27 0 36 0 46 0 22 0 32 0 06 0 11 0 19 5500 0 29 0 40 0 50 0 25 0 34 0 07 0 12 0 22 5750 0 32 0 43 0 56 0 31 0 45 0 07 0 12 0 25 6000 0 33 0 46 0 59 0 33 0 52 0 08 0 13 0 27 9 BLOWER DATA CEILING DIFFUSERS AIR RESISTANCE in w g RTD11 Step Down Diffuser FD11 Flush Unit Size Air Volume 2
28. 25 1425rpm Factory Q 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 1 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 53W80 X X X X Smoke Detector Supply and Return Power board and two sensors C1SNSR43B 1 53W81 X X X X NOTE Catalog and model numbers shown are for ordering field installed accessories OX Configure To Order Factory Installed or Field Installed Configure To Order Factory Installed X 7 Field Installed 2 OPTIONS ACCESSORIES Model Catalog Unit Model No Item Description Number Number 092 102 120 150 INDOOR AIR QUALITY Air Filters Healthy Climate High Efficiency Air Filters MERV 8 C1FLTR15B 1 50W61 X X X X 20 x 25 x 2 Order 4 per 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 ie plastic case with LCD dis
29. 4 27 20 Ampacity Power Exhaust ELECTRIC HEAT DATA Electric Heat Voltage 208V 240V 480V 600V Maximum Unit 15 kW 60 60 30 25 Overcurrent Electric Heat 22 5 kW 80 90 40 35 Protection 30 kW 100 110 60 45 45 kW 150 150 80 60 60 150 175 80 70 3 Minimum Unit 15 kW 53 59 29 23 Circuit Electric Heat 22 5 kW 72 81 40 32 Ampacity 30 kW 92 104 52 41 45 kW 131 149 74 60 60 kW 139 158 79 63 Maximum Unit 15 kW 60 70 35 25 Overcurrent Electric Heat 22 5 kW 80 90 45 35 Protection and 1 0 33 30 kW 100 110 60 45 HP 45 kW 150 175 80 70 Power Exhaust 60 kW 150 175 80 70 Minimum Unit 15 kW 56 62 31 25 Circuit Electric Heat 22 5 kW 75 84 42 34 Ampacity 1 0 33 30kW 95 107 53 43 HP 45 kW 134 152 76 61 Power Exhaust 60 kW 142 161 80 64 ELECTRICAL ACCESSORIES Disconnect 15 kW 54W56 54W56 54W56 54W56 22 5 kW 54W57 54W57 54W56 54W56 30 kW 54W57 54W57 54W56 54W56 45 kw 57W57 54W57 54W56 54W56 60 kw 4 Not available Not available 54W56 54W56 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 4 Disconnect must be field furnished Page 13 ELECTRICAL ELECTRIC HEAT DATA 12 5 TON 12 5 TON STANDARD EFFICIENCY R 410A 15054 1 Voltage 60hz 208 230V 3 P
30. 60V 3ph C1EHO450B 1G 56W51 X X X X 575V 3ph 450 1 56W52 X X X X 60 kW 208 230V 3ph CTEHO600B 1Y 55W02 X X 460V 3ph C1EHO600B 1G 55W03 X X 575V 3ph CTEHO600B 1J 55 04 X X 1 Lamps operate on 110 230V single phase power supply Step 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 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 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 O
31. 9 1312 4 89 7 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 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 9 for blower motors and drives See page 9 for wet coil and option accessory air resistance data MINIMUM AIR VOLUME REQUIRED FOR USE WITH OPTIONAL ELECTRIC HEAT Maximum Static Pressure 2 0 in w g 15 kW 22 5 kW 30 kW and 45 kW 2800 cfm 60 kW 4000 cfm 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 2 2 2 4 2 6 RPM BHP RPM BHPRPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 3750 1689 0 68 731 0 97 775 1 27 820 1 56 865 1 81 911 2 02 957 2 19 1004 2 35 110512 53110012 74 1151 2 99 1204 3 29 1258 3 61 4000 706 10 92 748 1 22 792 11 51 836 1 78 881 12 02 926 12 22 972 2 39 10182 57 1065 2 761111312 98 1163 3 25 1217 3 55 12713 87 4250 725 1 18 766 1 47 810 11 75 854 2 02 899 2 25 943 2 44 988 2 61 1033 2 81 10793 011
32. HO 7 5 15 22 5 30 45 60 Y FOR USE WITH KCA AND KHA UNITS B BOX HEATING SECTION A5 Supersedes Form No New Form No 534870W 537058 01 Litho U S A Page 40 7 5 15 22 5 30 45 amp 60kW J VOLTAGE SERIES UNITS DESCRIPTION COMPONENT DELAY ELECTRIC HEAT m HE3 J7 K9 1 2 7 15 3 ER JACK ELECTHT SUB BUS KIT RELAY HEAT K15 1 CONTACTOR ELECTRIC HT 1 16 1 CONTACTOR ELECTRIC HT 2 P P PLUG HEAT PLUG ELECTHT SUB BASE KIT SWITCH LIMIT PRIMARY ELECT HT o v 325 33 3 alala s i B z m Z zz 5 5 S AHE lt lt ol ol mmm d 4 d WIRING DIAGRAM HEATING ELETRIC NOT USED ON 7 5 15 AND 30 KW UNITS 7 5 15 22 5 30 45 60 G J FOR USE WITH KCA AND KHA UNITS B BOX TB3IS USED ON SOME UNITS 182 848 OR MAY BE USED Supersedes New Form No 534871W 537057 02 Lennox Commercial Page 41 Sequence of Operation 7 5 15 22 5 30 45 60 kW J M NOTE This sequence of operation is for all Electric SECOND STAGE HEAT Heat kW ratings Y through J voltages Each step of op 2 Heating demand initiates at W1 in thermostat eration is numbered and can be followed in sequence on the diagrams Operation for G J and M voltages will 3 24VAC W2 signal is routed through f
33. 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 37 ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT 24V POWER A ECONOMIZER ceu BLOWER G HEAT 1 W1 HEAT 2 W2 Wy COOL 1 Y1 COOL 2 Y2 24V COMMON DESCRIPTION COMPONENT SENSOR ELECTRONIC THERMOSTAT SENSOR CO2 CLOCK TIME JACK UNIT ECONOMIZER RELAY EXHAUST FAN PLUG ECONOMIZER BYPASS SENSOR MIXED AIR OR SUPPLY AIR SENSOR REMOTE THERMOSTAT TERMINAL STRIP CLASS Il VOLTAGE 2 63 3 3 COOL 1 Y1 65 3 T2 TB1 20 20 gt gt 2 g a lt COOL 2 Y2 DENOTES OPTIONAL COMPONENTS QLASS II FIELD WIRING a THERMOSTAT SUPPLIED BY USER 24V COMMON WIRING DIAGRAM 12 09 REMOVEP3 WHEN ECONOMIZERS USED ONLY ON KGA AND KHA 180 THROUGH 300 UNITS CONNECTION SCHEME FOR KCA KGA AND KHA 092 THROUGH 150 UNITS WITHOUT J3 MAXIMUM LOAD 20VA 24VAC CLASS II ECONOMIZER ONLY TIME CLOCK CONTACTS OPT CLOSED OCCUPIED ACCESSORIES XOUCHECREENTHEBMOSTAT ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT J3 AND P3 ARE NOT USED ON KCA KGA AND KHA SECTION C REV 2 0 092 THROUGH 150 UNITS WITHOUT ECONOMIZER Supersedes New Form No REMOVE JUMPER BETWEEN TB1 R AND 1 fee 07 537077 01 WHEN USING A NITE SETBACK THERMOSTAT Lennox Commercial POWER 1 Terminal strip TB1 en
34. P BHP 3000 677 10 24 719 0 55 764 0 87 813 1 18 866 1 45 920 1 67 975 1 8211026 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 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 4 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 5
35. R EXHAUST FAN MOTOR 1 o 09 266 OQ m 2 JACK DETECTOR ONE j 3 3 1 2 JACK SMOKE DETECTOR TWO JACK SMOKE DETECTOR TWO 1255 JACK MODULE CONTROL SMOKE DETECTION 9 R JACK SMOKE DETECTOR JUMPER 120 60 1 Ne Nay X CONTACTOR COMPRESSOR 1 a 6 5 e 2 CONTACTOR COMPRESSOR 2 WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURDENH R2 UNIT MUST BE GROUNDEDIN ACCORDANCBWITH NATIONAL AND 2 LOCAL CODES DISCONNECT ALL POWER BEFORE SERVICING c ZTETETETETETE EIE 5 4250 JACK SMOKE DETECTOR ONE CONTACTOR BLOWER RELAY OUTDOOR FAN RELAY EXHAUST FAN RELAY OVERFLOW DELAY JACK HEAT PLUG EXHAUST FAN COMPT PLUG EXHAUST FAN DENOTES OPTIONAL COMPONENTS JACK TEST LINE VOLTAGE FIELD INSTALLED PLUG TEST COOL GROUND PLUG OUTDOOR FANS 1 P132 PLuG EXHAUST FAN MOTOR 1 JACK SMOKE DETECTOR ONE JACK SMOKE DETECTOR ONE JACK SMOKE DETECTOR TWO JACK SMOKE DETECTOR TWO PLUG MODULE CONTROL SMOKE DETECTION SWITCH LIMIT LOW COMPRESSOR 1 SWITCH LIMIT HI PRESS COMP 1 SWITCH LIMIT HI TEMP COMPRESSOR 1 WIRING DIAGRAM 03 10 COOLING KCA KGA 092 102 120 150 G J M Y Supersedes New Form No ______ SWITCH FREEZESTAT 1 SWITCH FREEZESTAT COMP 2 SWITCH LOW PRESS LOW AMBIENT KIT COMP 2 5149 SWITCH OVERFLOW TRANSFORMER CONTROL 2009 Lennox Commercial Page 36 KCA092 150 Sequence of Operation
36. 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 20 Refer to the roof mount ing frame installation instructions for proper plenum construction and attachment B Transitions Optional supply return transitions LASRT08 10 is available for use with the KCA 7 5 ton units and LASRT10 12 is avail able for the 8 5 and 10 ton units utilizing optional C1CURB roof mounting frames KCA 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 Page 29 CONDENSER COILS Remove unit top panel and condenser section access panel Remove screws securing coil end plate to mullion Remove 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 ASSEMBLED ROOF MOUNTING FRAME SUPPLY AIR FIGURE 19 TYPICAL FLASHING DETAIL UNIT BASE BOTTOM UNIT BASE RAIL FIBERGLASS INSULATION Furnished COUNTER FLASHING NAILER STRIP Field Sup
37. UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE P2 IS USED ON 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 P HEAT 2 W2 DESCRIPTION COMPONENT MONITOR PHASE PROTECTION MODULE VOLTAGE REDUCTION m lt 144 COOL 1 Y1 COOL 2 Y2 SENSOR ONE SMOKE RETURN AIR SENSOR TWO SMOKE SUPPLY AIR MODULE CONTROL SMOKE DETECTION COMPRESSOR 1 171 220 240V 460V 575V UNITS 2 3 4 5 B10 1 2 6 Bi COMPRESSOR 2 MOTOR BLOWER MOTOR OUTDOOR 1 MOTOR OUTDOOR 2 MOTOR EKHAUST 1 CAPACITOR OUTDOOR 1 CAPACITOR OUTDOOR FAN 2 CAPACITOR EXHAUST FAN 1 8 CIRCUIT BREAKER T1 NOTE IF ANY WIRE IN THIS APPLIANCHS REPLACEDT MUST BE REPLACEDWITH WIRE OF LIKE SIZE RATING TERMINATION AND INSULATION THICKNESS 5 lt DL46 DELAY OVERFLOW SWITCH HEATER COMPRESSOR 1 HEATER COMPRESSOR 2 JACK HEAT JACK GFI RECEPTICLE JACK EXHAUST FAN COMPT 24 JACK EKHAUST FAN 35 JACK TEST J36 JACK TEST COOL 900 000 EQUIPMENT a c1 J132 JACK BLOWE
38. X 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 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 24L14 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 Configure To Order Factory Installed X Field Installed 4 SPECIFICATIONS General Data Nominal Tonnage 7 5 Ton 8 5 Ton 10 Ton 12 5 Ton Model Number KCA092S4B KCA102S4B KCA120S4B KCA150S4B Efficiency Type Standard Standard Standard Standard Blower Type Constant Air Constant Air Constant Air Constant Air Volume CAV Volume CAV Volume CAV Volume CAV Cool
39. ble 54W56 54W56 60 kw 4 Not available Not available 54W57 54W56 1 Extremes of operating range are plus and minus 10 2 HACR type breaker or fuse 3 Refer to National or Canadian Electrical Code manua Disconnect must be field furnished of line voltage to determine wire fuse and disconnect size requirements Page 14 ELECTRIC CAPACITIES 7 5 kW 15 kW 22 5 kW 30 kW 45 kW 60 kW hdd kW Btuh of kW Btuh No of kW Btuh No of kW Btuh No of No of kW Btuh of Input Output Stages Input Output Stages Output Stages Input Output Stages Input Output Stages Output Stages 208 5 6 19 100 1 11 3 38 600 1 16 9 57 700 2 22 5 76 800 2 33 8 115 300 2 45 0 153 600 2 220 6 3 21 500 1 12 6 43 000 1 18 9 64 500 2 25 2 86 000 2 37 8 129 000 2 50 4 172 000 2 230 6 9 23 600 1 13 8 47 100 1 20 7 70 700 2 27 5 93 900 2 41 3 141 000 2 55 1 188 000 2 240 7 5 25 600 1 15 0 51 200 1 22 5 76 800 2 30 0 102400 2 45 0 153 600 2 60 0 204 800 2 440 6 9 21 500 1 12 6 43 000 1 18 9 64 500 2 25 2 86 000 2 37 8 129 000 2 50 4 172 000 2 460 6 9 23 600 1 13 8 47 100 1 20 7 70 700 2 27 5 93 900 2 41 3 141 000 2 55 1 188 000 2 480 7 5 25 600 1 15 0 51 200 1 22 5 76 800 2 30 0 102 400 2 45 0 153 600 2 60 0 204 800 2 550 6 3 21 500 1 12 6 43
40. chanical 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 Any two stage heat two stage cool electronic ther mostat may be used 3 Honeywell T7300 thermostat 601 59 The Honeywell T7300 thermostat is a programmable in ternal or optional remote temperature sensing thermo stat The T7300 provides occupied and unoccupied changeover control I 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 J Drain Pan Overflow Switch 149 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 35 Vill Wiring Diagrams and Sequence of Operation KCA092 150 UNIT DIAGRAM A173 SENSOR 1 24V POWER NOTE FOR USE WITH COPPER CONDUCTORS ONLY REFER TO
41. cifications Page 5 al injury loss of life Installation and service must be performed by a qualified installer or service Blower Data Page 6 agency Electrical Electric Heat Data Page 11 ELECTROSTATIC DISCHARGE ESD yA Precautions and Procedures Electrical Heat Capacities Page 15 A CAUTION Parts Arrangement Page 16 l Unit Components Page 17 Electrostatic discharge can affect electronic components Take precautions during unit instal Placement and Installation Page 26 lation and service to protect the unit s electronic Ile Start U p 26 controls Precautions will help to avoid control SAI Sip ens to electrostatic discharge by putting E the furnace the control and the technician at the IV Charging Page 27 same electrostatic potential Neutralize electro V System Service Checks Page 28 static charge by touching and all tools unpainted unit surface such as the gas valve or VI Maintenance Page 28 blower deck before performing any service pro cedure VII Accessories Page 29 Vill Wiring Diagrams Page 36 Technical 1 2010 Lennox Industries Inc A CAUTION Danger of sharp edges Can cause in
42. city 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 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 1 Some scroll compressors have an internal vacuum protector that will unload scrolls when suction pressure goes below 20 psig 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 C 5 C and close at 169 F 18 F 76 C 10 C 3 Freezestats S49 and 50 Each unit is equipped with a low temperature switch freezes tat located on a return b
43. com pressor compartment 1 Disconnect Switch S48 or CB10 CB10 field installed only All units may be equipped with an optional disconnect switch S48 or circuit breaker CB10 S48 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 BLUE YELLOW SECONDARY primary voltage taps as shown in figure 4 while 460 G and 575 J voltage transformers use a single primary voltage tap 208 VOLTS 230 YOLT ORANGE PRIMARY FIGURE 4 3 Terminal Strip TB1 BLACK All indoor thermostat connections will be to TB1 located in the control area For thermostats without occupied and unoccupied modes a factory installed jumper across ter minals R and OC should be in place 4 Condenser Fan Capacitors C1 amp C2 Fan capacitors C1 and C2 are used to assist in the start up of condenser fans B4 and 5 Ratings will be on side of capaci tor or outdoor fan motor nameplate 5 Compressor Contactor K1 amp K2 All compressor contactors are three pole double break contactors with 24VAC coils In all KCA units K1 and K2 energize compressors B1 a
44. conomizer 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 3 through 6 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 Significant 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 o 1 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 3 KCA092 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 65 132 757F 30i 133 85 F 343 354 136 95 F 388 401 139 105 F 435 140 449 141 115 F 48
45. emperature limit for the electric heat section When 15 opens indicating a problem in the system contactor K15 is de energized When K15 is de energized first stage and all subse quent stages of heat are de energized For EHA102 150 units the electric heat section thermostat is factory set to open at 170 F 5 F 76 2 8 on a temperature rise and automatically reset at 130 F 6 F 54 4 3 3 on a temperature fall For EHA100 units the electric heat section thermostat is factory set to open at 160 F 5 F 71 0 2 8 on a temperature rise and automatically reset at 120 F 6 49 0 C 3 3 on a temperature fall The ther mostat is not adjustable 3 High Temperature Limit S20 157 158 15 160 amp 161 Secondary Limits are SPST N C manual reset thermostat Like the primary temperature limit S20 is wired in series with the first stage contactor coil K15 and second stage contactor coil K16 When 20 opens contac tors K15 K16 are de energized When the contactors are de energized first stage and all subsequent stages of heat are de energized The thermostat is factory set to open at 220 F 6 F 104 C 3 3 on a tempera ture rise and can be manually reset when temperature falls below 160 F 71 0 4 Terminal Strip TB2 Terminal strip TB2 is used for single point power installa tions only TB2 distributes L1 L2 and L3 power to TB3 Units with multi point power con
46. end 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 ona 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 compressor 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
47. ergizes 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 38 ECONOMIZER J10 yx AN MS7110K RANGE 2 10 VDC ZA OPTIONAL OUTDOOR THERMOSTAT TO REPLACE A USED ON C BOX UNITS DESCRIPTION RIZE SENSIBLE SENSOR ZX A62 ENTHALPY SENSOR OR RT27 USED COMPONENT amp 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 SENSOR SOLID STATE ENTHALPY CLOSED BE USED INSTEAD OF A7 AND A62 ENTHALPY SENSORS A62 SENSOR TB11 USED ON C BOX ONLY WITH MOTOR 7215 ZX REPLACE A7 OR RT26 WITH 620 OHM RESISTOR JACK ECONOMIZER FOR CONTROLS WITH GLOBAL ECON 104 JACK SENSOR OUTDOOR ENTHALPY 3105 LIACICSENSORRETURN AIR ENTHALPY ENTHALPY DESIGNATES OPTIONAL WIRING B LELUG ECONOMIZER CLASS II FIELD WIRING P104 PLUG SENSOR OUTDOOR ENTHALPY PLUG SENSOR RETURN AIR ENTHALPY WIRING DIAGRAM POT MINIMUM POSITION RESISTOR SENSIBLE 820 OHM IRT26 _ SENSOR OUTDOOR AIR TEMP 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
48. ferential 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 5 Make sure the connections are tight Discharge and suction pressures should operate at their normal start up ranges REFRIGERANT CIRCUITS 092 150 CONDENSER COIL STAGE2 CONDENSER COIL STAGE 1 EVAPORATOR COIL STAGE 2 BOTH FANS ARE ENERGIZED WITH A Y1 DEMAND CONDENSER FAN 1 EVAPORATOR COIL STAGE 1 FIGURE 16 C Safety or Emergency Shutdown Turn off power to unit Page 26 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 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 e
49. h 460V 3 Ph 575V 3 Ph Compressor 1 Rated Load Amps 19 Sur 74 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 1 5 112 Motors 2 total 6 3 ZA 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 5 5 5 Motor Full Load Amps 16 7 7 6 6 1 Unit Only 70 35 25 Overcurrent With 1 0 33 HP 70 35 25 Protection Power Exhaust Minimum Unit Only 53 27 22 Circuit With 1 0 33 HP 56 29 23 Ampacity Power Exhaust ELECTRIC HEAT DATA Electric Heat Voltage 208V 240V 480V 600V Maximum Unit 15 kw 70 70 35 25 Overcurrent Electric Heat 22 5 kW MEO 80 40 30 Protection 30 kW 490 100 50 40 45 kW 5125 150 80 60 60 kW 150 150 80 70 3 Minimum Unit 15 kW 53 53 27 22 Circuit Electric Heat 22 5 kW 64 73 37 30 Ampacity 30 kW 84 96 48 39 45 kw 123 141 71 57 60 kW 130 150 75 61 Maximum Unit 15 kw 70 70 35 25 Overcurrent Electric Heat 22 5 kW 70 80 40 35 Protection and 1 0 33 30 kW 90 100 50 40 HP 45kW 150 150 80 60 PowerExhaust 60 kW 4150 175 80 70 3 Minimum Unit 15 kw 56 56 29 23 Circuit Electric Heat 22 5 kW 67 76 38 31 Ampacity 1 0 33 30 kW 87 99 50 40 45 kW 126 144 72 58 Power Exhaust 60 kW 133 153 77 62 ELECTRICAL ACCESSORIES Disconnect 15 kw 54W56 54W56 54W56 54W56 22 5 kW 54W57 54W57 54W56 54W56 30 54W57 57W57 54W56 54W56 45 kw 4 Not available Not availa
50. ing Gross Cooling Capacity Btuh 88 900 100 483 119 640 144 800 Performance 1 Net Cooling Capacity 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 Tat 8 7 10 3 1225 1 EER Btuh Watt WA 11 2 11 2 EER Btuh Watt 11 4 11 4 11 4 11 2 Refrigerant R 410A R 410A R 410A R 410A Refrigerant Circuit 1 7 105 8 oz 8 Ibs 8 oz 10 Ibs 0 oz 14 16 0 oz Charge Circuit 2 7 lbs 0 oz 8 lbs 8 oz 10 16 0 oz 12 15 0 oz Furnished Electric Heat Available See page 3 7 5 15 22 5 30 amp 45 KW 15 22 5 30 45 amp 60 KW 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 5 5 3 3 Total Air volume cfm 7200 7400 7800 8 800 Indoor Net face area total sg 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 NPT coupling and size Expansion device type Balance port TXV removable head 3 Indoor Nominal motor output 2 hp 3 hp 5 hp 2 hp 3 hp 5 hp 2 hp 3 hp 5 hp 2 hp 3 hp 5 hp Blower and Maximum usable moto
51. it 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 B 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 16 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 dif
52. jury Take care when servicing unit to avoid accidental contact with 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 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 LTACDKCO9 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 BLOWER SUPPLY AIR Motors Belt Drive 2hp Factory Q Belt Drive 3hp Factory O Belt Drive 5 Factory Drive Kits Kit 1590 890rpm Factory O O See Blower Tables selection 2 800 1105 rpm Factory Kit 3 795 1195 Factory Kit 4 730 970rpm Factory Kit 5940 1200rpm Factory 6 1015 1300 rpm Factory Kitz10900 1135rpm Factory Kit 11 1040 1315rpm Factory Kit 12 11
53. lection 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 12 Page 22 D Optional Electric Heat Components Table 2 shows electric heat fuse ratings See Options Acces sories section see table of contents for KCA to EHA match ups See Electrical Electric Heat Data section see table of contents of this manual for electrical ratings and capacities All electric heat sections consist of electric heating ele ments exposed directly to the air stream See figure 14 EHA parts arrangement is shown in figures 14 and 15 Multiple stage elements are sequenced on and off in re sponse to thermostat demand 1 Contactors K15 K16 Contactors K15 and K16 are three pole double break contactors located on the electric heat vestibule All contactors are equipped with a 24VAC coil The coils in the K15 and K16 contactors are energized by a W2 thermostat demand K9 and DL2 Contactor K15 energizes the first stage heating elements while K16 energizes the second stage heating elements On M volt units contactors are CE approved by manufacturer Siemens See figure 5 2 High Temperature Limits 15 Primary 15 is a SPST N C auto reset thermostat located on the back panel of the electric heat section below the heating elements 15 is the high t
54. 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 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 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 calc
55. n 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 11 PULLEY ALIGNMENT ALIGNED BLOWER PULLEY MOTOR PULLEY NOT ALIGNED M a FIGURE 11 1 Loosen four bolts securing motor base to mounting frame See figure 10 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 tension as follows 1 Measure span length X See figure 12 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 def
56. nd B2 in response to thermostat demand On CE M volt units contactor is CE approved by manufacturer Siemens See figure 5 6 Condenser Fan Relay K10 Outdoor fan relay K10 is a DPDT relay with a 24VAC coil K10 energizes condenser fans B4 and 5 CONTACTOR H H H H Ee O UU FIGURE 5 7 Blower Contactor Blower contactor 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 Power Exhaust Relay K65 PED units Power exhaust relay K65 is a DPDT relay with a 24VAC coil K65 is used in all KCA units equipped with the op tional power exhaust dampers K65 is energized by the economizer enthalpy control A6 after the economizer dampers reach 5096 open adjustable When K65 closes exhaust fan B10 is energized 9 Blower Motor Overload Relay Switch S42 The blower motor overload relay is used in all units equipped with high efficiency motors The relay S42 is connected in line with the blower motor to monitor the current flow to the motor When the relay senses an overload condition a set of normally closed contacts open to de energize 24 power to T1 transformer Non CE units will be equipped with a relay manufactured by Telemecanique figure
57. nections will not use TB2 5 Terminal Strip TB3 Electric heat line voltage connections are made to terminal strip TB3 located in the upper left corner of the electric heat vestibule TB3 distributes power to the electric heat components 6 Heating Elements HE1 through HE6 Heating elements are composed of helix wound bare nichrome wire exposed directly to the air stream Three elements are connected in a three phase arrange ment The elements in 208 230V units are connected in a Delta arrangement Elements in 460 and 575V units are connected in Wye arrangement Each stage is energized independently by the corresponding contac tors located on the electric heat vestibule panel Once energized heat transfer is instantaneous High temperature protection is provided by primary and re dundant high temperature limits and overcurrent protection is provided by fuses 7 Fuse Fuse F3 are housed in a fuse block which holds three fuses Each F3 fuse is connected in series with each leg of electric heat Figure 15 and table 2 show the fuses used with each electric heat section For simplicity the ser vice manual labels the fuses F3 1 2 and F4 1 2 8 Unit Fuse Block F4 Three line voltage fuses F4 provide short circuit and ground fault protection to all cooling components in the KCA units with electric heat The fuses are rated in accor dance with the amperage of the cooling components ELECTRIC HEAT CONTROL ASSEMBLY 1
58. play rated for plenum COSNSRS51AE1L 87 52 x X X X 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 Aspiration Box for duct mounting non plenum rated CO sensors 87N53 or 77N39 ene 2 COMISC16AE1 90N43 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 3phase Factory Disconnect Switch See Electrical Electric Heat tables for selection 80 amp C1DISCO80B 1 54W56 OX OX OX OX 150amp C1DISC150B 1 54057 OX OX OX OX GFI Service Outlets LTAGFIK10 15 74M70 OX OX OX ELECTRIC HEAT 7 5 kW 208 230V 3ph C1EHOO75B 1Y 56W38 X X 460V 3ph C1EHOO75B 1G 56W39 X X 575V 3ph C1EHOO75B 1J 56W40 X X 15 kW 208 230V 3ph CTEHO015B 1Y 56W41 X X X X 460V 3ph C1EHO150B 1G 56W42 X X X X 575V 3ph C1EHO150B 1J 56W43 X X X X 22 5 kW 208 230V 3ph CTEHO225B 1Y 56W44 X X X X 460V 3ph 225 16 56W45 X X X X 575V 3ph 1 225 1 56W46 X X X X 30 kW 208 230V 3ph CTEHOS300B 1Y 56W47 X X X X 460V 3ph C1EHO300B 1G 56W48 X X X X 575V 3ph 00 1 56 49 X X X X 45 kW 208 230V 3ph CTEHO450B 1Y 56W50 X X X X 4
59. plied Furnished CANT STRIP Field Supplied RIGID INSULATION Field Supplied MOUNTING FRAME Extends around entire perimeter of unit FIGURE 20 ROOFING MATERIAL LAOAD M MOTORIZED OUTDOOR AIR DAMPER MOTORIZED DAMPER COVER PANEL SUPPLY AIR OPENING HORIZONTAL lt p wi COMPRESSOR RETURN AIR 54 SECTION OPENING LOWER PANEL MANUAL OUTDOOR AIR DAMPER COVER PANEL HORIZONTAL SUPPLY AIR OPENING RETURN AIR SECTION OPENING a LOWER PANEL FIGURE 21 HORIZONTAL COMPRESSOR Page 30 ECONOMIZER ACCESSORY PANEL MULLION DIVIDER PANEL Attach with two provided screws BOTTOM OF COMPRESSOR SECTION FLANGED RETURN AIR OPENING FIGURE 22 C LAOAD M Outdoor Air Dampers Field or Factory Installed Optional manual and motorized outdoor air dampers 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 operated damper position is manually set at installation and remains in that position See figure 21 D Supply and Return Diffusers Optional flush mount diffuser retum FD11 and extended mount diffuser
60. r output 2 3 hp 3 45 hp 2 3 hp 3 45 hp 2 3 hp 3 45 hp 2 3 hp 3 45 hp Drive US Only 5 75 hp 5 75 hp 5 75 hp 5 75 hp Selection Motor Drive kit number 2 hp 2hp 2hp 2 hp Kit 1590 890 rpm 1590 890 rpm Kit 1 590 890 rpm Kit 1 590 890 rpm Kit 2 800 1105 rpm Kit 2 800 1105 rpm Kit 2800 1105 Kit 2 800 105 rpm 795 1195 rpm Kit 795 1195 rpm Kit 3795 1195 rpm 795 1195 rpm 3 hp 3hp 3hp 3 hp Kit 4 730 970 rpm Kit 730 970 4 730 970 rpm Kit4 730 970 rpm Kit 5 940 1200 rpm Kit 5940 1200 rpm Kit 5 940 1200 rpm Kit 5 940 1200 rpm Kit 6 1015 1300 rpm Kit 6 1015 1300 rpm Kit 6 1015 1300 rpm Kit 6 1015 1300 rpm 5 hp 5 hp 5 5 Kit 10 900 1135 rpm 10 900 1135 rpm 10 900 1135 rpm 10 900 1135 rpm Kit 11 1040 1315 rpm Kit 11 1040 1315 rpm Kit 11 1040 1315 rpm 11 1040 1315 rpm Kit 12 1125 1425 rpm Kit 12 1125 1425 rpm 12 1125 1425 rpm 12 1125 1425 rpm Blower wheel nominal 1 15 X 15 1 15 X 15 1 15 X 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 Certified in accordance with the ULE certification program which is based on AHRI Standard 340 360 95 F
61. rom the thermostat be the same to TB1 After 15 primary limit and 20 secondary limit is proved the electric heat contactor K15 is en HEATING ELEMENTS 1 Terminal Strip TB3 is energized when the unit discon nect closes TB3 supplies line voltage to electric heat elements HE1 through HE7 Each element is protected by fuse F3 ergized Page 42
62. ssor 1 Rated Load Amps 18 1 6 1 4 4 Locked Rotor Amps 83 1 41 Compressor 2 Rated Load Amps 13 1 6 1 4 4 Locked Rotor Amps 83 1 41 33 Outdoor Fan Full Load Amps 24 11 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 2 2 2 Motor Full Load Amps 15 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 ELECTRIC HEAT DATA Electric Heat Voltage 208V 240V 480V 600V 2 Maximum Unitt 7 5 kW 50 50 25 15 Overcurrent Electric Heat 15 kW 50 60 30 25 Protection 22 5 kW 70 80 40 35 30 kW 90 100 50 40 45 kW 150 150 80 60 3 Minimum Unit 17 5 kW 42 42 20 15 Circuit Electric Heat 15 kW 49 55 27 22 Ampacity 22 5 kW 69 78 39 31 30 kW 88 100 50 40 45 kW 127 145 72 58 Maximum Unit 17 5 kW 50 50 25 20 Overcurrent Electric Heat 15 kW 60 60 30 25 Protection and 1 0 33 22 5 kW 80 90 40 35 HP 30 kW 100 110 60 45 Power Exhaust 45 kW 150 150 80 60 Minimum Unit 17 5 kW 45 45 22 16 Circuit Electric Heat 15 kW 52 58 29 23 Ampacity and 1 0 33 22 5 kW 72 81 40 32 HP 30 kW 91 103 51 41 Power Exhaust 45 kW 130 148 74 59 ELECTRICAL ACCESSORIES Disconnect 7 5 kW 54W56 54W56 54W56 54W56 15 kW 54W56 54W56 54W56 54W56 22 5 kW 54W56 54W56 54W56 54W56 30 kW 54W57 54W57 54W56 54W56 45 kW 54W57 54W57 54W56 54W56
63. the SPECIFI CATIONS table of contents in the front of this manual Units may be equipped with motors manufactured by vari ous manufacturers therefore electrical FLA and LRA specifications will vary See unit rating plate for informa tion 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 gt EDGES SHOULD BE PARALLEL ON BOTH ENDS BEFORE TIGHTENING MOTOR MOUNTING BASE IN PLACE REMOVE TWO SCREWS NA 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
64. ting 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 10 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 outdoor 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 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 10 ECONOMIZER OPERATION OUTDOOR AIR IS SUITABLE FOR FREE COOLING FREE COOL LED 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
65. ulation reads desired fresh air percentage Page 32 1 CALCULATE MINIMUM FRESH AIR PERCENTAGE MIKED AND RETURN AIR TEMPERATURE 20 29 0 10 0 10 20 30 40 23 18 12 7 1 4 F 50 10 60 70 16 1 B 80 27 90 32 100 38 C 10 20 30 30 40 40 50 50 60 tc o z Li PERCENT FRESH AIR 60 70 70 80 80 90 100 F 20 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 Settings Adjust settings when an optional IAQ sensor is installed 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 IAO sensor reads approximately 1000ppm Adjust the DCV SET potentiometer to the approximate setting specified by the controls contractor Refer to figure 24 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 24 Note DCV Max must be set higher than economizer mini mum position set
66. when an mixed air sensor is installed Page 33 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 25 Manual damper fresh air intake percentage can be determined in the same manner DAMPER MOTOR THUMBWHEEL FIGURE 25 F Gravity Exhaust Dampers Dampers are used in downflow see figure 26 and horizon tal see figure 27 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 KCA 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 26 FIGURE 27 Page 34 G Power Exhaust Fan The power exhaust fan

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