Table of Contents
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©2017
WARNING
Improper installation, adjustment, alteration, ser
vice or maintenance can cause property damage,
personal injury or loss of life. Installation and ser
vice must be performed by a licensed professional
HVAC installer or equivalent, service agency, or the
gas supplier
Table Of Contents
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RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
INSTALLATION
INSTRUCTIONS
KGA/KCA092
KGA/KCA102
KGA/KCA120
KGA/KCA150
GAS AND COOLING PACKAGED UNITS
507118-06
4/2017
Supersedes 10/2016
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(7.5 Ton)
(8.5 Ton)
(10 Ton)
(12-1/2 Ton)
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KGA SHOWN
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Related Manuals for Lennox KGA092KGA102KGA120KGA150
Summary of Contents for Lennox KGA092KGA102KGA120KGA150
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Page 1: Table Of Contents
©2017 INSTALLATION INSTRUCTIONS WARNING KGA/KCA092 Improper installation, adjustment, alteration, ser (7.5 Ton) vice or maintenance can cause property damage, KGA/KCA102 personal injury or loss of life. Installation and ser (8.5 Ton) vice must be performed by a licensed professional KGA/KCA120 HVAC installer or equivalent, service agency, or the (10 Ton) gas supplier... -
Page 2: Dimensions
KGA/KCA092, 102, 120, & 150 DIMENSIONS - Gas heat section shown 6-1/8 5-5/8 BOTTOM SUPPLY (143) (156) AIR OPENING 6-1/8 10-3/4 (156) (610) (711) (273) (508) (686) 60-1/8 (1527) BASE BOTTOM RETURN BOTTOM AIR OPENING POWER ENTRY 5-1/2 (140) Dia. 6-5/8 7 (178) (168) -
Page 3: Parts Arrangements
KGA092, 102, 120, & 150 PARTS ARRANGEMENT DISCONNECT / CIRCUIT BREAKER BLOWER EVAPORATOR CONDENSER (FACTORY OR FIELD MOTOR COIL FANS ECONOMIZER INSTALLED OPTION) CONDENSER (OPTIONAL) COIL BLOWER INVERTER (OPTIONAL) COMBUSTION AIR INDUCER GAS VALVE COMPRESSORS FILTERS BURNERS CONDENSATE (FOUR - 20 X 25 X 2”) DRAIN KCA092, 102, 120, &... -
Page 4: Shipping And Packing List
CAUTION NOTICE As with any mechanical equipment, contact with Roof Damage! sharp sheet metal edges can result in personal in This system contains both refrigerant and oil. jury. Take care while handling this equipment and Some rubber roofing material may absorb oil, wear gloves and protective clothing. -
Page 5: Unit Support
S The return air duct must be provided and sealed to 2- The frames or supports must be constructed with the unit. non-combustible materials and should be square and S Return air temperature range between 55°F (13°C) level to 1/16” per linear foot (5mm per linear meter) in any direction. -
Page 6: Condensate Drains
4- Place field‐provided H‐style pick in place just above CONDENSATE SIDE DRAIN CONNECTION top edge of unit. Frame must be of adequate strength and length. (H-style pick prevents damage CAULK AROUND CONDENSATE COUPLING to unit.) RIGGING NOTE - Allow clearance to *WEIGHT open doors when installing UNIT... -
Page 7: Connect Gas Piping
4- Lift front edge of the drain pan (to clear bottom drain 11- Use a field-provided 1” plug to seal side drain plug) and slide drain pan out of unit. See figure 6. connection. 12- Replace the condensate drain mullion and reinstall eight screws. -
Page 8: Pressure Test Gas Piping
OUTSIDE OF UNIT GAS PIPE CONNECTION BOTTOM GAS ENTRY THROUGH THE UNIT ALL ELBOWS ARE 3/4” MULLION BETWEEN HEAT AND COMPRES SOR SECTIONS 5” NIPPLE GROMMET TO GAS VALVE 4” NIPPLE 10” NIPPLE GROUND 7-1/2” NIPPLE JOINT UNION GROMMET 4” NIPPLE TO GAS TO GAS VALVE... -
Page 9: High Altitude Derate
Refer to unit nameplate for minimum circuit ampacity WARNING and maximum fuse size. 1- 230/460/575 volt units are factory wired. For 208V Danger of explosion. Can cause injury supply, disconnect the pink wire (230V) at all control or product or property damage. Do not power transformer(s). -
Page 10: Unit Power-Up
1- Observe suction and discharge pressures and 24 VOLT FIELD WIRING WITH ELECTRONIC AND blower rotation on unit start-up. ELECTRO-MECHANICAL THERMOSTATS If pressure differential is not observed or blower rotation is not correct: 2- Suction pressure must drop, discharge pressure must rise, and blower rotation must match rotation marking. - Page 11 STANDARD BLOWER ASSEMBLY SIDE VIEW TO INCREASE BELT TENSION 1- Loosen four bolts securing motor mounting base to frame. 2- Turn adjusting bolt to the right, or clockwise, to MOTOR ALLEN move the motor away from the blower housing. SCREW IMPORTANT - Gap between end of frame and motor PULLEY mounting base should be equal at both ends, i.e.
- Page 12 LOCATION OF STATIC PRESSURE READINGS INSTALLATIONS WITH DUCTWORK INSTALLATIONS WITH CEILING DIFFUSERS ROOFTOP UNIT ROOFTOP UNIT RETURN AIR READING LOCATION RETURN AIR READING RE RE SUPPLY SUPPLY LOCATION TURN TURN FIRST BRANCH OFF OF MAIN RUN MAIN DUCT RUN SUPPLY AIR SUPPLY AIR READING READING...
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Page 13: Blower Data
BLOWER DATA 092S AND 102S STANDARD EFFICIENCY 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 −... - Page 14 BLOWER DATA 092H AND 102H HIGH EFFICIENCY 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 −...
- Page 15 BLOWER DATA 120S STANDARD EFFICIENCY 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 −...
- Page 16 BLOWER DATA 120H HIGH EFFICIENCY AND 150S STANDARD EFFICIENCY 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 −...
- Page 17 BLOWER DATA FACTORY INSTALLED BELT DRIVE KIT SPECIFICATIONS Nominal Maximum Drive Kit Number RPM Range 590 - 890 800 - 1105 795 - 1195 3.45 730 - 970 3.45 940 - 1200 3.45 1015 - 1300 5.75 900 - 1135 5.75 1040 - 1315 5.75...
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Page 18: Cooling Start-Up
TABLE 3 MANUFACTURER'S NUMBERS DRIVE COMPONENTS DRIVE ADJUSTABLE SHEAVE FIXED SHEAVE BELT BROWNING NO. OEM PART NO. BROWNING NO. OEM PART NO. BROWNING NO. OEM PART NO. 1VP34x7/8 31K6901 AK61x1 100244-20 AX54 100245-25 1VP40x7/8 79J0301 AK59x1 31K6801 AX55 100245-26 1VP34x7/8 31K6901 AK46x1 100244-17... - Page 19 D If measured liquid temperature is lower than 2- Check each system separately with all stages operating. Compare the normal operating pressures the target liquid temperature, recover some (see tables 4 - 10) to the pressures obtained from the refrigerant from the system. gauges.
- Page 20 TABLE 5 102S Normal Operating Pressures Outdoor Coil Entering Air Temperature 65 °F 75 °F 85 °F 95 °F 105 °F 115 °F Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc (psig) (psig) (psig) (psig) (psig) (psig) (psig) (psig)
- Page 21 TABLE 6 120S Normal Operating Pressures Outdoor Coil Entering Air Temperature 65 °F 75 °F 85 °F 95 °F 105 °F 115 °F Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc (psig) (psig) (psig) (psig) (psig) (psig) (psig) (psig)
- Page 22 TABLE 7 150S Normal Operating Pressures Outdoor Coil Entering Air Temperature 65 °F 75 °F 85 °F 95 °F 105 °F 115 °F Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc (psig) (psig) (psig) (psig) (psig) (psig) (psig) (psig)
- Page 23 TABLE 8 092H Normal Operating Pressures Outdoor Coil Entering Air Temperature 65 °F 75 °F 85 °F 95 °F 105 °F 115 °F Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc (psig) (psig) (psig) (psig) (psig) (psig) (psig) (psig)
- Page 24 TABLE 9 102H Normal Operating Pressures Outdoor Coil Entering Air Temperature 65 °F 75 °F 85 °F 95 °F 105 °F 115 °F Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc (psig) (psig) (psig) (psig) (psig) (psig) (psig) (psig)
- Page 25 TABLE 10 120H Normal Operating Pressures Outdoor Coil Entering Air Temperature 65 °F 75 °F 85 °F 95 °F 105 °F 115 °F Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc (psig) (psig) (psig) (psig) (psig) (psig) (psig) (psig)
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Page 26: Gas Heat Start-Up
This unit is equipped with an automatic spark ignition Gas Heat Start-Up (Gas Units) system. There is no pilot. In case of a safety shutdown, FOR YOUR SAFETY READ BEFORE LIGHTING move thermostat switch to OFF and return the thermostat switch to HEAT to reset ignition control. -
Page 27: Heating Operation And Adjustments
5- Turn gas valve switch to OFF. See figure 18. On 3- Spark ignitor energizes and gas valve solenoid opens. Honeywell VR8305Q gas valves, turn the knob on the 4- Spark ignites gas, ignition sensor proves the flame gas valve clockwise to “OFF”. -
Page 28: Supply Air Inverter Start-Up
Note - Intake air CFM can also be determined using the Inverter Start-Up outdoor air temperature, return air temperature and mixed air temperature. Refer to the economizer or A-General outdoor air damper installation instructions. Units equipped with a supply air inverter are available Set Low Speed Minimum Position which provide two blower speeds. - Page 29 replace the LVC2 board. If no voltage is read, LVC2 BOARD TERMINAL DESIGNATIONS troubleshoot the VFD. 8- When LVC2 24VAC thermostat blower (G) input and 24VDC power are present, check the LVC2 low and high speed outputs. The LVC2 uses inverse logic to enable the blower;...
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Page 30: Service
C-Burners (Gas Units) Service Periodically examine burner flames proper The unit should be inspected once a year by a qualified appearance during the heating season. Before each service technician. heating season examine the burners for any deposits or blockage which may have occurred. CAUTION Clean burners as follows: Label all wires prior to disconnection when servic... - Page 31 5- Check the alignment of the ignitor and the sensor as 7- Replace access panel. shown in figure 25 and table 13. 8- Restore electrical power and gas supply. Follow 6- Replace burners and screws securing burner. lighting instructions attached to unit and use inspection port in access panel to check flame.
- Page 32 Clean combustion air inducer as follows: combustion air inducer gasket be replaced during reassembly. 1- Shut off power supply and gas to unit. 6- Clean combustion air inlet louvers on heat access 2- Disconnect pressure switch tubing from panel using a small brush. combustion air inducer port.