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Service Literature
The KGB packaged gas units are available in standard
cooling efficiency (024, 030, 036, 048 060, 072, 074 and
090). Cooling capacities range from 2 to 7-1/2 tons (7 to
26kW).
KGB024, 030, 036, 048, 060, 072, 074 units are avail­
able in 65,000 BTUH heat capacity /KGB036, 048, 060,
072, 074 and 090 units are available in 108,000 BTUH
(105,000 BTUH in earlier built units ) heat capacity.
KGB048, 060, 072, 074 and 090 units are available in
150,000 BTUH (44 kW) heat sizes. Two stage heat is
available in units with 108,000 (105,000 in earlier built
units) and 150,000 BTUH capacities. Gas heat sections
are designed with aluminized steel tube heat exchang­
ers.
Information contained in this manual is intended for use by
qualified service technicians only. All specifications are
subject to change. Procedures outlined in this manual are
presented as a recommendation only and do not super­
sede 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.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person­
al injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
WARNING
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.
CAUTION
As with any mechanical equipment, contact with
sharp sheet metal edges can result in personal in­
jury. Take care while handling this equipment and
wear gloves and protective clothing.
100004
May 2020
KGB024 through 090
Electrostatic discharge can affect electronic
components. Take precautions during unit instal­
lation and service to protect the unit's electronic
controls. Precautions will help to avoid control
exposure to electrostatic discharge by putting
the furnace, the control and the technician at the
same electrostatic potential. Neutralize electro­
static charge by touching hand and all tools on an
unpainted unit surface, such as the gas valve or
Blower deck, before performing any service pro­
cedure.
Spec. Gas Heat / High Altitude
II Placement and Installation
III Start Up Operation
IV Charging
V System Service Checks
VI Maintenance
VII Accessories
VIII Diagrams
Page 1
KGB SERIES
2 to 7-1/2 ton
7 to 26 kW
ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

CAUTION

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Summary of Contents for Lennox KGB Series

  • Page 1 KGB SERIES 2 to 7-1/2 ton Service Literature 100004 7 to 26 kW May 2020 KGB024 through 090 The KGB packaged gas units are available in standard cooling efficiency (024, 030, 036, 048 060, 072, 074 and 090). Cooling capacities range from 2 to 7-1/2 tons (7 to 26kW).
  • Page 2 OP T IONS / AC C ESSORIES Unit Model No. Item Model Catalog COOLING SYSTEM Condensate Drain Trap PVC - C1TRAP20AD2 76W26 Copper - C1TRAP10AD2 76W27 Conventional Fin/Tube Condenser Coil (replaces Environ™ Coil System) Factory ¹ O 74W42 Drain Pan Overflow Switch K1SNSR71AB1- Low Ambient Kit K1SNSR33AN2...
  • Page 3 O PTIONS / A C C ESSORIES Unit Model No. Item Model Catalog BLOWER - SUPPLY AIR Motors Direct Drive (ECM) - 0.33 hp (208/230V-1ph) Factory Direct Drive (ECM) - 0.50 hp (208/230V-1ph) Factory Direct Drive (ECM) - 0.75 hp (208/230V-1ph) Factory Direct Drive (ECM) - 1.0 hp (208/230V-1ph) Factory...
  • Page 4 OPTIONS / AC C ESSORIES Unit Model No. Item Model Catalog ECONOMIZER Standard Economizer With Outdoor Air Hood (Sensible Control) (Not for Title 24) Standard Economizer - Includes Barometric Relief K1ECON30A-3- 14D90 Dampers and Exhaust Hood Standard Economizer - No Exhaust Factory Standard Economizer Controls (Not for Title 24) Single Enthalpy Control...
  • Page 5 OPTIONS / AC C ESSORIES Unit Model No. Item Model Catalog INDOOR AIR QUALITY Air Filters Healthy Climate High MERV 8 (16 x 20 x 2) - C1FLTR15A-1- 54W20 ® Efficiency Air Filters 52W37 MERV 13 (16 x 20 x 2) - T1FLTR40A-1- Order 4 per unit MERV 8 (20 x 20 x 2) - C1FLTR15D-1- 54W21...
  • Page 6 SP EC IFIC ATIONS - D IRECT D RIVE BLOWER 2 TO N | 2 .5 TO N General Data Nominal Tonnage 2 Ton 2.5 Ton Model No. KGB024S4E KGB030S4E Efficiency Type Standard Standard Blower Type Multi-Speed Multi-Speed Direct Drive ECM Direct Drive ECM Cooling Gross Cooling Capacity - Btuh...
  • Page 7 SP EC IFIC ATIONS - D IRECT D RIVE BLOWER 3 TO N | 4 TO N General Data Nominal Tonnage 3 Ton 3 Ton 4 Ton 4 Ton Model No. KGB036S4E KGB036S4D KGB048S4E KGB048S4D Efficiency Type Standard Standard Standard Standard Blower Type Multi-Speed...
  • Page 8 SPEC IFIC ATION S - DIRECT DRIVE BLOWER 5 TO N General Data Nominal Tonnage 5 Ton 5 Ton Model No. KGB060S4E KGB060S4D Efficiency Type Standard Standard Blower Type Multi-Speed Multi-Speed Direct Direct Drive ECM Drive PSC Cooling Gross Cooling Capacity - Btuh 60,900 60,900 Performance...
  • Page 9 S PEC IF ICATIONS - BELT DRIVE BLOWER S IN GLE S P EED - 3 TO N | 4 TO N | 5 TO N General Data Nominal Tonnage 3 Ton 4 Ton 5 Ton Model No. KGB036S4B KGB048S4B KGB060S4B Efficiency Type Standard...
  • Page 10 SP EC IFIC ATIONS - BELT D RIVE BLOWER S ING LE S PEED - 6 TO N General Data Nominal Tonnage 6 Ton 6 Ton Model No. KGB072H4B KGB074S4B Efficiency Type High Standard Blower Type Single Speed Belt Drive Single Speed Belt Drive Cooling Gross Cooling Capacity - Btuh...
  • Page 11 SP EC IFIC ATIONS - BELT D RIVE BLOWER T WO - SP EED - 6 TO N General Data Nominal Tonnage 6 Ton 6 Ton Model No. KGB074S4T KGB074H4T Efficiency Type Standard High Blower Type Two Speed Belt Drive Two Speed Belt Drive Cooling Gross Cooling Capacity - Btuh...
  • Page 12 SP EC IFIC ATIONS - BELT D RIVE BLOWER SIN GLE AND T WO - SP EED - 7 . 5 TO N General Data Nominal Tonnage 7.5 Ton 7.5 Ton Model No. KGB090S4B KGB090S4T Efficiency Type Standard Standard Blower Type Single Speed Belt Drive Two Speed Belt Drive Cooling...
  • Page 13 SP EC IF ICATION S - STANDARD GAS HEAT T H REE P H AS E M O D ELS Model No. 072H 072H 072H 072H 072H 074H 074H 074H 074H 074H 090S 090S 074S 090S 074S 090S 074S 074S 074S Heat Input Type Standard...
  • Page 14 BLO WER DATA D IR ECT D R IVE ECM - 2 TO N | 2.5 TO N KGB024S4E | KGB030S4E BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 15 BLO WER DATA DIR ECT D RIVE ECM - 3 TO N KGB036S4E BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.). 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
  • Page 16 BLO WER DATA D IRECT DR IVE ECM - 4 TO N KGB048S4E BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (larger gas heat section, economizer, wet coil, etc.) See page 29. 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.) See page 30.
  • Page 17 BLO WER DATA D IRECT DR IVE ECM - 5 TO N KGB060S4E BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (larger gas heat section, economizer, wet coil, etc.) See page 29. 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.) See page 30.
  • Page 18 BLOWER DATA D IR ECT D R IVE P SC - 3 TO N | 4 TO N KGB036S4D | KGB048S4D BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (larger gas heat section, economizer, wet coil, etc.) See page 29.
  • Page 19 BLOWER D ATA D IR ECT D R IVE P S C - 5 TO N KGB060S4D BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (larger gas heat section, economizer, wet coil, etc.) See page 29. 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.) See page 30.
  • Page 20 BLOWER B ELT D R IVE (S IN GLE S P EED ) - 3 TO N KGB036S4B BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.). 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
  • Page 21 BLOWER DATA B ELT D R IVE (S IN GLE S P EED ) - 4 TO N KGB048S4B BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.).
  • Page 22 BLOWER DATA B ELT D R IVE (S IN GLE S P EED ) - 5 TO N KGB060S4B BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.).
  • Page 23 BLOWER DATA BELT D RIVE ( S IN GLE AND T WO - SP EED - 6 TO N (D O WN F LO W ) KGB074S4B | KGB074S4T BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.).
  • Page 24 BLOWER DATA BELT D RIVE ( SIN GLE AND T WO - SP EED ) - 6 TO N (HO R IZO NTA L) KGB074S4B | KGB074S4T BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.).
  • Page 25 BLO WER DATA BELT D RIVE ( S IN GLE AND T WO - SP EED ) - 6 TO N (D O WNF LO W ) KGB072H4B | KGB074H4T BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 26 BLO WER DATA BELT D R IVE ( SING LE AN D T WO - S PEED ) - 6 TO N ( HO R IZO NTA L) KGB072H4B | KGB074H4T BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 27 BLOWER DATA BELT D RIVE ( SING LE AND T WO - SP EED ) - 7 . 5 TO N (D O WNF LO W ) KGB090S4B | KGB090S4T BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 28 BLOWER DATA BELT D RIVE ( SINGLE AN D T WO - S PEED ) - 7. 5 TO N (HO R IZO NTA L) KGB090S4B | KGB090S4T BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 29 BLOWER DATA BELT DRIVE KIT SPECIFICATIONS - 036-074S Model Motor HP No. of Drive Kits and RPM Range Speeds Nominal Maximum 1.15 673-1010 - - - - - - - - - 897-1346 - - - - - - - - - 673-1010 - - - - - -...
  • Page 30 BLO WER DATA CEILING DIFFUSERS AIR RESISTANCE (in. w.g.) RTD9-65S Step–Down Diffuser RTD11-95S Step–Down Diffuser FD9-65S FD11-95S Air Volume Flush Flush 2 Ends 1 Side & All Ends & 2 Ends 1 Side & All Ends & Diffuser Diffuser Open 2 Ends Open Sides Open Open...
  • Page 31 ELECTR ICAL D ATA DIR ECT D RIVE ECM - 2 TO N | 2.5 TO N ECM Model No. KGB024S4E KGB030S4E Voltage - 60hz 208/230V - 1 Ph 208/230V - 1 Ph Compressor Rated Load Amps 10.9 13.5 Locked Rotor Amps Outdoor Fan Full Load Amps Motor...
  • Page 32 ELECTR ICA L DATA D IRECT DR IVE P SC - 3 TO N Model No. KGB036S4D 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph Voltage - 60hz Compressor Rated Load Amps Locked Rotor Amps Outdoor Fan Full Load Amps Motor Power Exhaust...
  • Page 33 ELECTR ICAL D ATA D IR ECT D R IVE P S C - 5 TO N Model No. KGB060S4D 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph Voltage - 60hz Compressor Rated Load Amps Locked Rotor Amps 38.9 Outdoor Fan Full Load Amps...
  • Page 34 KGB PARTS ARRANGEMENT FILTERS (4) BLOWER EVAPORATOR 024, 030, 036, 048 16 X 20 X 2” REFRIGERANT MOTOR COIL 060, 072, 090: 20 X 20 X 2” METERING DEVICE TB1 LOW VOLTAGE CONDENSER TERMINAL BLOCK ECONOMIZER (OPTIONAL) BLOWER CONDENSER COIL CONDENSATE DRAIN COMBUSTION...
  • Page 35 I-UNIT COMPONENTS 5-Fan Capacitor C1 (three phase) Fan capacitors C1 is used to assist in the start up of con­ All 2 through 7-1/2 ton (7 through 21 kW) units are built to denser fan B4. Ratings will be on side of capacitor or outdoor order units (BTO).
  • Page 36 14-Crankcase Heater Delay DL48 & Crankcase TABLE 1 STATUS Heater Relay K191 Slow Flash Normal operation. No call for heat. Delay DL48 and relay K191 keep crankcase heater de-en­ Fast Flash Normal operation. Call for heat. ergized during and immediately following compressor shut Internal Control Fault, No Power To Board Steady Off down.
  • Page 37 The control then proceeds to “steady state” mode where all the evaporator coil and a high pressure switch (S4) on the inputs are monitored to ensure the limit switch, rollout discharge line. See figure 5. A Low ambient switch (S11) is switch and prove switch are closed as well as flame is available as a field accessory for additional compressor pro­...
  • Page 38 KGB PLUMBING and S49 FREEZESTAT LOCATION DRIER CONTROL AND CONDENSER COIL EVAPORATOR COMPONENTS COIL SECTION REFRIGERANT METERING DEVICE RETURN AIR INDOOR BLOWER SECTION SECTION PROCESS TUBE (used for charging) HEAT SECTION COMPRESSOR 060, 090 024S, 030S, 036S, 048S 072/074 FIGURE 5 Page 38...
  • Page 39 2-Freezestat S49 ture drop. It is wired in line with the 24VAC compressor con­ tactor. When outdoor temperature drops below 40° F (4.5° Each unit is equipped with a low temperature switch C) the switch opens and de-energizes the compressor. (freezestat) located on a return bend of each evaporator When the compressor is de-energized the cooling demand coil.
  • Page 40 B-Determining Unit CFM - Single-Speed, Direct Drive BLOWER SPEED FACTORY SETTINGS Blowers 024, 030, & 048 Units 036 Units 060 Units 1- The following measurements must be made with air fil­ ters in place. Med* Low* 2- With all access panels in place, measure static pressure Low* Unused external to unit (from supply to return).
  • Page 41 FIELD-ADJUSTABLE BLOWER SPEEDS - DIRECT DRIVE 208/230V HIGH SPEED - ALL UNITS LOW SPEED L1-Terminal COM 024, 030, 036, 048, UNITS L2-Terminal HIGH L1-Terminal COM TERMINAL 1 L2-Terminal LOW REMAINS AT COMMON 1-COM 2-HI 3-MED 4-LOW MEDIUM SPEED 1-COM 024, 030, 036, 048 UNITS 2-HI L1-Terminal COM 3-MED...
  • Page 42 C-Determining Unit CFM - Multi-Stage, Direct Drive TABLE 4 TWO-SPEED BLOWER OPERATION Blowers KGB074, 090S4T UNITS 1- Refer to multi-stage direct drive blower tables, the Thermostat Blower Speed measured static pressure, and the factory-set blower G (P350/J350)* speed to determine CFM. G (P350/J351) High 2- If CFM is lower than the design specified CFM, move...
  • Page 43 BLOWER ASSEMBLY TO INCREASE CFM TO DECREASE CFM LOOSEN ALLEN SCREW & TURN PULLEY TURN PULLEY CLOCKWISE COUNTERCLOCKWISE SIDE VIEW LOOSEN ALLEN SCREW TO ADJUST CFM MOTOR ALLEN SCREW PULLEY TO INCREASE BELT TENSION 1-Loosen four bolts securing motor base to mounting frame.
  • Page 44 ADJUST BELT TENSIONER INSTALL BELT INDICATOR SHOULD BE MAXIMUM BETWEEN MINIMUM AND DRIVER TENSION TENSIONER MAXIMUM TENSION LINES PULLEY MINIMUM TENSION TIGHTEN MOUNTING BOLT TO 22 LB./FT. USING 9/16” WRENCH DRIVEN PULLEY BRACKET TIGHTEST BELT TENSIONER POSITION TIGHTER FACTORY-SET BELT POSITION POSITION FIGURE 14 ROTATE DRIVEN...
  • Page 45 TABLE 6 DRIVE COMPONENT MANUFACTURER'S NUMBERS DRIVE COMPONENTS MOTOR PULLEY BLOWER PULLEY BELTS Browning No. OEM Part No. Browning No. OEM Part No. Browning No. OEM Part No. Drive No. 1VP34 X 7/8 31K6901 AK54 X 1 100244-19 100245-17 1VP34 X 7/8 31K6901 AK49 X 1 100244-18...
  • Page 46 D-GAS HEAT COMPONENTS 2-Burner Box Assembly (Figure 17) KGB024, 030, 036, 048, 060, 072, 074S units are avail­ The burner assembly consists of a spark electrode, flame able in 65,000 BTUH (19 kW) heat capacity. KG036, sensing electrode and gas valve. Ignition board A3 controls all 048, 060, 072 074H and 090 units are available in functions of the assembly.
  • Page 47 3-Primary High Temperature Limit S10 ly after flame is sensed or at the end of the eight second trial for ignition. S10 is a SPST N.C. high temperature primary limit for gas On two stage natural gas units the inducer will operate heat in KGB024-090 units.
  • Page 48 III-START UP - OPERATION IGNITOR A-Preliminary and Seasonal Checks SPARK GAP SHOULD BE 1/8” 1- Make sure the unit is installed in accordance with the (3mm) installation instructions and applicable codes. 2- Inspect all electrical wiring, both field and factory installed for loose connections.
  • Page 49 HONEYWELL VR8215S GAS VALVE WARNING MANIFOLD Single-Stage MANIFOLD PRESSURE PRESSURE OUTLET Electric shock hazard. Can cause ADJUSTMENT injury or death. Before attempting to SCREW perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.
  • Page 50 C-Cooling Start up IV-CHARGING A-Refrigerant Charge and Check - All-Aluminum Coil Operation WARNING-Do not exceed nameplate charge under any 1- Initiate first and second stage cooling demands ac­ condition. cording to instructions provided with thermostat. This unit is factory charged and should require no further 2- KGB024/090 No Economizer Installed in Unit -A first-stage cooling demand (Y1) will energize com­...
  • Page 51 TABLE 7 580708-02 KGB/KCB024 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)
  • Page 52 TABLE 8 580709-02 KGB/KCB030 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)
  • Page 53 TABLE 9 580710-02 KGB/KCB036 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)
  • Page 54 TABLE 10 580711-02 KGB/KCB048 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)
  • Page 55 TABLE 11 580712-02 KGB/KCB 060 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)
  • Page 56 TABLE 12 580996-01 KGB/KCB 072H Normal Operating Pressures Outdoor Coil Entering Air Temperature 65 °F 75 °F 85 °F 95 °F 105 °F 115 °F 580996-01 KGB/KCB 072 Charging Curves Outdoor Temperature (°F) 115° 105° 95° 85° 75° 65° Suction Pressure (psig) Page 56...
  • Page 57 TABLE 13 580791-01 KGB/KCB 074S & H 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)
  • Page 58 TABLE 14 580544-02 KGB/KCB 090 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)
  • Page 59 B-Refrigerant Charge and Check - Fin/Tube Coil TABLE 16 580943-01 KGB/KCB030S Fin/Tube - W & W/O Reheat KG/KC 024S, 030S, 036S, 048S, 060S, 074S, 090S Outdoor Coil DIscharge Suction +5 Entering Air Temp +10psig psig WARNING-Do not exceed nameplate charge under any 65°...
  • Page 60 C - Charge Verification - Approach Method V- SYSTEM SERVICE CHECKS (Fin/Tube Coil Continued) A-Heating System Service Checks 1- Using the same thermometer, compare liquid tempera­ All KGB units are C.S.A. design certified without modifi­ ture to outdoor ambient temperature. cation.
  • Page 61 3-Testing Gas Supply Pressure Natural Gas Units - Low Fire - 2.0” w.c. Natural Gas Units - High Fire - 3.5” w.c. When testing gas supply pressure, connect test gauge to the LP Gas Units - Low Fire - 5.9” w.c. inlet pressure tap located on unit gas valve GV1.
  • Page 62 2- Remove lead from sensing electrode and install a TABLE 25 0-50DC microamp meter in series between the sens­ Unit Qty Filter Size - inches (mm) ing electrode and the sensing lead. 024, 030, 036, 048 16 X 20 X 2 (406 X 508 X 51) 3- Reconnect power and adjust thermostat for 072, 060, 090 20 X 20 X 2 (508 X 508 X 51)
  • Page 63 D-Combustion Air Inducer H-Condenser Coil All-Aluminum Environ Coils A combustion air proving switch checks combustion air in­ ducer operation before allowing power to the gas controller. Clean condenser coil annually with water and inspect Gas controller will not operate if inducer is obstructed. monthly during the cooling season.
  • Page 64 ASSEMBLED ROOF MOUNTING FRAME OUTDOOR AIR DAMPER MOTORIZED DAMPER ASSEMBLY FIGURE 24 DAMPER MOTOR TYPICAL FLASHING DETAIL UNIT BASE BOTTOM UNIT BASE MANUAL OUTDOOR AIR RAIL DAMPER - PAINTED SIDE FIBERGLASS FIGURE 26 INSULATION (Furnished) D-Supply and Return Diffusers (all units) Optional flush mount diffuser/return FD9-65 and COUNTER FLASHING FD11-95 and extended mount diffuser/return RTD9-65...
  • Page 65 ECONOMIZER CONTROLS A6 ENTHALPY CONTROLLER ENTHALPY SENSOR (OTHER SIDE OF PANEL) DAMPER MINI­ MUM POSITION ENTHALPY IAQ MAXIMUM CONTROL POSITION Open (set higher than minimum position) IAQ READING IS ABOVE SETPOINT DAMPER MOTOR IAQ SETPOINT Free Cool OUTDOOR AIR MIXED AIR SENSOR (R1) AND WIRING IN SUITABLE LED POWER EXHAUST WIRES...
  • Page 66 1- Set thermostat to occupied mode if the feature is avail­ 8- Draw a horizontal line where the two lines meet. Read able. Make sure jumper is in place between TB1 termi­ the percent of fresh air intake on the side. nals R and OC if using a thermostat which does not 9- If fresh air percentage is less than desired, adjust MIN have the feature.
  • Page 67 Economizer Operation Set damper minimum position in the same manner as economizer minimum position. Adjust motorized damper The occupied time period is determined by the thermostat position using the thumbwheel on the damper motor. See or energy management system. figure 29. Manual damper fresh air intake percentage can be determined in the same manner.
  • Page 68 POWER EXHAUST FAN Three different types of control systems may be used with the KGB series units. All thermostat wiring is connected to TB1 located in the control box. Each thermostat has addi­ tional control options available. See thermostat installation instructions for more detail.
  • Page 69 VIII-Wiring Diagrams and Sequence of Operation KGB024/060 P VOLTAGE UNIT DIAGRAM Page 69...
  • Page 70 KGB036/090 G, J, M &Y VOLTAGE UNIT DIAGRAM Page 70...
  • Page 71 KGB024/090 P, Y, G, J & M Voltage Sequence of Operation Power: 1. Line voltage from unit disconnect energizes transformer T1. T1 provides 24VAC power to terminal strip TB1. TB1 provides 24VAC to the unit cooling, heating and blower controls. Blower Operation: 2.
  • Page 72 KGB-074 Two-Stage Units 1. First-stage cooling demand Y1 and G is ener­ gized by the thermostat. G energizes blower. 2. Relay K239 directs voltage through relay K250 to energize contactor K3. 3. Blower contactor K3 energizes blower B3 on low speed.
  • Page 73 GAS HEAT FOR KGB024/090 UNITS End of Second Stage Heat: First Stage Heat: 10. Heating demand is satisfied. Terminal W2 (second The thermostat initiates W1 heating demand. stage) is de-energized. 24VAC is routed from TB1 to ignition control A3. A3 proves N.C. pri­ 11.
  • Page 74 ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT POWER: Terminal strip TB1 found in the main control box supplies thermostat components with 24VAC. OPERATION: TB1 receives data from the electronic thermostat A2 (Y1, Y2, W1, W2, G) and energizes the appropriate components for heat or cool demand. Page 74...
  • Page 75 ECONOMIZER SEQUENCE OF OPERATION POWER: Terminal strip TB1 found in the main control panel energizes the economizer components with 24VAC. OPERATION: Enthalpy sensor A7 and A62 (if differential enthalpy is used) communicates to the economizer control module A6 when to power the damper motor B7. Economizer control module A6 supplies B7 with 0 - 10 VDC to control the positioning of economizer.
  • Page 76 OUTDOOR AIR DAMPER SEQUENCE OF OPERATION OPERATION: Occupied Mode 24 volt signal from terminal “OC” on TB1 opens B7 dampers to minimum position. Unoccupied Mode Dampers remain closed. Page 76...

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