Lennox KCA092 Installation Instructions Manual
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Lennox KCA092 Installation Instructions Manual

Lennox KCA092 Installation Instructions Manual

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Litho U.S.A.
2012
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 qualified installer, ser-
vice agency or the gas supplier

Table Of Contents

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RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
04/12
*2P0412*
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INSTALLATION
INSTRUCTIONS
KGA/KCA092
KGA/KCA102
KGA/KCA120
KGA/KCA150
GAS AND COOLING PACKAGED UNITS
506913−01
4/2012
Supersedes 1/2012
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KGA SHOWN
*P506913-01*
(7.5 Ton)
(8.5 Ton)
(10 Ton)
(12−1/2 Ton)
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506913−01

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  • Page 1: Table Of Contents

    INSTALLATION Litho U.S.A. INSTRUCTIONS 2012 KGA/KCA092 WARNING (7.5 Ton) KGA/KCA102 Improper installation, adjustment, alteration, ser- (8.5 Ton) vice or maintenance can cause property damage, KGA/KCA120 personal injury or loss of life. Installation and ser- (10 Ton) vice must be performed by a qualified installer, ser-...

  • Page 2: Dimensions

    KGA/KCA092, 102, 120, & 150 DIMENSIONS − Gas heat section shown 6−1/8 5−5/8 BOTTOM SUPPLY (156) (143) 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.

  • Page 3: Parts Arrangements

    SUPPLY AIR VFD (OPTIONAL) COMBUSTION AIR INDUCER GAS VALVE COMPRESSORS FILTERS BURNERS CONDENSATE (FOUR − 20 X 25 X 2") DRAIN KCA092, 102, 120, & 150 PARTS ARRANGEMENT DISCONNECT / EVAPORATOR CIRCUIT BREAKER BLOWER CONDENSER COIL (FACTORY OR FIELD MOTOR FANS ECONOMIZER...

  • Page 4: Shipping And Packing List

    CAUTION WARNING Danger of sharp metallic edges. Can cause injury. Electric shock hazard and danger of Take care when servicing unit to avoid accidental explosion. Can cause injury, death or contact with sharp edges. product or property damage. Turn off gas and electrical power to unit before Shipping and Packing List performing...

  • Page 5: Unit Support

    If this unit has been used for heating or cooling of 2− The frames or supports must be constructed with buildings or structures under construction, the following non−combustible materials and should be square and conditions must be met or the warranty will be void: level to 1/16"...

  • 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: Control Wiring

    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 −...
  • 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 SUPPLY SUPPLY LOCATION TURN TURN FIRST BRANCH OFF OF MAIN RUN MAIN DUCT RUN SUPPLY AIR SUPPLY AIR READING READING DIFFUSER...

  • Page 13: Blower Data

    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 −...
  • Page 14 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 −...
  • Page 15 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 −...
  • Page 16 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...

  • Page 17: 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 18: For Your Safety Read Before Lighting

    6− If discharge pressure is high, remove refrigerant from D−Charge Verification − Approach Method−AHRI Testing the system. If discharge pressure is low, add 1− Using the same thermometer, compare liquid temperature to outdoor ambient refrigerant to the system. (at condenser outlet) S Add or remove charge in increments.

  • Page 19: Heating Operation And Adjustments

    HONEYWELL VR8205Q/VR8305Q SERIES GAS VALVE WARNING HIGH FIRE LOW FIRE Electric shock hazard. Can cause ADJUSTMENT ADJUSTMENT injury or death. Before attempting to MANIFOLD PRESSURE perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.

  • Page 20: Electric Heat Start−Up

    2− Combustion air pressure switch proves inducer MSAV Start−Up operation. After a 30−second pre−purge, power is A−General allowed to ignition control. Switch is factory set and Optional Multi−Stage Air Volume (MSAV ) units are requires no adjustment. available which provide two blower speeds. The blower 3−...
  • Page 21 Set Low Speed Minimum Position LVC2 BOARD TERMINAL DESIGNATIONS 1− Initiate a blower (G) only AND occupied demand from the room thermostat or control system. 2− Set the ventilation speed switch on the VFD control board to LO". 3− Rotate the low speed potentiometer on the VFD control board to set the low speed minimum damper position.

  • Page 22: Service

    B−Compressor Service If Interlink compressor replacement is necessary, call The unit should be inspected once a year by a qualified 1−800−4−LENNOX (1−800−453−6669). service technician. IMPORTANT CAUTION Some scroll compressors have an internal vacu- Label all wires prior to disconnection when servic- um protector that will unload scrolls when suc- ing controls.
  • Page 23 TABLE 11 IGNITOR Length − in. (mm) Unit Dimension Btuh Input Ignitor Sensor SPARK GAP 130K 7−3/4 (197) 11 (279) SHOULD BE 1/8" 180K 5 (127) 5−1/2 (140) (3mm) 240K 2−1/4 (57) 2−3/4 (70) 7− Replace access panel. 8− Restore electrical power and gas supply. Follow lighting instructions attached to unit and use inspection port in access panel to check flame.

  • Page 24: Heat Exchanger Assembly

    Clean combustion air inducer as follows: 6− Clean combustion air inlet louvers on heat access panel using a small brush. 1− Shut off power supply and gas to unit. F−Flue Passageway and Flue Box (Gas Units) 2− Disconnect pressure switch tubing from combustion air inducer port.

This manual is also suitable for:

Kga092Kga102Kca102Kga120Kca120Kga150 ... Show all

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