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Lennox KHC Series Service Literature
Lennox KHC Series Service Literature

Lennox KHC Series Service Literature

7.5 to 10 ton 26.3 to 35.2 kw

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S e r v i c e L i t e r a t u r e
The KHC commercial heat pump is available in 7.5, 8.5,
and 10 ton capacities. The
KHC092/102/120 refrigerant systems utilize two compres-
sors, two reversing valves, two accumulators, and other
parts common to a heat pump. Optional auxiliary electric
heat is factory or field installed in KHC units. Electric heat
operates in single or multiple stages depending on the kW
input size. 7.5kW through 60kW heat sections are avail-
able for the KHC heat pump.
KHC units are designed to accept any of several different
energy management thermostat control systems with min-
imum field wiring.
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
To prevent serious injury or death:
1- Lock-out/tag-out before performing maintenance.
2- If system power is required (e.g., smoke detector
maintenance), disable power to blower, remove
fan belt where applicable, and ensure all
controllers and thermostats are set to the "OFF"
position before performing maintenance.
3- Always keep hands, hair, clothing, jewelry, tools,
etc., away from moving parts.
WARNING
Improper
installation,
service or maintenance can cause property damage,
personal injury or loss of life. Installation and service
must be performed by a licensed professional HVAC
installer or equivalent, service agency, or the gas
supplier
UNIT INFORMATION
UNIT INFORMATION
KHC092 through 120
adjustment,
alteration,
100099
As with any mechanical equipment, contact with
sharp sheet metal edges can result in personal
injury. Take care while handling this equipment and
wear gloves and protective clothing.
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at disconnect
switch(es). Unit may have multiple power
supplies.
Options . . . . . . . . . . . . . . . . . . . . . .Page 2
Specifications . . . . . . . . . . . . . . . . . .Page 5
Blower Data . . . . . . . . . . . . . . . . . . Page 6
Electrical Data / Electric Heat Data . Page 10
I Unit Components . . . . . . . . . . . . . Page 15
II Placement and Installation . . . . . Page 28
III Start Up Operation . . . . . . . . . . . Page 28
IV Charging . . . . . . . . . . . . . . . . . . . Page 29
V System Service Checks . . . . . . . Page 30
VI Maintenance . . . . . . . . . . . . . . . . Page 30
VII Accessories . . . . . . . . . . . . . . . . Page 31
VIII Diagrams . . . . . . . . . . . . . . . . . . Page 38
Page 1
KHC SERIES
7.5 to 10 ton
26.3 to 35.2 kW
CAUTION
WARNING
Table of Contents

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Summary of Contents for Lennox KHC Series

  • Page 1 KHC SERIES UNIT INFORMATION UNIT INFORMATION 7.5 to 10 ton 26.3 to 35.2 kW 100099 S e r v i c e L i t e r a t u r e KHC092 through 120 The KHC commercial heat pump is available in 7.5, 8.5, and 10 ton capacities.
  • Page 2 OPT IONS / A C C ESSORIES Unit Model No Catalog Item Description Number COOLING SYSTEM Condensate Drain Trap 22H54 Copper 76W27 Drain Pan Overflow Switch 74W42 Low Ambient Kit 54W16 Refrigerant Type R-410A BLOWER - SUPPLY AIR Blower Motors Belt Drive - 2 hp Factory Belt Drive - 3 hp...
  • Page 3 OPT IONS / A C C ESSORIES Unit Model No Catalog Item Description Number INDOOR AIR QUALITY Healthy Climate High Efficiency Air Filters MERV 8 50W61 ® 20 x 25 x 2 (Order 4 per unit) MERV 13 52W41 MERV 16 21U41 Y3063 Replacement Media Filter With Metal Mesh Frame (includes non-pleated filter media)
  • Page 4 OPT IONS / A C C ESSORIES Unit Model No Catalog Item Description Number ECONOMIZER Standard Economizer (Not for Title 24) Standard Economizer with Single Temperature Control 13U45 Downflow or Horizontal Applications - Includes Barometric Relief Dampers and Air Hoods Standard Economizer Controls (Not for Title 24) 21Z09 Single Enthalpy Control...
  • Page 5 SP ECIF ICATIONS General Data Nominal Tonnage 7.5 Ton 8.5 Ton 10 Ton Model Number KHC092S4M KHC102S4M KHC120S4M Efficiency Type Standard Standard Standard Blower Type MSAV® (Multi-Stage MSAV® (Multi-Stage MSAV® (Multi-Stage Air Volume) Air Volume) Air Volume) Cooling Gross Cooling Capacity - Btuh 91,600 103,400 119,500...
  • Page 6 BLO WER DATA B ELT DR IVE - 7 .5 TO N KHC092S4M - 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 −...
  • Page 7 BLO WER DATA B ELT D R IVE - 8 .5 | 1 0 TO N KHC102S4M, KHC120S4M - 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 −...
  • Page 8 BLO WER 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 9 BLO WER DATA CEILING DIFFUSERS AIR RESISTANCE - in. w.g. RTD11 Step-Down Diffuser FD11 Flush Air Volume 1 Side, 2 Ends All Ends & Sides Diffuser Unit Size 2 Ends Open Open Open 2400 0.21 0.18 0.15 0.14 2600 0.24 0.21 0.18 0.17...
  • Page 10 ELECTRIC AL/ELECTRIC H EAT DATA 7 .5 TO N Model No. KHC092S4M Voltage - 60Hz 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph Compressor 1 Rated Load Amps 12.9 (Non-Inverter) Locked Rotor Amps Compressor 2 Rated Load Amps 13.7 (Non-Inverter) Locked Rotor Amps...
  • Page 11 ELECTR IC AL/ELECTRIC H EAT DATA 8 .5 TO N Model No. KHC102S4M Voltage - 60Hz 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph Compressor 1 Rated Load Amps 16.7 (Non-Inverter) Locked Rotor Amps 54.7 47.8 Compressor 2 Rated Load Amps 13.7...
  • Page 12 ELECTRIC AL/ELECTRIC H EAT DATA 10 TO N Model No. KHC120S4M Voltage - 60Hz 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph Compressor 1 Rated Load Amps 16.7 (Non-Inverter) Locked Rotor Amps 54.7 47.8 Compressor 2 Rated Load Amps 19.6 (Non-Inverter)
  • Page 13 ELECT RIC HEAT C A PACITIES 7.5 kW 15 kW 22.5 kW 30 kW 45 kW 60 kW Volts Btuh No. of Btuh No. of Btuh No. of Btuh No. of Btuh No. of Btuh No. of Input Input Output Stages Input Output...
  • Page 14 KHC Parts Arrangement FILTERS EVAPORATOR REVERSING (FOUR - 20 X 25 X 2”) COIL CONDENSER VALVE FANS CONDENSER COIL ECONOMIZER (OPTIONAL) SUPPLY AIR VFD BLOWER MOTOR ELECTRIC CONDENSATE HEAT COMPRESSORS DRAIN FIGURE 1 KHC Control Box Y, G, J Volt Units TB13 K132 K133...
  • Page 15 I-UNIT COMPONENTS 4-Transformer T18 T18 is a single line voltage to 24VAC transformer used in All 7.5, 8.5 and 10 ton units are configure to order units all KHC units. T18 is identical to T1 and is protected by a (CTO).
  • Page 16 11-Low Ambient Kit Relay (K58) If the jumper is removed before an additional 5-second period has elapsed (7 seconds total), the unit will remain Low ambient relay K58 is a DPDT relay with a 24V coil in defrost mode until the defrost pressure switch opens energized by a CMC1 output in the heating cycle.
  • Page 17 Supply Air Inverter Start-Up LVC2 (A183) VFD CONTROL BOARD A-General Units provide three blower speeds. The blower will operate at lower speeds when cooling demand is low and VENTILATION higher speeds when cooling demand is high. This results SPEED SWITCH in lower energy consumption.
  • Page 18 Set Low Speed Minimum Position 4 - If there is no thermostat signal, troubleshoot back toward the thermostat. 1 - Initiate a blower (G) only AND occupied demand 5 - Check the power LED on the board. See FIGURE from the room thermostat or control system. 2 - Set the ventilation speed switch on the VFD control board to “LO”.
  • Page 19 KHC PLUMBING DETAIL Outdoor Coil Driers Indoor Coil Reversing Valve L2 Reversing Valve L1 Compressor B2 Compressor B1 PRESSURE SWITCHES FRONT VIEW FIGURE 8 Page 19...
  • Page 20 B-Cooling Components 2-Freezestats S49 and S50 All units use independent cooling circuits consisting of Each unit is equipped with a low temperature switch separate compressors, condenser coils and evaporator (freezestat) located on a return bend of each evaporator coils. See FIGURE 8. Two draw-through-type condenser coil.
  • Page 21 6-Defrost Pressure Switch S46 and S104 OPERATION / ADJUSTMENT Belt-Driven Supply Air Inverter Units - Units are equipped The defrost pressure switch S46 and S104 are auto-reset with a phase monitor located in the control compartment. SPST N.C. pressure switches which open on a pressure The phase monitor will detect the phasing of incoming rise.
  • Page 22 MEASURE BELT TENSION PULLEY ALIGNMENT ALIGNED MOTOR BLOWER BELT PULLEY PULLEY FORCE NOT ALIGNED DEFLECTION 1/64” PER INCH OF SPAN OR 1.5mm PER 100mm OF SPAN FIGURE 10 2 - Apply perpendicular force to center of span (X) with enough pressure to deflect belt 1/64” for every inch FIGURE 9 of span length or 1.5mm per 100mm of span length.
  • Page 23 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 allel along gap.
  • Page 24 TABLE 5 MANUFACTURER’S NUMBERS DRIVE COMPONENTS ADJUSTABLE SHEAVE FIXED SHEAVE BELT DRIVE NO. BROWNING OEM PART BROWNING OEM PART BROWNING OEM PART 1VP34x7/8 31K6901 AK61x1 100244-20 AX54 100245-25 1VP40x7/8 79J0301 AK59x1 31K6801 AX55 100245-26 1VP34x7/8 31K6901 AK46x1 100244-17 AX52 100245-33 1VP44x7/8 53J9601 AK74x1...
  • Page 25 For EHA100 units, the electric heat section thermostat is factory set to open at 160F + 5F All KHC series units with electric heat use an electric (71.0C + 2.8C) on a temperature rise and automatically heat relay K9. K9 is a N.O. DPDT pilot relay intended to electrically isolate the unit’s 24V circuit from the electric...
  • Page 26 TABLE 6 KCC ELECTRIC HEAT SECTION FUSE RATING FUSE (3 each) EHA QUANTITY VOLTAGES & SIZE F3 - 1 F3 - 2 F3 - 3 F3 - 4 208/230V 25 Amp 250V ----- ----- ----- 460V 15 Amp 600V ----- ----- ----- EHA100-7.5...
  • Page 27 EHA 7.5, 15, 22.5, 30, 45, 60KW ELECTRIC HEAT SECTION PARTS ARRANGEMENT HEATING ELEMENTS SECONDARY HE1 - HE6 LIMIT S20 SECONDARY SECONDARY LIMIT S20 LIMIT S20 ELECTRIC HEAT VESTIBULE SECONDARY LIMIT S20 SECONDARY LIMIT S20 SECONDARY LIMIT S20 ELECTRIC HEAT THERMOSTAT PRIMARY ELECTRIC HEAT LIMIT CONTROL WIRE...
  • Page 28 II-PLACEMENT AND INSTALLATION TABLE 7 Make sure the unit is installed in accordance with the COOLING OPERATION - NO ECONOMIZER installation instructions and all applicable codes. See T’Stat Compressors OD Fans accessories section for conditions requiring use of the Compr. 1 Low Fan 1 On optional roof mounting frame.
  • Page 29 TABLE 9 REFRIGERANT STAGES - TWO FANS KHC092S NORMAL OPERATING PRESSURES Y1 Demand =Outdoor Fan 1 Energized CIRCUIT 1 CIRCUIT 2 Y2 Demand =Outdoor Fans 1 & 2 Energized Outdoor Coil Entering Air Dis. + 10 Suc. + 5 Dis. + 10 Suc.
  • Page 30 REMOVE FILTERS TABLE 12 Approach Temperature Liquid Temp. Minus Ambient Temp. Unit 1st Stage 2nd Stage 092S 5°F + 1 (2.8°C + 0.5) 4°F + 1 (2.2°C + 0.5) 102S 5°F + 1 (2.8°C + 0.5) 5°F + 1 (2.8°C + 0.5) 120S 4°F + 1 (2.2°C + 0.5) 7°F + 1 (3.9°C + 0.5)
  • Page 31 VII-OPTIONAL ACCESSORIES TYPICAL FLASHING DETAIL The accessories section describes the application of most UNIT BASE of the optional accessories which can be installed to the BOTTOM KHC units. UNIT BASE RAIL A-Drain Pan Overflow Switch S149 (optional) The overflow switch is used to interrupt cooling operation when excessive condensate collects in the drain pan.
  • Page 32 F-K1ECON20B / K1ECON22B-1 Economizer, TABLE 13 (Field- or Factory-Installed) Sensors Dampers will modulate to 55°F dis- charge air (RT6) when: See specific economizer installation instructions for more detail for both K1ECON20B and high performance Single OA Sensible OA temperature (S175) is lower than free cooling setpoint.
  • Page 33 C1DAMP20B-1 MOTORIZED OUTDOOR AIR DAMPER MOTORIZED DAMPER COVER PANEL HORIZONTAL SUPPLY AIR OPENING COMPRESSOR HORIZONTAL SECTION RETURN AIR OPENING LOWER PANEL C1DAMP10B-2 MANUAL OUTDOOR AIR DAMPER COVER PANEL MANUAL DAMPER HORIZONTAL SUPPLY AIR OPENING COMPRESSOR HORIZONTAL SECTION RETURN AIR OPENING LOWER PANEL FIGURE 23 Page 33...
  • Page 34 TABLE 14 A6 ENTHALPY CONTROLLER ENTHALPY FREE COOLING SETPOINTS Control Setting Enthalpy Setpoint At 50% RH 73° F (23° C) MUM POSITION 70° F (21° C) 67° F (19° C) 63° F (17° C) IAQ MAXIMUM POSITION Open *Setting A is recommended (set higher than Damper Minimum Position minimum position)
  • Page 35 CHART 1 CALCULATE MINIMUM FRESH AIR PERCENTAGE MIXED AND RETURN AIR TEMPERATURE OUTDOOR AIR TEMPERATURE FIGURE 25 DCV Set and Max Settings During the occupied time period dampers will open to DCV MAX when IAQ reading is above setpoint (regardless of Adjust settings when an optional IAQ sensor is thermostat demand or outdoor air suitability).
  • Page 36 TABLE 15 ECONOMIZER OPERATION-OUTDOOR AIR IS SUITABLE FOR FREE COOLING -- FREE COOL LED “ON” Damper Position Thermostat Demand Mechanical Cooling Unoccupied Occupied Closed Closed Closed Minimum Modulating Modulating Modulating Modulating Stage 1 Modulating Modulating Stage 2 TABLE 16 ECONOMIZER OPERATION-OUTDOOR AIR IS NOT SUITABLE FOR FREE COOLING -- FREE COOL LED “OFF” Damper Position Thermostat Demand Mechanical Cooling...
  • Page 37 I-Power Exhaust Fan A6 ENTHALPY CONTROLLER The power exhaust fan (PEF) requires the use of a gravity exhaust damper and economizer and is used in downflow ADJUST POWER applications only. See FIGURE 29. The PEF provides EXHAUST FAN exhaust air pressure relief and also runs when return air SETPOINT dampers are closed and the supply air blower is operating.
  • Page 38 VIII-Wiring Diagrams and Sequence of Operation Page 38...
  • Page 39 Sequence of Operation KHC092/102/120 Power: 12 - K2-1 N.O. contacts close energizing compressor B2 and K2-2 N.C. contacts open de-energizing 1 - Line voltage from unit disconnect energizes crankcase heater HR2. transformer T1 and T18. T1 provides 24VAC power to terminal strip TB1. TB1 provides 24VAC to the 13 - K10-1 N.O.
  • Page 40 SWITCH−LIMIT,SECONDARY ELECT HT 2 S158 SWITCH−LIMIT,SECONDARY ELECT HT 3 S159 SWITCH−LIMIT,SECONDARY ELECT HT 4 S160 SWITCH−LIMIT,SECONDARY ELECT HT 5 S161 SWITCH−LIMIT,SECONDARY ELECT HT 6 S159 S157 S160 K243 K242 K16-1 K15-1 S158 S159 S157 HEATING - ELECTRIC REV 3 Lennox Commercial Page 40...
  • Page 41 THERMOSTAT-ELECTRIC HEAT LIMIT SWITCH-LIMIT, SECONDARY ELECT HT S157 SWITCH LIMIT, SECONDARY ELECT HT 2 SWITCH LIMIT, SECONDARY ELECT HT 3 S158 S159 SWITCH LIMIT, SECONDARY ELECT HT 4 TERMINAL STRIP-UNIT TERMINAL STRIP-ELECTRIC HEAT HEATING-ELETRIC REV. 2 Lennox Commercial Page 41...
  • Page 42 Sequence of Operation -EHA 7.5, 15, 22.5, 30, 45, 60 kW - Y, G and J HEATING ELEMENTS: 6 - After a 30-second delay, DL2 closes energizing contactor K16. 1 - Terminal Strip TB3 is energized when the unit disconnect closes. TB3 supplies line voltage to 7 - N.O.
  • Page 43 ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT Page 43...
  • Page 44 ECONOMIZER A183 USED ON UNITS WITH VFD ONLY Page 44...

This manual is also suitable for:

Khc092s4mKhc102s4mKhc120s4m