Lennox KGB Series User Manual

Page 1
100004
KGB SERIES
Service Literature
2 to 7-1/2 ton
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).
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.
CAUTION
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.
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
Table of Contents
Options Page 2.......................
Specifications Page 6..................
Spec. Gas Heat / High Altitude Page 13...
Blower Data Page 14...................
Electrical Data Page 31.................
I Unit Components Page 35.............
II Placement and Installation Page 48.....
III Start Up Operation Page 48...........
IV Charging Page 50...................
V System Service Checks Page 60.......
VI Maintenance Page 62................
VII Accessories Page 63................
VIII Diagrams Page 69..................

Lennox KGB Series Specifications

General

Brand	Lennox
Model	KGB Series
Category	Heat Pump
Language	English

Summary

KGB024 through 090 Series Overview

General Unit Information

Details unit cooling capacities, heat capacities, and heat exchanger materials.

Safety Warnings

Highlights hazards from improper installation, adjustment, alteration, or service.

Electrostatic Discharge (ESD) Precautions

Provides procedures to protect electronic controls from ESD during installation/service.

Options and Accessories

Cooling System Options

Lists available options for the cooling system, including coils and drain components.

Heating System Options

Details heating system accessories like gas piping, vestibule heaters, and intake extensions.

Blower - Supply Air Options

Covers various motor types and drive kits for the supply air blower.

Cabinet Options

Includes options for combination coil/hail guards and corrosion protection.

Controls Options

Lists available control options such as smoke detectors and automation systems.

Economizer Options

Details standard, high-performance economizers, and related accessories.

Power Exhaust Fan Options

Specifies power exhaust fan options and barometric relief dampers.

Humiditrol® Condenser Reheat Option

Describes the option for dehumidification using condenser reheat.

Indoor Air Quality Options

Covers air filters and CO2 sensors for improved indoor air quality.

Roof Curbs

Lists available roof curb options for unit installation.

Specifications - Direct Drive Blower

General Data

Provides basic unit information like tonnage, model, efficiency, and blower type.

Cooling Performance

Details cooling capacity, airflow, sound rating, and power consumption.

Refrigerant Charge

Specifies refrigerant type and quantities for different coil systems.

Outdoor Coil Specifications

Details outdoor coil dimensions, motor, and fan specifications.

Indoor Blower Specifications

Outlines indoor blower motor HP and wheel dimensions.

Electrical Characteristics

Specifies voltage and frequency requirements for the unit.

Specifications - Belt Drive Blower

General Data

Provides basic unit information like tonnage, model, efficiency, and blower type.

Cooling Performance

Details cooling capacity, airflow, sound rating, and power consumption.

Refrigerant Charge

Specifies refrigerant type and quantities for different coil systems.

Indoor Blower & Drive Selection

Covers motor output and available drive kits for belt drive blowers.

Electrical Characteristics

Specifies voltage and frequency requirements for the unit.

Specifications - Gas Heat

Standard Gas Heat Specifications

Details heat input, output, temperature rise, and efficiency for gas heat.

Low NOx Gas Heat Specifications

Details heat input, output, temperature rise, and efficiency for low NOx gas heat.

High Altitude Derate

Provides guidelines for derating units at altitudes above 2000 ft.

Blower Data Tables

Direct Drive ECM - 2 Ton | 2.5 Ton Blower Data

Provides air volume data based on external static pressure for ECM blowers.

Direct Drive ECM - 3 Ton Blower Data

Provides air volume data based on external static pressure for ECM blowers.

Direct Drive ECM - 4 Ton Blower Data

Provides air volume data based on external static pressure for ECM blowers.

Direct Drive ECM - 5 Ton Blower Data

Provides air volume data based on external static pressure for ECM blowers.

Direct Drive PSC - 3 Ton | 4 Ton Blower Data

Provides air volume data based on external static pressure for PSC blowers.

Direct Drive PSC - 5 Ton Blower Data

Provides air volume data based on external static pressure for PSC blowers.

Belt Drive (Single Speed) - 3 Ton Blower Data

Provides air volume data based on external static pressure for belt drive blowers.

Belt Drive (Single Speed) - 4 Ton Blower Data

Provides air volume data based on external static pressure for belt drive blowers.

Belt Drive (Single Speed) - 5 Ton Blower Data

Provides air volume data based on external static pressure for belt drive blowers.

Belt Drive (Single and Two-Speed) - 6 Ton Blower Data

Provides air volume data for 6-ton belt drive blowers (downflow).

Belt Drive (Single and Two-Speed) - 7.5 Ton Blower Data

Provides air volume data for 7.5-ton belt drive blowers (downflow).

Electrical Data

Direct Drive ECM Electrical Data

Details electrical specifications for ECM units (2-5 Ton).

Direct Drive PSC Electrical Data

Details electrical specifications for PSC units (3-4 Ton).

Direct Drive PSC - 5 Ton Electrical Data

Details electrical specifications for 5-Ton PSC units.

KGB Parts Arrangement and Control Box

KGB Parts Arrangement (Figure 1)

Illustrates the location of major components within the unit.

KGB Control Box (Figure 2)

Shows the components located within the unit's control box.

Unit Components

Control Transformer and C.A.I. Transformers

Describes transformers supplying power to control circuits and inducer motor.

Transformer T4 and Terminal Strip TB1

Details T4 transformer for indoor blower and TB1 for thermostat connections.

Fan Capacitors and Compressor Contactor

Explains capacitors for fan/compressor and the compressor contactor K1.

Blower Control Components

Details blower contactors (K3, K37) and condenser fan relay (K10).

Burner Control A3

Describes the burner control's functions, status LED, and operation.

Compressor B1 and Cooling Components

Details compressor specifications, safety features, and cooling circuit components.

System Service Checks and Maintenance

Heating System Service Checks

Covers gas piping checks, pressure testing, and leak detection.

Charge Verification - Approach Method

Procedure for verifying refrigerant charge using approach temperature.

Charge Verification - Subcooling Method

Procedure for verifying refrigerant charge using subcooling temperature.

VI-Maintenance Overview

General guidelines for annual unit inspection and maintenance.

Filter Maintenance

Instructions for filter replacement and checking.

Burner Cleaning

Procedure for cleaning burners to ensure proper appearance and prevent blockage.

Accessories and Controls

Roof Mounting Frames (T1CURB/K1CURB)

Details installation requirements for roof mounting frames.

Transitions

Information on optional supply/return transitions.

Outdoor Air Dampers

Describes manual and motorized outdoor air dampers and their operation.

Economizer Operation

Explains economizer functionality and control module operation.

A6 Enthalpy Controller Settings

Details controller settings for free cooling and damper minimum position.

Optional Sensors

Describes differential and IAQ sensors for enhanced control.

Control Systems

Overview of available thermostat and control system types.

Optional Cold Weather Kit

Details the electric heater and thermostat switches for cold weather operation.

Wiring Diagrams and Sequence of Operation

KGB024/060 P Voltage Unit Diagram

Wiring diagram illustrating electrical connections for P voltage units.

Key to Components

Reference list for components shown in wiring diagrams.

KGB036/090 G, J, M &Y Voltage Unit Diagram

Wiring diagram for G, J, M & Y voltage units.

KGB024/090 P, Y, G, J & M Voltage Sequence of Operation

Describes the sequence of operation for power, blower, economizer, and cooling.

KGB-074 Two-Stage Units Cooling Sequence

Details the cooling sequence for two-stage units based on thermostat demand.

Wiring Diagram - 2 Speed A - Box and A+Box

Wiring diagram for 2-speed blower control systems.

Gas Heat Sequence of Operation

Outlines the sequence for first stage, second stage, and optional low ambient heat.