Lennox KGB048S4D 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 KGB048S4D Specifications

General

Product Type	Heat Pump
Series	KGB
Tonnage	4 Ton
Refrigerant Type	R-410A
Voltage	208/230V
Phase	1
Sound Level (Outdoor Unit)	76 dB
HSPF	8.20
Cooling Capacity	48000 BTU/h
Heating Capacity	48000 BTU/h

Summary

KGB Series Overview and Model Scope

General Safety Warnings

Crucial safety warnings for installation, electrical hazards, and sharp edges.

Electrostatic Discharge (ESD) Precautions

Procedures to prevent damage to electronic components from static discharge.

Direct Drive Blower Specifications (2 & 2.5 Ton)

Direct Drive Blower Specifications (3 & 4 Ton)

Direct Drive Blower Specifications (5 Ton)

Belt Drive Blower Specifications (3, 4, & 5 Ton)

Belt Drive Blower Specifications (6 Ton)

Belt Drive Blower Specifications (6 Ton - Two Speed)

Belt Drive Blower Specifications (7.5 Ton)

Gas Heat Specifications

Standard Gas Heat Performance

Performance data for standard gas heat configurations across models.

Low NOx Gas Heat Performance

Performance data for low NOx gas heat configurations across models.

Blower Data - Direct Drive ECM (2 & 2.5 Ton)

Blower Data - Direct Drive ECM (3 Ton)

Blower Data - Direct Drive ECM (4 Ton)

Blower Data - Direct Drive ECM (5 Ton)

Downflow Air Volume Data

Air volume (cfm) at various static pressures for downflow configurations.

Horizontal Air Volume Data

Air volume (cfm) at various static pressures for horizontal configurations.

Blower Data - Direct Drive PSC (3 & 4 Ton)

Downflow Air Volume Data (3 & 4 Ton)

Air volume (cfm) at various static pressures for downflow PSC units.

Horizontal Air Volume Data (3 & 4 Ton)

Air volume (cfm) at various static pressures for horizontal PSC units.

Blower Data - Direct Drive PSC (5 Ton)

Blower Data - Belt Drive (3 Ton)

Downflow Air Volume Data (3 Ton)

Air volume (cfm) at various static pressures for 3-ton belt drive units.

Horizontal Air Volume Data (3 Ton)

Air volume (cfm) at various static pressures for 3-ton belt drive units.

Blower Data - Belt Drive (4 Ton)

Downflow Air Volume Data (4 Ton)

Air volume (cfm) at various static pressures for 4-ton belt drive units.

Horizontal Air Volume Data (4 Ton)

Air volume (cfm) at various static pressures for 4-ton belt drive units.

Blower Data - Belt Drive (5 Ton)

Downflow Air Volume Data (5 Ton)

Air volume (cfm) at various static pressures for 5-ton belt drive units.

Horizontal Air Volume Data (5 Ton)

Air volume (cfm) at various static pressures for 5-ton belt drive units.

Blower Data - Belt Drive (6 Ton - Downflow)

Downflow Air Volume Data (6 Ton)

Air volume (cfm) at various static pressures for 6-ton downflow belt drive units.

Blower Data - Belt Drive (6 Ton - Horizontal)

Horizontal Air Volume Data (6 Ton)

Air volume (cfm) at various static pressures for 6-ton horizontal belt drive units.

Blower Data - Belt Drive (7.5 Ton - Downflow)

Downflow Air Volume Data (7.5 Ton)

Air volume (cfm) at various static pressures for 7.5-ton downflow belt drive units.

Blower Data - Belt Drive (7.5 Ton - Horizontal)

Horizontal Air Volume Data (7.5 Ton)

Air volume (cfm) at various static pressures for 7.5-ton horizontal belt drive units.

Electrical Data - Direct Drive ECM

2 & 2.5 Ton ECM Electrical Data

Electrical specifications for 2-ton and 2.5-ton Direct Drive ECM units.

3, 4, & 5 Ton ECM Electrical Data

Electrical specifications for 3-ton, 4-ton, and 5-ton Direct Drive ECM units.

Electrical Data - Direct Drive PSC

3 Ton PSC Electrical Data

Electrical specifications for 3-ton Direct Drive PSC units across voltage ranges.

4 Ton PSC Electrical Data

Electrical specifications for 4-ton Direct Drive PSC units across voltage ranges.

Electrical Data - Direct Drive PSC (5 Ton)

5 Ton PSC Electrical Data

Electrical specifications for 5-ton Direct Drive PSC units across voltage ranges.

Unit Components - Control Box Details

Unit Components - Control Functions and Safety

Gas Relay K72 and Burner Control A3

Description of gas relay and the primary burner control module.

Burner Control A3 Operation and Safety

Explanation of A3 functions, safety features, and warnings.

Unit Components - Cooling System

Compressor B1 and Safety Warnings

Description of the compressor and critical safety precautions.

Unit Components - Safety Switches and Blower

Freezestat and Pressure Switches (S49, S4, S11, S3)

Details on safety switches for temperature and pressure monitoring.

Determining Unit CFM - Direct Drive Blowers

Adjusting Blower Speeds - Direct Drive

208/230V Speed Adjustment Wiring

Wiring diagram for adjusting blower speed on 208/230V units.

460/575V Speed Adjustment Wiring

Wiring diagram for adjusting blower speed on 460/575V units.

Determining CFM and Belt Adjustment

CFM Calculation - Direct Drive and Belt Drive

Methods for calculating CFM and adjusting belt drive blower speeds.

Blower Belt Tension Adjustment Procedures

Blower Belt Adjustment and Field Drives

Pulley Adjustment for CFM and Belt Tension

Belt Tension Measurement and Adjustment Steps

Gas Heat Components Overview

Burner Box Assembly, Burners, and Orifices

Gas Heat Control Components and Ignition

High Temperature Limit and Rollout Switch

Gas Valves, Spark Electrode, and Safety

Information on gas valves (GV1), spark electrode, and related safety.

Ignition System and Installation Procedures

Unit Placement and Installation Guidelines

Unit Operation and Gas Valve Control

Safety Warnings for Unit Operation

Critical safety warnings before placing the unit into operation.

Placing Unit In Operation Steps

Cooling Start-up and Refrigerant Charging

Cooling Start-up Procedures by Model

Refrigerant Charge Verification and Safety

Procedures for verifying refrigerant charge and critical safety warnings.

Safety and Emergency Shutdown Procedures

Instructions for safely shutting down the unit in emergencies.

Refrigerant Charge Verification (Fin/Tube Coil)

Charge Verification Using Approach Method

Charge Verification Using Subcooling Method

System Service Checks - Charge and Heating

Charge Verification Methods (Continued)

Heating System Service Checks and Gas Piping

Gas Piping Testing Procedures

Guidelines for testing gas piping for leaks and pressure.

System Service Checks - Gas and Heat Exchanger

Gas Supply and Manifold Pressure Testing

Procedures for testing gas supply pressure and adjusting manifold pressure.

Proper Gas Flow and Heat Exchanger Access

System Checks and General Maintenance

Flame Sensing and Cooling System Checks

Economizer Controls and Setpoints

A6 Enthalpy Controller Operation

Economizer and DCV Settings Adjustment

DCV Set and Max Settings Adjustment

Economizer Modes and Power Exhaust

Wiring Diagrams and Sequence of Operation

KGB024/060 P Voltage Unit Wiring Diagram

Wiring Diagrams - Other Voltage Units

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

Sequence of Operation - Cooling

Cooling Demand Stages and Unit Operation

Sequence of Operation - KGB-074 Two-Stage Cooling

Two-Stage Cooling Operation Steps

Gas Heat Sequence of Operation

Gas Heat Wiring Diagram and Component Key

First and Second Stage Heat Operation

Economizer Controls and Operation

A6 Enthalpy Controller and Sensors