Lennox KGB060S4B 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 KGB060S4B Specifications

General

Brand	Lennox
Model	KGB060S4B
Category	Heat Pump
Language	English

Summary

Electrostatic Discharge (ESD) Precautions

Precautions and Procedures

Guidelines to prevent damage from static discharge during service.

Gas Heat Specifications

Standard Gas Heat Specs

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

Low NOx Gas Heat Specs

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

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

Blower Data - Direct Drive ECM (3 Ton)

Blower Data - Direct Drive ECM (4 Ton)

Blower Data - Direct Drive ECM (5 Ton)

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

3 & 4 Ton Standard Efficiency Downflow

Air volume data for 3 & 4 ton PSC blowers in downflow configuration.

3 & 4 Ton Standard Efficiency Horizontal

Air volume data for 3 & 4 ton PSC blowers in horizontal configuration.

Blower Data - Direct Drive PSC (5 Ton)

5 Ton Standard Efficiency Downflow

Air volume data for 5 ton PSC blowers in downflow configuration.

5 Ton Standard Efficiency Horizontal

Air volume data for 5 ton PSC blowers in horizontal configuration.

Blower Data - Belt Drive Single Speed (3 Ton)

Blower Data - Belt Drive Single Speed (4 Ton)

Blower Data - Belt Drive Single Speed (5 Ton)

Blower Data - Belt Drive (6 Ton)

Blower Data - Belt Drive (6 Ton Horizontal)

Blower Data - Belt Drive (7.5 Ton)

Blower Data - Belt Drive (6 Ton - Horizontal)

Blower Data - Belt Drive (7.5 Ton Downflow)

Downflow Air Volume Tables

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

Blower Data - Belt Drive (7.5 Ton Horizontal)

Horizontal Air Volume Tables

Provides air volume data for 7.5-ton belt drive blowers in horizontal.

Control Box Component Details

Gas Relay and Burner Control A3

Ignition Control Operation and Status

Describes the ignition control's operation, status LEDs, and trial for ignition.

Cooling System Components

Compressor B1 Description and Safety

Details the compressor, its specifications, and essential safety warnings.

Determining CFM for Direct Drive Blowers

Adjusting Blower Speed for Direct Drive

Speed Adjustment for 208/230V Units

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

Speed Adjustment for 460/575V Units

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

Determining CFM for Multi-Stage Direct Drive Blowers

CFM Calculation and Wiring Adjustments

Explains CFM determination and wiring adjustments for multi-stage direct drive.

Determining CFM for Belt Drive Blowers

CFM Adjustment and Belt Drive Operation

Details CFM determination and belt drive blower operation.

Gas Heat Components Overview

Heat Exchanger Functionality

Explains how the heat exchanger works for efficient heat transfer.

Burner Box Assembly Details

Describes the burner box components, including electrodes and gas valve.

Gas Heat Safety and Control Components

High Temperature Limit and Rollout Switch

Combustion Air Prove Switch and Inducer

Gas Valve, Capacitor, and Spark Electrode

Describes gas valves, inducer motor capacitor, and spark electrode assembly.

Ignition System Components

Ignitor and Flame Sensor Details

Describes the ignitor and flame sensor, including gap and positioning.

Unit Operation and Gas Valve Procedures

Initial Unit Operation Steps

Step-by-step guide for placing the unit into operation, including gas valve.

Cooling Start Up and Safety

Cooling Start-Up Sequence

Details the sequence for initiating cooling demands and compressor operation.

Refrigerant Charge and Check

Refrigerant Charge Procedure

Method for checking and adjusting refrigerant charge using approach method.

KGB/KCB024 Refrigerant Charging Curves

KGB/KCB030 Refrigerant Charging Curves

KGB/KCB036 Refrigerant Charging Curves

KGB/KCB048 Refrigerant Charging Curves

KGB/KCB060 Refrigerant Charging Curves

KGB/KCB072H Refrigerant Charging Curves

KGB/KCB074S & H Refrigerant Charging Curves

KGB/KCB090 Refrigerant Charging Curves

Normal Operating Pressures Table

Lists normal operating suction and discharge pressures for KGB/KCB090.

Charging Curves Graph

Visual representation of charging parameters based on outdoor temperature.

Refrigerant Charge and Check (Fin/Tube Coil)

Refrigerant Charge Verification Tables

Provides tables for verifying refrigerant charge for various models.

Charge Verification Methods

Approach Method for Charge Verification

Explains the approach method for verifying refrigerant charge.

Subcooling Method for Charge Verification

Details the subcooling method for verifying refrigerant charge.

Gas System Testing and Adjustment

Gas Supply and Manifold Pressure Testing

Procedures for testing gas supply and manifold pressures.

Proper Gas Flow and Heat Exchanger Checks

Flame Sensing and Electrode Checks

Details on flame sensing operation and electrode checks.

Economizer Control Module (A6)

Wiring Diagrams and Component Identification

KGB024/060 P Voltage Unit Diagram

Component Key and Descriptions

Wiring Diagrams for Various Voltage Units

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

Component Key and Descriptions (cont.)

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

Power and Blower Operation

Economizer and Cooling Demand Operation

Explains economizer demand and cooling stages.

Two-Stage Cooling Operation

Details the sequence for two-stage cooling in KGB-074 units.

KGB-074 Two-Stage Unit Sequence of Operation

Cooling Demand and Blower Control

Details how cooling demands activate the blower and relays.

Second Stage Cooling Activation

Explains how second-stage cooling engages the blower on high speed.

Gas Heat Sequence of Operation

First Stage Heat Operation

Describes the steps for initiating and operating first stage heating.

Second Stage Heat Operation

Details the process for initiating and operating second stage heating.

End of Stage Heat and Optional Kit

Thermostat Wiring and Operation

Thermostat Wiring Diagram

Thermostat Operation Sequence

Economizer Control Module Operation

Enthalpy Controller Operation and Sensors

Free Cooling Setpoint and Damper Control