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Lennox KGC Series - User Manual

Lennox KGC Series
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Page 1
UNIT INFORMATIONUNIT INFORMATION
Service Literature
CAUTION
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.
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 disconnect
switch(es). Unit may have multiple power
supplies.
Table of Contents
Options . . . . . . . . . . . . . . . . . . . . . .Page 2

Spec. Gas Heat / High Altitude . . . Page 9
Blower Data . . . . . . . . . . . . . . . . . . Page 7
Electrical Data. . . . . . . . . . . . . . . . . Page 11
I Unit Components . . . . . . . . . . . . . Page 14
II Placement and Installation . . . . . Page 27
III Start Up Operation . . . . . . . . . . . Page 27
IV Charging . . . . . . . . . . . . . . . . . . . Page 30
V System Service Checks . . . . . . . Page 36
VI Maintenance . . . . . . . . . . . . . . . . Page 38
VII Accessories . . . . . . . . . . . . . . . . Page 40
VIII Diagrams . . . . . . . . . . . . . . . . . . Page 48

packaged gas units are available in standard cooling
󰀩       

heat sections are designed with aluminized steel tube
heat exchangers.
󰀨-
ent energy management thermostat control systems with
-


-
       -
able.
Information contained in this manual is intended for use

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.



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, adjustment, alteration,
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
KGC SERIES
7.5 to 12.5 ton
100097
KGC092 through 150
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Lennox KGC Series Specifications

General IconGeneral
BrandLennox
ModelKGC Series
CategoryAir Conditioner
LanguageEnglish

Summary

Service Literature

KGC092 through 150

Identifies the specific model series covered by the service literature.

Options; Accessories

Cooling System

Lists available options and accessories for the cooling system.

Heating System

Lists available options and accessories for the heating system.

Blower - Supply Air

Details options and accessories related to the supply air blower.

Cabinet

Lists cabinet-related options and accessories.

Controls

Details available control options and accessories.

Indoor Air Quality

Lists options and accessories for improving indoor air quality.

UVC Germicidal Lamps

Details UVC germicidal lamp options and accessories.

Humiditrol Dehumidification Reheat Option

Describes the Humiditrol® dehumidification reheat option.

Electrical

Lists electrical options and accessories.

Economizer

Details economizer options and accessories.

Economizer Accessories

Lists accessories specifically for the economizer system.

Outdoor Air

Details options and accessories related to outdoor air intake.

Power Exhaust

Lists power exhaust options and accessories.

Roof Curbs

Details roof curb options for unit installation.

Ceiling Diffusers

Lists options for ceiling diffusers.

Specifications

General Data

Provides general data and specifications for the units.

Cooling Performance

Details the cooling performance specifications of the units.

Refrigerant Charge

Specifies the refrigerant charge amounts for different circuits.

Gas Heating Options Available

Indicates availability of gas heating options.

Compressor Type (number)

Specifies the type and number of compressors used.

Outdoor Coils

Provides specifications for the outdoor coil.

Outdoor Coil Fans

Details specifications for the outdoor coil fans.

Indoor Coils

Provides specifications for the indoor coil.

Indoor Blower and Drive Selection

Details specifications for indoor blower and drive selection.

Filters

Specifies filter types and sizes.

Electrical Characteristics

Details the electrical characteristics of the units.

Gas Heat

Provides specifications related to gas heating performance.

High Altitude Derate

Details derating information for high altitude installations.

Blower Data

KGC092 S4 M and KGC102 S4 M - Base Unit

Blower data specific to KGC092S4M and KGC102S4M base units.

Maximum Static Pressure With Gas Heat

Specifies maximum static pressure with gas heat section.

Minimum Air Volume Required For Different Gas Heat Sizes

Lists minimum air volume requirements for various gas heat sizes.

KGC120 S4 M and KGC150 S4 M - Base Unit

Blower data specific to KGC120S4M and KGC150S4M base units.

Factory Installed Belt Drive Kit Specifications

Details specifications for factory installed belt drive kits.

Power Exhaust Fan Performance

Provides performance data for the power exhaust fan.

Factory Installed Options;Field Installed Accessory Air Resistance

Air resistance data for factory and field installed options.

Ceiling Diffusers Air Resistance

Details air resistance for various ceiling diffusers.

Ceiling Diffuser Air Throw Data

Provides air throw data for ceiling diffusers.

Electrical Data

7.5 Ton

Electrical data specific to the 7.5 Ton unit model.

Electrical Accessories

Lists electrical accessories and related data.

8.5 Ton

Electrical data specific to the 8.5 Ton unit model.

10 Ton

Electrical data specific to the 10 Ton unit model.

12.5 Ton

Electrical data specific to the 12.5 Ton unit model.

Field Wiring Notes

Provides important notes regarding field wiring.

Parts Arrangement

KGC Control Box Y, G, J Volt Units

Diagram showing the arrangement of components in the KGC control box.

I-UNIT COMPONENTS

Electrostatic Discharge (ESD) Precautions and Procedures

Safety precautions for handling electronic components with ESD concerns.

Control Box Components

Details the various components found within the unit's control box.

Plumbing and Refrigerant Circuit Detail

Compressor 1

Details the plumbing and refrigerant circuit for Compressor 1.

Compressor 2

Details the plumbing and refrigerant circuit for Compressor 2.

B-Cooling Components

KGC150 Evaporators

Specifics about the evaporators used in KGC150 units.

Operation and Adjustments

Three Phase Scroll Compressor Voltage Phasing

Procedure for ensuring correct voltage phasing for compressors.

Supply Air Inverter Units

Notes on operation and features of supply air inverter units.

Blower Operation

Instructions and guidelines for blower operation.

Blower Access

Details on how to access the blower assembly for service.

STANDARD BLOWER ASSEMBLY

D-Determining Unit CFM

Procedure for determining unit CFM using blower data.

E-Blower Belt Adjustment

Instructions for adjusting blower belt tension and alignment.

LOCATION OF STATIC PRESSURE READINGS

F-Check Belt Tension

Procedure for checking and verifying belt tension.

G-Field-Furnished Blower Drives

Information on field-furnished blower drives.

D-GAS HEAT COMPONENTS

1-Heat Exchanger

Details about the gas heat exchanger.

2-Burner Box Assembly

Describes the components of the burner box assembly.

3-Flame Rollout Limits S47

Information on flame rollout limits.

4-Primary High Temperature Limit S10

Details on the primary high temperature limit.

5-Combustion Air Prove Switches S18

Information on combustion air prove switches.

6-Combustion Air Inducers B6

Details on combustion air inducer operation and components.

7-Combustion Air Motor Capacitors C3

Specifications for combustion air motor capacitors.

8-Gas Valves GV1

Details on the two-stage gas valves.

9-Spark Electrodes

Information on the spark electrode assembly for ignition.

10-Flame Sensor

INTEGRATED CONTROL BOARD A3

11-Burner Control A3

Details on the burner control module and its functions.

Operation

Describes the operational sequence of the integrated control board.

II-PLACEMENT AND INSTALLATION

III-STARTUP - OPERATION

Covers unit startup procedures and operational checks.

C-Placing Unit In Operation

Instructions for placing the unit into operation.

D-Safety or Emergency Shutdown

Procedures for unit safety and emergency shutdown.

E - Cooling Start Up

Steps for initiating cooling start-up.

COOLING OPERATION

NO ECONOMIZER

Describes cooling operation without an economizer.

WITH ECONOMIZER

Describes cooling operation with an economizer.

Three Phase Scroll Compressor Voltage Phasing

Ensuring correct voltage phasing for compressors.

IV-CHARGING

A-All Aluminum Outdoor Coil

Procedure for charging the all-aluminum outdoor coil.

B-Refrigerant Charge and Check - Fin;Tube Coil

Charge Verification - Approach Method - AHRI Testing (Fin;Tube Coil Continued)

V-SYSTEMS SERVICE CHECKS

A-Heating System Service Checks

Covers service checks for the heating system.

5-High Altitude

Service checks related to high altitude operation.

6-Proper Gas Flow

Procedure for checking proper gas flow.

7-Heat Exchanger

Service checks related to the heat exchanger.

8-Flame Sensing

Details on checking the flame sensing system.

B-Cooling System Service Checks

Covers service checks for the cooling system.

VI-MAINTENANCE

A-Filters

Maintenance procedures for unit filters.

B-Lubrication

Information regarding lubrication requirements.

C-Burners (Gas Units)

Maintenance procedures for gas unit burners.

D-Combustion Air Inducer

Maintenance procedures for the combustion air inducer.

E-Flue Passageway and Flue Box (Gas Units)

Maintenance for flue passageway and box.

F-Evaporator Coil

Maintenance procedures for the evaporator coil.

G-Condenser Coil

Maintenance procedures for the condenser coil.

H-Supply Air Blower Wheel

Maintenance for the supply air blower wheel.

I-Electrical

Electrical checks for maintenance.

VII-OPTIONAL ACCESSORIES

A-LP; Propane Kit

Details on the LP/Propane conversion kit.

B-Drain Pan Overflow Switch S149 (optional)

Information on the optional drain pan overflow switch.

C-C1 CURB Mounting Frames

Details on C1CURB mounting frames for installation.

D-Transitions

Information on optional supply/return transitions.

E-Supply and Return Diffusers

Details on optional supply and return diffusers.

F-Outdoor Air Dampers C1 DAMP20 B-1 and C1 DAMP10 B-2

Information on optional outdoor air dampers.

G-K1 ECON20 B; K1 ECON22 B-1 Economizer, (Field- or Factory-Installed)

Details on K1ECON20B/K1ECON22B-1 economizer installation.

A6 ENTHALPY CONTROLLER

ENTHALPY FREE COOLING SETPOINTS

Defines enthalpy free cooling setpoints.

Damper Minimum Position

Setting the minimum position for dampers.

A6 Enthalpy Control LEDs

Explanation of the A6 enthalpy control LEDs.

DCV Set and Max Settings

Adjusting DCV (Demand Control Ventilation) settings.

Economizer Operation

Describes economizer operation modes.

Outdoor Air Not Suitable

Economizer operation when outdoor air is not suitable.

Outdoor Air Suitable

Economizer operation when outdoor air is suitable.

H-Outdoor Air Dampers

I-Gravity Exhaust Dampers

Details on gravity exhaust dampers.

J-Power Exhaust Fan

K-Optional Cold Weather Kit (Canada only)

Information on the optional cold weather kit for Canada.

L-Control Systems

M-Smoke Detectors A171 and A172

N-Hot Gas Reheat Start-Up and Operation

General

General overview of hot gas reheat start-up and operation.

Reheat Setpoint

Details on setting the reheat control.

Check-Out

Procedure for checking hot gas reheat operation.

Default Reheat Operation

VIII-Wiring Diagrams and Sequence of Operation

Sequence of Operation

Power

Describes the power sequence for unit operation.

Blower Operation

Details the sequence for blower operation.

Economizer Operation

Describes the sequence for economizer operation.

1 st Stage Cooling (compressor B1)

Sequence of operation for 1st stage cooling.

2 nd Stage Cooling (compressor B2)

Sequence of operation for 2nd stage cooling.

WIRING DIAGRAM

GAS HEAT SEQUENCE OF OPERATION

First Stage Heat

Sequence of operation for first stage heat.

Second Stage Heat

Sequence of operation for second stage heat.

End of Second Stage Heat

Sequence for ending second stage heat.

End of First Stage Heat

Sequence for ending first stage heat.

Optional Low Ambient Kit:(ETL;CSA -50° C Low Ambient Kit)

Sequence for optional low ambient kit operation.

ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT

ECONOMIZER

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