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Lennox KGC092 - User Manual

Lennox KGC092
35 pages
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2022
WARNING
Improper installation, adjustment, alteration, ser
vice or maintenance can cause property damage,
personal injury or loss of life. Installation and ser
vice must be performed by a licensed professional
HVAC installer or equivalent, service agency, or the
gas supplier
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.
Table Of Contents
Dimensions Page 2.................................
Parts Arrangements Page 3.........................
Shipping and Packing List Page 4....................
General Page 4....................................
Safety Page 4.....................................
Unit Support Page 5................................
Duct Connection Page 6............................
Rigging Unit For Lifting Page 6.......................
Condensate Drains Page 6..........................
Connect Gas Piping Page 8.........................
Pressure Test Gas Piping Page 9.....................
High Altitude Derate Page 9.........................
Electrical Connections Page 9.......................
Unit Power-Up Page 11..............................
Blower Operation and Adjustments Page 11............
INSTALLATION
INSTRUCTIONS
KGC/KCC092
KGC/KCC102
KGC/KCC120
KGC/KCC150
(7.5 Ton)
(8.5 Ton)
(10 Ton)
(12-1/2 Ton)
GAS AND COOLING PACKAGED UNITS
507118-13
8/2022
Supersedes 507118-12
Cooling Start-Up Page 18............................
Gas Heat Start-Up Page 26...........................
Heating Operation and Adjustments Page 27............
Electric Heat Start-Up Page 27........................
Supply Air Inverter Start-Up Page 28...................
Hot Gas Reheat Operation and Start-Up Page 31........
Service Page 32....................................
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 mainte
nance), 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 part
s.
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
KGC SHOWN
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Lennox KGC092 Specifications

General IconGeneral
BrandLennox
ModelKGC092
CategoryAir Conditioner
LanguageEnglish

Summary

KG;KC 092, 102, 120, & 150 DIMENSIONS

KG 092, 102, 120, & 150 PARTS ARRANGEMENT

KC 092, 102, 120, & 150 PARTS ARRANGEMENT

Shipping and Packing List

General

Safety

UNIT CLEARANCES

Figure 1 shows unit clearances for installation.

Unit Support

A-Downflow Discharge Application

Details roof mounting for downflow discharge units using C1CURB.

B-Horizontal Discharge Applications

Provides guidance for horizontal discharge applications including kit use.

Duct Connection

Rigging Unit For Lifting

RIGGING

Table showing weights for rigging units.

Condensate Drains

Rear Drain Connection

Instructions for modifying the unit for rear condensate drain.

Bottom Drain Connection

Instructions for modifying the unit for bottom condensate drain.

Connect Gas Piping (Gas Units)

Pressure Test Gas Piping (Gas Units)

High Altitude Derate

Electrical Connections

A-Wiring

Instructions for routing power and making electrical connections.

B-Unbalanced Three-Phase Voltage - VFD

Guidance on operating with unbalanced three-phase power and VFDs.

Control Wiring

A-Thermostat Location

Guidance on proper placement of room thermostats.

B-Control Wiring

Notes on unit operation with cooling stages and thermostat types.

24 VOLT FIELD WIRING WITH ELECTRONIC AND ELECTRO-MECHANICAL THERMOSTATS

Wiring diagram for thermostats and control board TB1.

Unit Power-Up

A-General

General checks before applying power to the unit.

Blower Operation and Adjustments

A-Three Phase Scroll Compressor Voltage Phasing

Ensuring correct compressor and blower rotation for three-phase units.

B-Blower Operation

How blower operation is controlled via thermostat settings.

C-Blower Access

Procedure for accessing and removing the blower assembly.

Determining Unit CFM

STANDARD BLOWER ASSEMBLY

Procedure for adjusting motor pulley to set blower CFM.

LOCATION OF STATIC PRESSURE READINGS

INSTALLATIONS WITH DUCTWORK

Diagram for static pressure readings with ductwork.

INSTALLATIONS WITH CEILING DIFFUSERS

Diagram for static pressure readings with ceiling diffusers.

E-Blower Belt Adjustment

PULLEY ALIGNMENT

Diagram showing proper alignment of motor and blower pulleys.

F-Check Belt Tension

MEASURE BELT TENSION

Diagram and explanation for checking belt tension.

G-Field-Furnished Blower Drives

BLOWER DATA

BLOWER DATA

BLOWER DATA

FACTORY INSTALLED BELT DRIVE KIT SPECIFICATIONS

Specifications for factory-installed belt drive kits.

POWER EXHAUST FAN PERFORMANCE

Performance data for power exhaust fans.

FACTORY INSTALLED OPTIONS;FIELD INSTALLED ACCESSORY AIR RESISTANCE

Air resistance data for various options and accessories.

Cooling Start-Up

A-Operation

Instructions for operating the unit in cooling mode.

TABLE 5

Cooling operation table for units without an economizer.

TABLE 6

Cooling operation table for units with an economizer.

REFRIGERANT STAGES - 092, 102, 120, 150

Diagram illustrating refrigerant stages for specific models.

B-R410 A Refrigerant

C-Refrigerant Charge and Check - All-Aluminum Coil

KG;KC 092, 102, 120, 150

Specifics for refrigerant charge check on all-aluminum coils.

TABLE 7 581125-01

092 S Charging Curves - All-Aluminum Coil

Graph showing charging curves for KG/KC 092S units.

TABLE 8 581126-01

102 S Charging Curves - All-Aluminum Coil

Graph showing charging curves for KG/KC 102S units.

TABLE 9 581127-01

120 S Charging Curves - All-Aluminum Coil

Graph showing charging curves for KG/KC 120S units.

TABLE 10 581128-01

150 S Charging Curves - All-Aluminum Coil

Graph showing charging curves for KG/KC 150S units.

D-Refrigerant Charge and Check - Fin;Tube Coil

TABLE 11 581129-01

Pressures for KGC/KCC092S Fin/Tube coils.

TABLE 12 581130-01

Pressures for KGC/KCC102S Fin/Tube coils.

TABLE 13 581131-01

Pressures for KGC/KCC120S Fin/Tube coils.

TABLE 14 581132-01

Pressures for KGC/KCC150S Fin/Tube coils.

Charge Verification - Approach Method - AHRI Testing

(Fin;Tube Coil Continued)

Approach method for AHRI testing of fin/tube coils.

E-Compressor Controls

1- High Pressure Switches (S4, S7)

Protection for compressors via high pressure switches.

2- Freezestats (S49, S50)

Switches to prevent evaporator freeze-up.

3- Crankcase Heater (HR1, HR2)

Oil heaters for compressors to prevent slugging.

Gas Heat Start-Up (Gas Units)

FOR YOUR SAFETY READ BEFORE LIGHTING

Safety precautions before lighting the gas burner.

A-Placing Unit In Operation

Steps for initial operation and gas valve handling.

Heating Operation and Adjustments (Gas Units)

A-Heating Sequence of Operation

Sequence of operation for gas heating mode.

B-Ignition Control Diagnostic LEDs

Table of LED flash codes for ignition control diagnostics.

C-Limit Controls

Information on factory-set limit controls.

D-Heating Adjustment

Notes on factory-set heating adjustments.

Electric Heat Start-Up (KC Units)

Inverter Start-Up

A-General

Overview of inverter-driven blower operation and speeds.

B-Set Maximum Blower CFM

Procedure to adjust blower pulley for maximum CFM.

C-Set Blower Speed During Ventilation (Units With Standard Economizers Only)

Setting low speed for ventilation with standard economizers.

D-Set Damper Minimum Position (Units With Standard Economizers Only)

Setting minimum damper positions for ventilation.

Set Low Speed Minimum Position

Troubleshoot LVC2 Board (A183)

LVC2 BOARD TERMINAL DESIGNATIONS

Diagram of LVC2 board terminals and their functions.

TABLE 17

Table of LVC2 board blower outputs and corresponding voltages.

TABLE 18 UNIT OPERATION

Hot Gas Reheat Start-Up And Operation

General

Overview of hot gas reheat mode and its function.

L14 Reheat Coil Solenoid Valve

Information on the reheat coil solenoid valve.

Reheat Setpoint

How to adjust the reheat setpoint.

Check-Out

Procedure to test hot gas reheat operation.

Default Reheat Operation

Details on default reheat operation from Table 18.

REHEAT MODE REFRIGERANT ROUTING

Diagram showing refrigerant flow for reheat mode.

Service

A-Filters

Procedure for checking and replacing air filters.

B-Lubrication

Information on motor lubrication.

C-Burners (Gas Units)

Instructions for inspecting and cleaning gas burners.

BURNER BOX ASSEMBLY

Diagram of the burner box assembly.

IGNITOR

Information on checking the ignitor spark gap.

Ignitor and Sensor Position

TABLE 19

Table for ignitor and sensor position based on Btuh input.

D-Combustion Air Inducer (Gas Units)

BURNER BOX

Diagram showing ignitor and sensor positions.

Clean combustion air inducer as follows:

HEAT EXCHANGER ASSEMBLY

Diagram of the heat exchanger assembly with components.

E-Flue Passageway and Flue Box (Gas Units)

F-Evaporator Coil

G-Condenser Coil

H-Supply Air Blower Wheel

START-UP REPORT

Inspections and Checks

Section for recording initial inspection and check results.

Cooling Checks

Section for recording cooling performance data.

Blower Checks

Section for recording blower performance checks.

Heating Checks - Electric

Section for recording electric heating performance.

Heating Checks - Gas

Section for recording gas heating performance.

Accessory Checks

Section for recording accessory performance.

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