Lennox KGC102 User Manual

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

Lennox KGC102 Specifications

General

Brand	Lennox
Model	KGC102
Category	Air Conditioner
Language	English

Summary

KGC Series Unit Information

KGC092 Through 150 Models

Safety Warnings and Cautions

Highlights critical safety precautions for operation and maintenance.

Accessory Options Details

Unit Specifications Overview

General Data and Performance

Provides general unit data, tonnage, efficiency, and performance metrics.

Refrigerant Charge

Details refrigerant types and quantities for various coils.

Outdoor and Indoor Coil Specifications

Gas Heat Specifications

Gas Heating Performance Details

Provides input/output BTU, temperature rise, and air volume for gas heat.

High Altitude Derate

Explains derating procedures for units installed at high altitudes.

Blower Performance Data

Base Unit Blower Specs (KGC092/102S4M)

Base Unit Blower Specs (KGC120/150S4M)

Static Pressure and Air Volume Tables

Electrical Data (7.5 & 8.5 Ton)

Electrical Data (10 & 12.5 Ton)

Voltage and Component Amperage

Details electrical data including voltage and component amps.

Unit Components Overview

Parts Arrangement Diagram

Unit Components Details

Electrostatic Discharge (ESD) Precautions

Control Box Component Breakdown

Details individual components within the control box.

Plumbing and Refrigerant Circuit

Refrigerant Circuit Detail Diagram

Illustrates the plumbing and refrigerant circuit details.

Cooling System Components

Cooling Components Description

Compressor and Component Details

Compressor Safety and Protection

Details compressor safety features and protection devices.

Thermal Protectors and Freezestats

Explains thermal protectors and freezestat functions.

High Pressure Switches

Describes the function of high pressure switches.

Low Ambient Kit and Crankcase Heaters

Blower Compartment and Operation

Indoor Blower Motor (B3) Details

Unit Operation and Adjustments

Covers compressor phasing, blower operation, and access.

Blower Assembly Adjustment

Determining Unit CFM and Pulley Adjustment

Guides for setting unit CFM by adjusting the motor pulley.

Blower Belt Adjustment Procedures

Gas Heat Components

Heat Exchanger Description

Explains the design and function of the heat exchanger.

Burner Box Assembly Details

Describes the components within the burner box assembly.

Gas Heat Safety and Components

Flame Rollout Limits

Details the function of flame rollout limits.

Primary High Temperature Limit

Explains the primary high temperature limit switch.

Combustion Air Prove Switches

Describes the combustion air prove switch operation.

Combustion Air Inducers and Capacitors

Gas Valve and Ignition Components

Gas Valves (GV1) Operation

Explains the operation of the two-stage gas valve.

Spark Electrode Installation and Gapping

Details spark electrode installation and proper gapping.

Flame Sensor Operation

Describes the function and placement of the flame sensor.

Integrated Control Board A3

Burner Control A3 Functions

Outlines the four main functions of the burner control.

Control Status LEDs and Tables

Ignition Control A3 Operation

Ignition Control Sequence of Operation

Details the sequence of operation for ignition control.

Installation and Startup Procedures

Placement and Installation Requirements

Covers unit placement and installation according to codes.

Startup - Operation Checks

Details preliminary and seasonal checks before startup.

Heating Startup Safety Precautions

Highlights critical safety warnings before lighting the unit.

Unit Operation and Shutdown

Placing Unit in Operation

Guides for placing the unit into operation and gas valve handling.

Safety or Emergency Shutdown

Provides instructions for safe unit shutdown.

Cooling Start Up

Refrigerant Charging Procedures

All Aluminum Outdoor Coil Charging

Provides procedures for charging the all-aluminum outdoor coil.

Charging Curves - All-Aluminum Coil

KG/KC 092S Charging Curves

Presents charging curves for KG/KC 092S models.

KG/KC 102S Charging Curves

Presents charging curves for KG/KC 102S models.

KG/KC 120S Charging Curves

Presents charging curves for KG/KC 120S models.

KG/KC 150S Charging Curves

Presents charging curves for KG/KC 150S models.

Fin/Tube Coil Refrigerant Charge

Fin/Tube Coil Charging Procedure

Provides procedures for charging the fin/tube coil.

Safety and Handling Warnings

Highlights safety warnings for refrigerant handling.

Charging Procedure and Important Notes

Details the charging procedure and important notes.

Refrigerant Charge Verification

Fin/Tube Coil AHRI Testing

Approach Temperature Tables

System Service Checks

Heating System Service Checks

Covers service checks for the heating system.

Gas Piping Inspection and Testing

Details gas piping inspection, testing, and safety.

Manifold Pressure Check and Adjustment

Explains how to check and adjust manifold pressure.

High Altitude and Gas Flow Checks

High Altitude Derate Information

Proper Gas Flow Measurement

Flame Sensing Procedure and Safety

Describes flame sensing and associated safety precautions.

Combustion Air Inducer Maintenance

Combustion Air Inducer Cleaning Procedure

Economizer Control and Settings

Enthalpy Controller (A6) Overview

Enthalpy Control LEDs and Setpoints

Hot Gas Reheat Operation

Reheat System Overview

Reheat Coil Solenoid Valve

Reheat Setpoint and Check-Out

Wiring Diagrams and Components

Wiring Diagram Overview

Important Wiring Notes and Warnings

Highlights critical notes and safety warnings for wiring.

Sequence of Operation

Power, Blower, and Economizer Operation

1st Stage Cooling Operation

2nd Stage Cooling Operation

Gas Heat Wiring Diagram

Wiring Diagram Components Key

Important Wiring Notes

Gas Heat Sequence of Operation

First Stage Heat Sequence

Describes the sequence for first stage heating.

Second Stage Heat Sequence

Describes the sequence for second stage heating.

End of Stage Sequences

Optional Low Ambient Kit Sequence

Electronic Thermostat Wiring

Thermostat Wiring Diagram Overview

Thermostat Wiring Diagram Components

Key Components and Notes

Important Wiring Notes and Guidelines

Electronic Thermostat Sensor Details

Sensor and Component Key

Sensor Usage Notes and Wiring Designations

Economizer Wiring and Components

Economizer Wiring Diagram Overview

Economizer Component Key and Notes