Lennox KCB036, KGA048, KCA048, KGB048, KCB048 Installation Instructions Manual
...
Litho U.S.A.
©2015
INSTALLATION
INSTRUCTIONS
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
Table Of Contents
Dimensions Page 2.................................
Parts Arrangements Page 3.........................
Shipping and Packing List Page 4....................
General Page 4....................................
Requirements Page 4...............................
Unit Support Page 5................................
Duct Connection Page 5............................
Rigging Unit For Lifting Page 6.......................
Horizontal Air Discharge Page 6......................
Condensate Drains Page 6..........................
Gas Piping Page 8.................................
Pressure Test Gas Piping Page 9.....................
High Altitude Derate Page 9.........................
Electrical Connections Page 9.......................
Blower Operation and Adjustments Page 11............
Cooling Start-Up Page 42............................
Gas Heat Start-Up Page 51...........................
Heating Operation and Adjustments Page 52............
Electric Heat Start-Up Page 52........................
Service Page 53....................................
KGB/KCB024
KGB/KCB030
KGA/KCA036
KGB/KCB036
KGA/KCA048
KGB/KCB048
KGA/KCA060
KGB/KCB060
KGA/KCA072
KGB/KCB072
KGB/KCB074
KGA/KCA090
GAS AND COOLING PACKAGED UNITS
507348-04
12/2015
Supersedes 507348-01, -02, -03
2-Ton
2-1/2-Ton
3-Ton
3-Ton
4-Ton
4-Ton
5-Ton
5-Ton
6-Ton
6-Ton
6-Ton
6-Ton
7-1/2 Ton
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
KG SHOWN
KG / KC 024, 030, 036, 048, 060, 072, 074, 090 DIMENSIONS in. - Gas heat section shown
Model
No.
KGA/KCA036, 048, 060
KGB/KCB024, 030, 036, 048
KGA/KCA072, 090
KGB/KCB060, 074
7/8
(22)
2-1/4
(Overall dimensions
same as end view
without economizer)
(57)
A
7/8
(22)
OPENING WITH HORIZONTAL
ECONOMIZER INSTALLED
END VIEW
A
in. mm
18-3/4 476
22-1/2 572
30-7/16
(773)
UNIT RETURN AIR DUCT
2-1/4
(57)
5-5/8
(143)
AA
7 (178)
29
(737)
47 (1192)
BASE
DD CC
43-3/8 (1102) KGA/KCA072, 090
& KGB/KCB060, 074
35-3/8 (899) KGA/KCA036-060
& KGB/KCB024-048
3-1/2 (89)
LIFTING HOLES
(For rigging)
16-1/4
(413)
11
(279)
BOTTOM
RETURN
AIR
OPENING
BOTTOM
SUPPLY
AIR
OPENING
6-5/8
(168)
26-1/2
(673)
CONDENSATE
OUTLET
(EITHER SIDE)
26-1/2
(673)
18
(457)
5 (127)
20
CENTER
(508)
OF
GRAVITY
FF
BOTTOM
CONDENSATE
OUTLET
BOTTOM POWER ENTRY
3 X 8 (76 X 203)
TOP VIEW (Base)
83-1/4 (2115) 024 thru 074
96-1/4 (2445) 090
FLUE/VENT
OUTLET
5-1/2
(140)
85-1/4 (2165) 024 thru 074 BASE
98-1/4 (2496) 090 BASE
ELECTRICAL
INLET
SIDE VIEW
25-3/4 (654)
024 thru 074
38-3/4 (984) 090
9-1/2
(241)
INLET
GAS
15
(381)
27
(686)
BB
EE
1 (25)
45
(1143)
1 (25)
47 (1194)
BASE
(Without Economizer)
END VIEW
KG/KC 024, 030, 036, 048, 060, 072, 074, 090
38-7/8 (987) KGA/KCA036-060
& KGB/KCB024-048
46-7/8 (1191) KGA/KCA072, 090
& KGB/KCB060, 072, 074
Page 2
FORKLIFT SLOTS
(Front, Back and
Blower End)
BACK VIEW
20
(508)
5-1/2
(140)
19-1/2
(495)
18-3/8
HORIZONTAL
SUPPLY AIR
OPENING
11
(467)
(279)
HORIZONTAL
RETURN AIR
OPENING
(Without Economizer)
2 (51)
29
(737)
5-1/2
(140)
KG 024, 030, 036, 048, 060, 072, 074, 090 PARTS ARRANGEMENT (KGA090 shown)
FILTERS (4)
ECONOMIZER
(OPTIONAL)
CONDENSATE
DRAIN
EVAPORATOR
COIL
COMBUSTION
AIR INDUCER
REFRIGERANT
METERING DEVICE
BLOWER
BURNERS
GAS VALVE
BLOWER
MOTOR
COMPRESSOR
TB1 LOW VOLTAGE
TERMINAL BLOCK
CONDENSER
FAN
CONDENSER
COIL
KC 024, 030, 036, 048, 060, 072, 074, 090 PARTS ARRANGEMENT (KCA090 shown)
ECONOMIZER
(OPTIONAL)
FILTERS (4)
EVAPORATOR
COIL
REFRIGERANT
METERING DEVICE
BLOWER
TB1 LOW VOLTAGE
TERMINAL BLOCK
CONDENSER
CONDENSER
FAN
COIL
CONDENSATE
DRAIN
BLOWER
MOTOR
ELECTRIC HEAT
(Optional)
Page 3
COMPRESSOR
507348-04 12/2015
CAUTION
Danger of sharp metallic edges. Can cause injury.
Take care and wear protective clothing when
servicing unit to avoid accidental contact with
sharp edges.
Shipping and Packing List
Package 1 of 1 contains:
1- Assembled unit
Check unit for shipping damage. Receiving party should
contact last carrier immediately if shipping damage is found.
General
IMPORTANT
The Clean Air Act of 1990 bans the intentional vent
ing of refrigerant (CFC's and HCFC's) as of July 1,
1992. Approved methods of recovery, recycling or
reclaiming must be followed. Fines and/or incar
ceration may be levied for non-compliance.
UNIT CLEARANCES
C
B
These instructions are intended as a general guide
and do not supersede local codes in any way.
Authorities having jurisdiction should be consulted
before installation.
The KG units are available in three heating inputs. The KC
cooling packaged rooftop unit is the same basic design as
the KG unit except for the heating section. Optional
electric heat is available for KC units. KG and KC units
have identical refrigerant circuits with respective 2, 2-1/2,
3, 4, 5 and 6 ton cooling capacities. In addition, KG/KC
units are available with 7-1/2 tons of cooling.
KGA/KCA 036, 048 & 060 units are equipped with a
fin/tube condenser coil. KGA/KCA072, 090 and
KGB/KCB024, 030, 036, 048, 060, 072, 074 units are
equipped with a lightweight, all-aluminum condenser coil.
Availability of units and options varies by brand.
Requirements
See figure 1 for unit clearances.
NOTICE
Roof Damage!
This system contains both refrigerant and oil.
Some rubber roofing material may absorb oil,
causing the rubber to swell. Bubbles in the rubber
roofing material can cause leaks. Protect the roof
surface to avoid exposure to refrigerant and oil
during service and installation. Failure to follow
this notice could result in damage to roof surface.
WARNING
Electric shock hazard and danger of
explosion. Can cause injury, death or
product or property damage. Turn off
gas and electrical power to unit before
performing any maintenance or
servicing operations on the unit. Follow
lighting instructions attached to unit
when putting unit back into operation
and after service or maintenance.
D
A
FIGURE 1
1
Unit
Clearance
Service
Clearance
Clearance to
Combustibles36(914)1(25)1(25)1(25)
Minimum Opera
tion Clearance36(914)36(914)36(914)36(914)
*KC 090 unit A dimension is 36” (1219mm).
Note - Entire perimeter of unit base requires support when elevated above
mounting surface.
1
Service Clearance - Required for removal of serviceable parts.
Clearance to Combustibles - Required clearance to combustible material
(gas units).
Minimum Operation Clearance - Required clearance for proper unit operation.
A
in.(mm)Bin.(mm)Cin.(mm)Din.(mm)
48*
(1219)36(914)36(914)36(914)
To p
Clearance
Unob
structed
Unob
structed
Unob
structed
Use of this unit as a construction heater or air conditioner
is not recommended during any phase of construction.
Very low return air temperatures, harmful vapors and
operation of the unit with clogged or misplaced filters will
damage the unit.
If this unit has been used for heating or cooling of
buildings or structures under construction, the following
conditions must be met or the warranty will be void:
A room thermostat must control the unit. The use of
fixed jumpers that will provide continuous heating or
cooling is not allowed.
A pre-filter must be installed at the entry to the return
air duct.
The return air duct must be provided and sealed to
the unit.
Return air temperature range between 55°F (13°C)
and 80°F (27°C) must be maintained.
Air filters must be replaced and pre-filters must be
removed upon construction completion.
The input rate and temperature rise must be set per
the unit rating plate.
KG/KC 024, 030, 036, 048, 060, 072, 074, 090
Page 4
The heat exchanger, components, duct system, air
filters and evaporator coil must be thoroughly
cleaned following final construction clean-up.
The unit operating conditions (including airflow,
cooling operation, ignition, input rate, temperature
rise and venting) must be verified according to these
installation instructions.
Unit Support
In downflow discharge installations, install the unit on a
non-combustible surface only. Unit may be installed on
combustible surfaces when used in horizontal discharge
applications or in downflow discharge applications when
installed on a T1CURB or K1CURB roof mounting frame.
KG/KC 024, 030, 036, 048, 060, 072 and 074 units are
installed on T1CURB frames. KG/KC 090 units are
installed on K1CURB frames.
NOTE - Securely fasten roof frame to roof per local codes.
A-Downflow Discharge Application
Roof Mounting with T1CURB or K1CURB
1- The T1CURB/K1CURB roof mounting frame must be
installed, flashed and sealed in accordance with the
instructions provided with the frame.
2- The T1CURB/K1CURB roof mounting frame should
be square and level to 1/16” per linear foot (5mm per
linear meter) in any direction.
3- Duct must be attached to the roof mounting frame
and not to the unit; supply and return plenums must
be installed before setting the unit.
Installer's Roof Mounting Frame
Many types of roof frames can be used to install the unit
depending upon different roof structures. Items to keep
in mind when using the building frame or supports are:
1- The base is fully enclosed and insulated, so an
enclosed frame is not required.
2- The frames or supports must be constructed with
non-combustible materials and should be square and
level to 1/16” per linear foot (5mm per linear meter)
in any direction.
3- Frame or supports must be high enough to prevent
any form of moisture from entering unit.
Recommended minimum frame height is 14”
(356mm).
4- Duct must be attached to the roof mounting frame
and not to the unit. Supply and return plenums must
be installed before setting the unit.
5- Units require support along all four sides of unit base.
Supports must be constructed of steel or suitably
treated wood materials.
NOTE-When installing a unit on a combustible surface for
downflow discharge applications, a T1CURB/K1CURB
roof mounting frame is required.
B-Horizontal Discharge Applications
1- Units which are equipped with an optional
economizer and installed in horizontal airflow
applications must use a horizontal conversion kit.
2- Specified installation clearances must be maintained
when installing units. Refer to figure 1.
3- Top of support slab should be approximately 4”
(102mm) above the finished grade and located so no
run-off water from higher ground can collect around
the unit.
4- Units require support along all four sides of unit base.
Supports must be constructed of steel or suitably
treated wood materials.
Duct Connection
All exterior ducts, joints and openings in roof or building
walls must be insulated and weather-proofed with
flashing and sealing compounds in accordance with
applicable codes. Any duct passing through an
unconditioned space must be insulated.
CAUTION
In downflow applications, do not drill or punch
holes in base of unit. Leaking in roof may occur if
unit base is punctured.
Page 5
507348-04 12/2015
Rigging Unit For Lifting
Rig unit for lifting by attaching four cables to holes in unit
base rail. See figure 2.
RIGGING
UNIT
KG
KC
*Maximum weight with all avail
able installed accessories.
LIFTING POINT SHOULD
IMPORTANT - ALL
PANELS MUST BE IN
PLACE FOR RIGGING.
*WEIGHT
LBS. KG.
883
862
BE DIRECTLY ABOVE
CENTER OF GRAVITY
401
391
CAUTION - Do not
walk on unit.
2- Leave the horizontal return air cover in place.
3- Locate the separately ordered horizontal air
discharge kit. Place the kit panel over the downflow
return air opening.
4- Remove and retain the barometric relief dampers and
lower hood.
5- Install return air duct beneath outdoor air intake. See
figure 4. Install barometric relief damper in lower
hood and install in ductwork as shown in figure 4.
UNIT SUPPLY AND RETURN AIR OPENINGS
HORIZONTAL
HORIZONTAL
RETURN AIR
OPENING
SUPPLY AIR
OPENING
FIGURE 2
1- Detach wooden base protection before rigging.
2- Remove all six base protection brackets before
setting unit.
3- Connect rigging to the unit base using both holes in
each corner.
4- All panels must be in place for rigging.
5- Place field‐provided H‐style pick in place just above
top edge of unit. Frame must be of adequate
strength and length. (H-style pick prevents damage
to unit.)
Horizontal Air Discharge
Unit is shipped with panels covering the horizontal supply
and return air openings. Remove horizontal covers and
place over downflow openings for horizontal air discharge.
See figure 3. Secure in place with sheet metal screws.
Units Equipped With An Optional Economizer
1- Remove the horizontal supply air cover and position
over the downflow supply air opening. Secure with
sheet metal screws.
DOWNFLOW
RETURN AIR
OPENING
DOWNFLOW
SUPPLY AIR
OPENING
FIGURE 3
HORIZONTAL RETURN AIR DUCTWORK
WITH ECONOMIZER
UNITUNIT
HORIZONTAL
RETURN AIR
DUCT
INSTALL BAROMETRIC RELIEF DAMPERS
AND HOOD IN RETURN AIR DUCT
FIGURE 4
Condensate Drains
Make drain connection to the 1” N.P.T. drain coupling
provided on unit.
Note - The drain pan is made with a glass reinforced
engineered plastic capable of withstanding typical joint
torque but can be damaged with excessive force. Tighten
pipe nipple hand tight and turn an additional quarter turn.
KG/KC 024, 030, 036, 048, 060, 072, 074, 090
Page 6
A trap must be installed between drain connection and an
open vent for proper condensate removal. See figure 5 or
6. It is sometimes acceptable to drain condensate onto
the roof or grade; however, a tee should be fitted to the
trap to direct condensate downward. The condensate line
must be vented. Check local codes concerning
condensate disposal. Refer to pages 1 and 2 for
condensate drain location.
CONDENSATE SIDE DRAIN CONNECTION
CAULK AROUND CONDENSATE COUPLING
NOTE - Allow clearance to
open doors when installing
condensate piping.
Minimum Pitch
1” (25 mm) per
10' (3 m) of line
OPEN VENT
UNIT
MOUNTING
FRAME
If the unit has hinged panels, two hinge screws must
be removed in addition to the mullion screws. See
figure 8.
CONDENSATE
DRAIN MULLION
FIGURE 7
UNITS WITH HINGED PANELS
CONDENSATE
DRAIN MULLION
FIGURE 5
CONDENSATE BOTTOM DRAIN CONNECTION
UNIT
DRAIN PAN
CAULK AROUND
CONDENSATE COUPLING
OPEN VENT
MOUNTING
FRAME
Minimum Pitch
1” (25 mm) per 10'
(3 m) of line
FIGURE 6
Units are shipped with the drain coupling facing the front
of the unit. Condensate can be drained from the back or
bottom of the unit with the following modifications. The
unit can be installed in either downflow or horizontal air
discharge regardless of condensate drain location.
Rear Drain Connection
1- Remove the condensate drain mullion. See figure 7.
Remove the two panels on each side of the mullion.
REMOVE
TWO
SCREWS
FIGURE 8
2- Lift the front edge of the drain pan and slide pan out
of unit. See figure 9.
REMOVE DRAIN PAN
DRAIN PAN
FIGURE 9
3- Make sure the cap over the unit bottom drain hole is
secure.
4- Rotate the drain pan until the downward slope is
toward the back of the unit. Slide the drain pan back
into the unit. Be careful not to dislodge the cap over
the bottom drain hole.
5- From the back side of the unit, pull the drain pan
coupling through the rear condensate opening.
6- Replace the condensate drain mullion.
Page 7
507348-04 12/2015
Bottom Drain Connection
1- Remove the condensate drain mullion. See figure 7.
2- Lift the front edge of the drain pan and slide pan out
of unit. See figure 9.
3- Turn the drain pan upside down and drill a pilot hole
through the bottom of the drain pan in the center of
the coupling. See figure 10.
BOTTOM CONDENSATE DRAIN
CAUTION: Be careful not to
damage the coupling threads
when drilling the hole.
After drilling the pilot
hole, drill a 7/8” hole from
the inside of the pan.
DRILL A PILOT
HOLE IN CENTER
OF COUPLING
FIGURE 10
4- From the inside of the pan, use a Vari-Bit® bit to
enlarge the hole to 7/8”. Do not damage coupling
threads.
5- Remove the cap over the unit bottom drain hole.
6- Slide the drain pan back into the unit.
Connect Gas Piping (Gas Units)
Before connecting field-provided piping, check with gas
company or authorities having jurisdiction for local code
requirements. When installing gas supply piping, length
of run from gas meter must be considered in determining
pipe size for 0.5” w.c. (.12kPa) maximum pressure drop.
Do not use supply pipe smaller than unit gas connection.
Operating pressures at the unit gas connection must be
as shown in table 1.
TABLE 1
OPERATING PRESSURE AT GAS CONNECTION “w.c.
Natural Gas LP / Propane Gas
Min. Max. Min. Max.
024-090 4.5 10.5 11 13
When making piping connections a drip leg should be
installed on vertical pipe runs to serve as a trap for
sediment or condensate. A 1/8” N.P.T. plugged tap is
located on gas valve for test gauge connection. Refer to
Heating Start-Up section for tap location. Install a ground
joint union between the gas control manifold and the
main manual shut-off valve. See figure 11 for gas supply
piping entering outside the unit. Figure 12 shows
complete bottom gas entry piping.
Compounds used on threaded joints of gas piping shall be
resistant to the action of liquified petroleum gases.
OUTSIDE OF UNIT GAS PIPE CONNECTION
TO GAS
VALV E
7- From the back side of the unit, pull the drain pan
coupling through the rear condensate opening.
8- From the front side of the unit, move the drain pan
until the bottom coupling settles into the unit bottom
drain opening. Once in place, check to make sure the
coupling is still positioned through the rear
condensate drain hole.
9- Use a field-provided 1” plug to seal side drain
connection.
10- Replace the condensate drain mullion.
KG/KC 024, 030, 036, 048, 060, 072, 074, 090
Page 8
JOINT UNION
TO GAS
SUPPLY
GAS PIPING
SUPPORT
GROUND
MANUAL MAIN
SHUT-OFF VALVE
FIGURE 11
DRIP LEG
(REFER TO
LOCAL CODES)
BOTTOM ENTRY GAS PIPING COMPLETED
PRESSURE TEST GAS LINE
GROUND
JOINT UNION
STREET
ELBOW
7” NIPPLE
2-1/2” NIPPLE
DRIP LEG
Grommets for both gas pipe openings are field provided.
TO GAS
VALV E
TO GAS
SUPPLY
MANUAL MAIN
SHUT-OFF VALVE
FIGURE 12
Pressure Test Gas Piping (Gas Units)
When pressure testing gas lines, the gas valve must
be disconnected and isolated. Gas valves can be
damaged if subjected to more than 0.5 psig (3.48kPa).
See figure 13.
NOTE-Codes may require that manual main shut-off valve
and union (furnished by installer) be installed in gas line
external to unit. Union must be of the ground joint type.
After all connections have been made, check all piping
connections for gas leaks. Also check existing unit gas
connections up to the gas valve; loosening may occur
during installation. Use a leak detection solution or other
preferred means. Do not use matches, candles, or other
sources of ignition to check for gas leaks.
CAUTION
Some soaps used for leak detection are corrosive
to certain metals. Carefully rinse piping thoroughly
after leak test has been completed. Do not use
matches, candles, flame or othe sources of ignition
to check for gas leaks.
WARNING
Danger of explosion. Can cause injury
or product or property damage. Do not
use matches, candles, flame or other
sources of ignition to check for leaks.
NOTE-In case emergency shut down is required, turn off
the main manual shut-off valve and disconnect main
power to unit. These devices should be properly labeled
by the installer.
MANUAL MAIN
SHUT-OFF VALVE
GAS VALVE
CAP
FIGURE 13
High Altitude Derate
Locate the high altitude conversion sticker in the unit
literature bag. Fill out the conversion sticker and affix next
to the unit nameplate.
Refer to table 2 for high altitude adjustments.
TABLE 2
HIGH ALTITUDE DERATE
Altitude Ft.* Gas Manifold Pressure
2000-4500 See Unit Nameplate
4500 And Above Derate 2% / 1000 Ft. Above Sea Level
*Units installed at 0-2000 feet do not need to be modified.
NOTE ‐ This is the only permissible derate for these units.
Electrical Connections
POWER SUPPLY
Do not apply power or close disconnect switch until
installation is complete. Refer to start-up directions.
Refer closely to unit wiring diagram.
Refer to unit nameplate for minimum circuit ampacity
and maximum fuse size.
1- Units are factory-wired for 230,460,575 volt supply.
For 208V supply
from the 208V terminal on the control transformer.
Move the wire from the transformer 240V terminal to
the 208V terminal. Place the insulated terminal cover
on the unused 240V terminal.
2- Route power through the bottom power entry area.
On KG units, connect power wiring to L1, L2 and L3
on the top of K1 in control area above compressor.
On KC units, route power wiring to TB2. Secure
power wiring with factory-installed wire ties
provided in control box. See unit wiring diagram.
, remove the insulated terminal cover
Page 9
507348-04 12/2015
CONTROL WIRING
A-Thermostat Location
Room thermostat mounts vertically on a standard 2” X 4”
handy box or on any non-conductive flat surface.
Locate thermostat approximately 5 feet (1524mm)
above the floor in an area with good air circulation at
average temperature. Avoid locating the room
thermostat where it might be affected by:
-drafts or dead spots behind doors and in corners
-hot or cold air from ducts
-radiant heat from sun or appliances
-concealed pipes and chimneys
B-Control Wiring
1- Route thermostat cable or wires from subbase to
control area above compressor (refer to unit
dimensions to locate bottom and side power entry).
IMPORTANT - Unless field thermostat wires are rated
for maximum unit voltage, they must be routed away
from line voltage wiring. Use wire ties located near the
lower left corner of the controls hat section to secure
thermostat cable.
Use18 AWG wire for all applications using remotely
installed electro-mechanical and electronic
thermostats.
2- Install thermostat assembly in accordance with
instructions provided with thermostat.
3- Connect thermostat wiring to TB1 terminal board on
the lower side of the controls hat section. Wire as
shown in figure 14 for electro-mechanical and
electronic thermostats. If using other temperature
control devices or energy management systems see
instructions and wiring diagram provided by
manufacturer.
24 VOLT FIELD WIRING WITH ELECTRONIC AND
ELECTRO-MECHANICAL THERMOSTATS
TB1
NOT ALL TERMINALS
ARE FOUND ON ALL
THERMOSTATS
Jumper terminals R and
OC when thermostat has
A2 THERMOSTAT
Note - On electro-mechanical thermo
stats set anticipator at 0.1 amps.
no night setback terminals.
FIGURE 14
IMPORTANT-Terminal connections at the wall plate or
subbase must be made securely. Loose control wire
connections may allow unit to operate but not with proper
response to room demand.
INSTALLATIONS WITH DUCTWORK
ROOFTOP UNIT
READING LOCATION
SUPPLY
MAIN
RE
TURN
FIRST BRANCH
OFF OF MAIN RUN
DUCT RUN
LOCATION OF STATIC PRESSURE READINGS
INSTALLATIONS WITH CEILING DIFFUSERS
ROOFTOP UNIT
RETURN AIR
SUPPLY
SUPPLY AIR
READING
LOCATION
SUPPLY AIR
READING
LOCATION
DIFFUSER
FIGURE 15
RE
TURN
RETURN AIR
READING
LOCATION
KG/KC 024, 030, 036, 048, 060, 072, 074, 090
Page 10
Blower Operation and Adjustments
KG/KC 024 and 030 units are equipped with direct drive
blowers only. KG/KC 036, 048 and 060 units are equipped
with either direct drive or belt drive blowers. KG/KC 072,
074 and 090 units are available with belt drive blowers
only. KG/KC 074 units are equipped with two-stage
blowers. The blower will operate at high speed with a Y2
thermostat demand and low speed with a Y1 thermostat
demand. Low speed operation delivers approximately ⅔
of the air volume of high speed. Two-speed blower
operation results in lower energy consumption.
IMPORTANT
Three phase scroll compressors must be phased
sequentially for correct compressor and blower
rotation. Follow “COOLING START-UP” section of
installation instructions to ensure proper compres
sor and blower operation.
A-Blower Operation
Initiate blower demand at thermostat according to
instructions provided with thermostat. Unit will cycle on
thermostat demand. The following steps apply to
applications using a typical electro-mechanical
thermostat.
1- Blower operation is manually set at the thermostat
subbase fan switch. With fan switch in ON position,
blowers will operate continuously.
2- With fan switch in AUTO position, the blowers will
cycle with demand. Blowers and entire unit will be off
when system switch is in OFF position.
FIELD-ADJUSTABLE BLOWER SPEEDS - DIRECT DRIVE 208/230V
HIGH SPEED - ALL UNITS
L1-Terminal COM
TERMINAL 1
REMAINS AT
COMMON
L2-Terminal HIGH
B-Determining Unit CFM - Direct Drive Blowers
1- The following measurements must be made with air
filters in place.
2- With all access panels in place, measure static
pressure external to unit (from supply to return). Add
any additional air resistance for options and
accessories shown in accessory air resistance tables.
Blower performance data is based on static pressure
readings taken in locations shown in figure 15.
Note - Static pressure readings can vary if not taken
where shown.
3- Use figure 16 to determine the factory set blower
speed.
BLOWER SPEED FACTORY SETTINGS
024, 030, &
036 Units
1
2
3
4
Com
Hi
Med
Low*
048 Units
1
2
3
4
Com
Hi
Med*
Low
060 Units
1
2
3
4
Com
Hi
Low*
Unused
*Factory Setting
FIGURE 16
4- Use direct drive blower tables, the measured static
pressure and the factory-set blower speed to
determine CFM. If CFM is lower or higher than the
design specified CFM, move the leads as shown in
figure 17 for 208/230 volt units and figure 18 for
460/575 volt units.
LOW SPEED
024, 030, 036, 048, UNITS
L1-Terminal COM
L2-Terminal LOW
MEDIUM SPEED
024, 030, 036, 048 UNITS
L1-Terminal COM
L2-Terminal MED
SPEED
TAPS
1-COM
2-HI
3-MED
4-LOW
1-COM
2-HI
3-MED
4-LOW
FIGURE 17
1-COM
2-HI
3-MED
4-LOW
LOW SPEED
060 UNITS
L1-Terminal COM
L2-Terminal LOW
1-COM
2-HI
3-LOW
4-
Page 11
507348-04 12/2015
FIELD-ADJUSTABLE BLOWER SPEEDS - DIRECT DRIVE - 460/575V
TAPE BACK AND SECURE
UNUSED ISOLATION LEAD
TO CAPACITOR WIRES.
Do not park
isolation lead
HIGH SPEED
L1-Terminal COM
L2-Terminal HI
LOW SPEED 036, 048 UNITS
Park isolation
lead into
terminal HI
L1-Terminal COM
L2-Terminal LOW
MEDIUM SPEED 036, 048 UNITS
L1-Terminal COM
L2-Terminal MED
Park isolation
lead into
terminal HI
1-COM
2-HI
3-MED
4-LOW
FIGURE 18
C-Determining Unit CFM - Belt Drive Blowers
IMPORTANT - KGB/KCB074 blower (G thermostat)
CFM MUST BE ADJUSTED IN HIGH SPEED.
Disconnect factory-installed J350 low speed
connector from P350. Connectors are located near the
bottom of the control box. Connect J351 high speed
connector to P350. Once blower CFM is set, J350 can
be reconnected to operate the blower on low during
ventilation only demands. See table 3.
TABLE 3
TWO-SPEED BLOWER OPERATION
KGB/KCB074 UNITS
Thermostat Blower Speed
G (P350/J350)* Low
G (P350/J351) High
W1 High
W2 High
Y1 Low
Y2 High
*Factory-installed jack/plug connection.
1- The following measurements must be made with air
filters in place.
2- With all access panels in place, measure static
pressure external to unit (from supply to return).
Blower performance data is based on static pressure
readings taken in locations shown in figure 15.
1-COM
2-HI
3-MED
4-LOW
Park isolation
lead into
terminal HI
LOW SPEED 060 UNITS
L1-Terminal COM
L2-Terminal LOW
1-COM
2-HI
3-LOW
4
1-COM
2-HI
3-MED
4-LOW
Note - Static pressure readings can vary if not taken
where shown.
3- Measure the indoor blower wheel RPM.
4- Referring to belt drive blower tables, use static
pressure and RPM readings to determine unit CFM.
Use the air resistance tables when installing units
with any of the options or accessories listed.
5- The blower RPM can be adjusted at the motor pulley.
Loosen Allen screw and turn adjustable pulley
clockwise to increase CFM. Turn counterclockwise to
decrease CFM. See figure 19. Do not exceed
minimum and maximum number of pulley turns as
shown in table 4.
6- KGB/KCB074 Unit Only -
If low speed during ventilation is desired, replace
J351 connector with J350.
TABLE 4
MINIMUM AND MAXIMUM PULLEY ADJUSTMENT
Belt Min. Turns Open Maxi. Turns Open
A Section No minimum 5
D-Blower Belt Adjustment
Maximum life and wear can be obtained from belts only
if proper pulley alignment and belt tension are
maintained. Tension new belts after a 24-48 hour
period of operation. This will allow belt to stretch and
seat grooves. Make sure blower and motor pulley are
aligned as shown in figure 20.
KG/KC 024, 030, 036, 048, 060, 072, 074, 090
Page 12
BLOWER ASSEMBLY
TO INCREASE CFM
LOOSEN ALLEN SCREW &
TURN PULLEY CLOCKWISE
SIDE VIEW
MOTOR
TO INCREASE BELT TENSION
1-Loosen four bolts securing motor base to mounting
frame.
2-Slide the motor downward to tighten the belt.
3-Tighten four bolts on motor base.
TO DECREASE CFM
TURN PULLEY
COUNTERCLOCKWISE
ALLEN
SCREW
PULLEY
LOOSEN ALLEN
SCREW TO
ADJUST CFM
LOOSEN FOUR BOLTS AND
SLIDE BLOWER MOTOR
DOWNWARD TO TIGHTEN BELT
FIGURE 19
1- Loosen four bolts securing motor base to mounting
frame. See figure 19.
2- To increase belt tension -
Slide blower motor downward to tighten the belt. This
increases the distance between the blower motor and
the blower housing.
3- To loosen belt tension -
Slide blower motor upward to loosen the belt. This
decreases the distance between the blower motor
and the blower housing.
4- Tighten four bolts securing motor base to the
mounting frame.
E-Blower Belt Adjustment - M Volt Units With 3 HP
Blowers Equipped With A Belt Tensioner
1- Remove blower belt.
PULLEY ALIGNMENT
ALIGNED
2- Remove bracket from blower housing. See figure 22.
3- Remove the screw from the back side of the bracket.
4- Move the tensioner to the appropriate adjustment
hole and reinstall screw.
5- Replace bracket.
6- Replace blower belt. See figure 23.
F-Check Belt Tension - Units Not Equipped With A
Belt Tensioner
Overtensioning belts shortens belt and bearing life.
Check belt tension as follows:
1- Measure span length X. See figure 21.
2- Apply perpendicular force to center of span (X) with
enough pressure to deflect belt 1/64” for every inch
of span length or 1.5mm per 100mm of span length.
Example: Deflection distance of a 40” span would be
40/64” or 5/8”.
Example: Deflection distance of a 400mm span
would be 6mm.
MOTOR
PULLEY
BELT
NOT ALIGNED
FIGURE 20
BLOWER
PULLEY
3- Measure belt deflection force. For a used belt, the
deflection force should be 5 lbs. (35kPa). A new belt
deflection force should be 7 lbs. (48kPa).
A force below these values indicates an
undertensioned belt. A force above these values
indicates an overtensioned belt.
Page 13
507348-04 12/2015
G-Field-Furnished Blower Drives
For field-furnished blower drives, use belt drive blower
tables to determine BHP and RPM required. Reference
the drive kit specification table and manufacturer's drive
number table.
MEASURE BELT TENSION
INSTALL BELT
TENSIONER
1
DRIVER
PULLEY
FORCE
DEFLECTION 1/64” PER INCH OF SPAN
OR 1.5mm PER 100mm OF SPAN
FIGURE 21
ADJUST BELT TENSIONER
MAXIMUM
TENSION
INDICATOR SHOULD BE
BETWEEN MINIMUM AND
MAXIMUM TENSION LINES
MINIMUM
TENSION
TIGHTEN MOUNTING
BOLT TO 22 LB./FT.
USING 9/16” WRENCH
2
DRIVEN
PULLEY
3
ROTATE DRIVEN
PULLEY TO SEAT BELT
BRACKET
TENSIONER
FACTORY-SET
POSITION
BELT POSITION
FIGURE 22
KG/KC 024, 030, 036, 048, 060, 072, 074, 090
TIGHTEST
BELT
POSITION
TIGHTER
4
FIGURE 23
Page 14
BLOWER DATA - DIRECT DRIVE - KGB024
BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.
FOR ALL UNITS ADD:
1 - Any factory installed options air resistance (larger gas heat section, economizer, wet coil, etc.) See page 41.
2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.) See page 41.
External Static
Pressure (in. w.g.)
High Medium Low High Medium Low
2 Ton Standard Efciency (Downow) KGB024S
0.0 1275 979 878 1453 1140 926
0.1 1262 960 834 1440 1124 912
0.2 1243 938 790 1420 1096 884
0.3 1218 909 746 1396 1065 853
0.4 1186 866 710 1352 1033 822
0.5 1137 838 657 1316 986 774
0.6 1104 795 604 1263 954 727
0.7 1055 752 534 1210 906 680
0.8 990 694 463 1158 859 632
0.9 925 637 392 1070 764 538
1.0 794 523 290 928 669 477
2 Ton Standard Efciency (Horizontal) KGB024S
0.0 1204 937 818 1370 1098 879
0.1 1186 913 788 1352 1066 864
0.2 1164 882 748 1327 1034 839
0.3 1137 860 710 1300 1001 809
0.4 1104 818 670 1263 968 768
0.5 1070 775 612 1227 925 728
0.6 1031 733 554 1190 881 688
0.7 991 690 500 1136 816 628
0.8 937 626 432 1081 751 557
0.9 804 566 362 1009 665 492
1.0 678 497 287 900 565 416
208 VOLTS 230 VOLTS
Air Volume (cfm) at Various Blower Speeds
Page 15
BLOWER DATA - DIRECT DRIVE - KGB030
BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.
FOR ALL UNITS ADD:
1 - Any factory installed options air resistance (larger gas heat section, economizer, wet coil, etc.) See page 41.
2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.) See page 41.
External Static
Pressure (in. w.g.)
High Medium Low High Medium Low
2.5 Ton Standard Efciency (Downow) KGB030S
0.0 1211 949 852 1365 1097 916
0.1 1251 946 826 1422 1099 908
0.2 1241 952 794 1419 1112 893
0.3 1234 915 749 1419 1074 861
0.4 1213 880 702 1402 1038 824
0.5 1178 846 661 1366 1003 795
0.6 111 8 790 585 1302 942 720
0.7 1054 751 518 1231 900 655
0.8 964 675 460 1130 815 600
0.9 882 626 368 1037 762 501
1.0 729 494 286 859 606 412
2.5 Ton Standard Efciency (Horizontal) KGB030S
0.0 1163 930 815 1312 1075 875
0.1 1173 912 783 1333 1060 861
0.2 1169 888 746 1337 1037 839
0.3 1152 858 704 1325 1007 809
0.4 1122 822 657 1297 969 772
0.5 1079 779 606 1252 923 728
0.6 1023 730 549 1191 870 676
0.7 953 674 488 1114 808 617
0.8 871 613 422 1020 739 550
0.9 775 545 350 911 662 476
1.0 666 470 274 785 578 395
208 VOLTS 230 VOLTS
Air Volume (cfm) at Various Blower Speeds
Page 16
BLOWER DATA - DIRECT DRIVE - KGA/KGB036, KGA/KGB048
BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.
FOR ALL UNITS ADD:
1 - Any factory installed options air resistance (larger gas heat section, economizer, wet coil, etc.) See page 41.
2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.) See page 41.
External Static
Pressure (in. w.g.)
High Medium Low High Medium Low High Medium Low
3 and 4 Ton Standard Efciency (Downow) KGA/KGB036S and KGA/KGB048S
0.0 1873 1561 1123 2094 1783 1321 2064 1727 1216
0.1 1993 1601 1148 2168 1797 1338 2105 1744 1229
0.2 1913 1601 1137 2098 1803 1308 2050 1694 1198
0.3 1858 1527 1078 2036 1725 1261 1987 1638 1167
0.4 1801 1496 1046 1973 1679 1219 1905 1598 1148
0.5 1763 1467 987 1910 1647 1177 1862 1559 1108
0.6 1709 1414 897 1830 1560 1080 1781 1509 1057
0.7 1617 1368 806 1727 1519 986 1698 1449 982
0.8 1472 1269 730 1604 1419 918 1614 1389 920
0.9 1359 1162 487 1478 1363 706 1488 1346 792
1.0 961 922 370 1093 1083 590 1167 1099 703
3 and 4 Ton Standard Efciency (Horizontal) KGA/KGB036S and KGA/KGB048S
0.0 1799 1530 1073 2012 1747 1263 2015 1756 1251
0.1 1868 1544 1088 2032 1733 1268 2071 1760 1279
0.2 1802 1494 1068 1976 1682 1228 2014 1700 1226
0.3 1735 1432 1014 1900 1618 1185 1937 1634 1187
0.4 1666 1397 980 1825 1568 1142 1878 1597 1174
0.5 1615 1350 904 1750 1516 1078 1801 1558 1124
0.6 1564 1305 842 1675 1440 1014 1743 1479 1060
0.7 1462 1228 758 1562 1364 928 1664 1415 982
0.8 1330 1151 670 1449 1287 842 1512 1335 865
0.9 1194 1011 464 1298 1185 671 1393 1297 733
1.0 878 878 355 998 1032 565 1060 1063 618
208 VOLTS 230 VOLTS 460/575 VOLTS
Air Volume (cfm) at Various Blower Speeds
Page 17
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