Lennox KGA092KGA102KGA120KGA150, KCA092, KCA150, KCA120, KCA102 Installation Instructions Manual

©2017
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
INSTALLATION INSTRUCTIONS
KGA/KCA092 KGA/KCA102 KGA/KCA120
(7.5 Ton)
(8.5 Ton)
(10 Ton)
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 5............................
Rigging Unit For Lifting Page 5.......................
Condensate Drains Page 6..........................
Connect Gas Piping Page 7.........................
Pressure Test Gas Piping Page 8.....................
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
KGA/KCA150
GAS AND COOLING PACKAGED UNITS
507118-06 4/2017 Supersedes 10/2016
High Altitude Derate Page 9.........................
Electrical Connections Page 9.......................
Unit Power-Up Page 10..............................
Blower Operation and Adjustments Page 10............
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...................
Service Page 30....................................
(12-1/2 Ton)
KGA SHOWN
KGA/KCA092, 102, 120, & 150 DIMENSIONS - Gas heat section shown
4-1/8 (105)
19-3/4
(502)
27-3/4
(705)
58-1/8 (1476)
BOTTOM
POWER ENTRY
5-1/2 (140) Dia.
46-7/8 (1191)
43-3/8 (1102)
6-1/8 (156)
60-1/8 (1527)
BASE
7 (178)
(25)
6-1/8 (156)
(686)
OPTIONAL DISCONNECT
(FACTORY INSTALLED)
1
24
(610)
27
BOTTOM RETURN
AIR OPENING
6-5/8 (168)
7 (178)
34-7/8
(886)
CONDENSATE DRAIN (FRONT)
5-3/8 (137)
10-3/4
(273)
BOTTOM
CONDENSATE
TOP VIEW
18-1/2
5-5/8
BOTTOM SUPPLY
(143)
28
(711)
20
(508)
101-1/4
(2572)
99-1/4 (2521)
GAS SUPPLY
INLET
(470)
AIR OPENING
BASE
FLUE
OUTLET
46-7/8
(1191)
6
(152)
60-1/8 (1527)
END VIEW
OPTIONAL RETURN AIR OPENING
WITH ECONOMIZER AND HORIZONTAL
DISCHARGE KIT (required)
(Field Installed)
3-1/2
(89)
ELECTRIC
INLETS
15-1/2
(394)
6-1/8 (156)
34-7/8
(886)
31-1/2
(800)
FORKLIFT SLOTS
39-7/8 (1013)
(BOTH SIDES)
101-1/4
(2572)
SIDE VIEW
HORIZONTAL
SUPPLY AIR
OPENING
CONDENSATE DRAIN (BACK)
30
66-3/8 (1686)
(762)
SIDE VIEW
(Horizontal Openings)
LIFTING HOLES
(FOR RIGGING)
15-1/2
(394)
5-3/8
HORIZONTAL
(137)
RETURN AIR
OPENING
WITHOUT ECONOMIZER
1-5/8
(41)
30
(762)
12-1/8
(308)
Page 2
KGA092, 102, 120, & 150 PARTS ARRANGEMENT
DISCONNECT /
ECONOMIZER
(OPTIONAL)
INVERTER
(OPTIONAL)
COMPRESSORS
CIRCUIT BREAKER (FACTORY OR FIELD INSTALLED OPTION)
FILTERS
(FOUR - 20 X 25 X 2”)
EVAPORATOR
COIL
CONDENSATE
DRAIN
BLOWER
MOTOR
BLOWER
GAS VALVE
CONDENSER
FANS
CONDENSER
COIL
COMBUSTION
AIR INDUCER
BURNERS
KCA092, 102, 120, & 150 PARTS ARRANGEMENT
ECONOMIZER
(OPTIONAL)
INVERTER
(OPTIONAL)
COMPRESSORS
DISCONNECT /
CIRCUIT BREAKER (FACTORY OR FIELD INSTALLED OPTION)
(FOUR - 20 X 25 X 2”)
EVAPORATOR
COIL
FILTERS
BLOWER
MOTOR
BLOWER
CONDENSATE
DRAIN
CONDENSER
FANS
CONDENSER
COIL
ELECTRIC
HEAT
Page 3
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.
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
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 KGA units are available in three heating inputs. The KCA cooling packaged rooftop unit is the same basic design as the KGA unit except for the heating section. Optional electric heat is available for KCA units. KGA and KCA units have identical refrigerant circuits with respective 7-1/2, 8‐1/2, 10, and 12-1/2 ton cooling capacities.
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.
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
Optional
Outdoor
Air Hood
D
C
B
Units are available with an optional supply air inverter. The blower will operate at lower speeds when demand is low and increase to higher speeds when demand is high. Refer to Inverter Start-Up section.
Availability of units and options varies by brand.
Safety
See figure 1 for unit clearances.
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.
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.
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)
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)
60
(1524)36(914)36(914)60(914)
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.
Page 4
To p
Clearance
Unob
structed
Unob
structed
Unob
structed
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.
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 an C1CURB roof mounting frame.
NOTE - Securely fasten roof frame to roof per local codes.
CAUTION
To reduce the likelihood of supply / return air by pass and promote a proper seal with the RTU, duct work / duct drops / diffuser assemblies must be supported independently to the building structure.
A-Downflow Discharge Application
Roof Mounting with C1CURB
Make sure the cap over the unit bottom drain hole is secure.
1- The C1CURB roof mounting frame must be installed,
flashed and sealed in accordance with the instructions provided with the frame.
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, an C1CURB roof mounting frame is required.
B-Horizontal Discharge Applications
1- Units installed in horizontal airflow applications must
use a horizontal conversion kit (K1HECK00).
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.
2- The C1CURB 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.
CAUTION
In downflow applications, do not drill or punch holes in base of unit. Leaking in roof may occur if unit base is punctured.
Rigging Unit For Lifting
Rig unit for lifting by attaching four cables to holes in unit base rail. See figure 2.
1- Detach wooden base protection before rigging.
2- Connect rigging to the unit base using both holes in
each corner.
3- All panels must be in place for rigging.
Page 5
4- 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.)
CONDENSATE SIDE DRAIN CONNECTION
CAULK AROUND CONDENSATE COUPLING
RIGGING
UNIT
KGA KCA
*Maximum weight with all available ins talled accessories.
*WEIGHT
LBS. KG. 1401 1366
636 620
LIFTING POINT SHOULD
BE DIRECTLY ABOVE CENTER OF GRAVITY
CAUTION - Do not
walk on unit.
IMPORTANT - ALL
PANELS MUST BE IN
PLACE FOR RIGGING.
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
FIGURE 3
CONDENSATE BOTTOM DRAIN CONNECTION
UNIT
DRAIN PAN
CAULK AROUND
CONDENSATE COUPLING
OPEN VENT
FIGURE 2
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.
A trap must be installed between drain connection and an open vent for proper condensate removal. See figure 3 or
4. 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 2 and 3 for condensate drain location.
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 heat access door. See figure 5. 2- Remove filter access door.
MOUNTING
FRAME
Minimum Pitch
1” (25 mm) per 10'
(3 m) of line
FIGURE 4
FILTER
ACCESS DOOR
HEAT
ACCESS DOOR
CONDENSATE
DRAIN MULLION
FIGURE 5
3- Remove eight screws holding condensate drain
mullion and remove mullion.
Page 6
4- Lift front edge of the drain pan (to clear bottom drain
plug) and slide drain pan out of unit. See figure 6.
DRAIN PAN
FIGURE 6
5- Make sure the cap over the unit bottom drain hole is
secure.
6- 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.
7- From the back side of the unit, pull the drain pan
coupling through the rear condensate opening.
8- Replace the condensate drain mullion and reinstall
eight screws.
9- Reinstall access doors.
11- Use a field-provided 1” plug to seal side drain
connection.
12- Replace the condensate drain mullion and reinstall
eight screws.
13- Reinstall access doors.
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 7
Connect Gas Piping (Gas Units)
Bottom Drain Connection
1- Remove heat access door. See figure 5.
2- Remove filter access door.
3- Remove eight screws holding condensate drain
mullion and remove mullion.
4- Lift front edge of the drain pan (to clear bottom drain
plug) and slide drain pan out of unit. See figure 6.
5- 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 7.
®
6- From the inside of the pan, use a Vari-Bit
bit to enlarge the hole to 7/8”. Do not damage coupling threads.
7- Remove the cap over the unit bottom drain hole.
8- Slide the drain pan back into the unit.
9- From the back side of the unit, pull the drain pan
coupling through the rear condensate opening.
10- 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.
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. For natural gas units, operating pressure at the unit gas connection must be a minimum of 4.7” w.c. (1.19kPa) and a maximum of 10.5” (2.60kPa) w.c. For LP/propane gas units, operating pressure at the unit gas connection must be a minimum of 11” w.c. (2.74kPa) and a maximum of 13.0” w.c. (3.23kPa).
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 8 for gas supply piping entering outside the unit. Figure 9 shows bottom gas entry piping through the curb. Figure 10 shows bottom gas entry piping through the unit.
Compounds used on threaded joints of gas piping shall be resistant to the action of liquified petroleum gases.
Page 7
OUTSIDE OF UNIT GAS PIPE CONNECTION
TO GAS
VALV E
GROUND
JOINT UNION
ALL ELBOWS ARE 3/4”
10” NIPPLE
GROMMET
7-1/2” NIPPLE
BOTTOM GAS ENTRY
THROUGH THE UNIT
MULLION BETWEEN
HEAT AND COMPRES
SOR SECTIONS
GROMMET
5” NIPPLE
4” NIPPLE
4” NIPPLE
TO GAS SUPPLY
GAS PIPING
SUPPORT
MANUAL MAIN
SHUT-OFF VALVE
BOTTOM ENTRY GAS PIPING
THROUGH THE CURB
MULLION BETWEEN
HEAT AND COMPRES
SOR SECTIONS
4” NIPPLE
FIGURE 8
DRIP LEG
TO GAS
VALV E
(REFER TO
LOCAL CODES)
4” NIPPLE
TO GAS
VALV E
7”
NIPPLE
ALTERNATE
KNOCKOUTS
ROOF MOUNTING
FRAME
TO GAS
SUPPLY
DRIP LEG
GROUND
JOINT UNION
4” NIPPLE
MANUAL MAIN
SHUT-OFF VALVE
3-1/2” NIPPLE
3” NIPPLE
FIGURE 10
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 11.
GROMMET
ALL ELBOWS ARE 3/4”
MANUAL MAIN
SHUT-OFF VALVE
TO GAS SUPPLY
10” NIPPLE
ROOF
MOUNTING
FRAME
FIGURE 9
5” NIPPLE
7-1/2” NIPPLE
GROUND
JOINT UNION
4” NIPPLE
3-1/2” NIPPLE
3” NIPPLE
DRIP LEG
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.
Page 8
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.
PRESSURE TEST GAS LINE
MANUAL MAIN
SHUT-OFF VALVE
GAS VALVE
FIGURE 11
CAP
Refer to unit nameplate for minimum circuit ampacity and maximum fuse size.
1- 230/460/575 volt units are factory wired. For 208V
supply, disconnect the pink wire (230V) at all control power transformer(s). Reconnect the pink wire (208V). Tape the exposed end of the 230V pink wire.
2- Route power through the bottom power entry area
and connect to L1, L2, and L3 on the bottom of TB2 in control box for gas units or units equipped with electric heat. Route power to F4 on cooling only units (no electric heat). Route power to S48 disconnect switch when the option is factory-installed. See unit wiring diagram.
3- Connect separate 120v wiring to optional GFCI outlet
pigtails.
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
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 1 for high altitude adjustments.
TABLE 1
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.
B-Control Wiring
1- Route thermostat cable or wires from subbase to
control box (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 12 for electro-mechanical and electronic thermostats. If using other temperature control devices or energy management systems see instructions and wiring diagram provided by manufacturer.
Page 9
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 no night setback terminals
A2 THERMOSTAT
Note - On electro-mechanical thermo stats set anticipator at 0.1 amps.
on units equipped with an economizer.
FIGURE 12
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.
1- Observe suction and discharge pressures and
blower rotation on unit start-up.
If pressure differential is not observed or blower rotation is not correct:
2- Suction pressure must drop, discharge pressure
must rise, and blower rotation must match rotation marking.
3- Disconnect all remote electrical power supplies.
4- Reverse any two field-installed wires connected to
the line side of K3, TB2 or F4. Do not reverse wires at blower contactor or compressors.
5- Make sure the connections are tight.
Discharge and suction pressures should operate at their normal start‐up ranges.
Supply Air Inverter Units - Units are equipped with a phase monitor located in the control compartment. The phase monitor will detect the phasing of incoming power. If the incoming power is out of phase or if any of the three phases are lost, the indicating LED on the phase monitor will turn red and the unit will not start. In normal operation with correct incoming power phasing, the LED will be green.
Unit Power-Up
A-General
1- Make sure that unit is installed in accordance with the
installation instructions and applicable codes.
2- Inspect all electrical wiring, both field‐ and
factory‐installed, for loose connections. Tighten as required.
3- Check to ensure that refrigerant lines do not rub
against the cabinet or against other refrigerant lines.
4- Check voltage at main unit power connection.
Voltage must be within range listed on nameplate. If not, consult power company and have voltage condition corrected before starting unit.
5- Make sure filters are in place before start‐up.
6- Make sure there is no heating, cooling, or blower
demand from thermostat. Apply power to unit.
Blower Operation and Adjustments
A-Three Scroll Compressor Voltage Phasing
Three phase scroll compressors must be phased sequentially to ensure correct compressor and blower rotation and operation. Compressor and blower are wired in phase at the factory. Power wires are color-coded as follows: line 1-red, line 2-yellow, line 3-blue.
B-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.
C-Blower Access
The blower assembly is secured to a sliding frame which allows the blower motor to be pulled out of the unit. See figure 13.
1- Loosen the reusable wire tie which secures the
blower wiring to the blower motor mounting plate.
2- Remove and retain screws on either side of sliding
frame. Pull frame toward outside of unit.
3- Slide frame back into original position when finished
servicing. Reattach the blower wiring in the previous location on the blower motor base using the wire tie.
4- Replace retained screws on either side of the sliding
frame.
Page 10
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