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)
Table Of Contents
DimensionsPage 2.................................
Parts ArrangementsPage 3.........................
Shipping and Packing ListPage 4....................
GeneralPage 4....................................
SafetyPage 4.....................................
Unit SupportPage 5................................
Duct ConnectionPage 5............................
Rigging Unit For LiftingPage 5.......................
Condensate DrainsPage 6..........................
Connect Gas PipingPage 7.........................
Pressure Test Gas PipingPage 8.....................
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
KGA/KCA150
GAS AND COOLING PACKAGED UNITS
507118-06
4/2017
Supersedes 10/2016
High Altitude DeratePage 9.........................
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.
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
2000-4500See Unit Nameplate
4500 And AboveDerate 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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