Lennox KDB024, KDB048, KDB036, KDB060 Installation Instructions Manual

2017

INSTALLATION

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 or service agency.

CAUTION

As with any mechanical equipment, contact with sharp sheet metal edges can result in personal in jury. Take care while handling this equipment and wear gloves and protective clothing.

Table Of Contents

Dimensions Page 2.................................

Shipping and Packing List Page 3....................

General Page 3....................................

Requirements Page 3...............................

Unit Support Page 4................................

Duct Connection Page 5............................

RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE

INSTRUCTIONS

KDB024 (2 TON) KDB036 (3 TON) KDB048 (4 TON) KDB060 (5 TON)

ROOFTOP PACKAGED UNITS

507626-01 04/2017 Supersedes 8/2016

Rigging Unit For Lifting Page 5.......................

Condensate Drains Page 6..........................

Electrical Connections Page 9.......................

Unit Power-Up Page 9..............................

Blower Operation and Adjustments Page 10............

Defrost Control Board Page 30........................

Service Page 33....................................

KDB024, 036, 048, 060 PARTS ARRANGEMENT

ECONOMIZER

(OPTIONAL)

INDOOR

TXV

CONDENSATE

DRAIN

FILTERS

COMBUSTION

AIR INDUCER

BURNERS

TB1 LOW VOLTAGE

TERMINAL BLOCK

EVAPORATOR

COIL

GAS VALVE

BLOWER

REVERSING

VALV E

CONDENSER

FAN

OUTDOOR

TXV

CONDENSER

COIL

COMPRESSOR

KDB024, 030, 036, 048, 060 DIMENSIONS

Model

KDB024, 036

KDB048, 060

2-1/4

(57)

(Overall dimensions same as end view without economizer)

No.

7/8

(22)

30-7/16

(773)

7/8

UNIT RETURN AIR DUCT

(22)

OPENING WITH HORIZONTAL

ECONOMIZER INSTALLED

END VIEW

in. mm

18-3/4 476

22-1/2 572

2-1/4

(57)

5-5/8 (143)

7 (178)

(737)

47 (1192)

BASE

3-1/2 (89)

LIFTING HOLES

(For rigging)

16-1/4

(413)

DD CC

(279)

26-1/2

(673)

6-5/8 (168)

BOTTOM

RETURN

AIR

OPENING

BOTTOM

SUPPLY

AIR

OPENING

(457)

5 (127)

(508)

BOTTOM

CONDENSATE

OUTLET

CENTER

GRAVITY

BOTTOM POWER ENTRY

3 X 8 (76 X 203)

25-3/4 (654) 024 thru 074

38-3/4 (984) 090

9-1/2 (241)

TOP VIEW (Base)

83-1/4 (2115) 024, 036 96-1/4 (2445) 048, 060

ELECTRICAL

INLET

GAS

INLET

(381)

(686)

CONDENSATE

OUTLET

(EITHER SIDE)

43-3/8 (1102) KDB048, 060

35-3/8 (899) KDB024, 036

26-1/2

(673)

FLUE/VENT

OUTLET

5-1/2 (140)

85-1/4 (2165) 024 thru 036 BASE

98-1/4 (2496) 060 BASE

SIDE VIEW

1 (25)

(1143)

1 (25)

47 (1194)

BASE

(Without Economizer)

END VIEW

38-7/8 (987) KDB024, 036

46-7/8 (1191) KDB048, 060

Page 2

FORKLIFT SLOTS

(Front, Back and

Blower End)

BACK VIEW

(508)

5-1/2 (140)

19-1/2

(495)

18-3/8

HORIZONTAL

SUPPLY AIR

OPENING

(467)

(279)

HORIZONTAL

RETURN AIR

OPENING

(Without Economizer)

2 (51)

(737)

5-1/2 (140)

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.

KDB units have 2, 3, 4, and 5-ton cooling capacities. Units are available in three gas heating inputs.

KDB036, 048, and 060 3-phase units are equipped with two-speed, belt or direct drive supply air blowers. KDB024, 036, 048 and 060 1-phase units are equipped with variable speed, direct drive blowers. These units will provide supply air at lower speeds when cooling demand is low and increase to higher speeds when cooling demand is high. Refer to Blower Operation section.

Availability of units and options varies by brand.

Requirements

The KDB unit is ETL/CSA certified for outdoor installations only at the clearances to combustible materials listed on unit nameplate and in figure 1.

Installation of KDB dual fuel heat pumps must conform with standards in National Fire Protection Association (NFPA) “Standard for Installation of Air Conditioning and Ventilating Systems NFPA No. 90A,” “Standard for Installation of Residence Type Warm Air Heating and Air conditioning Systems NFPA No. 90B,” local municipal building codes and manufacturer's installation instructions.

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.

The National Electric Code (ANSI/NFPA No. 70-1984) is available from:

National Fire Protection Association 1 Batterymarch Park PO Box 9101 Quincy, MA 02269-9101

UNIT CLEARANCES

FIGURE 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.

Service Clearance - Required for removal of serviceable parts. Clearance to Combustibles - Required clearance to combustible

material. Minimum Operation Clearance - Required clearance for proper unit operation.

in.(mm)Bin.(mm)Cin.(mm)Din.(mm)

(1524)36(914)36(914)36(914)

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.

The KDB unit is ETL/CSA certified as a dual fuel heat pump with cooling and auxiliary gas heat for non-residential use only at the clearances to combustible materials as listed on the unit nameplate and in figure 1.

Installation of ETL/CSA certified units must conform with current standard C273.5 “Installation Requirements for Heat Pumps” and applicable local codes. Authorities having jurisdiction should be consulted before installation.

Page 3

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-filter must be

removed upon construction completion.

 The unit 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, and heating operation) must be

verified according to these installation instructions.

WARNING

Electric shock hazard and danger of explosion. Can cause injury, death or product or property damage. Turn off electrical power to unit before performing any maintenance or servicing operations on the unit.

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 Support

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

1- The C1CURB roof mounting frame must be installed,

flashed and sealed in accordance with the instructions provided with the frame.

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 unit 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 unit on a combustible surface for downflow discharge applications, the C1CURB 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.

Page 4

3- Top of support slab should be at least 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 weatherproofed 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.

Rigging Unit For Lifting

1- Detach wooden base protection before rigging.

2- Connect rigging to the unit base using both holes in

each corner. See figure 2.

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.

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

RETURN AIR

OPENING

SUPPLY AIR

OPENING

3- All panels must be in place for rigging.

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.)

Unit

All

*Maximum weight with all avail able installed accessories.

CAUTION: DO NOT

WALK ON UNIT.

Weight*

Lbs. Kg.

894 406

Lifting Point Should

Be Directly Above Center Of Gravity.

DOWNFLOW RETURN AIR

OPENING

DOWNFLOW SUPPLY AIR

OPENING

FIGURE 3

HORIZONTAL RETURN AIR DUCTWORK

WITH ECONOMIZER

HORIZONTAL

RETURN AIR

DUCT

UNITUNIT

FIGURE 2

INSTALL BAROMETRIC RELIEF DAMPERS

AND HOOD IN RETURN AIR DUCT

FIGURE 4

Page 5

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.

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

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 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

1- Remove the condensate drain mullion. See figure 7.

Remove the two panels on each side of the mullion.

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

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

2- Lift the front edge of the drain pan and slide pan out

of unit. See figure 9.

3- Make sure the cap over the unit bottom drain hole is

secure.

UNITS WITH HINGED PANELS

CONDENSATE

DRAIN MULLION

REMOVE

TWO

SCREWS

FIGURE 8

Page 6

REMOVE DRAIN PAN

DRAIN PAN

BOTTOM CONDENSATE DRAIN

CAUTION: Be careful not to

damage the coupling threads

when drilling the hole.

DRILL A PILOT

HOLE IN CENTER

OF COUPLING

FIGURE 9

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 and reinstall

screws.

7- Reinstall access doors.

Bottom Drain Connection

1- Remove the condensate drain mullion. See figure 7.

If the unit has hinged panels, two hinge screws must be removed in addition to the mullion screws. See figure 8.

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.

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.

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.

After drilling the pilot

hole, drill a 7/8” hole from

the inside of the pan.

FIGURE 10

9- Use a field-provided 1” plug to seal side drain

connection.

10- Replace the condensate drain mullion and reinstall

screws.

11- Reinstall access doors.

Connect Gas Piping

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 4.5” w.c. (1.12kPa) 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 11 for gas supply piping entering outside the unit. Figure 12 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

TO GAS SUPPLY

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

GAS PIPING

SUPPORT

MANUAL MAIN

SHUT-OFF VALVE

DRIP LEG

(REFER TO

LOCAL CODES)

FIGURE 11

BOTTOM ENTRY GAS PIPING COMPLETED

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

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.

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

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 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.

Page 8

Electrical Connections

POWER SUPPLY

Do not apply power or close disconnect switch until installation is complete. Refer to start-up directions.

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). insulated terminal cover 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

and connect to the top of K1 compressor contactor or factory-installed disconnect or circuit breaker. Secure power wiring with factory-installed wire ties provided in control box. See unit wiring diagram.

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 (1524 mm) 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

IMPORTANT - Unless field thermostat wires are rated for maximum unit voltage, they must be routed away from line voltage wiring.

B-Control Wiring

1- Route thermostat cable or wires from subbase to

unit 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 front of the control 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 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 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.

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.

Page 9

Blower Operation and Adjustments

KD 024 units are equipped with multi-tap ECM, direct drive blowers only.

KD 036, 048 and 060 units are equipped with either multi-tap ECM, direct drive or two-stage belt drive blowers.

The blower will operate at high speed with Y2 thermostat demand and low speed with a Y1 thermostat demand. Low speed operation delivers approximately 2/3 of 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.

Belt Drive Blowers

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.

Direct Drive Blowers

1- Loosen the reusable wire tie which secures the

controls and high voltage blower wiring to the blower housing.

2- Remove and retain screws in front and on either side

of blower housing. 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 in front and on either side of

the blower housing.

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.

1- Loosen the reusable wire tie which secures the

blower wiring to the blower motor mounting plate.

LOCATION OF STATIC PRESSURE READINGS

INSTALLATIONS WITH DUCTWORK

ROOFTOP UNIT

RETURN AIR

READING LOCATION

SUPPLY

MAIN

DUCT RUN

RE

TURN

FIRST BRANCH

OFF OF MAIN RUN

SUPPLY AIR

READING

LOCATION

FIGURE 15

SUPPLY AIR

Page 10

3- Use figure 16 to determine the factory-set blower

speed.

INSTALLATIONS WITH CEILING DIFFUSERS

ROOFTOP UNIT

RETURN AIR

READING

RE

TURN

LOCATION

READING

SUPPLY

DIFFUSER

LOCATION

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 16.

BLOWER SPEED FACTORY SETTINGS

Gray

Pink

Green/Yellow

Yellow

Common

GND

High

Green

White

Brown

4- 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 18. Do not exceed minimum and maximum number of pulley turns as shown in table 2.

TABLE 2

MINIMUM AND MAXIMUM PULLEY ADJUSTMENT

Belt

A Section 0 5

*No minimum number of turns open when B belt is used on pulleys 6” O.D. or larger.

Minimum

Turns Open

Maximum

Turns Open

D-Blower Belt Adjustment

FIGURE 16

C-Determining Unit CFM - Belt Drive Blowers

IMPORTANT - Direct drive multi-tap ECM blower unit CFM is determined by the blower motor speed tap. Refer to the Direct Drive Variable Speed Start-Up section.

1- The following measurements must be made with a

dry indoor coil. Run blower without a cooling demand. Measure the indoor blower shaft RPM. Air filters must be in place when measurements are taken.

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.

Note - Static pressure readings can vary if not taken where shown.

3- Referring to pages 17 to 22, use static pressure and

RPM readings to determine unit CFM. Use page 23 when installing units with any of the optional accessories listed.

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 in the pulley grooves. Make sure blower and motor pulleys are aligned as shown in figure 17.

1- Loosen four bolts securing motor base to mounting

frame. See figure 18.

PULLEY ALIGNMENT

ALIGNED

MOTOR PULLEY

BELT

NOT ALIGNED

BLOWER

PULLEY

FIGURE 17

Page 11

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

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.

To loosen belt tension -

Slide blower motor upward to loosen the belt. This decreases the distance between the blower motor and the blower housing.

LOOSEN ALLEN

SCREW TO

ADJUST CFM

LOOSEN FOUR BOLTS AND

SLIDE BLOWER MOTOR

DOWNWARD TO TIGHTEN BELT

FIGURE 18

(35-48kPa). For a new 5hp belt, the deflection force should be 7-10lbs. (48-69kPa).

A force below these values indicates an undertensioned belt. A force above these values indicates an overtensioned belt.

MEASURE BELT TENSION

3- Tighten four bolts securing motor base to the

mounting frame.

E-Check Belt Tension

Overtensioning belts shortens belt and bearing life. Check belt tension as follows:

1- Measure span length X. See figure 19.

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.

3- Measure belt deflection force. For a new 2 and 3hp

belt, the deflection force should be 5.0-7.0 lbs.

FORCE

DEFLECTION 1/64” PER INCH OF SPAN

OR 1.5mm PER 100mm OF SPAN

FIGURE 19

F-Field-Furnished Blower Drives

For field-furnished blower drives, use pages to determine BHP and RPM required. Reference pages 17 to 23 to determine the drive number. Reference table 3 for drive component manufacturer's numbers.

Page 12

BLOWER DATA - DIRECT DRIVE - HIGH EFFICIENCY 2 TON

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 (economizer, wet coil, etc.) See page 23. 2 - Any eld installed accessories air resistance (electric heat, duct resistance, diffuser, etc.) See page 23.

External Static

Pressure in. w.g.

DOWNFLOW KDB024H4E

0.0 635 825 918 1121 1336

0.1 547 763 861 1071 1290

0.2 433 699 806 1031 1253

0.3 371 636 749 986 1212

0.4 280 559 677 927 1166

0.5 217 481 605 868 1120

0.6 - - - - - - 548 819 1071

0.7 - - - - - - 491 773 1029

0.8 - - - - - - 442 714 983

0.9 - - - - - - 393 653 929

1.0 - - - - - - - - - 604 879

HORIZONTAL KDB024H4E

0.0 602 815 908 1096 1302

0.1 509 750 852 1057 1263

0.2 413 689 793 1007 1227

0.3 340 625 736 964 1189

0.4 266 561 679 918 1142

0.5 220 501 620 864 1100

0.6 - - - - - - 560 809 1061

0.7

0.8 - - - - - - 444 706 964

0.9 - - - - - - 390 661 913

1.0 - - - - - - 352 612 872

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

- - - - - - 500 752 1015

Air Volume at Specic Blower Taps (cfm)

Page 13

BLOWER DATA - DIRECT DRIVE - HIGH EFFICIENCY 3 TON

BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.

External Static

Pressure in. w.g.

DOWNFLOW KDB036H4E

0.0 893 1035 1375 1600 1840

0.1 838 965 1330 1574 1780

0.2 768 895 1277 1543 1748

0.3 705 800 1253 1505 1712

0.4 645 750 1200 1473 1677

0.5 575 690 1150 1435 1638

0.6 - - - - - - 1095 1390 1608

0.7 - - - - - - 1052 1345 1577

0.8 - - - - - - 1004 1302 1528

0.9 - - - - - - 950 1260 1491

1.0 - - - - - - 900 1218 1455

HORIZONTAL KDB036H4E

0.0 900 1045 1379 1599 1810

0.1 828 970 1305 1549 1749

0.2 777 900 1264 1504 1718

0.3 702 800 1216 1479 1677

0.4 635 750 1173 1434 1649

0.5 553 685 1131 1399 1622

0.6 - - - - - - 1078 1359 1577

0.7

0.8 - - - - - - 986 1280 1509

0.9 - - - - - - 933 1236 1471

1.0 - - - - - - 885 1196 1438

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

- - - - - - 1038 1315 1544

Air Volume at Specic Blower Taps (cfm)

Page 14

BLOWER DATA - DIRECT DRIVE - HIGH EFFICIENCY 4 TON

BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.

External Static

Pressure in. w.g.

DOWNFLOW KDB048H4E

0.0 1225 1310 1561 2015 2168

0.1 1167 1254 1514 1995 2143

0.2 1112 1203 1473 1977 2126

0.3 1052 1145 1424 1942 2097

0.4 1000 1098 1387 1917 2078

0.5 939 1040 1343 1888 2049

0.6 894 996 1300 1854 2020

0.7 840 941 1250 1819 1991

0.8 780 883 1201 1787 1952

0.9 734 839 1159 1749 1914

1.0 681 784 1115 1704 1856

HORIZONTAL KDB048H4E

0.0 1185 1265 1504 1983 2120

0.1 1130 1213 1467 1957 2098

0.2 1085 1171 1432 1932 2077

0.3 1035 1125 1395 1906 2054

0.4 978 1069 1347 1870 2023

0.5 929 1023 1304 1841 1992

0.6 880 977 1267 1811 1962

0.7

0.8 764 863 1175 1740 1900

0.9 718 820 1133 1710 1869

1.0 549 712 1096 1652 1772

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

822 920 1224 1776 1931

Air Volume at Specic Blower Taps (cfm)

Page 15

BLOWER DATA - DIRECT DRIVE - HIGH EFFICIENCY 5 TON

BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.

External Static

Pressure in. w.g.

DOWNFLOW KDB060H4E

0.0 1351 1405 1801 1982 2339

0.1 1303 1359 1769 1956 2310

0.2 1254 1314 1736 1928 2281

0.3 1206 1268 1703 1900 2253

0.4 1158 1222 1669 1870 2224

0.5 1109 1177 1634 1838 2195

0.6 1061 1131 1598 1806 2166

0.7 1012 1085 1561 1772 2137

0.8 964 1040 1524 1736 2108

0.9 915 994 1486 1700 2080

1.0 867 949 1446 1662 2051

HORIZONTAL KDB60H4E

0.0 1329 1353 1728 1886 2206

0.1 1284 1320 1708 1872 2189

0.2 1239 1285 1685 1859 2174

0.3 1193 1258 1661 1832 2157

0.4 1147 1218 1636 1814 2135

0.5 1100 1178 1608 1796 2118

0.6 1052 1125 1579 1770 2102

0.7

0.8 955 1044 1516 1716 2058

0.9 906 991 1481 1689 2036

1.0 856 938 1445 1654 2020

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5

1004 1085 1548 1743 2080

Air Volume at Specic Blower Taps (cfm)

Page 16

BLOWER DATA - BELT DRIVE 3 TON

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.). 2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.).

See page 23 for blower motors and drives and wet coil and options/accessory air resistance data.

DOWNFLOW KDB036H4T

Air

Volume

cfm

700 447 0.09 517 0.12 589 0.15 663 0.17 739 0.19 815 0.20 883 0.23 938 0.25

800 465 0.10 534 0.14 605 0.17 678 0.19 753 0.21 825 0.23 890 0.25 946 0.27

900 486 0.12 554 0.16 623 0.20 695 0.22 767 0.23 836 0.25 897 0.28 953 0.30

1000 508 0.15 576 0.19 643 0.22 713 0.24 783 0.26 848 0.28 907 0.30 961 0.33

1100 533 0.18 599 0.22 665 0.25 733 0.27 800 0.28 863 0.31 919 0.34 971 0.36

1200 560 0.21 625 0.25 689

1300 591 0.24 654 0.28 716 0.31 779 0.33 841 0.35 897 0.38 948 0.41 996 0.44

1400 631 0.26 690 0.30 748 0.34 807 0.36 864 0.39 916 0.42 964 0.46 1011 0.49

1500 676 0.28 729 0.33 782 0.36 835 0.40 887 0.43 935 0.47 981 0.50 1028 0.54

Air

Volume

cfm

700 988 0.27 1039 0.29 1088 0.31 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

800 996 0.30 1047 0.32 1098 0.34 1144 0.36 1185 0.39 1224 0.42 - - - - - - - - - - - -

900 1004 0.33 1055 0.35 1106 0.37 1152 0.40

1000 1011 0.36 1062 0.38 1111 0.41 1157 0.43 1199 0.47 1238 0.50 1276 0.53 1311 0.56

1100 1020 0.39 1070 0.41 1118 0.44 1163 0.47 1206 0.51 1245 0.54 1282 0.58 1318 0.61

1200 1031 0.43 1079 0.45 1127 0.48 1171 0.52 1213 0.55 1252 0.59 1289 0.62 1324 0.66

1300 1044 0.47 1091 0.49 1137 0.53 1181 0.56 1221 0.60 1259 0.64 1296 0.68 1330 0.71

1400 1058 0.51 1105 0.54 1150 0.57 1191 0.61 1231 0.65 1268 0.69 1303 0.73 1337 0.77

1500 1074 0.56 1120 0.59 1163 0.63 1203 0.67 1241 0.71 1277 0.75 1312 0.79 1345 0.82

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

0.28 755 0.30 820 0.32 879 0.34 932 0.37 983 0.40

0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

External Static - in. w.g.

1193 0.43 1232 0.46 1269 0.49 1305 0.52

Page 17

BLOWER DATA - BELT DRIVE 3 TON

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.). 2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.).

See page 23 for blower motors and drives and wet coil and options/accessory air resistance data.

HORIZONTAL KDB036H4T

Air

Volume

cfm

700 445 0.08 516 0.11 591 0.13 670 0.15 753 0.16 820 0.19 870 0.22 918 0.24

800 463 0.09 534 0.12 608 0.14 685 0.16 766 0.18 830 0.21 878 0.24 926 0.27

900 485 0.11 554 0.14 627 0.16 703 0.18 780 0.21 841 0.23 888 0.27 935 0.30

1000 509 0.13 578 0.16 649 0.19 722 0.21 796 0.23 854 0.26 900 0.29 947 0.33

1100 537 0.16 605 0.19 674 0.21 744 0.24 813 0.26 868 0.29 913 0.33 959 0.36

1200 567 0.19 633 0.22 700

1300 599 0.22 664 0.25 729 0.28 793 0.30 853 0.33 902 0.37 945 0.41 990 0.44

1400 634 0.26 697 0.29 758 0.31 819 0.34 875 0.38 921 0.42 964 0.46 1008 0.49

1500 669 0.30 730 0.33 789 0.36 846 0.39 897 0.42 941 0.47 983 0.51 1028 0.54

Air

Volume

cfm

700 969 0.27 1021 0.29 1071 0.32 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

800 977 0.29 1030 0.32 1082 0.34 1128 0.37 1169 0.40 1205 0.42 - - - - - - - - - - - -

900 986 0.32 1039 0.35 1090 0.37 1137 0.40

1000 997 0.35 1048 0.38 1098 0.41 114 0.44 1184 0.47 1221 0.50 1255 0.53 1287 0.56

1100 1008 0.39 1059 0.41 1107 0.44 1150 0.47 1191 0.51 1228 0.54 1263 0.57 1295 0.60

1200 1022 0.43 1071 0.45 1117 0.48 1160 0.52 1200 0.55 1237 0.59 1271 0.62 1303 0.66

1300 1037 0.47 1058 0.50 1130 0.53 1171 0.57 1210 0.60 1246 0.64 1280 0.68 1312 0.71

1400 1054 0.52 1100 0.54 1144 0.58 1183 0.62 1221 0.66 1256 0.70 1290 0.73 1321 0.77

1500 1073 0.57 1117 0.60 1159 0.64 1197 0.67 1234 0.71 1268 0.75 1301 0.79 1332 0.83

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

0.24 768 0.27 833 0.30 884 0.33 928 0.37 974 0.40

0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

External Static - in. w.g.

1177 0.43 1214 0.46 1248 0.49 1280 0.51

Page 18

BLOWER DATA - BELT DRIVE 4 TON

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.). 2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.).

See page 23 for blower motors and drives and page 30 for wet coil and options/accessory air resistance data.

DOWNFLOW KDB048H4T

Air

Volume

cfm

900 466 0.10 525 0.14 586 0.17 646 0.20 729 0.20 821 0.19 899 0.20 953 0.23

1000 484 0.12 543 0.16 603 0.19 664 0.22 745 0.23 834 0.23 908 0.24 959 0.26

1100 505 0.15 563 0.18 622 0.22 682 0.25 762 0.26 847 0.26 917 0.27 966 0.30

1200 527 0.18 584 0.21 643 0.25 702 0.28 779 0.30 860 0.30 927 0.31 973 0.34

1300 550 0.21 607 0.25 664 0.29 722 0.32 797 0.33 875 0.34 937 0.35 981 0.38

1400 574 0.25 630

1500 603 0.28 659 0.32 714 0.36 770 0.39 839 0.41 907 0.42 962 0.44 1002 0.47

1600 651 0.29 703 0.33 754 0.37 806 0.41 867 0.43 927 0.45 976 0.48 1014 0.51

1700 708 0.30 754 0.34 800 0.38 846 0.42 898 0.46 949 0.49 992 0.53 1028 0.57

1800 764 0.31 804 0.36 844 0.40 884 0.45 927 0.49 970 0.54 1008 0.58 1044 0.63

1900 812 0.34 847 0.39 881 0.44 916 0.49 953 0.54 990 0.59 1025 0.64 1061 0.69

2000 857 0.42 889 0.47 920 0.52 952 0.57 986 0.62 1020 0.68 1055 0.73 1091 0.77

Air

Volume

cfm

900 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1000 996 0.31 1034 0.35 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1100 1001 0.34 1040 0.38 1083 0.42 1128 0.46 1176 0.49 - - - - - - - - - - - - - - - - - -

1200 1008 0.38 1047 0.42 1089 0.46 1133 0.49 1180 0.53 1224 0.56 1261 0.60 - - - - - -

1300 1017 0.42 1055 0.46 1097 0.50 1139 0.53 1184 0.57 1228 0.60 1264 0.63 1295 0.67

1400 1026 0.46 1065 0.50 1106 0.54 1147 0.57 1191 0.61 1233 0.64 1269 0.68 1300 0.71

1500 1038 0.51 1076 0.55 1117 0.59 1157 0.62 1199 0.65 1240 0.69 1275 0.72 1305 0.76

1600 1050 0.56 1089 0.60

1700 1065 0.61 1103 0.65 1142 0.69 1181 0.73 1221 0.76 1259 0.80 1292 0.83 1320 0.88

1800 1081 0.67 1118 0.71 1156 0.75 1194 0.79 1234 0.82 1271 0.86 1302 0.90 1330 0.94

1900 1098 0.73 1135 0.77 1172 0.81 1209 0.85 1248 0.88 1284 0.92 1314 0.97 1341 1.01

2000 1128 0.82 1164 0.86 1201 0.89 1239 0.93 1276 0.97 1310 1.01 1336 1.06 1362 1.10

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

0.29 687 0.32 744 0.35 817 0.37 890 0.38 949 0.39 991 0.42

0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60

RPM BHP RPM BHP RPM BHP

1129 0.64 1168 0.67 1209 0.71 1249 0.74 1282 0.78 1312 0.82

External Static - in. w.g.

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Page 19

BLOWER DATA - BELT DRIVE 4 TON

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.). 2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.).

See page 23 for blower motors and drives and wet coil and options/accessory air resistance data.

HORIZONTAL KDB048H4T

Air

Volume

cfm

900 464 0.10 514 0.13 576 0.15 644 0.17 728 0.18 817 0.19 893 0.21 951 0.24

1000 482 0.12 533 0.15 595 0.17 662 0.19 744 0.21 829 0.22 902 0.24 957 0.27

1100 504 0.14 556 0.17 617 0.20 683 0.22 762 0.24 843 0.25 912 0.28 965 0.31

1200 528 0.17 581 0.20 641 0.23 706 0.25 782 0.27 859 0.29 924 0.31 974 0.34

1300 556 0.21 609 0.24 669 0.26 731 0.29 804 0.31 877 0.33 938 0.35 985 0.38

1400 592 0.24 645 0.27 702

1500 641 0.26 692 0.29 746 0.33 801 0.36 862 0.38 921 0.41 970 0.44 1011 0.48

1600 696 0.28 743 0.32 792 0.35 842 0.39 894 0.42 945 0.45 988 0.49 1027 0.53

1700 750 0.31 792 0.35 836 0.39 880 0.43 924 0.47 968 0.51 1007 0.55 1043 0.59

1800 799 0.35 837 0.39 875 0.43 913 0.48 952 0.52 990 0.56 1026 0.61 1061 0.65

1900 840 0.40 873 0.45 907 0.49 941 0.54 976 0.58 1011 0.63 1045 0.67 1080 0.72

2000 883 0.48 913 0.53 944 0.57 976 0.62 1009 0.67 1043 0.71 1078 0.76 1112 0.8

Air

Volume

cfm

900 995 0.28 1034 0.31 1077 0.35 1121 0.38 - - - - - - - - - - - - - - - - - - - - - - - -

1000 999 0.31 1038 0.34 1081 0.38 1124 0.41 1168 0.44 1211 0.47 - - - - - - - - - - - -

1100 1006 0.34 1044 0.38 1086 0.41 1129 0.44 1171 0.47 1213 0.50 1253 0.53 1293 0.56

1200 1014 0.38 1052 0.42 1093 0.45 1135 0.48 1176 0.51 1217 0.54 1257 0.58 1296 0.61

1300 1023 0.42 1061 0.46 1102 0.50 1143 0.53 1184 0.56 1224 0.59 1263 0.62 1302 0.66

1400 1035 0.47 1073 0.51 1112 0.54 1153 0.57 1193 0.61 1232 0.64 1271 0.67 1309 0.71

1500 1048 0.52 1086 0.56 1125 0.59 1164 0.63 1204 0.66 1243 0.69 1280 0.73 1317 0.77

1600 1063 0.57 1100 0.61 1139 0.65

1700 1079 0.63 1116 0.67 1154 0.71 1192 0.74 1230 0.78 1267 0.81 1302 0.85 1337 0.89

1800 1097 0.69 1133 0.73 1171 0.77 1209 0.80 1246 0.84 1281 0.88 1315 0.92 1349 0.96

1900 1116 0.76 1152 0.80 1189 0.84 1226 0.87 1262 0.91 1296 0.95 1329 0.99 1361 1.03

2000 1148 0.84 1183 0.88 1220 0.92 1257 0.96 1291 1.00 1323 1.04 1354 1.08 1385 1.12

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

0.30 763 0.32 830 0.35 898 0.37 953 0.39 997 0.43

0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60

RPM BHP RPM BHP RPM BHP RPM BHP

External Static - in. w.g.

RPM BHP RPM BHP RPM BHP RPM BHP

1178 0.68 1216 0.71 1254 0.75 1291 0.79 1326 0.83

Page 20

BLOWER DATA - BELT DRIVE 5 TON

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.). 2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.).

See page 23 for blower motors and drives and wet coil and options/accessory air resistance data.

DOWNFLOW KDB060H4T

Air

Volume

cfm

1100 512 0.15 571 0.19 630 0.23 690 0.26 770 0.26 854 0.26 922 0.27 970 0.30

1200 535 0.18 593 0.22 651 0.26 710 0.30 788 0.30 868 0.30 933 0.31 978 0.34

1300 559 0.22 616 0.26 674 0.29 732 0.34 807 0.34 883 0.34 944 0.35 987 0.38

1400 584 0.26 641 0.29 698 0.33 755 0.37 827 0.37 899 0.38 956 0.40 997 0.43

1500 615 0.29 671 0.33 726 0.36 782 0.41 850 0.41 917 0.42 970 0.44 1009 0.47

1600 665 0.30 716 0.34 768

1700 723 0.31 768 0.35 814 0.39 860 0.47 910 0.47 959 0.50 1001 0.54 1037 0.58

1800 779 0.32 818 0.37 857 0.41 897 0.50 939 0.50 980 0.55 1018 0.59 1054 0.64

1900 826 0.36 859 0.41 894 0.45 928 0.56 964 0.56 1000 0.61 1036 0.66 1072 0.70

2000 857 0.42 889 0.47 920 0.52 952 0.62 986 0.62 1020 0.68 1055 0.73 1091 0.77

2100 878 0.49 909 0.54 940 0.59 973 0.70 1006 0.70 1041 0.75 1076 0.80 1112 0.85

2200 897 0.55 929 0.61 961 0.66 994 0.78 1028 0.78 1063 0.83 1099 0.89 1134 0.93

2300 918 0.62 950 0.68 983 0.74 1017 0.86 1052 0.86 1087 0.92 1122 0.97 1157 1.02

2400 941 0.70 974

Air

Volume

cfm

1100 1006 0.35 1045 0.39 1089 0.43 1134 0.46 - - - - - - - - - - - - - - - - - - - - - - - -

1200 1013 0.38 1053 0.42 1095 0.46 1139 0.50 1186 0.53 1230 0.57 1266 0.60 - - - - - -

1300 1022 0.42 1062 0.46 1104 0.50 1146 0.54 1192 0.57 1234 0.60 1269 0.64 1301 0.68

1400 1033 0.47 1072 0.51 1114 0.55 1155 0.58 1199 0.61 1240 0.65 1275 0.68 1305 0.72

1500 1045 0.52 1085 0.56 1125 0.60 1165 0.63 1208 0.66 1248 0.69 1281 0.73 1311 0.77

1600 1059 0.57 1098 0.61 1138 0.65

1700 1074 0.62 1113 0.66 1152 0.70 1190 0.74 1231 0.77 1268 0.80 1299 0.84 1328 0.89

1800 1091 0.68 1129 0.72 1167 0.76 1205 0.80 1244 0.83 1280 0.87 1310 0.91 1338 0.95

1900 1109 0.75 1146 0.79 1183 0.82 1221 0.86 1260 0.90 1294 0.94 1323 0.98 1349 1.02

2000 1128 0.82 1164 0.86 1201 0.89 1239 0.93 1276 0.97 1310 1.01 1336 1.06 1362 1.10

2100 1148 0.89 1185 0.93 1221 0.97 1258 1.01 1294 1.05 1325 1.09 1351 1.14 1376 1.19

2200 1170 0.97 1206 1.01 1242 1.05 1277 1.09 1311 1.14 1341 1.18 1365 1.23 1390 1.28

2300 1193 1.06 1228 1.09 1262 1.14 1295 1.19 1327 1.24 1355 1.29 1380 1.33 1406 1.37

2400 1216 1.15 1250 1.19

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

0.38 819 0.44 879 0.44 937 0.46 985 0.49 1022 0.52

0.77 1008 0.83 1042 0.96 1077 0.96 1111 1.01 1146 1.06 1181 1.11

0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

1282 1.24 1313 1.30 1343 1.36 1371 1.40 1396 1.44 1423 1.48

External Static - in. w.g.

1177 0.68 1218 0.71 1257 0.75 1290 0.79 1319 0.83

Page 21

BLOWER DATA - BELT DRIVE 5 TON

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.). 2 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.).

See page 23 for blower motors and drives and wet coil and options/accessory air resistance data.

HORIZONTAL KDB060H4T

Air

Volume

cfm

1100 509 0.15 562 0.18 624 0.20 691 0.22 771 0.24 852 0.25 919 0.28 970 0.31

1200 535 0.18 589 0.21 650 0.23 715 0.25 792 0.27 869 0.29 932 0.32 980 0.35

1300 564 0.21 618 0.24 678 0.27 741 0.29 815 0.31 887 0.33 946 0.36 991 0.39

1400 604 0.24 657 0.27 715 0.30 775 0.33 842 0.35 908 0.37 962 0.40 1004 0.43

1500 656 0.26 706 0.30 760 0.33 814 0.36 874 0.39 931 0.41 979 0.45 1019 0.48

1600 712 0.29 758 0.32 807

1700 766 0.32 808 0.36 850 0.40 892 0.44 936 0.47 978 0.51 1016 0.56 1052 0.60

1800 814 0.36 851 0.40 888 0.44 925 0.49 963 0.53 1000 0.57 1035 0.62 1071 0.66

1900 853 0.41 886 0.46 919 0.50 952 0.55 986 0.60 1021 0.64 1056 0.69 1091 0.73

2000 883 0.48 913 0.53 944 0.57 976 0.62 1009 0.67 1043 0.71 1078 0.76 1112 0.80

2100 906 0.56 936 0.60 967 0.65 999 0.70 1033 0.75 1067 0.79 1101 0.84 1135 0.88

2200 930 0.64 960 0.68 991 0.73 1024 0.78 1058 0.83 1092 0.88 1126 0.92 1160 0.96

2300 954 0.72 985 0.77 1017 0.82 1051 0.87 1085 0.92 1119 0.96 1152 1.00 1186 1.04

2400 981 0.81 1013

Air

Volume

cfm

1100 1010 35.00 1049 0.38 1091 0.42 1134 0.45 1176 0.78 1218 0.51 1258 0.54 1297 0.57

1200 1019 0.38 1058 0.42 1099 0.46 1141 0.49 1182 0.52 1223 0.55 1263 0.58 1302 0.61

1300 1030 0.43 1068 0.47 1108 0.50 1149 0.53 1190 0.56 1230 0.59 1270 0.63 1308 0.66

1400 1042 0.47 1080 0.51 1120 0.55 1160 0.58 1200 0.61 1240 0.65 1278 0.68 1315 0.72

1500 1056 0.53 1094 0.57 1133 0.60 1172 0.63 1212 0.67 250 0.70 1288 0.74 1324 0.77

1600 1071 0.58 1109 0.62 1147 0.66

1700 1088 0.64 1126 0.68 1164 0.72 1202 0.75 1240 0.78 1276 0.82 1311 0.86 1345 0.90

1800 1107 0.70 1143 0.74 1181 0.78 1219 0.81 1256 0.85 1290 0.89 1324 0.93 1357 0.97

1900 1126 0.77 1163 0.81 1200 0.85 1237 0.88 1273 0.92 1306 0.96 1339 1.00 1371 1.04

2000 1148 0.84 1183 0.88 1220 0.92 1257 0.96 1291 1.00 1323 1.04 1354 1.08 1385 1.12

2100 1170 0.92 1206 0.96 1242 1.00 1277 1.04 1310 1.08 1340 1.13 1370 1.17 1401 1.21

2200 1195 1.00 1230 1.04 1265 1.08 1299 1.13 1330 1.18 1359 1.23 1388 1.27 1418 1.31

2300 1220 1.08 1254 1.13 1288 1.17 1320 1.23 1350 1.28 1378 1.34 1406 1.38 1435 1.42

2400 1245 1.18 1278 1.22

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

0.36 855 0.39 906 0.43 955 0.46 997 0.50 1035 0.54

0.86 1046 0.91 1079 0.96 1113 1.00 1180 1.05 1180 1.09 1213 1.13

0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

1311 1.28 1341 1.33 1370 1.40 1397 1.45 1425 1.50 1454 1.54

External Static - in. w.g.

1186 0.69 1225 0.72 1263 0.76 1299 0.80 1334 0.83

Page 22

BLOWER DATA

BELT DRIVE KIT SPECIFICATIONS

Model

No.

036 0.75 0.86 2 low 449-673

048 0.75 0.86 2 - - - low 497-673

060 1 1.15 2 low 555-833

NOTE - Using total air volume and system static pressure requirements determine from blower performance tables rpm and motor hp required. Maximum usable hp of motors furnished are shown. In Canada, nominal motor hp is also maximum usable motor hp. If motors of comparable hp are used, be sure to keep within the service factor limitations outlined on the motor nameplate.

OPTIONS / ACCESSORIES AIR RESISTANCE - in. w.g.

Air Volume

cfm

800 0.01 0.01 0.02 0.02 0.04 0.04 0.05 1000 0.02 0.01 0.02 0.02 0.04 0.04 0.07 1200 0.02 0.01 0.02 0.02 0.04 0.04 0.07 1400 0.03 0.02 0.02 0.03 0.04 0.04 0.07 1600 0.04 0.03 0.03 0.04 0.04 0.04 0.07 1800 0.05 0.04 0.03 0.05 0.05 0.05 0.07 2000 0.06 0.05 0.04 0.06 0.05 0.05 0.08 2200 0.08 0.06 0.04 0.07 0.05 0.05 0.08 2400 0.09 0.07 0.05 0.08 0.05 0.05 0.08 2600 0.10 0.08 0.05 0.09 0.06 0.05 0.08 2800 0.11 0.09 0.06 0.10 0.06 0.05 0.08 3000 0.13 0.10 0.07 0.11 0.06 0.05 0.08

Motor HP No. of

Nominal Maximum A01 A02 A03 A05 A06 A07

Speeds

Drive Kits and RPM Range

- - - - - - - - - - - - - - -

high 673-1010

1 1.15 2 - - - - - - - - - low 598-897

- - - - - -

high 897-1346

- - - - - - - - - - - -

high 745-1117

2 2.3 2 - - - - - - - - - - - - low 714-953

- - -

high 1071-1429

high 833-1250

2 2.3 2 low 808-1032

high 1212-1548

Wet Indoor Coil Gas Heat

024 036, 048 060 Medium Input High Input MERV 8 MERV 13

Economizer

Filters

CEILING DIFFUSERS AIR RESISTANCE (in. w.g.)

Air Volume

cfm

2 Ends

Open

RTD9-65S Step–Down Diffuser FD9-65S Flush

1 Side &

All Ends & Sides Open

2 Ends Open

800 0.15 0.13 0.11 0.11 1000 0.19 0.16 0.14 0.14 1200 0.25 0.20 0.17 0.17 1400 0.33 0.26 0.20 0.20 1600 0.43 0.32 0.20 0.24 1800 0.56 0.40 0.30 0.30 2000 0.73 0.50 0.36 0.36 2200 0.95 0.63 0.44 0.44

Page 23

Diffuser

MANUFACTURER'S NUMBERS

TABLE 3

DRIVE COMPONENTS

MOTOR PULLEY BLOWER PULLEY BELTS

Drive No.

A01 1VP34 X 3/8 31K6901 AK54 X 1 100244-19 A40 100245-17

A02 1VP34 X 3/8 31K6901 AK49 X 1 100244-18 A39 100245-16

A03 1VP34 X 3/8 31K6901 AK44X 1 100244-16 A39 100245-16

A04 1VP40 X 3/8 79J0301 AK49 X 1 100244-18 A41 100245-18

A05 1VP34 X 3/8 31K6901 AK41 X 1 100244-15 A38 100245-15

A06 1VP44 X 3/8 P-8-1488 AK51 X 1 18L2201 A41 100245-18

A07 1VP50 X 3/8 53J1501 AK54 X 1 100244-19 AX43 73K8201

A08 1VP44 X 3/8 P-8-1488 AK46 X 1 100244-17 A40 100245-17

Browning No. OEM Part No. Browning No. OEM Part No. Browning No. OEM Part No.

Start-Up

IMPORTANT

If unit is equipped with a crankcase heater. Make sure heater is energized 24 hours before unit startup to prevent compressor damage as a result of slugging.

A-Start-Up

Heating

1- Set thermostat or temperature control device to

initiate a first-stage heating demand.

2- A first-stage heating demand (W1) will energize

compressors 1 and the outdoor fan.

Note - L1 reversing valve is de-energized in the heating mode.

Cooling

1- Initiate first and second stage cooling demands

according to instructions provided with thermostat. See table 4 for operation.

2- Units contain one refrigerant circuit or stage.

Note - Units are equipped with two-stage compressors.

3- Unit is charged with R-410A refrigerant. See unit

rating plate for correct amount of charge.

4- Refer to Refrigerant Charge and Check section for

proper method to check refrigerant charge.

TABLE 4

COOLING OPERATION

T'Stat

Demand

No Economizer or Outdoor Air Unsuitable

Y1 Compressor Low Speed* OD Fan Low Sp.

Y2 Compressor High Speed** OD Fan High Sp.

Unit Equipped With An Economizer

Y1 Economizer na

Economizer + Compressor

Low Speed*

Energized

OD Fan Low Sp.

*67% of full capacity **100% of full capacity

Note - The reversing valve is energized at the same time as the compressor.

Page 24

B-Three Phase 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.

1- Observe suction and discharge pressures and

blower rotation on unit start-up.

2- Suction pressure must drop, discharge pressure

must rise, and blower rotation must match rotation marking.

If pressure differential is not observed or blower rotation is not correct:

3- Disconnect all remote electrical power supplies.

4- Reverse any two field-installed wires connected to

the line side of K1 contactor. Do not reverse wires at blower contactor.

Make sure the connections are tight.

Discharge and suction pressures should operate at their normal start‐up ranges.

C-Refrigerant Charge and Check

WARNING-Do not exceed nameplate charge under any condition.

This unit is factory charged and should require no further adjustment. If the system requires additional refrigerant,

reclaim the charge,

evacuate the system, and add

required nameplate charge.

NOTE - System charging is not recommended below 60F (15C). In temperatures below 60F (15C), the charge must be weighed into the system.

If weighing facilities are not available, or to check the charge, use the following procedure:

IMPORTANT - Charge unit in standard cooling mode.

1- Make sure outdoor coil is clean. Attach gauge

manifolds and operate unit at full CFM in cooling mode with economizer disabled until system stabilizes (approximately five minutes). Make sure all outdoor air dampers are closed.

2- Compare the normal operating pressures (see table

5 through 8) to the pressures obtained from the gauges. Check unit components if there are significant differences.

3- Measure the outdoor ambient temperature and the

suction pressure. Refer to the appropriate circuit charging curve to determine a target liquid temperature.

Note - Pressures are listed for sea level applications.

4- Use the same thermometer to accurately measure the

liquid temperature (in the outdoor section).

 If measured liquid temperature is higher than the target liquid temperature, add refrigerant to the system.

 If measured liquid temperature is lower than the target liquid temperature, recover some refrigerant from the system.

5- Add or remove charge in increments. Allow the

system to stabilize each time refrigerant is added or removed.

6- Continue the process until measured liquid

temperature agrees with the target liquid temperature. Do not go below the target liquid temperature when adjusting charge. Note that suction pressure can change as charge is adjusted.

7- Example KDB024: At 95°F outdoor ambient and a

measured suction pressure of 130psig, the target liquid temperature is 102°F. For a measured liquid temperature of 112°F, add charge in increments until measured liquid temperature agrees with the target liquid temperature.

Page 25

TABLE 5

KDB024H Normal Operating Pressures

Outdoor Coil Entering Air Temperature

65 °F 75 °F 85 °F 95 °F 105 °F 115 °F

Suct

(psig)

113 217 114 254 11 7 295 119 342 121 395 124 455

120 222 125 259 123 304 128 349 130 401 133 459

141 226 143 262 142 303 145 353 148 404 154 465

154 233 162 270 167 312 170 358 171 410 175 466

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

TABLE 6

KDB036H Normal Operating Pressures

Outdoor Coil Entering Air Temperature

65 °F 75 °F 85 °F 95 °F 105 °F 115 °F

Suct

(psig)

113 230 115 268 11 7 310 119 358 121 412 121 471

121 233 123 273 125 314 128 364 130 417 130 476

142 240 142 278 144 321 146 370 149 425 151 483

157 247 163 286 165 330 168 378 170 431 173 491

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

TABLE 7

KDB048H Normal Operating Pressures

Outdoor Coil Entering Air Temperature

65 °F 75 °F 85 °F 95 °F 105 °F 115 °F

Suct

(psig)

107 234 109 272 11 0 314 112 363 116 409 11 7 462

115 242 117 279 11 9 321 121 366 123 415 123 470

129 247 134 284 137 328 140 375 143 425 144 480

134 251 145 292 154 335 159 382 162 432 164 489

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

TABLE 8

KDB060H Normal Operating Pressures

Outdoor Coil Entering Air Temperature

65 °F 75 °F 85 °F 95 °F 105 °F 115 °F

Suct

(psig)

105 236 106 274 109 317 11 2 365 115 419 11 9 474

115 243 119 280 11 9 324 122 372 124 422 129 480

135 251 137 289 139 332 142 381 146 432 148 489

152 261 157 300 160 344 163 392 166 443 170 500

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Page 26

130

120

110

100

KDB 024H Charging Curves

Outdoor Temperature (°F)

115°

105°

95°

85°

Liquid Temperature (° F)

65°

110 120 130 140 150 160 170

Suction Pressure (psig)

KDB 036H Charging Curves

Outdoor Temperature (°F)

130

120

110

100

75°

180

115°

105°

95°

Liquid Temperature (° F)

110 120 130 140 150 160 170

85°

75°

65°

180

Suction Pressure (psig)

Page 27

Liquid Temperature (° F)

130

120

110

100

KDB 048H Charging Curves

Outdoor Temperature (°F)

115°

105°

95°

85°

75°

65°

Liquid Temperature (° F)

130

120

110

100

110 120 130 140 150 160 170

Suction Pressure (psig)

KDB 060H Charging Curves

Outdoor Temperature (°F)

115°

105°

95°

85°

75°

100

110 120 130 140 150 160 170

65°

Suction Pressure (psig)

Page 28

D - Compressor Controls

See unit wiring diagram to determine which controls are used in each unit. Optional controls are identified on wiring diagrams by arrows at junction points.

1- Freezestat (S49)

Switch de-energizes compressor when indoor coil temperature falls below 29F (-2C) to prevent coil freeze-up. Switch resets when indoor coil temperature reaches 58F (15C).

2- High Pressure Switch (S4)

Auto-reset switch is located on the discharge line. Switch opens at 640 psig and closes at 475 psig. Switch is wired directly into the defrost control (CMC1), which provides a 5 strike lockout feature.

3- Defrost Switch (S6)

100269 Series Only Defrost switch closes to initiate defrost when liquid line temperature falls to 42° F (5.6°C). Defrost switch opens when liquid line temperature reaches 70°F (21°C) to terminate defrost. If the liquid line temperature does not rise above 70°F (21°C), the CMC1 will terminate defrost after 14 minutes. The defrost switch is located on the liquid line between the outdoor expansion valve and the distributor

a defrost cycle begins and operates for 14 minutes. The defrost switch can terminate the defrost cycle before the 14 minutes elapses if liquid line temperature reaches 70°F (21°C).

Note - The defrost control will not energize a defrost cycle unless the unit has been operating in heating mode for an accumulated 90 minutes (default) on 100269 series boards. The run time interval can be changed by moving the jumper on the CMC board timing pins. See figure 20. The defrost interval can be adjusted to 30, 60, or 90 minutes. If the timing selector jumper is not in place, the control defaults to a 90-minute defrost interval.

DEFROST CONTROL BOARD CMC1

TIMING JUMPER:

100269 SERIES: 90 MINUTES

DIAGNOSTIC

LEDS

4- Ambient and Coil Temperature Sensors (RT13, RT21)

100135 Series Only

Both sensors provide input to the defrost control which cycles defrost. The ambient sensor is located on the inside of the corner mullion on the back of the outdoor coil section. The coil sensor is located on a return bend on the front of the outdoor coil.

5- Defrost Controls (CMC1)

Gas heat is energized during defrost to maintain discharge air temperature.

100269 Series Time/Temperature

When the liquid line temperature drops below 42°F (5.6°C), the defrost switch closes and signals the defrost control that a defrost cycle is needed. If the defrost switch is still closed after 90 minutes (default),

100269 SERIES:REMOVED

AT THE FACTORY TO DIS

ABLE COMPRESSOR DELAY

FIGURE 20

Page 29

DEFROST CONTROL BOARD CMC1

DEFROST TEMPERATURE

TERMINATION JUMPER:

100135-06: 50

5F(105C)

DIAGNOSTIC

LEDS

Defrost Control Board

The defrost control ensures that the heat pump outdoor coil does not ice excessively during the heating mode. The defrost control uses input from a defrost switch on 100269 series defrost control boards. The defrost control uses input from a coil and an ambient temperature sensor on 100135 series defrost control boards.

Defrost Test Option

COIL AND AMBI

ENT SENSOR

CONNECTIONS

DELAY PINS

REVERSING

VALV E

PRESSURE

SWITCH CIRCUIT

CONNECTIONS

24V TERMINAL

STRIP

CONNECTIONS

FIGURE 21

5- Defrost Controls (CMC1) - Continued

100135 Series Demand Defrost Control

After 34 minutes of heating mode operation, if the difference between the ambient temperature (RT13) and the coil temperature (RT21) is higher than the maximum difference allowed by the control, the defrost control will initiate defrost. The defrost control will also initiate defrost after 6 hours of heating mode operation when coil temperatures remain below 35°F (2°C). The defrost cycle ends when the coil temperature is higher than the termination temperature (50°F default) or after 14 minutes of operation. If the defrost is terminated by the 14-minute timer, another defrost cycle will be initiated after 34 minutes of run time.

Note - The defrost termination temperature can be adjusted to 50, 70, 90 or 1005F. The jumper termination pin is factory-set at 505F (105 C). If the temperature jumper is not installed, the default termination temperature is 905F (325C). See figure 21.

A TEST option is provided for troubleshooting. The TEST mode may be started any time the unit is in the heating mode and the defrost thermostat is closed or jumpered. If the timing jumper is in the TEST position at power‐up, the defrost control will ignore the test pins. When the jumper is placed across the TEST pins for two seconds, the control will enter the defrost mode. If the jumper is removed before an additional 5-second period has elapsed (7 seconds total), the unit will remain in defrost mode until the defrost pressure switch opens or 14 minutes have passed. If the jumper is not removed until after the additional 5-second period has elapsed, the defrost will terminate and the test option will not function again until the jumper is removed and re-applied.

Diagnostic LEDs

The defrost board uses two LEDs for diagnostics. The LEDs flash a sequence according to the condition.

TABLE 9

Defrost Control Board Diagnostic LED

Mode

No power to control OFF OFF

Normal operation / power to control

Anti‐short cycle lockout

Low pressure switch, freezestat fault

Low pressure switch, freezestat lockout

High pressure switch fault

High pressure switch lockout

*Ambient sensor fault Simultaneous FAST flash

*Coil sensor fault Alternating FAST flash

Green LED

(DS2)

Simultaneous Slow FLASH

Alternating Slow FLASH

OFF Slow FLASH

OFF ON

Slow FLASH OFF

ON OFF

Red LED (DS1)

*100135-06 board only

Page 30

Gas Heat Start-Up

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING

Electric shock hazard. Can cause injury or death. Do not use this unit if any part has been under water. Immediately call a qualified service technician to inspect the unit and to replace any part of the control system and any gas control which has been under water.

This unit is equipped with an automatic spark ignition system. There is no pilot. In case of a safety shutdown, move thermostat switch to OFF and return the thermostat switch to HEAT to reset ignition control.

A-Placing Unit In Operation

WARNING

Danger of explosion and fire. Can cause injury or product or property damage. You must follow these instructions exactly.

WARNING

Danger of explosion. Can cause injury or product or property damage. If over heating occurs or if gas supply fails to shut off, shut off the manual gas valve to the appliance before shutting off electrical supply.

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.

WARNING

SMOKE POTENTIAL

The heat exchanger in this unit could be a source of smoke on initial firing. Take precautions with re spect to building occupants and property. Vent ini tial supply air outside when possible.

Gas Valve Operation for Honeywell VR8215S or White Rodgers 36J54 (figure 22 and 23)

1- Set outdoor thermostat setpoint above the outdoor

ambient temperature to disable heat pump operation.

2- Set thermostat to lowest setting.

3- Turn off all electrical power to appliance.

4- This appliance is equipped with an ignition device

which automatically lights the burner. Do not try to light the burner by hand.

5- Open or remove the control section access panel.

6- Move gas valve switch to OFF. See figure 22 or 23.

7- Wait five (5) minutes to clear out any gas. If you then

smell gas, STOP! Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you do not smell gas, go to the next step.

8- Move gas valve switch to ON. See figure 22 or 23.

9- Close or replace the control section access panel.

10- Turn on all electrical power to appliance.

11- Set thermostat to desired setting.

NOTE - When unit is initially started, steps 1 through 9 may need to be repeated to purge air from gas line.

BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

Use only your hand to push in or turn the gas control knob or switch. Never use tools. If the switch will not move, or the knob will not push in or turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

WARNING

Danger of explosion. Can cause injury or death. Do not attempt to light manually. Unit has a direct spark ignition system.

Page 31

HONEYWELL VR8215S GAS VALVE

MANIFOLD

PRESSURE

ADJUSTMENT

SCREW

INLET

PRESSURE

PORT

Single-Stage

Gas valve switch shown in ON position.

FIGURE 22

MANIFOLD

PRESSURE

OUTLET

WHITE RODGERS 36J54 GAS VALVE

Two- Stage

MANIFOLD

PRESSURE TAP

INLET

PRESSURE

TAP

Gas valve switch is shown in OFF position.

HIGH FIRE

ADJUSTMENT

LOW FIRE

ADJUSTMENT

FIGURE 23

6- The ignition sequence will start. 7- If the appliance does not light the first time (gas line

not fully purged), it will attempt up to two more

ignitions before locking out. 8- If lockout occurs, repeat steps 1 through 10. 9- If the appliance will not operate, follow the

instructions “Turning Off Gas to Appliance” and call

your service technician or gas supplier.

Turning Off Gas to Unit

1- If using an electromechanical thermostat, set to the

lowest setting. 2- Before performing any service, turn off all electrical

power to the appliance. 3- Open or remove the control section access panel. 4- Move gas valve switch to OFF. 5- Close or replace the control section access panel.

WARNING

12- Spark ignitor energizes and gas valve solenoid opens.

13- Spark ignites gas, ignition sensor proves the flame

and combustion continues.

14- If flame is not detected after first ignition trial, ignition

control will repeat steps 3 and 4 two more times before locking out the gas valve.

15- For troubleshooting purposes, an ignition attempt

after lock out may be re-established manually. Move thermostat to “OFF” and return thermostat switch to “HEAT” position.

B-Ignition Control Diagnostic LED's

TABLE 10

IGNITION CONTROL HEARTBEAT LED STATUS

LED

Flashes

Indicates

Slow Normal operation. No call for heat.

Fast Normal operation. Call for heat.

Steady Off

Internal control fault OR no power to control OR Gas Valve Relay Fault.

Steady On Control internal failure.

2 Lockout. Failed to detect or sustain flame.

Prove switch open or closed or rollout switch open.

Limit switch is open and/or limit has opened three times.

Flame sensed but gas valve solenoid not energized.

C-Limit Controls

Limit controls are factory-set and are not adjustable. The primary limit is located to the right of the combustion air inducer. See figure 28.

Danger of explosion. Can cause injury or death. Do not attempt to light manually. Unit has a direct spark ignition system.

Heating Operation and Adjustments

A-Heating Sequence of Operation

1- Set outdoor thermostat setpoint above the outdoor

ambient temperature to disable heat pump operation. 2- On a heating demand the combustion air inducer

starts immediately. 3- Combustion air pressure switch proves inducer

operation. After a 30-second pre-purge, power is

allowed to ignition control. Switch is factory set and

requires no adjustment.

If the primary limit trips three times in the same heating cycle, heating operation will de-energize. Heating will automatically restart after one hour if a heating demand is present. To initiate heating during the one hour timed-off interval, reset the thermostat.

D-Heating Adjustment

Main burners are factory-set and do not require adjustment.

The following manifold pressures are listed on the gas valve.

Natural Gas Units - Low Fire - 2.0” w.c. Natural Gas Units - High Fire - 3.5” w.c. LP Gas Units - Low Fire - 5.9” w.c. LP Gas Units - High Fire - 10.5” w.c.

Page 32

Service

The unit should be inspected once a year by a qualified service technician.

CAUTION

Label all wires prior to disconnection when servic ing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

A-Lubrication

All motors are lubricated at the factory. No further lubrication is required.

B-Filters

Units are equipped with four filters. See table 11. Filters should be checked monthly and replaced when necessary with filters of like kind and size. Take note of air flow direction marking on filter frame when reinstalling filters. See figure 24.

TABLE 11

UNIT FILTERS

Unit Qty Filter Size - in. (mm)

KDB024, 036 4 16 X 20 X 2 (406 X 508 X 51)

KDB048, 060 4 20 X 20 X 2 (508 X 508 X 51)

NOTE-Filters must be U.L.C. certified or equivalent for use in Canada.

REMOVE FILTERS

PULL TO REMOVE

FILTERS

FIGURE 24

E-Indoor Coil

Inspect and clean coil at beginning of each cooling and heating season. Clean using mild detergent or commercial coil cleanser. Flush coil and condensate drain with water taking care not to get insulation, filters and return air ducts wet.

F-Outdoor Coil

C-Supply Air Blower Wheel

Annually inspect supply air blower wheel for accumulated dirt or dust. Turn off power before attempting to remove access panel or to clean blower wheel.

D-Filter Drier

The unit is equipped with a bi-flow filter drier. if replacement is necessary, order another of like design.

CLEAN FIN/TUBE CONDENSER COIL

TOP VIEW

SUPPLY

AIR

BLOWER

CONDENSER ACCESS PANEL

ENDPLATE IS SECURED TO MULLION

CONDENSER

COILS

Clean condenser coil annually with detergent or commercial coil cleaner and inspect monthly during the cooling season.

Condenser coils are made of two formed slabs. Dirt and debris may become trapped between the slabs. To clean between slabs, carefully separate coil slabs and wash them thoroughly. See figure 25. Flush coils with water following cleaning.

1- Remove unit top panel and condenser section access

panel.

2- Remove screws securing coil end plate to mullion.

3- Remove wire ties connecting coil slabs and separate

slabs 3-4” (76-102mm).

4- Clean coils with detergent or commercial coil cleaner.

5- Rinse thoroughly with water and reassemble

6- Secure coil slabs together using field-provided wire

ties.

FIGURE 25

Page 33

WARNING

This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm.

G-Burners

Periodically examine burner flames for proper appearance during the heating season. Before each heating season examine the burners for any deposits or blockage which may have occurred.

Clean burners as follows:

1- Turn off both electrical power and gas supply to unit.

IGNITOR

SPARK GAP

SHOULD BE 1/8”

(3mm)

FIGURE 27

WARNING

2- Remove blower access panel.

3- Remove top burner box panel and screws securing

burners to burner support and lift the individual

burners or the entire burner assembly from the

orifices. See figure 26. Clean as necessary.

4- Locate the ignitor under the right burners. Check

ignitor spark gap with appropriately sized twist drills

or feeler gauges. See figure 27.

5- Replace burners and screws securing burner. See

figure 26.

6- Replace access panel.

BURNER BOX ASSEMBLY

FLAME

SENSOR

Danger of explosion. Can cause injury or death. Do not overtighten main burner mounting screws. Snug tighten only.

7- Restore electrical power and gas supply. Follow

lighting instructions attached to unit and use inspection port in access panel to check flame.

H-Combustion Air Inducer

A combustion air proving switch checks combustion air inducer operation before allowing power to the gas controller. Gas controller will not operate if inducer is obstructed.

Under normal operating conditions, the combustion air inducer wheel should be checked and cleaned prior to the heating season. However, it should be examined periodically during the heating season to establish an ideal cleaning schedule. With power supply disconnected, the condition of the inducer wheel can be determined by looking through the vent opening.

Clean combustion air inducer as follows:

1- Shut off power supply and gas to unit.

BURNER

ASSEMBLY

GAS MANIFOLD

IGNITOR

FIGURE 26

GAS VALVE

2- Disconnect pressure switch air tubing from

combustion air inducer port.

3- Remove the mullion on the right side of the heat

section.

4- Remove and retain screws securing combustion

air inducer to flue box. Remove vent connector. See figure 28.

5- Clean inducer wheel blades with a small brush and

wipe off any dust from housing. Clean accumulated dust from front of flue box cover.

6- Replace the mullion on the right side of the heat

section.

Page 34

HEAT EXCHANGER ASSEMBLY

HEAT

EXCHANGER

TUBE

16- Return combustion air inducer motor and vent

connector to original location and secure with retained screws. It is recommended that the combustion air inducer gasket be replaced during reassembly.

COMBUSTION

AIR INDUCER

BURNER

ROLLOUT

SWITCH

PRIMARY

LIMIT

FIGURE 28

VENT

CONNECTOR

FLUE BOX

COVER

GAS VALVE

17- Clean combustion air inlet louvers on heat access

panel using a small brush.

18- Replace mullion.

J-Flue Passageway and Flue Box

1- Remove combustion air inducer assembly as

described in section J.

2- Remove flue box cover. Clean with a wire brush as

required.

3- Clean tubes with a wire brush.

4- Reassemble the unit. The flue box cover gasket and

combustion air inducer gasket should also be replaced during reassembly.

Page 35

Lennox KDB024, KDB048, KDB036, KDB060 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual