Page 1
506393−01
*P506393-01*
11/10
*2P1110*
2010
Litho U.S.A.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
personal injury or loss of life. Installation and service must be performed by a qualified installer, service agency or the gas supplier
CAUTION
Danger of sharp metallic edges. Can cause injury.
Take care when servicing unit to avoid accidental
contact with sharp edges.
INSTALLATION
INSTRUCTIONS
KHA180 (15-TON)
KHA240 (20-TON)
HEAT PUMP UNITS
506393−01
11/2010
Supersedes 10/2010
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Table Of Contents
Dimensions Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Arrangement Page 3. . . . . . . . . . . . . . . . . . . . .
Shipping And Packing List Page 3. . . . . . . . . . . . . . .
General Page 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements Page 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Support Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Connection Page 5. . . . . . . . . . . . . . . . . . . . . . .
Rigging Unit For Lifting Page 5. . . . . . . . . . . . . . . . . .
Condensate Drains Page 5. . . . . . . . . . . . . . . . . . . . .
Electrical Connections Page 6. . . . . . . . . . . . . . . . . .
Unit Power−Up Page 7. . . . . . . . . . . . . . . . . . . . . . . . .
Blower Operation and Adjustment Page 8. . . . . . . .
Cooling Start−Up Page 12. . . . . . . . . . . . . . . . . . . . . . .
Defrost Control Board Page 14. . . . . . . . . . . . . . . . . . .
Heating Start−Up Page 15. . . . . . . . . . . . . . . . . . . . . . .
Service Page 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 2
Page 2
506393−01 11/2010
KHA180 & 240 Dimensions
BOTTOM POWER ENTRY
127 X 203 mm (5 X 8 in.)
BOTTOM SUPPL
Y
AIR OPENING S
BOTTOM RETURN
AIR OPENIN G
4−1/4
(108)
28
4 (102)
102
(4)
12−3/8
(314)
20 (508)
15 (381)
60−1/2 (1537)
AA BB
CC
DD
CENTER OF
GRAVITY
EE
FF
TOP VIEW
(711)
28
(711)
12−3/8
(314)
3−1/4
(83)
54−1/4
(1378)
51
(1295)
90−1/8
(2289)
29−1/4
(743)
91−1/8 (2315)
BASE
CONDENSA
TE
DRAIN
5−3/8
(137)
SIDE
ELECTRICAL
INLETS
END VIEW SIDE VIEW
129−1/2 (3289)
BASE
128−1/2
(3264)
LIFTING HOLES
(For Rigging
Front and Back)
1/2
(13)
FORKLIFT SLOTS
(Front and Left Sides Only)
(11
4)
4−1/2
20 (508)
ALTERNATE (THRU THE BASE)
CONDENSA
TE DRAIN LOCATION
1−5/8 in. (41 mm) Diameter
18 (457)
28−3/8
(721)
5−5/8 (143)
91−1/8 (2315)
BASE
129−1/2 (3289)
BASE
54−1/4
(1378)
Page 3
Page 3
KHA180, 240
KHA180 & 240 Parts Arrangement
INDOOR COIL
OUTDOOR
FANS
OUTDOOR
COIL
CONDENSATE
DRAIN
FILTERS
(SIX − 24 X 24 X 2")
ECONOMIZER
(OPTIONAL)
ELECTRIC HEAT
(OPTIONAL)
COMPRESSORS
BLOWERS
FILTER
DRIERS
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.
Availability of units and options varies by brand.
Requirements
The KHA unit is ETL certified for outdoor installations only
at the clearances to combustible materials listed on unit
nameplate and in figure 1.
Installation of KHA 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.
The National Electric Code (ANSI/NFPA No. 70−1984) is
available from:
National Fire Protection Association
470 Atlantic Avenue
Boston, MA 02210
UNIT CLEARANCES
C
D
B
A
Outdoor
Air Hood
FIGURE 1
1
Unit
Clearance
A
in.(mm)Bin.(mm)Cin.(mm)Din.(mm)
To p
Clearance
Service
Clearance
45
(1143)36(914)36(914)66(1676)
Unob-
structed
Minimum Opera-
tion Clearance45(1143)36(914)36(914)41(1041)
Unob-
structed
Note − Entire perimeter of unit base requires support when elevated above
mounting surface.
1
Service Clearance − Required for removal of serviceable parts.
Minimum Operation Clearance − Required clearance for proper unit operation.
Page 4
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506393−01 11/2010
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.
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 KHA unit is ETL/CSA certified as a heat pump with
cooling and with or without auxiliary electric 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.
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.
IMPORTANT
The Clean Air Act of 1990 bans the intentional venting 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 incarceration may be levied for non−compliance.
Unit Support
NOTE − Securely fasten roof frame to roof per local codes.
A−Downflow Discharge Application
Roof Mounting with LARMF18/36
1− The LARMF18/36 roof mounting frame must be
installed, flashed and sealed in accordance with the
instructions provided with the frame.
2− The LARMF18/36 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 KHA unit; supply and return plenums
must be installed before setting the unit.
4− Trim and discard any pieces of exposed insulation which
extend past the edges of the roof mounting frame.
Installer’s Roof Mounting Frame
Many types of roof frames can be used to install the KHA
unit, depending upon different roof structures. Items to
keep in mind when using the building frame or supports
are:
1− The KHA 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 KHA 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 an KHA unit on a combustible
surface for downflow discharge applications, the
LARMF18/36 roof mounting frame is required.
Page 5
Page 5
KHA180, 240
B−Horizontal Discharge Applications
1− Units installed in horizontal airflow applications must
use an LARMFH18/36 horizontal roof mounting
frame. The supply air duct connects to the horizontal
supply air opening on the LARMFH18/36. The return
air duct connects to the unit horizontal return air
opening. Refer to unit dimensions.
2− Specified installation clearances must be maintained
when installing KHA units. Refer to figure 1.
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.
In downflow applications, do not drill or punch
holes in base of unit. Leaking in roof may occur if
unit base is punctured.
CAUTION
!
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.
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 top of unit.)
Condensate Drains
Remove plug and make drain connection to the 1" N.P.T.
drain coupling provided on unit. A trap must be installed
between drain connection and an open vent for proper
condensate removal. See figure 3. It is sometimes
acceptable to drain condensate onto the roof or grade;
however, a tee should be fitted to the trap to direct
condensate downward. The condensate line must be
vented. Check local codes concerning condensate disposal.
Refer to pages 1 and 2 for condensate drain location.
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.
2350
2635
KHA180
KHA240
FIGURE 2
Lifting Point Should
Be Directly Above
Center Of Gravity.
CAUTION: DO NOT
WALK ON UNIT.
UNIT
WEIGHT*
LBS. KG.
1066
1195
*Maximum weight with all
available accessories.
FIGURE 3
UNIT
Minimum Pitch
1" (25 mm) per 10’
(3 m) of line
MOUNTING
FRAME
CONDENSATE DRAIN CONNECTION
OPEN VENT
CAULK AROUND
CONDENSATE
COUPLING
Page 6
Page 6
506393−01 11/2010
Electrical Connections
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.
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− Units are factory−wired for 240/460/575 volt supply.
For 208V supply,
remove the 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 L1, L2, and L3 on TB2 in incoming
power enclosure. 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 (1524mm)
above the floor in an area with good air circulation at
average temperature. Avoid locating the room
thermostat where it might be affected by:
−drafts or dead spots behind doors and in corners
−hot or cold air from ducts
−radiant heat from sun or appliances
−concealed pipes and chimneys
B−Control Wiring
1− Route thermostat cable or wires from subbase to
unit TB1 in 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 in control area
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 as shown
in figure 4 for electro−mechanical and electronic
thermostats. If using other temperature control
devices or energy management systems see
instructions and wiring diagram provided by
manufacturer.
IMPORTANT−Terminal connections at the subbase and
TB1 must be made securely. Loose control wire
connections may allow unit to operate but not with proper
response to room demand.
24 VOLT FIELD WIRING WITH ELECTRONIC AND
ELECTRO−MECHANICAL THERMOSTATS
NOT ALL TERMINALS
ARE FOUND ON ALL
THERMOSTATS
Note − On electro−mechanical thermostats set anticipator at 0.1 amps.
Remove jumper between TB1−R
and TB1−OC when a night setback thermostat is installed.
A2 THERMOSTAT
TB1
FIGURE 4
Page 7
Page 7
KHA180, 240
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 disconnect switch. 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− Apply power to unit.
Page 8
Page 8
506393−01 11/2010
Blower Operation And Adjustments
A−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 TB2. Do not reverse wires at blower
contactor.
5− Make sure the connections are tight.
Discharge and suction pressures should operate at
their normal start-up ranges.
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− Set thermostat or temperature control device fan
switch to AUTO or ON. With fan switch in ON position,
blower will operate continuously. With fan switch in
AUTO position, the blower will cycle with demand.
2− Blower and entire unit will be off when thermostat or
temperature control device system switch is in OFF
position.
C−Blower Access
The blower assembly is secured to a sliding base which
allows the entire assembly to be pulled out of the unit. See
figure 5.
1− Remove the clamp which secures the blower wiring
to the blower motor base.
2− Remove and retain screws on either side of sliding
base. Pull base toward outside of unit. When pulling
the base out further than 12" (305mm), disconnect
wiring to K3 blower contactor T1, T2, and T3. Pull
wiring toward blower to allow enough slack to slide
the base out further.
BLOWER ASSEMBLY
TO INCREASE BELT TENSION
1− Loosen four screws securing blower motor to
sliding base.
2− Turn adjusting screw to the left, or counter-
clockwise, to move the motor downward and
tighten the belt.
3− Tighten four screws.
TO INCREASE CFM
LOOSEN ALLEN SCREW &
TURN PULLEY CLOCKWISE
TO DECREASE CFM
TURN PULLEY
COUNTERCLOCKWISE
FIGURE 5
BLOWER
WHEEL
BLOWER
MOTOR
PULLEY
ALLEN
SCREW
BLOWER ASSEMBLY
SLIDING BASE
BELT TENSION
ADJUSTING
SCREWS
LOOSEN (4) SCREWS TO
ADJUST BELT TENSION
REMOVE SCREWS TO
SLIDE BLOWER
ASSEMBLY OUT OF UNIT
Page 9
Page 9
KHA180, 240
3− 3−Slide base back into original position when
finished servicing. Replace the clamp and blower
wiring in the previous location on the blower motor
base. Reconnect wiring to K3 if it was disconnected.
4− Replace retained screws on either side of the sliding
base.
5− Tighten two bolts on motor pulley side.
IMPORTANT − Align top edges of blower motor base and
mounting frame base parallel before tightening two bolts
on the other side of base. Motor shaft and blower shaft
must be parallel.
6− Tighten two bolts on other side of base.
D−Determining Unit CFM
1− The following measurements must be made with a
dry indoor coil and with air filters in place. Run blower
without a cooling demand. Measure the indoor
blower shaft RPM.
2− With all access panels in place, measure static
pressure external to unit (from supply to return).
3− Referring to page 10, use static pressure and RPM
readings to determine unit CFM. Use page 11 when
installing units with any of the optional accessories
listed.
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 5. Tighten Allen screw after
adjustment. Do not exceed minimum and maximum
number of pulley turns as shown in table 1.
TABLE 1
MINIMUM AND MAXIMUM PULLEY ADJUSTMENT
Belt
Minimum
Turns Open
Maximum
Turns Open
A Section No minimum 5
B Section 1* 6
*No minimum number of turns open when B belt is used on
pulleys 6" O.D. or larger.
E−Blower Belt Adjustment
Maximum life and wear can be obtained from belts only if
proper pulley alignment and belt tension are maintained.
Tension new belts after a 24−48
hour period of operation.
This will allow belt to stretch and seat grooves. Make sure
blower and motor pulley are aligned as shown in figure 6.
1− Loosen four screws securing blower motor to sliding
base. See figure 5.
2− To increase belt tension −
Turn belt tension adjusting screw to the left, or
counterclockwise, to tighten the belt. This increases
the distance between the blower motor and the
blower housing.
To loosen belt tension −
Turn the adjusting screw to the right, or clockwise to
loosen belt tension.
FIGURE 6
PULLEY ALIGNMENT
BELT
BLOWER
PULLEY
MOTOR
PULLEY
NOT ALIGNED
ALIGNED
F−Check Belt Tension
Overtensioning belts shortens belt and bearing life.
Check belt tension as follows:
1− Measure span length X. See figure 7.
MEASURE BELT TENSION
FIGURE 7
DEFLECTION 1/64" PER INCH OF SPAN
OR 1.5mm PER 100mm OF SPAN
FORCE
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 used belt, the
deflection force should be 5 lbs. (35kPa) . A new belt
deflection force should be 7 lbs. (48kPa).
A force below these values indicates and
undertensioned belt. A force above these values
indicates an overtensioned belt.
G−Field−Furnished Blower Drives
For field−furnished blower drives, use pages 10 and 11 to
determine BHP and RPM required. Reference page 10 to
determine the drive number and table 2 to determine the
manufacturer’s model number.
Page 10
BLOWER DATA
BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL & AIR FILTERS IN PLACE
FOR ALL UNITS ADD:
1 - Wet indoor coil air resistance of selected unit.
2 - Any factory installed options air resistance (heat section, economizer, etc.)
3 - Any eld installed accessories air resistance (duct resistance, diffuser, etc.)
Then determine from blower table blower motor output and drive required.
See page 11 for wet coil and option/accessory air resistance data.
MINIMUM AIR VOLUME REQUIRED FOR USE WITH OPTIONAL ELECTRIC HEAT
All units require 6000 cfm minimum air with electric heat.
Air
Volume
cfm
4750 575 1.10 660 1.45 740 1.80 810 2.15 870 2.50 930 2.85 985 3.20 1040 3.55 1085 3.90 1135 4.25 1180 4.65 1225 5.00
5000 585 1.25 670 1.60 750 1.95 815 2.30 880 2.70 940 3.05 995 3.40 1045 3.80 1095 4.15 1140 4.50 1185 4.90 1230 5.30
5250 595 1.35 680 1.70 755 2.10 825 2.50 890 2.90 945 3.25 1000 3.65 1050 4.00 1100 4.40 1150 4.80 1195 5.20 1235 5.60
5500 605 1.45
5750 615 1.60 700 2.00 775 2.45 840 2.85 905 3.25 960 3.65 1015 4.10 1065 4.50 1115 4.95 1160 5.35 1205 5.80 1250 6.25
6000 630 1.75 710 2.15 785 2.60 850 3.05 910 3.45 970 3.90 1025 4.35 1075 4.80 1120 5.20 1170 5.65 1215 6.10 1255 6.55
6250 640 1.90 720 2.35 795 2.80 860 3.25 920 3.70 975 4.15 1030 4.60 1080 5.05 1130 5.50 1175 5.95 1220 6.45 1265 6.90
6500 650 2.05 730 2.50 805 3.00 870 3.45 930 3.95 985 4.40 1040 4.85 1090 5.35 1140 5.85 1185 6.30 1225 6.75 1270 7.25
6750 665 2.20 745 2.70 815 3.20 880 3.70 940 4.20 995
7000 675 2.35 755 2.90 825 3.40 890 3.95 950 4.45 1005 4.95 1055 5.40 1105 5.95 1155 6.45 1200 6.95 1240 7.45 1285 8.00
7250 690 2.60 765 3.10 835 3.65 900 4.15 955 4.65 1015 5.25 1065 5.75 1115 6.25 1160 6.75 1205 7.30 1250 7.85 1290 8.35
7500 700 2.75 775 3.30 845 3.85 910 4.45 965 4.95 1020 5.50 1075 6.05 1125 6.60 1170 7.15 1215 7.65 1260 8.25 1300 8.75
7750 715 3.00 790 3.55 855 4.10 920 4.70 975 5.25 1030 5.80 1080 6.35 1130 6.90 1180 7.50 1225 8.05 1265 8.60 1305 9.15
8000 725 3.20 800 3.80 865 4.35 930 4.95 985 5.50 1040 6.10 1090 6.70 1140 7.25 1185 7.85 1230 8.40
0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 2.20 2.40 2.60
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
690 1.85 765 2.25 835 2.65 895 3.05 955 3.45 1010 3.85 1060 4.25 1110 4.70 1155 5.10 1200 5.50 1240 5.90
TOTAL STATIC PRESSURE - In. w.g.
4.65 1045 5.10 1095 5.60 1145 6.10 1190 6.60 1235 7.10 1275 7.60
1275 9.00 1315 9.60
8250 740 3.40 810 4.00 880 4.65 940 5.25 995 5.85 1050 6.45 1100 7.05 1150 7.65 1195 8.25 1240 8.85 1280 9.40 1325 10.05
8500 750 3.65 825 4.30 890 4.90 950 5.55 1005 6.15 1060 6.80 1110 7.40 1160 8.05 1205 8.65 1250 9.25 1290 9.85 1330 10.45
8750 765 3.90 835 4.55 900 5.20 960 5.85 1015 6.45 1070 7.15 1120 7.75 1165 8.35 1215 9.05 1255 9.65 1300 10.30 1340 10.90
9000 780 4.20 850 4.85 910 5.50 970 6.15 1025 6.80 1080 7.50 1130 8.15 1175 8.75 1220 9.40 1265 10.10 1310 10.80 1350 11.40
9250 790 4.45 860 5.15 925 5.85 985 6.55 1040 7.20 1090 7.85 1140 8.55 1185 9.20 1230 9.85 1275 10.55 1315 11.20 - - - - - -
9500 805 4.75 875 5.45
9750 820 5.05 885 5.75 950 6.55 1005 7.20 1060 7.95 1110 8.65 1160 9.40 1205 10.05 1250 10.80 1295 11.50 - - - - - - - - - - - -
10,000 835 5.40 900 6.15 960 6.85 1015 7.60 1070 8.35 1120 9.05 1170 9.80 1215 10.50 1260 11.25 - - - - - - - - - - - - - - - - - -
10,250 845 5.65 910 6.45 970 7.20 1030 8.00 1080 8.75 1135 9.55 1180 10.25 1225 11.00 - - - - - - - - - - - - - - - - - - - - - - - -
10,500 860 6.00 925 6.85 985 7.65 1040 8.40 1095 9.20 1145 10.00 1190 10.70 1235 11.45 - - - - - - - - - - - - - - - - - - - - - - - -
10,750 875 6.40 940 7.25 1000 8.05 1055 8.85 1105 9.65 1155 10.45 1200
11,000 890 6.80 950 7.60 1010 8.45 1065 9.30 1115 10.05 1165 10.90 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
935 6.15 995 6.90 1050 7.60 1100 8.25 1150 8.95 1195 9.60 1240 10.30 1285 11.05 - - - - - - - - - - - -
11.20 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Page 10
Page 11
BLOWER DATA
FACTORY INSTALLED OPTIONS/FIELD INSTALLED ACCESSORY AIR RESISTANCE - in. w.g.
Air Volume
cfm
4000 .02 .04 - - - - - - .04 .06 .06
4250 .02 .04 - - - - - - .04 .06 .07
4500 .02 .05 - - - - - - .04 .07 .07
4750 .02 .05 - - - - - - .04 .07 .08
5000 .03 .05 - - - - - - .05 .07 .08
5250 .03 .06 - - - - - - .05 .07 .09
5500 .03 .07 - - - - - - .05 .07 .10
5750 .03 .07 - - - - - - .05 .08 .11
6000 .04 .08 .01 - - - .05 .08 .11
6250 .04 .08 .01 .01 .05 .08 .12
6500 .04 .09 .01 .02 .05 .08 .13
6750 .05 .10 .01 .03 .05 .08 .14
7000 .05 .10 .01 .04 .06 .08 .15
7250 .06 .11 .01 .05 .06 .09 .16
7500 .06 .12 .01 .06 .06 .09 .17
8000 .07 .13 .02 .09 .06 .09 .19
8500 .08 .15 .02 .11 .06 .09 .21
9000 .09 .16 .04 .14 .07 .10 .24
9500 .10 .18 .05 .16 .07 .10 .26
10,000 .11 .20 .06 .19 .07 .11 .29
10,500 .12 .22 .09 .22 .07 .11 .31
11,000 .14 .24 .11 .25 .08 .11 .34
Wet Indoor Coil
Electric Heat Economizer
180S 240S MERV 8 MERV 13
Filters
Horizontal Roof
Curb
Page 11
Page 12
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506393−01 11/2010
TABLE 2
MANUFACTURER’S NUMBERS
Drive
No.
H.P.
DRIVE COMPONENTS
RPM ADJUSTABLE SHEAVE FIXED SHEAVE BELTS SPLIT BUSHING
Min Max Supplier No.
OEM Part
No.
Supplier No.
OEM Part
No.
Supplier
No.
OEM Part
No.
Supplier
No.
OEM Part
No.
1 3 535 725 1VP40x7/8 79J0301 BK95X1−7/16 80K1601 BX59 59A5001 N/A N/A
2 3 710 965 1VP40x7/8 79J0301 BK72x1-7/16 100244−13 BX56 63K0501 N/A N/A
3
5
685 865 1VP50x1−1/8 P−8−1977 BK100x1-7/16 39L1301 BX61 93J9801 N/A N/A
4 5 850 1045 1VP65x1−1/8 100239−03 BK110H 100788−06 BX65 100245−08 H−1−7/16 49M6201
5 5 945 1185 1VP60x1−1/8 41C1301 BK90H 100788−04 BX61 93J9801 H−1−7/16 49M6201
6 7.5 850 1045 1VP65x1−3/8 78M7101 BK110H 100788−06 BX66 97J5901 H−1−7/16 49M6201
7 7.5, 10 945 1185 1VP60x1−3/8 78L5501 BK90H 100788−04 BX63 97J5501 H−1−7/16 49M6201
8 7.5 1045 1285 1VP65x1−3/8 78M7101 BK90H 100788−04 BX64 97J5801 H−1−7/16 49M6201
10 10 1045 1285 1VP65x1−3/8 78M7101 1B5V86 78M8301 5VX670 100245−21 B−1−7/16 100246−01
11 10 1135 1365 1VP65x1−3/8 78M7101 1B5V80 100240−05 5VX660 100245−20 B−1−7/16 100246−01
Cooling Start−Up
A−Start−Up
1− Remove coil covers before starting unit.
2− Set thermostat or temperature control device fan
switch to AUTO or ON. Set thermostat or temperature
control device to initiate a first−stage cooling demand.
A first−stage (Y1) cooling demand will energize
compressor 1 and outdoor fans 1 & 2. An increased
cooling demand (Y2) will initiate compressor 2 and
outdoor fans 3 & 4. On units with an economizer,
when outdoor air is acceptable, a first−stage
demand will energize the economizer; a
second−stage demand will energize compressor 1
and outdoor fans 1 & 2.
3− Refrigerant circuits are factory charged with R−410A
refrigerant. See unit rating plate for correct amount of
charge.
4− Units contain two refrigerant circuits or systems. See
figure 8.
B−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:
BLOWER
INDOOR COIL
BLOWER
180 & 240 REFRIGERANT CIRCUITS
FIGURE 8
COMPRESSOR 1 COMPRESSOR 2
OUTDOOR
COIL 2
COND.
FAN 1
COND.
FAN 2
COND.
FAN 4
COND.
FAN 3
OUTDOOR COIL 1
1− Attach gauge manifolds and operate unit in cooling
mode with economizer disabled until system
stabilizes (approximately five minutes). Make sure all
outdoor air dampers are closed.
2− Check each system separately with all stages
operating.
3− Use a thermometer to accurately measure the
outdoor ambient temperature.
4− Apply the outdoor temperature to table 3 or 4 to
determine normal operating pressures. Pressures
are listed for sea level applications at 80
F dry bulb
and 67
F wet bulb return air.
5− Compare the normal operating pressures to the
pressures obtained from the gauges. Minor
variations in these pressures may be expected due to
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KHA180, 240
differences in installations. Significant differences
could mean that the system is not properly charged
or that a problem exists with some component in the
system. Correct any system problems before
proceeding.
6− If discharge pressure is high, remove refrigerant from
the system. If discharge pressure is low, add
refrigerant to the system.
Add or remove charge in increments.
Allow the system to stabilize each time
refrigerant is added or removed.
7− Use the following approach method along with the
normal operating pressures to confirm readings.
TABLE 3
KHA180 NORMAL OPERATING PRESSURES
Outdoor
Coil En-
tering
Air Temp
Circuit 1 Circuit 2
Dis. +10
psig
Suc. +5
psig
Dis. +10
psig
Suc. +5
psig
65F 270 138 270 135
75F 312 139 312 135
85F 356 142 356 136
95F 403 144 404 138
105F 455 147 458 140
115F 512 147 515 145
TABLE 4
KHA240 NORMAL OPERATING PRESSURES
Outdoor
Coil En-
tering
Air Temp
Circuit 1 Circuit 2
Dis. +10
psig
Suc. +5
psig
Dis. +10
psig
Suc. +5
psig
65F 275 135 278 135
75F 315 138 318 136
85F 359 140 364 138
95F 407 142 413 140
105F 457 144 466 141
115F 517 146 527 145
C−Charge Verification − Approach Method − AHRI Testing
1− Using the same thermometer, compare liquid
temperature to outdoor ambient temperature.
Approach Temperature = Liquid temperature (at
condenser outlet) minus ambient temperature.
2− Approach temperature should match values in table
5. An approach temperature greater than value
shown indicates an undercharge. An approach
temperature less than value shown indicates an
overcharge.
3− The approach method is not valid for grossly over or
undercharged systems. Use table 3 or 4 as a guide
for typical operating pressures.
TABLE 5
APPROACH TEMPERATURES
Unit
Liquid Temp. Minus Ambient Temp.
1st Stage 2nd Stage
180 & 240
12°F + 1
(6.7°C +
0.5)
12°F + 1
(6.7°C +
0.5)
D−Compressor Controls
1− High Pressure Switches (S4, S7)
Compressor circuits are protected by a high pressure
switch which cuts out at 640 psig +
10 psig (4413 kPa
+
70 kPa).
2− Freezestats (S49, S50)
Switches de−energize compressors when indoor coil
temperature falls below 29F (−2C) to prevent coil
freeze−up. Switches reset when indoor coil
temperature reaches 58F (15C).
3− Defrost Switches (S6, S9)
Defrost switches close to initiate defrost when liquid
line temperature falls to 35F (1.7C). The defrost
switch is located on the liquid line between the
outdoor expansion valve and the distributor
4− Defrost Termination Switches (S46, S104)
Defrost pressure switches open to terminate defrost
when vapor line (discharge pressure during cooling
and defrost) pressure reaches 450 psig (3103 kPa).
5− Defrost Controls (CMC1, CMC2)
Defrost is liquid line temperature initiated and
operates for 14 minutes unless terminated by vapor
line pressure drop.
When the liquid line temperature drops below 35°F,
the defrost switch closes and signals the defrost
control that a defrost cycle is needed. If the defrost
switch is still closed after 60 minutes (default), a
defrost cycle begins and operates for 14 minutes.
The defrost pressure switch can terminate the defrost
cycle before the 14 minutes elapses if vapor line
pressure reaches 450 +
10 psi.
6− Electric heat is energized during defrost to maintain
discharge air temperature.
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506393−01 11/2010
Defrost Control Board
The defrost thermostat, defrost pressure switch and the
defrost control work together to ensure that the heat
pump outdoor coil does not ice excessively during the
heating mode.
Compressor Accumulated Run−Time Interval
The defrost control will not energize a defrost cycle unless
the unit has been operating in heating mode for an
accumulated 60 minutes (default). The run time interval
can be changed by moving the jumper on the CMC board
timing pins. See figure 9.
The defrost interval can be adjusted to 30, 60, or 90
minutes. The defrost timing jumper is factory−installed to
provide a 60−minute defrost interval. If the timing selector
jumper is not in place, the control defaults to a 90−minute
defrost interval.
Note − When adjusting timing pins, set both CMC1 and
CMC2 defrost controls to the same defrost interval.
Defrost Test Option
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 6
Defrost Control Board Diagnostic LED
Indicates LED 1 LED 2
Normal operation /
power to board
Synchronized
Flash with LED 2
Synchronized
Flash with LED 1
Board failure /
no power
Off Off
Board failure On On
Pressure switch open Flash On
DEFROST CONTROL BOARD CMC1 AND CMC2
90
test
60 30
TIMING
JUMPER
TIMING PINS
(SECONDS)
24V
TERMINAL
STRIP
DIAGNOSTIC
LEDs
FIGURE 9
Page 15
Page 15
KHA180, 240
Heating Start−Up
1− Set thermostat or temperature control device to
initiate a first−stage heating demand.
A first−stage heating demand (W1) will energize
compressors 1 and 2. All four outdoor fans are
energized with a W1 demand.
KHA Units With Optional Electric Heat −
An increased heating demand (W2) will energize
electric heat.
Service
CAUTION
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose you
to fiberglass wool. Breathing this may cause lung
cancer. (Fiberglass wool is known to the State of
California to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact
your supervisor.
P.O. Box 799900
Dallas, TX 75379−9900
The unit should be inspected once a year by a qualified
service technician.
A−Lubrication
All motors are lubricated at the factory. No further
lubrication is required.
Blower shaft bearings are prelubricated. For extended
bearing life, relubricate at least once every two years with
a lithium base grease, such as Alvania 3 (Shell Oil),
Chevron BRB2 (Standard Oil) or Regal AFB2 (Texas Oil).
Use a hand grease gun for relubrication. Add only enough
grease to purge through the bearings so that a bead of
grease appears at the seal lip contacts.
B−Filters
Units are equipped with six 24 X 24 X 2" filters. Filters
should be checked 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 10.
NOTE−Filters must be U.L.C. certified or equivalent for
use in Canada.
FIGURE 10
REMOVE FILTERS
PULL TO
REMOVE
FILTERS
C−Indoor Coil
Inspect and clean coil at beginning of each cooling and
heating season. Clean using mild detergent or
commercial coil cleaner. Flush coil and condensate drain
with water taking care not to get insulation, filters and
return air ducts wet.
D−Outdoor Coil
Clean outdoor coil annually with detergent or commercial
coil cleaner and inspect monthly during the cooling season.
Outdoor 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 11. Flush coils with water
following cleaning.
Note − Remove all screws and gaskets prior to cleaning
procedure and replace upon completion.
E−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.
Page 16
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506393−01 11/2010
TOP VIEW
OUTDOOR
COIL
FIGURE 11
1− Remove unit outdoor section top panel and outdoor
coil access panel.
2− Remove screws securing coil end plates to mullions.
3− Remove wire ties connecting coils 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.
CLEAN CONDENSER COIL
END PLATE IS
SECURED TO
MULLION
INDOOR COIL
OUTDOOR
COIL
OUTDOOR
COIL ACCESS
PANEL
END PLATE IS
SECURED TO
MULLION
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