Lennox ZHA092, ZHA120, ZHA102 Installation Instructions Manual

Litho U.S.A.

2014

INSTALLATION
INSTRUCTIONS

WARNING

Improper installation, adjustment, alteration, ser
vice or maintenance can cause property damage,
personal injury or loss of life. Installation and ser
vice must be performed by a licensed professional
HVAC installer or equivalent or service agency.

Table Of Contents

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

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

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

Safety Page 3.....................................

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

Duct Connection Page 4............................

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

Condensate Drains Page 5..........................

RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE

ZHA092
ZHA102
ZHA120

HEAT PUMP PACKAGED UNITS

507257-01
7/2014

Electrical Connections Page 6.......................

Unit Power-Up Page 6..............................

Blower Operation and Adjustments Page 7............

Heating Start-Up Page 13............................

Cooling Start-Up Page 13............................

Electric Heat Start-Up Page 17........................

Defrost Control Board Page 18........................

Service Page 19....................................

(7.5- Ton)

(8.5 -Ton)

(10 -Ton)

TB1 LOW VOLTAGE

TERMINAL STRIP

CONDENSER

FANS

TB13 HIGH VOLTAGE

TERMINAL STRIP

CONDENSER

COIL

EVAPORATOR

COIL

COMPRESSORS

F4 FUSE

BLOCK

(OPTIONAL)

TB2 TERMINAL

BLOCK (OPTIONAL)

20 x 24 x 2”

FILTERS

(BEHIND COIL)

ELECTRIC HEAT

CONTROLS

INVERTER

(OPTIONAL)

BLOWER

HOUSING

BLOWER

MOTOR

ELECTRIC HEAT

(OPTIONAL)

ZH 092, 102 & 120 DIMENSIONS

POWER ENTRY

18

(457)

BOTTOM

(See Table)

16

(406)

(356)

Holes required for Optional Bottom Power Entry Kit

BOTTOM POWER ENTRY

Threaded
Conduit Fittings
(Provided in Kit)

A
B
C

A
B

14

28-1/4

(718)

C

BASE

95-3/8
(2423)

1/2

1/2
1-1/4

39

(991)

BOTTOM RETURN

AIR OPENING

BOTTOM

SUPPLY

AIR

OPENING

15

(381)

Wire
Use

ACC.

24V

POWER

10-1/2

(267)

10-1/2

(267)

TOP VIEW

Hole Diameter

Required in

Unit Base (Max.)

7/8 (23)

7/8 (23)

1-3/4 (44)

14-1/2

(368)

39-3/8
(1000)

28-1/4

(718)

5 (127)

60-1/8
(1527)
BASE

(25)

58-1/8

93-3/8
(2372)

48-7/8
(1241)

HORIZONTAL

42-5/8

(1083)

3-3/8

(86)

14-1/2

(368)

6 (152)

1

FORKLIFT SLOTS

(BOTH SIDES)

95-3/8
(2423)

BASE

3-1/2 (89)

TYP.

LIFTING HOLES
(FOR RIGGING)

FRONT VIEW

(1476)

CONDENSATE

OUTLET

SUPPLY

30-1/4

(768)

37-3/4

(959)

60-1/8

(1527)

8-3/4
(222)

HORIZONTAL

6-7/8
(175)

RETURN

5-3/16

(132)

6 (152)

14-5/8

(371)

38-3/4

(984)

48-7/8
(1241)

END VIEW

3-3/8

(86)

POWER

ENTRY

38-5/8

(981)

26-5/8

(676)

END VIEW

Page 2

CAUTION

Danger of sharp metallic edges. Can cause injury.
Take care when servicing unit to avoid accidental
contact with sharp edges.

Shipping and Packing List

Package 1 of 1 contains:

1- Assembled unit
Check unit for shipping damage. Receiving party should
contact last carrier immediately if shipping damage is found.

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. Follow
lighting instructions attached to unit
when putting unit back into operation
and after service or maintenance.

General

These instructions are intended as a general guide
and do not supersede local codes in any way.
Authorities having jurisdiction should be consulted
before installation.

The ZH packaged rooftop units are available in 7-1/2,
8‐1/2 and 10 ton cooling capacities. Optional electric
heat is available.

Units are available with an optional supply air inverter.
During cooling, the blower will operate at lower speeds
when demand is low and increase to higher speeds
when demand is high. During a blower only demand, the
blower will operate at low speed. During a heating
demand, the blower will operate at high speed.

Availability of units and options varies by brand.

Safety

See figure 1 for unit clearances.

Use of this unit as a construction heater or air conditioner
is not recommended during any phase of construction.
Very low return air temperatures, harmful vapors and
operation of the unit with clogged or misplaced filters will
damage the unit.

UNIT CLEARANCES

OUTDOOR AIR

C

D

A

HOOD

B

FIGURE 1

1

Unit

Clearance

Service

Clearance

Minimum Opera

tion Clearance36(914)36(914)60(1524)36(914)

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.

A

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

36

(914)36(914)60(1524)36(914)

To p

Clearance

Unob

structed

Unob

structed

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.

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.

Page 3

If this unit has been used for heating or cooling of
buildings or structures under construction, the following
conditions must be met or the warranty will be void:

 A room thermostat must control the unit. The use of

fixed jumpers that will provide continuous heating or
cooling is not allowed.

 A pre-filter must be installed at the entry to the return

air duct.

 The return air duct must be provided and sealed to

the unit.

 Return air temperature range between 55°F (13°C)

and 80°F (27°C) must be maintained.

 Air filters must be replaced and pre-filters must be

removed upon construction completion.

Installer's Roof Mounting Frame

Many types of roof frames can be used to install the unit
depending upon different roof structures. Items to keep
in mind when using the building frame or supports are:

1- The base is fully enclosed and insulated, so an

enclosed frame is not required.

2- The frames or supports must be constructed with

non-combustible materials and should be square and
level to 1/16” per linear foot (5mm per linear meter)
in any direction.

3- Frame or supports must be high enough to prevent

any form of moisture from entering unit.
Recommended minimum frame height is 14”
(356mm).

 The input rate and temperature rise must be set per

the unit rating plate.

 The heat exchanger, components, duct system, air

filters and evaporator coil must be thoroughly
cleaned following final construction clean-up.

 The unit operating conditions (including airflow,

cooling operation, ignition, input rate, temperature
rise and venting) must be verified according to these
installation instructions.

Unit Support

In downflow discharge installations, install the unit on a
non-combustible surface only. Unit may be installed on
combustible surfaces when used in horizontal discharge
applications or in downflow discharge applications when
installed on an Z1CURB roof mounting frame.

NOTE - Securely fasten roof frame to roof per local codes.

A-Downflow Discharge Application

Roof Mounting with Z1CURB

4- Duct must be attached to the roof mounting frame

and not to the unit. Supply and return plenums must
be installed before setting the unit.

5- Units require support along all four sides of unit base.

Supports must be constructed of steel or suitably
treated wood materials.

NOTE-When installing a unit on a combustible surface for
downflow discharge applications, an Z1CURB roof
mounting frame is required.

B-Horizontal Discharge Applications

1- Specified installation clearances must be maintained

when installing units. Refer to figure 1.

2- Top of support slab should be approximately 4”

(102mm) above the finished grade and located so no
run-off water from higher ground can collect around
the unit.

3- Units require support along all four sides of unit base.

Supports must be constructed of steel or suitably
treated wood materials.

1- The Z1CURB roof mounting frame must be installed,

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

2- The Z1CURB 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.

Duct Connection

All exterior ducts, joints and openings in roof or building
walls must be insulated and weather-proofed with
flashing and sealing compounds in accordance with
applicable codes. Any duct passing through an
unconditioned space must be insulated.

CAUTION

In downflow applications, do not drill or punch
holes in base of unit. Leaking in roof may occur if
unit base is punctured.

Page 4

Rigging Unit For Lifting

UNIT ALIGNMENT BRACKETS

Rig unit for lifting by attaching four cables to holes in unit
base rail. See figure 2.

1- Detach wooden base protection before rigging.

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

each corner.

3- All panels must be in place for rigging.

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.)

5- All Units -

Partially lift unit and remove five (5) L-brackets which
secure the protective base board. See figure 2.

Important - Protective wooden base board
must be removed before setting unit.

6- New roof curbs (89-3/8” in length) -

Remove the three alignment brackets shown in figure 3.

7- Existing roof curbs (81-3/4” in length) -

Set unit on roof curb positioning alignment brackets
as shown in figure 3.

RIGGING - ALL UNITS

Unit

*Maximum weight with all avail
able installed accessories.

IMPORTANT - ALL

PANELS MUST BE IN

PLACE FOR RIGGING.

*Weight

Lbs. Kg.

1270ZH576

LIFTING POINT SHOULD

BE DIRECTLY ABOVE
CENTER OF GRAVITY

NEW ROOF CURBS (89-3/8” IN LENGTH):

Remove all three brackets.

EXISTING ROOF CURBS (81-3/4” LONG):

Set unit on roof curb positioning alignment brackets as shown.

THREE (3) UNIT

ALIGNMENT

BRACKETS

ROOF CURB

FIGURE 3

Condensate Drains

Make drain connection to the 1” N.P.T. drain coupling
provided on unit.

Note - The drain pan is made with a glass reinforced
engineered plastic capable of withstanding typical joint
torque but can be damaged with excessive force. Tighten
pipe nipple hand tight and turn an additional quarter turn.

A trap must be installed between drain connection and an
open vent for proper condensate removal. See figure 4. It
is sometimes acceptable to drain condensate onto the
roof or grade; however, a tee should be fitted to the trap to
direct condensate downward. The condensate line must
be vented. Check local codes concerning condensate
disposal. Refer to page 2 for condensate drain location.

Units are shipped with the drain coupling facing the right
side of the unit. The unit can be installed in either
downflow or horizontal air discharge regardless of
condensate drain location.

CAUTION - Do not

walk on unit.

REMOVE FIVE (5)

L-BRACKETS AND BASE

PROTECTION BOARD

FIGURE 2

Page 5

CONDENSATE DRAIN CONNECTION

CAULK AROUND CONDENSATE COUPLING

Minimum Pitch
1” (25 mm) per
10' (3 m) of line

OPEN VENT

FIGURE 4

UNIT

MOUNTING

FRAME

Electrical Connections

POWER SUPPLY

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

Refer to unit nameplate for minimum circuit ampacity
and maximum fuse size.

1- 230/460/575 volt units are factory wired. For 208V

supply, disconnect the pink wire (230V) at all control
power transformer(s). Reconnect the pink wire
(208V). Tape the exposed end of the 230V pink wire.

2- Route power through the bottom power entry area

and connect to L1, L2, and L3 on the bottom of
TB13 in control box. Route power to S48
disconnect switch when the option is
factory-installed. 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

control box (refer to unit dimensions to locate bottom
and side power entry).

IMPORTANT - Unless field thermostat wires are rated
for maximum unit voltage, they must be routed away
from line voltage wiring. Use wire ties located near the
lower left corner of the controls hat section to secure
thermostat cable.

Use18 AWG wire for all applications using remotely
installed electro-mechanical and electronic
thermostats.

2- Install thermostat assembly in accordance with

instructions provided with thermostat.

3- Connect thermostat wiring to TB1 terminal board on

the left side of the controls area. Wire as shown in
figure 5 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

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 5

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 6

Blower Operation and Adjustments



A-Three Scroll Compressor Voltage Phasing

Three phase scroll compressors must be phased
sequentially to ensure correct compressor and blower
rotation and operation. Compressor and blower are
wired in phase at the factory. Power wires are
color-coded as follows: line 1-red, line 2-yellow, line
3-blue.

1- Observe suction and discharge pressures and

blower rotation on unit start-up.

B-Blower Operation

Initiate blower demand at thermostat according to
instructions provided with thermostat. Unit will cycle on
thermostat demand. The following steps apply to
applications using a typical electro-mechanical
thermostat.

1- Blower operation is manually set at the thermostat

subbase fan switch. With fan switch in ON position,
blowers will operate continuously.

2- With fan switch in AUTO position, the blowers will

cycle with demand. Blowers and entire unit will be off
when system switch is in OFF position.

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

2- Suction pressure must drop, discharge pressure

must rise, and blower rotation must match rotation
marking.

3- Disconnect all remote electrical power supplies.

4- Reverse any two field-installed wires connected to

the line side of K3, TB2 or F4. Do not reverse wires
at blower contactor or compressors.

5- Make sure the connections are tight.

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

SIDE VIEW

MOTOR

ALLEN

SCREW

PULLEY

STANDARD BLOWER ASSEMBLY

BLOWER

HOUSING

C-Blower Access

The blower assembly is secured to a sliding frame which
allows the blower motor to be pulled out of the unit. See
figure 6.

1- Loosen the reusable wire tie which secures the

blower wiring to the blower motor mounting plate.

2- Remove and retain screws on either side of sliding

frame. Pull frame toward outside of unit.

3- Slide frame back into original position when finished

servicing. Reattach the blower wiring in the previous
location on the blower motor base using the wire tie.

4- Replace retained screws on either side of the sliding

frame.

TO INCREASE BELT TENSION

1- Loosen four bolts securing motor mounting base

to frame.

2- Turn adjusting bolt to the right, or clockwise, to

move the motor away from the blower housing.

IMPORTANT - Gap between end of frame and motor
mounting base should be equal at both ends, i.e. par
allel along gap.

3- Tighten four bolts securing motor mounting base

to frame.

MOTOR

MOUNTING

BASE

4- Relieve tension on two adjusting bolts.

GAP BETWEEN EDGES SHOULD

BE PARALLEL ON BOTH ENDS

BEFORE TIGHTENING MOTOR

MOUNTING BASE IN PLACE

BLOWER

FRAME

LOOSEN BEFORE

ADJUSTING BELT TENSION

(TWO EACH SIDE)

MOTOR

BELT ADJUSTING BOLTS

- TURN CLOCKWISE
TO TIGHTEN BELT

FIGURE 6

Page 7

D-Determining Unit CFM

1- The following measurements must be made with a

dry indoor coil and air filters in place.

Units Not Equipped With An Inverter -

Run blower without a cooling demand.

Units Equipped With An Inverter -

Initiate high speed blower without a cooling demand.
Disconnect high pressure switches S4 and S7. Run
the blower with Y1 and Y2 demands.

2- Measure the indoor blower shaft RPM.

3- 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 7.

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

4- Referring to page 10 or 11, use static pressure and

RPM readings to determine unit CFM. Use page 12
when installing units with any of the optional
accessories listed.

5- The blower RPM can be adjusted at the motor pulley.

Loosen Allen screw and turn adjustable pulley
clockwise to increase CFM. Turn counterclockwise to
decrease CFM. See figure 6. Do not exceed minimum
and maximum number of pulley turns as shown in
table 1.

TABLE 1

MINIMUM AND MAXIMUM PULLEY ADJUSTMENT

Belt

A Section 0 5

B Section 1* 6

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

Minimum

Turns Open

Maximum

Turns Open

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 in the pulley grooves. Make sure blower and motor
pulleys are aligned as shown in figure 8.

1- Loosen four bolts securing motor base to mounting

frame. See figure 6.

2- To increase belt tension -

Turn both adjusting bolts to the right, or clockwise, to
move the motor outward and tighten the belt. This
increases the distance between the blower motor and
the blower housing.

To loosen belt tension -

Turn the adjusting bolts to the left, or
counterclockwise to loosen belt tension.

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- Units Equipped With An Inverter -

Reconnect high pressure switches S4 and S7.

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

SUPPLY AIR

FIGURE 7

Page 8

3- Tighten two bolts on each side of the motor mounting

base. This secures the mounting base to the frame.

INSTALLATIONS WITH CEILING DIFFUSERS

ROOFTOP UNIT

RETURN AIR

READING

RE

TURN

LOCATION

READING

SUPPLY

DIFFUSER

LOCATION

MOTOR
PULLEY

PULLEY ALIGNMENT

ALIGNED

BLOWER

BELT

PULLEY

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

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

NOT ALIGNED

FIGURE 8

F-Check Belt Tension

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

1- Measure span length X. See figure 9.

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.

MEASURE BELT TENSION

FORCE

DEFLECTION 1/64” PER INCH OF SPAN

OR 1.5mm PER 100mm OF SPAN

FIGURE 9

F-Field-Furnished Blower Drives

For field-furnished blower drives, use pages 10 through
12 to determine BHP and RPM required. Reference table
2 for drive component manufacturer's numbers.

Page 9

BLOWER DATA

092S STANDARD EFFICIENCY BELT DRIVE BLOWER − BASE UNIT

BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY (NO HEAT SECTION) WITH DRY INDOOR COIL AND 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 required.

See page 12 for blower motors and drives.

See page 12 for wet coil and option/accessory air resistance data.

MINIMUM AIR VOLUME REQUIRED FOR USE WITH OPTIONAL ELECTRIC HEAT (Maximum Static Pressure - 2.0 in. w.g.)

7.5kW, 15 kW, 22.5 kW - 2065 cfm

30 kW - 2250 cfm

45 kW - 2625 cfm

Total

Air

Volume

cfm

1750 494 0.11 562 0.34 632 0.56 702 0.74 771 0.85 838 0.96 902 1.07 961 1.19 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

2000 514 0.26 581 0.49 650 0.70 719 0.87 786 0.98 852 1.09 915 1.20 972 1.32 1026 1.47 1076 1.65 - - - - - - - - - - - - - - - - - -

2250 533 0.41 599 0.62 667 0.82 735 0.99 802 1.10 866 1.21 928 1.33

2500 553 0.55 619 0.76 685 0.95 753 1.10 818 1.22 881 1.34 942 1.47 997 1.62 1048 1.80 1096 1.99 1142 2.20 1188 2.41 1237 2.64

2750 573 0.70 638 0.90 705 1.08 771 1.22 835 1.35 897 1.49 957 1.63 1011 1.80 1061 1.99 1108 2.19 1154 2.41 1200 2.63 1249 2.87

3000 594 0.85 659 1.05 725 1.22 791 1.36 853 1.50 915 1.65 973 1.81 1026 1.99 1075 2.20 1121 2.42 1167 2.64 1213 2.87 1262 3.12

3250 617 1.01 682 1.20 747 1.37 812 1.52 873 1.67 934 1.83 990 2.01 1042 2.21 1089 2.43 1135 2.66 1181 2.90 1228 3.13 1277 3.38

3500 640 1.17 706 1.36 771 1.53 834 1.70 895 1.86 954 2.03 1008

3750 665 1.34 731 1.54 796 1.72 857 1.89 917 2.07 975 2.26 1027 2.48 1076 2.72 1121 2.97 1166 3.22 1212 3.46 1261 3.71 1311 3.96

4000 692 1.54 758 1.75 822 1.93 882 2.11 940 2.30 996 2.51 1047 2.76 1094 3.02 1139 3.27 1184 3.52 1230 3.77 1280 4.03 1330 4.29

4250 722 1.76 787 1.97 849 2.15 908 2.35 965 2.56 1018 2.79 1067 3.06 1113 3.33 1157 3.59 1202 3.85 1250 4.11 1300 4.38 1352 4.65

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6

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

Total Static Pressure − in. w.g.

984 1.46 1037 1.63 1085 1.81 1132 2.01 1178 2.21 1226 2.43

2.23 1058 2.46 1105 2.69 1150 2.93 1196 3.17 1243 3.41 1293 3.65

Page 10

BLOWER DATA

102S, 120S STANDARD EFFICIENCY BELT DRIVE BLOWER − BASE UNIT

BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY (NO HEAT SECTION) WITH DRY INDOOR COIL AND 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 required.

See page 12 for blower motors and drives.

See page 12 for wet coil and option/accessory air resistance data.

MINIMUM AIR VOLUME REQUIRED FOR USE WITH OPTIONAL ELECTRIC HEAT (Maximum Static Pressure - 2.0 in. w.g.)

15 kW, 22.5 kW - 2065 cfm

30 kW - 2250 cfm

45 kW - 2625 cfm

60 kW - 3500 cfm

Total

Air

Volume

cfm

2000 542 0.43 602 0.60 664 0.75 732 0.89 802 1.02 869 1.15 927 1.27 979 1.41 1029 1.57 1079 1.75 1129 1.95 1179 2.15 1230 2.37

2250 560 0.55 619 0.71 681 0.86 748 1.00 817 1.14 882 1.27 939 1.41 991 1.57 1041 1.74 1090 1.93 1140 2.13 1190 2.35 1241 2.57

2500 579 0.68 637 0.83 699 0.98 766 1.12 834 1.26 897 1.41 953

2750 599 0.81 657 0.97 719 1.11 785 1.25 851 1.41 913 1.57 968 1.74 1020 1.93 1068 2.13 1116 2.34 1165 2.56 1215 2.78 1268 3.01

3000 620 0.95 678 1.11 741 1.25 806 1.40 870 1.58 930 1.75 985 1.94 1036 2.14 1084 2.36 1131 2.58 1180 2.80 1230 3.02 1283 3.26

3250 643 1.10 701 1.26 764 1.41 828 1.57 891 1.76 950 1.95 1003 2.16 1053 2.38 1100 2.61 1148 2.83 1196 3.06 1246 3.29 1299 3.52

3500 667 1.26 726 1.43 788 1.58 851 1.77 913 1.97 970 2.17 1023 2.41 1071 2.65 111 8 2.88 1165 3.11 1213 3.33 1264 3.57 1317 3.81

3750 693 1.44 752 1.61 813 1.78 876 1.98 936 2.20 992 2.43

4000 720 1.65 779 1.82 840 2.00 902 2.22 961 2.46 1015 2.71 1064 2.98 1111 3.24 1156 3.48 1203 3.72 1253 3.96 1305 4.22 1359 4.48

4250 748 1.86 807 2.04 868 2.24 929 2.48 986 2.75 1038 3.02 1086 3.30 1132 3.57 1177 3.81 1224 4.05 1274 4.31 1327 4.57 1382 4.85

4500 778 2.09 837 2.28 898 2.51 957 2.78 1012 3.07 1062 3.37 1108 3.65 1154 3.92 1199 4.17 1247 4.41 1297 4.67 1350 4.94 1405 5.22

4750 809 2.34 868 2.56 929 2.82 986 3.12 1038 3.43 1087 3.74 1132 4.03 1177 4.29 1223 4.54 1270 4.79 1321 5.04 1374 5.31 1428 5.58

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6

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

Total Static Pressure − in. w.g.

1.57 1005 1.74 1054 1.92 1103 2.12 1152 2.33 1202 2.55 1254 2.79

1043 2.68 1091 2.93 1137 3.17 1183 3.40 1232 3.64 1284 3.88 1338 4.13

5000 841 2.62 901 2.87 960 3.17 1015 3.50 1065 3.83 1112

5250 875 2.93 935 3.23 992 3.56 1044 3.91 1092 4.26 1138 4.57 1182 4.85 1226 5.10 1272 5.34 1320 5.57 - - - - - - - - - - - - - - - - - -

5500 9 11 3.30 969 3.63 1024 4.00 1074 4.37 1120 4.71 1165 5.02 1208 5.29 1253 5.53 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

5750 948 3.71 1004 4.08 1056 4.48 1104 4.85 1148 5.19 1192 5.49 1235 5.74 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

6000 985 4.18 1039 4.59 1088 5.00 1134 5.37 1177 5.69 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

6250 1022 4.70 1073 5.14 1120 5.54 - - - - - - - - - - - -

4.14 1157 4.43 1201 4.69 1247 4.94 1295 5.18 1345 5.42 1398 5.68 - - - - - -

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

Page 11

BLOWER DATA

FACTORY INSTALLED BELT DRIVE KIT SPECIFICATIONS

Nominal

hp

2 2.3 1 590 - 890

2 2.3 2 800 - 1105

2 2.3 3 795 - 1195

3 3.45 4 730 - 970

3 3.45 5 940 - 1200

3 3.45 6 1015 - 1300

5 5.75 10 900 - 1135

5 5.75 11 1040 - 1315

5 5.75 12 1125 - 1425

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

NOTE – Units equipped with option are limited to a motor service factor of 1.0.

POWER EXHAUST FAN PERFORMANCE

Return Air System Static Pressure Air Volume Exhausted

Maximum

Drive Kit Number RPM Range

hp

in. w.g. cfm

0 3175

0.05 2955

0.10 2685

0.15 2410

0.20 2165

0.25 1920

0.30 1420

0.35 1200

FACTORY INSTALLED OPTIONS/FIELD INSTALLED ACCESSORY AIR RESISTANCE - in. w.g.

Air

Volume

cfm

Wet Indoor Coil

092 102, 120

Electric

Heat

Economizer

MERV 8 MERV 13

1750 0.04 0.04 0.03 0.05 0.01 0.03 0.00

2000 0.05 0.05 0.03 0.06 0.01 0.03 0.00

2250 0.06 0.06 0.04 0.08 0.01 0.04 0.00

2500 0.07 0.07 0.04 0.11 0.01 0.05 0.00

2750 0.08 0.08 0.05 0.12 0.02 0.05 0.00

3000 0.10 0.09 0.06 0.13 0.02 0.06 0.02

3250 0.11 0.10 0.06 0.15 0.02 0.06 0.02

3500 0.12 0.11 0.09 0.15 0.03 0.07 0.04

3750 0.14 0.13 0.09 0.15 0.03 0.08 0.07

4000 0.15 0.14 0.09 0.19 0.04 0.08 0.09

4250 0.17 0.15 0.13 0.19 0.04 0.09 0.11

4500 0.19 0.17 0.14 0.22 0.04 0.09 0.12

4750 0.20 0.18 0.17 0.25 0.05 0.10 0.16

5000 0.22 0.20 0.20 0.29 0.06 0.10 0.18

5250 0.24 0.22 0.22

0.32 0.06 0.11 0.19

5500 0.25 0.23 0.25 0.34 0.07 0.12 0.22

5750 0.27 0.25 0.31 0.45 0.07 0.12 0.25

6000 0.29 0.27 0.33 0.52 0.08 0.13 0.27

Filters

Adaptor Plate

Return Air

Page 12

MANUFACTURER'S NUMBERS

TABLE 2

DRIVE

NO.

1 1VP34x7/8 31K6901 AK61x1 100244-20 A44 44L5501

2 1VP40x7/8 79J0301 AK59x1 31K6801 AX45 100245-23

3 1VP34x7/8 31K6901 AK46x1 100244-17 A41 100245-18

4 1VP44x7/8 P-8-1488 AK74x1 100244-21 AX48 100245-50

5 1VP50x7/8 P-8-2187 AK69x1 37L4701 AX48 100245-50

6 1VP50x7/8 P-8-2187 AK64x1 12L2501 AX46 31K7101

10 1VP50x1-1/8 P-8-1977 BK77x1 49K4001 BX50 100245-49

11 1VP50x1-1/8 P-8-1977 BK67x1 100244-24 BX46 100245-48

12 1VP50x1-1/8 P-8-1977 BK62x1 100244-23 BX46 100245-48

ADJUSTABLE SHEAVE FIXED SHEAVE BELT

BROWNING NO. OEM PART NO. BROWNING NO. OEM PART NO. BROWNING NO. OEM PART NO.

DRIVE COMPONENTS

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. Both outdoor fans are
energized with a W1 demand.

Note - L1 and L2 reversing valves are de-energized in the
heating mode.

KHA Units With Optional Electric Heat -

An increased heating demand (W2) will energize
electric heat. Electric heat is also energized during
the defrost cycle (W1) to maintain discharge air
temperature.

Cooling Start-Up

A-Operation

Supply Air Inverter Units - Refer to the Supply Air
Inverter Start-Up section.

1- Initiate first and second stage cooling demands

according to instructions provided with thermostat.

2- No Economizer Installed in Unit -

A first-stage cooling demand (Y1) will energize
compressor 1 and both condenser fans. An
increased cooling demand (Y2) will energize
compressor 2.

Units Equipped With Economizer -

When outdoor air is acceptable, a first-stage
cooling demand (Y1) will energize the economizer.
An increased cooling demand (Y2) will energize
compressor 1 and both condenser fans. When
outdoor air is not acceptable unit will operate as
though no economizer is installed.

3- Units contain two refrigerant circuits or stages. See

figure 10.

Page 13

4- Each refrigerant circuit is separately charged with

R-410A refrigerant. See unit rating plate for correct
amount of charge.

5- Refer to Cooling Operation and Adjustment section for

proper method to check refrigerant charge.

B-Refrigerant Charge and Check - Fin/Tube Coil

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:

REFRIGERANT STAGES

OUTDOOR

COIL

STAGE 1

OUTDOOR

COIL

STAGE 2

OUTDOOR
FAN 1 (B4)

1

2

OUTDOOR
FAN 2 (B5)

(BOTH FANS ARE ENERGIZED

WITH A Y1 DEMAND)

INDOOR

COIL

STAGE 2

INDOOR

COIL

STAGE 1

FIGURE 10

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- Check each system separately with all stages

operating. Compare the normal operating pressures
(see tables 3 - 5) 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.

C-Compressor Controls

1- High Pressure Switches (S4, S7)

Compressor circuits are protected by a high pressure
switch which cuts out at 640 psig +
+

70 kPa).

10 psig (4413 kPa

2- High Temperature Limit Switches (S5, S8)

Switches de-energize compressors when the
temperature on top of the compressor exceeds
248F (120C). Switches reset when temperature
cools to 169F (76C).

3- Defrost Switches (S6, S9)

Defrost switches close to initiate defrost when liquid
line temperature falls to 35F (1.7C). The defrost
switch is located on the liquid line between the
outdoor expansion valve and the distributor

4- Defrost Termination Switch (S104)

Defrost pressure switch opens to terminate defrost
when vapor (discharge pressure during cooling and
defrost) pressure reaches 450 psig (3103 kPa).

5- Defrost Controls (CMC1)

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 pressure
reaches 450 +

10 psi.

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

7- Example ZH 092S Circuit 1: At 95°F outdoor ambient

and a measured suction pressure of 130psig, the
target liquid temperature is 103°F. For a measured
liquid temperature of 106°F, add charge in
increments until measured liquid temperature agrees
with the target liquid temperature.

Page 14

TABLE 3

092S Normal Operating Pressures

Outdoor Coil Entering Air Temperature

65 F 75 F 85 F 95 F 105 F 115 F

Suct

(psig)

95 244 98 285 100 325 104 372 108 424 11 3 485

105 251 108 289 112 337 115 385 11 8 436 121 492

Circuit 1 110 253 11 8 297 126 346 128 398 136 450 135 505

113 260 122 302 130 351 137 404 144 458 143 515

119 240 124 281 128 322 131 368 135 419 138 473

Circuit 2

124 244 127 281 131 325 134 371 139 422 144 477

133 241 142 293 149 338 152 387 158 436 159 488

136 253 144 291 154 336 162 386 169 436 174 492

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

092S Charging Curves

Outdoor Temperature (°F)

130

115°

120

Circuit 1

Circuit 2

11

105°

110

95°

100

85°

90

75°

80

65°

70

95 175

105 115 125 135 145 155 165

Suction Pressure (psig)

Page 15

TABLE 4

102S Normal Operating Pressures

Outdoor Coil Entering Air Temperature

65 F 75 F 85 F 95 F 105 F 115 F

Suct

(psig)

105 250 107 287 111 330 114 375 11 6 425 120 487

113 256 11 7 296 119 337 120 383 121 430 127 491

Circuit 1 124 265 132 309 137 355 141 405 145 459 145 515

129 268 138 312 146 363 153 415 159 472 160 530

116 260 11 9 298 123 340 126 385 131 437 136 405

125 266 128 306 131 347 137 398 140 447 145 503

Circuit 2 136 271 142 313 148 359 152 409 155 462 157 519

144 271 152 321 159 370 166 421 171 477 172 534

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

102S Charging Curves

130

Circuit 1
Circuit 2

120

11

110

100

85°

90

75°

80

65°

70

100 110 120 130 140 150 170160

Suction Pressure (psig)

Outdoor Temperature (°F)

115°

105°

95°

Page 16

TABLE 5

120S Normal Operating Pressures

Outdoor Coil Entering Air Temperature

65 F 75 F 85 F 95 F 105 F 115 F

Suct

(psig)

107 257 11 0 294 11 2 338 115 384 11 9 436 121 493

Circuit 1 113 261 11 7 302 11 9 342 122 387 125 438 128 492

124 268 128 309 135 356 140 406 144 458 146 512

133 274 141 319 148 366 153 417 161 474 161 531

114 265 11 5 302 119 345 122 390 125 443 130 496

Circuit 2 121 269 125 310 127 354 131 401 134 448 137 498

132 279 140 319 145 365 148 414 152 469 155 524

137 284 147 329 155 379 163 430 171 486 171 539

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

Suct

(psig)

Disc

(psig)

120S Charging Curves

Outdoor Temperature (°F)

130

Circuit 1
Circuit 2

120

11

110

95°

100

85°

90

75°

80

65°

70

105 115 125 135 145 155 175165

Suction Pressure (psig)

115°

105°

Electric Heat Start-Up

Optional electric heat will stage on and cycle with
thermostat demand. Number of stages of electric heat will
vary depending on electric heat assembly. See electric
heat wiring diagram on unit for sequence of operation.

Page 17

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) on 100269-02 boards;
90 minutes (default) on 100269-04 boards. The run time
interval can be changed by moving the jumper on the
CMC board timing pins. See figure 11.

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.

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

Board failure /
no power

Board failure On On

Anti-short cycle
lockout

Synchronized
Flash with LED 2

Off Off

Alternating slow flash

Synchronized
Flash with LED 1

TIMING JUMPER
100269-02: 60 MINUTES
100269-04: 90 MINUTES

100269-02:INSTALLED AT

THE FACTORY TO DISABLE

COMPRESSOR DELAY

100269-04:REMOVED AT

THE FACTORY TO DISABLE

COMPRESSOR DELAY

DEFROST CONTROL BOARD CMC1

DIAGNOSTIC

LEDS

FIGURE 11

Page 18

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.

WARNING

The State of California has determined that this
product may contain or produce a chemical or
chemicals, in very low doses, which may cause se
rious illness or death. It may also cause cancer,
birth defects, or reproductive harm.

A-Filters

Units are equipped with 20 X 24 X 2” temporary filters
which must be replaced prior to building occupation.
Refer to local codes or appropriate jurisdiction for
approved filters.

To change filters, open filter access panel on back side
of unit. See figure 12. Lift filter stop to remove filters.
See figure 13.

IMPORTANT

Some scroll compressors have an internal vacu
um protector that will unload scrolls when suc
tion pressure goes below 20 psig. A hissing
sound will be heard when the compressor is run
ning unloaded. Protector will reset when low
pressure in system rises above 40 psig. DO NOT
REPLACE COMPRESSOR.

BACK OF UNIT

LIFT UP AND PULL

OUT (TOOLLESS)

FILTER ACCESS PANEL

FIGURE 12

REMOVE FILTERS

SLIDE FILTER STOP UP

TO REMOVE FILTERS

WARNING

Units are shipped from the factory with temporary
filters. Replace filters before building is occupied.
Damage to unit could result if filters are not re
placed with approved filters. Refer to appropriate
codes.

Approved filters should be checked monthly and
replaced when necessary. Take note of air flow direction
marking on filter frame when reinstalling filters. See
figure 13.

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

B-Compressor

If Interlink compressor replacement is necessary, call
1-800-4-LENNOX (1-800-453-6669).

FIGURE 13

C-Lubrication

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

Page 19

G-Indoor Coil

Inspect and clean coil at beginning of each cooling 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.

H-Outdoor Coil

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

Outdoor coils are made of single and two formed slabs.

CLEAN OUTDOOR COIL

ENDPLATE IS SECURED TO MULLION

TOP VIEW

SUPPLY

AIR

RETURN

AIR

On units with two slabs, dirt and debris may become
trapped between the slabs. To clean between slabs,
carefully separate coil slabs and wash them thoroughly.
See figure 14. Flush coils with water following cleaning.

Note - Remove all screws and gaskets prior to cleaning
procedure and replace upon completion.

J-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.

K-Filter Drier

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

1- Remove screws securing coil end plate to mullion.

2- Remove wire ties connecting coils slabs and separate

slabs 3-4” (76-102mm).

3- Clean coils with detergent or commercial coil cleaner.

4- Rinse thoroughly with water and reassemble

5- Secure coil slabs together using field-provided wire

ties.

.

OUTDOOR

COILS

FIGURE 14

Page 20