LENNOX KCA 092, KCA 102, KCA 120, KCA 150 packaged cooling unit Service Literature

KCA SERIES
Corp. 1011−L9
Service Literature
7.5 to 12.5 ton
26.3 to 42 kW
KCA092 through 150
The KCA 7.5, 8.5, 10 and 12.5 ton (092, 102, 120, 150)
packaged cooling units are available in standard cooling
efficiency. Optional auxiliary electric heat is factory or
field installed in KCA units. Electric heat operates in
single or multiple stages depending on the kW input
size. 7.5kW through 60kW heat sections are available
for the KCA heat pump.
All KCA units are designed to accept any of several different energy management thermostat control systems with
minimum field wiring. Factory or field provided control options connect to the unit with jack plugs. When "plugged
in" the controls become an integral part of the unit wiring.
CAUTION
Information contained in this manual is intended for use by
qualified service technicians only. All specifications are subject to change. Procedures outlined in this manual are presented as a recommendation only and do not supersede or
replace local or state codes.
Danger of sharp metallic edges. Can cause injury.
Take care when servicing unit to avoid accidental
contact with sharp edges.
WARNING
If the unit must be lifted for service, rig unit by attaching four
cables to the holes located in the unit base rail (two holes at
each corner). Refer to the installation instructions for the proper
rigging technique.
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
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 or service
agency.
Options / Accessories . . . . . . . . . . . . . . . . . . . . . . Page 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
Blower Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
Electrical / Electric Heat Data . . . . . . . . . . . . . . . Page 11
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect electronic
components. Take precautions during unit installation and service to protect the unit’s electronic
controls. Precautions will help to avoid control
exposure to electrostatic discharge by putting
the furnace, the control and the technician at the
same electrostatic potential. Neutralize electrostatic charge by touching hand and all tools on an
unpainted unit surface, such as the gas valve or
blower deck, before performing any service procedure.
Electrical Heat Capacities . . . . . . . . . . . . . . . . . . . Page 15
Parts Arrangement . . . . . . . . . . . . . . . . . . . . . . . . Page 16
I− Unit Components . . . . . . . . . . . . . . . . . . . . . . Page 17
II− Placement and Installation . . . . . . . . . . . . . . Page 26
III− Start−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26
IV− Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 27
V− System Service Checks . . . . . . . . . . . . . . . . . Page 28
VI− Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . Page 28
VII− Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 29
VIII−Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . Page 36
Page 1
 2010 Lennox Industries Inc.
OPTIONS / ACCESSORIES
Model
Number
Item Description
Catalog
Number
Unit Model No
092 102 120
150
COOLING SYSTEM
Compressor Crankcase Heater
208/230V- 3ph - K1CCHT02B-1Y
54W17
X
X
X
460V-3ph - K1CCHT02B-1G
54W18
X
X
X
575V-3ph - K1CCHT02B-1J
54W19
X
X
X
PVC - LTACDKP09/36
76M18
X
X
X
X
Copper - LTACDKC09/36
76M19
X
X
X
X
Factory
O
O
O
O
74W42
X
X
X
X
Standard
O
O
O
O
54W16
X
X
X
X
R-410A
O
O
O
O
Belt Drive - 2 hp
Factory
O
O
O
O
Belt Drive - 3 hp
Factory
O
O
O
O
Belt Drive - 5 hp
Factory
O
O
O
O
Kit #1 590-890 rpm
Factory
O
O
O
O
Kit #2 800-1105 rpm
Factory
O
O
O
O
Kit #3 795-1195 rpm
Factory
O
O
O
O
Kit #4 730-970 rpm
Factory
O
O
O
O
Kit #5 940-1200 rpm
Factory
O
O
O
O
Kit #6 1015-1300 rpm
Factory
O
O
O
O
Condensate Drain Trap
Corrosion Protection
Drain Pan Overflow Switch
K1SNSR71AB1-
Efficiency
Low Ambient Kit
K1SNSR33B-1
Refrigerant Type
BLOWER - SUPPLY AIR
Motors
Drive Kits
See Blower Data Tables for selection
Kit #10 900-1135 rpm
Factory
O
O
O
O
Kit #11 1040-1315 rpm
Factory
O
O
O
O
Kit #12 1125-1425 rpm
Factory
O
O
O
O
Coil Guards
K1GARD20B-1
55W08
X
X
X
X
Hail Guards
K1GARD10B1
55W11
X
X
X
X
Factory
O
O
O
O
K1HECK00B-1
51W25
X
X
X
X
C1CONV10B-1
54W96
X
X
X
X
---
X
X
X
X
CABINET
Hinged Access Panels
Horizontal Discharge Kit
Return Air Adaptor Plate (for L Series and T-Class™ replacement)
®
CONTROLS
Commercial Controls
L Connection® Building Automation System
Smoke Detector - Supply or Return (Power board and one sensor)
C1SNSR44B-1
53W80
X
X
X
X
Smoke Detector - Supply and Return (Power board and two sensors)
C1SNSR43B-1
53W81
X
X
X
X
NOTE - Catalog and model numbers shown are for ordering field installed accessories.
OX - Configure To Order (Factory Installed) or Field Installed
O = Configure To Order (Factory Installed)
X = Field Installed
Page 2
OPTIONS / ACCESSORIES
Model
Number
Item Description
Catalog
Number
Unit Model No
092 102 120
150
INDOOR AIR QUALITY
Air Filters
Healthy Climate® High Efficiency Air Filters
MERV 8 - C1FLTR15B-1
50W61
X
X
X
X
20 x 25 x 2 (Order 4 per unit)
Replacement Media Filter With Metal Mesh
Frame (includes non-pleated filter media)
Indoor Air Quality (CO2) Sensors
MERV 13 - C1FLTR40B-1
C1FLTR30B-1-
52W41
Y3063
X
X
X
X
X
X
X
X
Sensor - Wall-mount, off-white plastic cover with LCD display
C0SNSR50AE1L
77N39
X
X
X
X
Sensor - Wall-mount, off-white plastic cover, no display
C0SNSR52AE1L
87N53
X
X
X
X
Sensor - Black plastic case with LCD display, rated for plenum
mounting
C0SNSR51AE1L
87N52
X
X
X
X
C0MISC19AE1
87N54
X
X
X
X
C0MISC19AE1-
85L43
X
X
X
X
C0MISC16AE1-
90N43
X
X
X
X
C1UVCL10B-1
54W62
X
X
X
X
Sensor - Wall-mount, black plastic case, no display, rated for
plenum mounting
CO2 Sensor Duct Mounting Kit - for downflow applications
Aspiration Box - for duct mounting non-plenum rated CO2 sensors
(87N53 or 77N39)
UVC Germicidal Lamps
Healthy Climate® UVC Light Kit (208/230v-1ph)
ELECTRICAL
1
Voltage 60 hz
208/230V - 3 phase
Factory
O
O
O
O
460V - 3 phase
Factory
O
O
O
O
575V - 3 phase
Factory
O
O
O
O
80 amp - C1DISC080B-1
54W56
OX
OX
OX
OX
150 amp - C1DISC150B-1
54W57
OX
OX
OX
OX
LTAGFIK10/15
74M70
OX
OX
OX
OX
208/230V-3ph - C1EHO075B-1Y
56W38
X
X
460V-3ph - C1EHO075B-1G
56W39
X
X
575V-3ph - C1EHO075B-1J
56W40
X
X
208/230V-3ph - C1EHO015B-1Y
56W41
X
X
X
X
460V-3ph - C1EHO150B-1G
56W42
X
X
X
X
575V-3ph - C1EHO150B-1J
56W43
X
X
X
X
208/230V-3ph - C1EHO225B-1Y
56W44
X
X
X
X
460V-3ph - C1EHO225B-1G
56W45
X
X
X
X
575V-3ph - C1EHO225B-1J
56W46
X
X
X
X
208/230V-3ph - C1EHO300B-1Y
56W47
X
X
X
X
460V-3ph - C1EHO300B-1G
56W48
X
X
X
X
Disconnect Switch - See Electrical/Electric Heat tables for selection
GFI Service Outlets
ELECTRIC HEAT
7.5 kW
15 kW
22.5 kW
30 kW
45 kW
60 kW
575V-3ph - C1EHO300B-1J
56W49
X
X
X
X
208/230V-3ph - C1EHO450B-1Y
56W50
X
X
X
X
460V-3ph - C1EHO450B-1G
56W51
X
X
X
X
575V-3ph - C1EHO450B-1J
56W52
X
X
X
X
208/230V-3ph - C1EHO600B-1Y
55W02
X
X
460V-3ph - C1EHO600B-1G
55W03
X
X
575V-3ph - C1EHO600B-1J
55W04
X
X
Lamps operate on 110-230V single-phase power supply. Step-down transformer may be ordered separately for 460V and 575V units. Alternately, 110V power supply
may be used to directly power the UVC ballast(s)
1
NOTE - Catalog and model numbers shown are for ordering field installed accessories.
OX - Configure To Order (Factory Installed) or Field Installed
O = Configure To Order (Factory Installed)
X = Field Installed
Page 3
OPTIONS / ACCESSORIES
Model
Number
Item Description
Catalog
Number
Unit Model No
092 102 120
150
ECONOMIZER
Economizer
K1ECON20B-1
54W55
OX
OX
OX
OX
Single Enthalpy Control
C1SNSR64FF1
53W64
OX
OX
OX
OX
Differential Enthalpy Control (order 2)
C1SNSR64FF1
53W64
X
X
X
X
LAGEDH03/15
53K04
X
X
X
X
Motorized Dampers with outdoor air hood
C1DAMP20B-1
53W49
OX
OX
OX
OX
Manual Dampers with outdoor air hood
C1DAMP10B-1
53W48
OX
OX
OX
OX
208/230V-3ph - K1PWRE10B-1Y
53W44
X
X
X
X
460V-3ph - K1PWRE10B-1G
53W45
X
X
X
X
575V-3ph - K1PWRE10B-1J
53W46
X
X
X
X
8 in. height
C1CURB23B-1
54W46
X
X
X
X
14 in. height
C1CURB20B-1
54W47
X
X
X
X
18 in. height
C1CURB21B-1
54W48
X
X
X
X
24 in. height
C1CURB22B-1
54W49
X
X
X
X
8 in. height
C1CURB12B-1
54W44
X
X
X
X
14 in. height
C1CURB10B-1
54W43
X
X
X
X
24 in. height
C1CURB11B-1
54W45
X
X
X
X
C1CURB55B-1
54W50
X
X
X
X
X
X
X
Economizer with Single Temperature Control - Downflow or
Horizontal With Barometric Relief Dampers (downflow) and Air
Hoods
Economizer Controls
Horizontal Barometric Relief Dampers With Exhaust Hood
Horizontal Barometric Relief Dampers - Exhaust Hood Furnished
OUTDOOR AIR
Outdoor Air Dampers
POWER EXHAUST
Standard Static
ROOF CURBS - DOWNFLOW
Clip Curb
Standard
Adjustable Pitched Curb
14 in. height
CEILING DIFFUSERS
Step-Down - Order one
Flush - Order one
Transitions (Supply and Return) - Order one
NOTE - Catalog and model numbers shown are for ordering field installed accessories.
OX - Configure To Order (Factory Installed) or Field Installed
O = Configure To Order (Factory Installed)
X = Field Installed
Page 4
RTD11-95
29G04
RTD11-135
29G05
RTD11-185
29G06
FD11-95
29G08
FD11-135
29G09
FD11-185
29G10
LASRT08/10
24L14
LASRT10/12
49K55
LASRT15
49K56
X
X
X
X
X
X
X
X
X
SPECIFICATIONS
General Data
Cooling
Performance
Nominal Tonnage
Model Number
Efficiency Type
Blower Type
Gross Cooling Capacity - Btuh
1
Net Cooling Capacity - Btuh
AHRI Rated Air Flow - cfm
Total Unit Power - kW
1
EER (Btuh/Watt)
2
IEER (Btuh/Watt)
Refrigerant Type
Refrigerant
Circuit 1
Charge
Circuit 2
Furnished
Electric Heat Available - See page 3
Compressor Type (number)
Outdoor
Net face area (total) - sq. ft.
Coils
Tube diameter - in.
Number of rows
Fins per inch
Outdoor
Motor - (No.) hp
Coil Fans
Motor rpm
Total Motor watts
Diameter - (No.) in.
Number of blades
Total Air volume - cfm
Indoor
Net face area (total) - sq. ft.
Coils
Tube diameter - in.
Number of rows
Fins per inch
Drain connection - Number
and size
Expansion device type
3
Indoor
Nominal motor output
Blower and
Maximum usable motor output
Drive
(US Only)
Selection
Motor - Drive kit number
7.5 Ton
KCA092S4B
Standard
Constant Air
Volume CAV
88,900
86,000
3,000
7.7
11.2
11.4
R-410A
7 lbs. 8 oz.
7 lbs. 0 oz.
8.5 Ton
KCA102S4B
Standard
Constant Air
Volume CAV
100,483
97,000
3,400
8.7
11.2
11.4
R-410A
8 lbs. 8 oz.
8 lbs. 8 oz.
10 Ton
KCA120S4B
Standard
Constant Air
Volume CAV
119,640
115,000
3,800
10.3
11.2
11.4
R-410A
10 lbs. 0 oz.
10 lbs. 0 oz.
12.5 Ton
KCA150S4B
Standard
Constant Air
Volume CAV
144,800
138,000
4,300
12.5
11
11.2
R-410A
14 lbs. 0 oz.
12 lbs. 0 oz.
7.5,15,22.5,30 & 45 KW
15,22.5,30,45 & 60 KW
Scroll (2)
Scroll (2)
Scroll (2)
Scroll (2)
20.42
24.5
28.0
28.0
3/8
3/8
3/8
3/8
2
2
2
3
20
20
20
20
(2) 1/3
(2) 1/3
(2) 1/3
(2) 1/2
1075
1075
1075
1075
670
670
670
830
(2) 24
(2) 24
(2) 24
(2) 24
3
3
3
3
7200
7400
7800
8,800
12.78
12.78
12.78
13.54
3/8
3/8
3/8
3/8
2
2
3
4
14
14
14
14
(1) 1 in. NPT coupling
Balance port TXV, removable head
2 hp, 3 hp, 5 hp
2 hp, 3 hp, 5 hp
2 hp, 3 hp, 5 hp
2 hp, 3 hp, 5 hp
2.3 hp, 3.45 hp,
2.3 hp, 3.45 hp,
2.3 hp, 3.45 hp,
2.3 hp, 3.45 hp,
5.75 hp
5.75 hp
5.75 hp
5.75 hp
2 hp
2 hp
2 hp
2 hp
4
Kit 1 590-890 rpm 4 Kit 1 590-890 rpm
Kit 1 590-890 rpm
Kit 1 590-890 rpm
Kit 2 800-1105 rpm Kit 2 800-1105 rpm Kit 2 800-1105 rpm
Kit 2 800-105 rpm
Kit 3 795-1195 rpm Kit 3 795-1195 rpm Kit 3 795-1195 rpm Kit 3 795-1195 rpm
3 hp
3 hp
3 hp
3 hp
4
Kit 4 730-970 rpm
Kit 4 730-970 rpm
Kit 4 730-970 rpm
Kit 4 730-970 rpm
Kit 5 940-1200 rpm Kit 5 940-1200 rpm Kit 5 940-1200 rpm Kit 5 940-1200 rpm
Kit 6 1015-1300 rpm Kit 6 1015-1300 rpm Kit 6 1015-1300 rpm Kit 6 1015-1300 rpm
5 hp
5 hp
5 hp
5 hp
Kit 10 900-1135 rpm Kit 10 900-1135 rpm Kit 10 900-1135 rpm 4 Kit 10 900-1135 rpm
Kit 11 1040-1315 rpm Kit 11 1040-1315 rpm Kit 11 1040-1315 rpm Kit 11 1040-1315 rpm
Kit 12 1125-1425 rpm Kit 12 1125-1425 rpm Kit 12 1125-1425 rpm Kit 12 1125-1425 rpm
Blower wheel nominal
(1) 15 X 15
(1) 15 X 15
(1) 15 X 15
(1) 15 X 15
diameter x width - in.
Filters
Type of filter
Disposable
Number and size - in.
(4) 20 x 25 x 2
Electrical characteristics
208/230V, 460V or 575V - 60 hertz - 3 phase
NOTE - Net capacity includes evaporator blower motor heat deduction. Gross capacity does not include evaporator blower motor heat deduction.
1
Certified in accordance with the ULE certification program, which is based on AHRI Standard 340/360; 95°F outdoor air temperature and 80°F db/67°F wb entering
evaporator air; minimum external duct static pressure.
2
Integrated Energy Efficiency Ratio certified and tested according to AHRI Standard 340/360..
3
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.
4
Standard motor and drive kit furnished with unit.
Page 5
BLOWER DATA
092 AND 102 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 field installed accessories air resistance (duct resistance, diffuser, etc.)
Then determine from blower table blower motor output required.
See page 9 for blower motors and drives.
See page 9 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.)
7.5 kW, 15 kW, 22.5 kW, 30 kW and 45 kW - 2800 cfm
Total
Air
Volume
cfm
Total Static Pressure − in. w.g.
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2
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
2250
- - - - - - - - - - - - 707 0.14 753 0.50 800 0.84 847 1.15 892 1.38 934 1.53 979 1.65 1051 1.86 1126 2.12 1183 2.36 1238 2.62
2500
- - - - - - - - - - - - 714 0.29 758 0.64 803 0.97 849 1.26 893 1.48 936 1.63 983 1.75 1052 1.96 1124 2.22 1184 2.49 1241 2.77
2750
- - - - - - 680 0.11 721 0.45 763 0.78 807 1.09 852 1.37 896 1.58 940 1.74 989 1.88 1053 2.08 1121 2.34 1185 2.63 1244 2.93
3000
- - - - - - 689 0.29 728 0.61 770 0.93 812 1.23 856 1.49 901 1.70 947 1.87 996 2.02 1055 2.21 1120 2.47 1186 2.78 1248 3.10
3250
661 0.17 698 0.46 737 0.78 777 1.09 819 1.38 862 1.63 908 1.84 955 2.01 1004 2.17 1059 2.36 1122 2.62 1189 2.94 1252 3.28
3500
672 0.36 708 0.65 746 0.95 786 1.25 827 1.53 870 1.78 916 1.99 965 2.17 1013 2.33 1065 2.52 1126 2.79 1193 3.12 1257 3.47
3750
684 0.56 719 0.85 756 1.14 795 1.43 836 1.70 880 1.95 927 2.16 976 2.34 1023 2.51 1073 2.71 1133 2.98 1198 3.32 1263 3.67
4000
697 0.78 731 1.05 768 1.34 807 1.62 848 1.89 892 2.13 940 2.34 988 2.53 1034 2.71 1083 2.91 1141 3.19 1205 3.53 1270 3.89
4250
710 1.00 745 1.27 781 1.55 819 1.83 861 2.09 906 2.33 954 2.55 1001 2.74 1046 2.93 1094 3.14 1151 3.42 1214 3.76 1278 4.12
Page 6
BLOWER DATA
120 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 field installed accessories air resistance (duct resistance, diffuser, etc.)
Then determine from blower table blower motor output required.
See page 9 for blower motors and drives.
See page 9 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, 30 kW and 45 kW - 2800 cfm
60 kW - 4000 cfm
Total
Air
Volume
cfm
Total Static Pressure − in. w.g.
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2
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
3000
- - - - - - 677 0.24 719 0.55 764 0.87 813 1.18 866 1.45 920 1.67 975 1.82 1026 1.96 1076 2.13 1126 2.35 1176 2.63 1225 2.92
3250
650 0.14 688 0.43 730 0.73 775 1.04 823 1.34 875 1.60 930 1.81 985 1.97 1036 2.12 1086 2.31 1136 2.54 1186 2.83 1235 3.13
3500
663 0.35 700 0.63 741 0.92 786 1.22 834 1.5 886 1.76 942 1.96 997 2.14 1048 2.31 1097 2.51 1147 2.75 1196 3.04 1245 3.35
3750
676 0.57 714 0.84 754 1.12 798 1.41 846 1.68 899 1.93 956 2.14 1010 2.32 1060 2.51 1109 2.72 1158 2.98 1207 3.27 1255 3.58
4000
691 0.79 728 1.05 768 1.33 812 1.61 860 1.88 914 2.12 971 2.34 1023 2.53 1072 2.73 1121 2.95 1169 3.22 1218 3.51 1266 3.83
4250
706 1.03 743 1.28 783 1.55 827 1.82 876 2.09 931 2.33 987 2.55 1037 2.76 1085 2.97 1133 3.20 1181 3.47 1229 3.76 1277 4.08
4500
722 1.27 759 1.52 799 1.78 844 2.05 894 2.31 949 2.56 1003 2.79 1052 3.00 1098 3.22 1145 3.46 1193 3.73 1241 4.03 1289 4.34
4750
739 1.53 776 1.77 817 2.03 862 2.30 913 2.56 968 2.81 1020 3.04 1066 3.27 1112 3.49 1158 3.74 1205 4.01 1253 4.30 1301 4.61
5000
757 1.79 794 2.04 835 2.30 882 2.56 934 2.83 988 3.08 1036 3.32 1081 3.55 1125 3.78 1171 4.02 1218 4.29 1265 4.59 1312 4.89
Page 7
BLOWER DATA
150 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 field installed accessories air resistance (duct resistance, diffuser, etc.)
Then determine from blower table blower motor output required.
See page 9 for blower motors and drives.
See page 9 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, 30 kW and 45 kW - 2800 cfm
60 kW - 4000 cfm
Total
Air
Volume
cfm
Total Static Pressure − in. w.g.
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2
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
3750
689 0.68 731 0.97 775 1.27 820 1.56 865 1.81 911 2.02 957 2.19 1004 2.35 1051 2.53 1100 2.74 1151 2.99 1204 3.29 1258 3.61
4000
706 0.92 748 1.22 792 1.51 836 1.78 881 2.02 926 2.22 972 2.39 1018 2.57 1065 2.76 1113 2.98 1163 3.25 1217 3.55 1271 3.87
4250
725 1.18 766 1.47 810 1.75 854 2.02 899 2.25 943 2.44 988 2.61 1033 2.81 1079 3.01 1127 3.25 1178 3.52 1230 3.82 1284 4.14
4500
744 1.45 786 1.73 829 2.01 873 2.27 917 2.49 961 2.67 1005 2.87 1050 3.07 1096 3.29 1143 3.53 1193 3.81 1245 4.11 1298 4.43
4750
764 1.73 806 2.01 849 2.28 893 2.53 936 2.74 980 2.94 1023 3.15 1068 3.37 1113 3.60 1160 3.84 1210 4.12 1261 4.42 1314 4.74
5000
785 2.02 827 2.30 870 2.57 914 2.81 957 3.02 1000 3.23 1043 3.46 1087 3.69 1131 3.92 1178 4.17 1227 4.44 1278 4.74 1330 5.05
5250
807 2.33 850 2.61 893 2.87 937 3.11 979 3.33 1021 3.55 1064 3.80 1107 4.03 1151 4.27 1197 4.51 1245 4.78 1295 5.08 1347 5.38
5500
831 2.66 874 2.94 917 3.2 960 3.43 1002 3.67 1043 3.91 1085 4.16 1127 4.39 1171 4.63 1216 4.87 1264 5.14 1313 5.42 1364 5.72
5750
856 3.00 899 3.29 943 3.55 985 3.79 1026 4.04 1066 4.30 1107 4.55 1149 4.78 1192 5.00 1237 5.24 1284 5.50 - - - - - - - - - - - -
6000
883 3.38 927 3.66 970 3.93 1010 4.19 1050 4.46 1089 4.72 1129 4.95 1171 5.17 1213 5.40 1257 5.63 - - - - - - - - - - - - - - -
6250
912 3.78 956 4.07 997 4.35 1036 4.63 1074 4.90 1113 5.15 1152 5.37 1193 5.58 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Page 8
BLOWER DATA
FACTORY INSTALLED BELT DRIVE KIT SPECIFICATIONS
Nominal
hp
Maximum
hp
Drive Kit Number
RPM Range
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
POWER EXHAUST FAN PERFORMANCE
Return Air System Static Pressure
Air Volume Exhausted
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.
Wet Indoor Coil
MERV 8
MERV 13
Return Air
Adaptor
Plate
0.08
0.01
0.04
0.00
0.04
0.11
0.01
0.05
0.00
0.17
0.05
0.12
0.02
0.05
0.00
0.19
0.06
0.13
0.02
0.06
0.02
0.18
0.23
0.06
0.15
0.02
0.06
0.02
0.21
0.26
0.09
0.15
0.03
0.07
0.04
0.16
0.23
0.29
0.09
0.15
0.03
0.08
0.07
4000
0.17
0.25
0.31
0.09
0.19
0.04
0.08
0.09
4250
0.20
0.27
0.34
0.13
0.19
0.04
0.09
0.11
4500
0.21
0.30
0.37
0.14
0.22
0.04
0.09
0.12
4750
0.23
0.32
0.40
0.17
0.25
0.05
0.10
0.16
5000
0.26
0.35
0.43
0.20
0.29
0.06
0.10
0.18
5250
0.27
0.36
0.46
0.22
0.32
0.06
0.11
0.19
5500
0.29
0.40
0.50
0.25
0.34
0.07
0.12
0.22
5750
0.32
0.43
0.56
0.31
0.45
0.07
0.12
0.25
6000
0.33
0.46
0.59
0.33
0.52
0.08
0.13
0.27
Air Volume
cfm
150
Electric
Heat
Economizer
092, 102
120
2250
0.07
0.10
0.13
0.04
2500
0.09
0.12
0.15
2750
0.09
0.12
3000
0.11
0.15
3250
0.13
3500
0.14
3750
Page 9
Filters
BLOWER DATA
CEILING DIFFUSERS AIR RESISTANCE - in. w.g.
RTD11 Step-Down Diffuser
Unit Size
Air Volume
cfm
092 Models
102 & 120 Models
150 Models
2 Ends Open
1 Side, 2 Ends
Open
All Ends & Sides
Open
FD11 Flush
Diffuser
2400
0.21
0.18
0.15
0.14
2600
0.24
0.21
0.18
0.17
2800
0.27
0.24
0.21
0.20
3000
0.32
0.29
0.25
0.25
3200
0.41
0.37
0.32
0.31
3400
0.50
0.45
0.39
0.37
3600
0.61
0.54
0.48
0.44
3800
0.73
0.63
0.57
0.51
3600
0.36
0.28
0.23
0.15
3800
0.40
0.32
0.26
0.18
4000
0.44
0.36
0.29
0.21
4200
0.49
0.40
0.33
0.24
4400
0.54
0.44
0.37
0.27
4600
0.60
0.49
0.42
0.31
4800
0.65
0.53
0.46
0.35
5000
0.69
0.58
0.50
0.39
5200
0.75
0.62
0.54
0.43
4200
0.22
0.19
0.16
0.10
4400
0.28
0.24
0.20
0.12
4600
0.34
0.29
0.24
0.15
4800
0.40
0.34
0.29
0.19
5000
0.46
0.39
0.34
0.23
5200
0.52
0.44
0.39
0.27
5400
0.58
0.49
0.43
0.31
5600
0.64
0.54
0.47
0.35
5800
0.70
0.59
0.51
0.39
CEILING DIFFUSER AIR THROW DATA
Model No.
092 Models
102, 120
Models
150 Models
Air Volume
1
Effective Throw Range
RTD11 Step-Down
FD11 Flush
cfm
ft.
ft.
2600
24 - 29
19 - 24
2800
25 - 30
20 - 28
3000
27 - 33
21 - 29
3200
28 - 35
22 - 29
3400
30 - 37
22 - 30
3600
25 - 33
22 - 29
3800
27 - 35
22 - 30
4000
29- 37
24 - 33
4200
32 - 40
26 - 35
4400
34 - 42
28 - 37
5600
39 - 49
28 - 37
5800
42 - 51
29 - 38
6000
44 - 54
40 - 50
6200
45 - 55
42 - 51
6400
46 - 55
43 - 52
6600
47 - 56
45 - 56
Throw is the horizontal or vertical distance an air stream travels on leaving the outlet or diffuser
before the maximum velocity is reduced to 50 ft. per minute. Four sides open.
1
Page 10
ELECTRICAL/ELECTRIC HEAT DATA
7.5 TON STANDARD EFFICIENCY (R-410A)
1
Voltage - 60hz
Compressor 1
Rated Load Amps
Locked Rotor Amps
Compressor 2
Rated Load Amps
Locked Rotor Amps
Outdoor Fan
Full Load Amps
(total)
Motors (2)
Power Exhaust
7.5 TON
208/230V - 3 Ph
13.1
83.1
13.1
83.1
2.4
(4.8)
460V - 3 Ph
6.1
41
6.1
41
1.3
(2.6)
KCA092S4
575V - 3 Ph
4.4
33
4.4
33
1
(2)
Full Load Amps
2.4
1.3
1
(1) 0.33 HP
Service Outlet 115V GFI (amps)
Indoor Blower
Horsepower
Full
Load Amps
Motor
15
2
7.5
15
2
3.4
15
2
2.7
Unit Only
With (1) 0.33 HP
50
50
25
25
15
20
42
45
20
22
15
16
2
Maximum
Overcurrent
Protection
Minimum
3
Circuit
Power Exhaust
Unit Only
With (1) 0.33 HP
Power Exhaust
Ampacity
ELECTRIC HEAT DATA
Electric Heat Voltage
2
Unit+
7.5 kW
Maximum
15 kW
Electric Heat
Overcurrent
22.5 kW
Protection
30 kW
45 kW
3
Unit+
7.5 kW
Minimum
15 kW
Electric Heat
Circuit
22.5
kW
Ampacity
30 kW
45 kW
2
7.5 kW
Unit+
Maximum
15 kW
Electric Heat
Overcurrent
22.5
kW
and (1) 0.33
Protection
30 kW
HP
45 kW
Power Exhaust
3
Minimum
Unit+
Circuit
Electric Heat
Ampacity
and (1) 0.33
HP
7.5 kW
15 kW
22.5 kW
30 kW
45 kW
Power Exhaust
ELECTRICAL ACCESSORIES
Disconnect
7.5 kW
15 kW
22.5 kW
30 kW
45 kW
1
2
3
208V
50
50
70
90
150
42
49
69
88
127
50
60
80
100
150
240V
50
60
80
100
150
42
55
78
100
145
50
60
90
110
150
480V
25
30
40
50
80
20
27
39
50
72
25
30
40
60
80
600V
15
25
35
40
60
15
22
31
40
58
20
25
35
45
60
45
52
72
91
130
45
58
81
103
148
22
29
40
51
74
16
23
32
41
59
54W56
54W56
54W56
54W57
54W57
54W56
54W56
54W56
54W57
54W57
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
Extremes of operating range are plus and minus 10% of line voltage.
HACR type breaker or fuse.
Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.
Page 11
ELECTRICAL/ELECTRIC HEAT DATA
8.5 TON STANDARD EFFICIENCY (R-410A)
1
Voltage - 60hz
Compressor 1
Rated Load Amps
Locked Rotor Amps
Compressor 2
Rated Load Amps
Locked Rotor Amps
Outdoor Fan
Full Load Amps
(total)
Motors (2)
Power Exhaust
8.5 TON
208/230V - 3 Ph
14.5
98
14.5
98
2.4
(4.8)
460V - 3 Ph
6.3
55
6.3
55
1.3
(2.6)
KCA102S4
575V - 3 Ph
6
41
6
41
1
(2)
Full Load Amps
2.4
1.3
1
(1) 0.33 HP
Service Outlet 115V GFI (amps)
Indoor Blower
Horsepower
Full
Load Amps
Motor
15
2
7.5
15
2
3.4
15
2
2.7
Unit Only
With (1) 0.33 HP
50
60
25
25
20
25
45
48
21
22
19
20
2
Maximum
Overcurrent
Protection
Minimum
3
Circuit
Power Exhaust
Unit Only
With (1) 0.33 HP
Power Exhaust
Ampacity
ELECTRIC HEAT DATA
Electric Heat Voltage
2
Unit+
7.5 kW
Maximum
15 kW
Electric Heat
Overcurrent
22.5
kW
Protection
30 kW
45 kW
3
Unit+
7.5 kW
Minimum
15 kW
Electric Heat
Circuit
22.5
kW
Ampacity
30 kW
45 kW
2
7.5 kW
Unit+
Maximum
15 kW
Electric Heat
Overcurrent
and (1) 0.33 22.5 kW
Protection
30 kW
HP
45 kW
Power Exhaust
3
Minimum
Unit+
Circuit
Electric Heat
Ampacity
and (1) 0.33
HP
7.5 kW
15 kW
22.5 kW
30 kW
45 kW
Power Exhaust
ELECTRICAL ACCESSORIES
Disconnect
7.5 kW
15 kW
22.5 kW
30 kW
45 kW
1
2
3
208V
50
50
70
90
150
45
49
69
88
127
60
60
80
100
150
240V
50
60
80
100
150
45
55
78
100
145
60
60
90
110
150
480V
25
30
40
50
80
21
27
39
50
72
25
30
40
60
80
600V
20
25
35
40
60
19
22
31
40
58
25
25
35
45
60
48
52
72
91
130
48
58
81
103
148
22
29
40
51
74
20
23
32
41
59
54W56
54W56
54W56
54W57
54W57
54W56
54W56
54W56
54W57
57W57
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
Extremes of operating range are plus and minus 10% of line voltage.
HACR type breaker or fuse.
Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.
Page 12
ELECTRICAL/ELECTRIC HEAT DATA
10 TON STANDARD EFFICIENCY (R-410A)
1
Voltage - 60hz
Compressor 1
Rated Load Amps
Locked Rotor Amps
Compressor 2
Rated Load Amps
Locked Rotor Amps
Outdoor Fan
Full Load Amps
(total)
Motors (2)
10 TON
KCA120S4
575V - 3 Ph
5.7
38.9
5.7
38.9
1
(2)
208/230V - 3 Ph
16
110
16
110
2.4
(4.8)
460V - 3 Ph
7.8
52
7.8
52
1.3
(2.6)
Full Load Amps
2.4
1.3
1
(1) 0.33 HP
Service Outlet 115V GFI (amps)
Indoor Blower
Horsepower
Full
Load Amps
Motor
15
3
10.6
15
3
4.8
15
3
3.9
60
60
30
30
20
25
52
54
25
27
19
20
Power Exhaust
2
Maximum
Overcurrent
Protection
Minimum
3
Circuit
Unit Only
With (1) 0.33 HP
Power Exhaust
Unit Only
With (1) 0.33 HP
Power Exhaust
Ampacity
ELECTRIC HEAT DATA
Electric Heat Voltage
2
Unit+
15 kW
Maximum
Overcurrent
Electric Heat
Protection
3
Minimum
Circuit
Unit+
Electric Heat
Ampacity
2
Maximum
Unit+
Overcurrent
Electric Heat
Protection
and (1) 0.33
HP
3
Minimum
Power Exhaust
Unit+
Circuit
Electric Heat
Ampacity
and (1) 0.33
HP
208V
60
240V
60
480V
30
600V
25
22.5 kW
30 kW
45 kW
60 kW
15 kW
22.5 kW
30 kW
45 kW
60 kW
15 kW
22.5 kW
30 kW
45 kW
60 kW
80
100
150
150
53
72
92
131
139
60
80
100
150
150
90
110
150
175
59
81
104
149
158
70
90
110
175
175
40
60
80
80
29
40
52
74
79
35
45
60
80
80
35
45
60
70
23
32
41
60
63
25
35
45
70
70
15 kW
22.5 kW
30 kW
45 kW
60 kW
56
75
95
134
142
62
84
107
152
161
31
42
53
76
80
25
34
43
61
64
54W56
54W57
54W57
57W57
4
Not available
54W56
54W57
54W57
54W57
4
Not available
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
54W56
Power Exhaust
ELECTRICAL ACCESSORIES
Disconnect
15 kW
22.5 kW
30 kW
45 kW
60 kW
Extremes of operating range are plus and minus 10% of line voltage.
HACR type breaker or fuse.
3
Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.
4
Disconnect must be field furnished.
1
2
Page 13
ELECTRICAL/ELECTRIC HEAT DATA
12.5 TON STANDARD EFFICIENCY (R-410A)
1
Voltage - 60hz
Compressor 1
Rated Load Amps
Locked Rotor Amps
Compressor 2
Rated Load Amps
Locked Rotor Amps
Outdoor Fan
Full Load Amps
(total)
Motors (2)
12.5 TON
KCA150S4
575V - 3 Ph
7.4
50
7.4
50
1.2
. (2.4)
208/230V - 3 Ph
19
123
19
123
3
. (6)
460V - 3 Ph
9.7
62
9.7
62
1.5
. (3)
Full Load Amps
2.4
1.3
1
(1) 0.33 HP
Service Outlet 115V GFI (amps)
Indoor Blower
Horsepower
Full
Load Amps
Motor
15
5
16.7
15
5
7.6
15
5
6.1
70
70
35
35
25
25
53
56
27
29
22
23
Power Exhaust
2
Maximum
Overcurrent
Protection
Minimum
3
Circuit
Unit Only
With (1) 0.33 HP
Power Exhaust
Unit Only
With (1) 0.33 HP
Power Exhaust
Ampacity
ELECTRIC HEAT DATA
Electric Heat Voltage
2
Unit+
15 kW
Maximum
22.5
kW
Electric Heat
Overcurrent
30
kW
Protection
45 kW
60 kW
3
Unit+
15 kW
Minimum
Electric Heat 22.5 kW
Circuit
30 kW
Ampacity
45 kW
60 kW
2
15 kW
Unit+
Maximum
Electric Heat 22.5 kW
Overcurrent
30 kW
and (1) 0.33
Protection
45 kW
HP
60 kW
Power Exhaust
3
Minimum
Unit+
Circuit
Electric Heat
Ampacity
and (1) 0.33
HP
15 kW
22.5 kW
30 kW
45 kW
60 kW
Power Exhaust
ELECTRICAL ACCESSORIES
Disconnect
15 kW
22.5 kW
30 kW
45 kW
60 kW
208V
70
4
70
4
90
4
125
150
53
64
84
123
130
70
4
70
4
90
150
4
150
240V
70
80
100
150
150
53
73
96
141
150
70
80
100
150
175
480V
35
40
50
80
80
27
37
48
71
75
35
40
50
80
80
600V
25
30
40
60
70
22
30
39
57
61
25
35
40
60
70
56
67
87
126
133
56
76
99
144
153
29
38
50
72
77
23
31
40
58
62
54W56
54W57
54W57
4
Not available
4
Not available
54W56
54W57
57W57
4
Not available
4
Not available
54W56
54W56
54W56
54W56
54W57
54W56
54W56
54W56
54W56
54W56
Extremes of operating range are plus and minus 10% of line voltage.
HACR type breaker or fuse.
Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.
4
Disconnect must be field furnished.
1
2
3
Page 14
ELECTRIC HEAT CAPACITIES
Volts
Input
7.5 kW
15 kW
22.5 kW
30 kW
45 kW
60 kW
kW Btuh No. of kW Btuh No. of kW Btuh No. of kW
Btuh No. of kW
Btuh No. of kW
Btuh No. of
Input Output Stages Input Output Stages Input Output Stages Input Output Stages Input Output Stages Input Output Stages
208
5.6
19,100
1
11.3 38,600
1
16.9 57,700
2
22.5 76,800
2
33.8 115,300
2
45.0 153,600
2
220
6.3
21,500
1
12.6 43,000
1
18.9 64,500
2
25.2 86,000
2
37.8 129,000
2
50.4 172,000
2
230
6.9
23,600
1
13.8 47,100
1
20.7 70,700
2
27.5 93,900
2
41.3 141,000
2
55.1 188,000
2
240
7.5
25,600
1
15.0 51,200
1
22.5 76,800
2
30.0 102,400
2
45.0 153,600
2
60.0 204,800
2
440
6.9
21,500
1
12.6 43,000
1
18.9 64,500
2
25.2 86,000
2
37.8 129,000
2
50.4 172,000
2
460
6.9
23,600
1
13.8 47,100
1
20.7 70,700
2
27.5 93,900
2
41.3 141,000
2
55.1 188,000
2
480
7.5
25,600
1
15.0 51,200
1
22.5 76,800
2
30.0 102,400
2
45.0 153,600
2
60.0 204,800
2
550
6.3
21,500
1
12.6 43,000
1
18.9 64,500
2
25.2 86,000
2
37.8 129,000
2
50.4 172,000
2
575
6.9
23,600
1
13.8 47,100
1
20.7 70,700
2
27.5 93,900
2
41.3 141,000
2
55.1 188,000
2
600
7.5
25,600
1
15.0 51,200
1
22.5 76,800
2
30.0 102,400
2
45.0 153,600
2
60.0 204,800
2
Page 15
KCA PARTS ARRANGEMENT
ECONOMIZER
(OPTIONAL)
DISCONNECT /
CIRCUIT BREAKER
(FACTORY OR FIELD
INSTALLED OPTION)
EVAPORATOR
COIL
BLOWER
MOTOR
CONDENSER
FANS
CONDENSER
COIL
BLOWER
BLOWER
COMPRESSORS
ELECTRIC
HEAT
CONDENSATE
DRAIN
FILTERS
(FOUR − 20 X 25 X 2")
FIGURE 1
KCA CONTROL BOX − Y, G, J−VOLT UNITS
KCA CONTROL BOX − M VOLT CE UNITS
K1
K2
K3
K65
K65
K2
K3
T1
T1
K10
K10
S42
S176 S177
K1
S42
K125
FIGURE 2
FIGURE 3
Page 16
I−UNIT COMPONENTS
CONTACTOR
All 7.5 through 12.5 ton (26.3 through 44 kW) units are configure to order units (CTO). The KCA unit components are
shown in figure 1. All units come standard with removable
unit panels. All L1, L2 and L3 wiring is color coded; L1 is red,
L2 is yellow and L3 is blue.
A−Control Box Components
KCA control box components are shown in figure 2 and 3.
The control box is located in the upper portion of the compressor compartment.
FIGURE 5
7−Blower Contactor K3
1−Disconnect Switch S48 or CB10
(CB10 field−installed only)
All units may be equipped with an optional disconnect switch
S48 or circuit breaker CB10. S48 and CB10 are toggle
switches, which can be used by the service technician to disconnect power to the unit.
Blower contactor K3, used in all units, is a three-poledouble-break contactor with a 24VAC coil used to energize
the indoor blower motor B3 in response to blower demand.
K3 is energized by a thermostat cooling demand. On M−volt
CE units, the contactor is CE approved by manufacturer
(Siemens). See figure 5.
2−Control Transformer T1 all units
8−Power Exhaust Relay K65 (PED units)
All use a single line voltage to 24VAC transformer
mounted in the control box. Transformer supplies power
to control circuits in the unit. The transformer is rated at
70VA and is protected by a 3.5 amp circuit breaker
(CB8). The 208/230 (Y) voltage transformers use two
primary voltage taps as
208/230V TRANSFORMER
BLUE
YELLOW
shown in figure 4, while
SECONDARY
460 (G) and 575 (J)
voltage transformers
208 VOLTS
use a single primary
RED
voltage tap.
230 VOLTS
Power exhaust relay K65 is a DPDT relay with a 24VAC
coil. K65 is used in all KCA units equipped with the optional power exhaust dampers. K65 is energized by the
economizer enthalpy control A6, after the economizer
dampers reach 50% open (adjustable) When K65
closes, exhaust fan B10 is energized.
ORANGE PRIMARY
BLACK
FIGURE 4
3−Terminal Strip TB1
All indoor thermostat connections will be to TB1 located in
the control area. For thermostats without occupied and
unoccupied" modes, a factory installed jumper across terminals R and OC should be in place.
4−Condenser Fan Capacitors C1 & C2
Fan capacitors C1 and C2 are used to assist in the start up of
condenser fans B4 and B5. Ratings will be on side of capacitor or outdoor fan motor nameplate.
9−Blower Motor Overload Relay Switch (S42)
The blower motor overload relay is used in all units equipped
with high efficiency motors. The relay (S42) is connected in
line with the blower motor to monitor the current flow to the
motor. When the relay senses an overload condition, a set of
normally closed contacts open to de−energize 24VAC power
to T1 transformer. Non−CE units will be equipped with a relay
manufactured by Telemecanique figure 7 or Siemens figure
8. M−volt CE units will be equipped with a relay manufactured by Siemens. See figure 6.
10−Compressor Overload Relays S176, S177
(M−volt CE units)
Relays are wired in series with the appropriate compressor contactor and monitor the current flow to the compressor motor. When the relay senses an overload condition,
N.C. contacts open to de−energize the compressor. Relays are manufactured by Siemens; see figure 6.
COMPRESSOR OVERLOAD RELAYS
5−Compressor Contactor K1 & K2
All compressor contactors are three-pole-double-break
contactors with 24VAC coils. In all KCA units, K1 and K2
energize compressors B1 and B2 in response to thermostat
demand. On CE M−volt units, contactor is CE approved by
manufacturer (Siemens). See figure 5.
SET RELAYS
TO MAXIMUM
OVERLOAD
SETTING
6−Condenser Fan Relay K10
Outdoor fan relay K10 is a DPDT relay with a 24VAC coil. K10
energizes condenser fans B4 and B5.
FIGURE 6
Page 17
LINE VOLTAGE IN
TELEMECANIQUE OVERLOAD RELAY
TRIP
INDICATION
WINDOW
AMP SETTING
POINTER
CLEAR
COVER
(SHOWN
CLOSED)
DETAIL SHOWING RESET BUTTON
ADJUSTED TO MANUAL POSITION
STOP
BUTTON
(RED)
Lift clear cover and turn adjustment screw
counterclockwise. Reset screw will pop out
when pointer is in M (manual position). Close
cover to lock reset screw into position.
AMP SETTING
CONTROL
(BLUE DIAL)
RED TEST
BUTTON
(Push To Test)
LOAD VOLTAGE OUT
BLUE RESET SCREW
(Shown in AUTO position as
shipped from the factory)
Lift clear cover to adjust relay amp setting according to value given on the blower motor nameplate.
Proper relay amp setting equals motor nameplate FLA X service factor of 1.15 X .95.
Cover must also be lifted to adjust control mode from automatic reset to manual reset (see detail
above) and to test the control.
Control must be in the manual reset mode to perform a test. Use a pointed object to press the small
red test button. A yellow marker should appear in the trip indication window to the right of the amp
setting control. Press the blue reset screw to reset the relay.
The red STOP button opens the normally closed contacts which power the blower motor. This button
stops blower motor operation as long as it is pressed in.
FIGURE 7
SIEMENS OVERLOAD RELAY
BLUE RESET BUTTON IN
FACTORY-SET AUTO MODE
(Turn clockwise to H for
manual reset)
GREEN TRIP INDICATOR
(Flush with surface −− not tripped;
Above surface −− tripped)
RED TEST BUTTON
AMP ADJUSTMENT DIAL
Adjust relay amp setting according to value given on the blower motor nameplate. Proper relay amp
setting equals motor nameplate FLA X service factor of 1.15 X .95.
Use small slotted screwdriver to adjust control mode from automatic reset (A) to manual reset (H).
Control must be in the manual reset mode (H) to perform a test. Press the red test button. Green trip
indicator should pop out. Press the blue reset screw to reset the relay.
FIGURE 8
Page 18
KCA092,102, 120, 150 PLUMBING AND COMPRESSOR CIRCUITS DETAIL
OUTDOOR
COIL STAGE 2
INDOOR COIL
STAGE 2
INDOOR COIL
STAGE 1
DRIERS
OUTDOOR COIL
STAGE 1
COMPRESSOR
2
COMPRESSOR
1
COMPRESSOR 2
S8 THERMAL
PROTECTOR
COMPRESSOR 1
S5 THERMAL
PROTECTOR
SUCTION
LINE
SUCTION
LINE
DISCHARGE
LINE
DISCHARGE
LINE
S7 HIGH
PRESSURE
SWITCH
S4 HIGH
PRESSURE
SWITCH
PRESSURE
TAP
PRESSURE
TAP
FIGURE 9
Page 19
B−Cooling Components
2−Thermal Protectors S5, S8
All units use independent cooling circuits consisting of separate compressors, condenser coils and evaporator coils.
See figure 9. Two draw−through type condenser fans are
used in KCA092/150 units. All units are equipped with beltdrive blowers which draw air across the evaporator during
unit operation.
Some compressors have thermal protectors located on top
of the compressor. The protectors open at 248F + 9F
(120C + 5C) and close at 169F + 18F (76C + 10C).
Cooling may be supplemented by a factory- or fieldinstalled economizer. The evaporators are slab type and
are stacked. Each evaporator uses a thermostatic expansion valve as the primary refrigerant metering device. Each
evaporator is also equipped with enhanced fins and rifled
tubing.
In all units each compressor is protected by S49 and S50 freezestats and S4 and S7 high pressure switches (on each
evaporator). Low ambient switches (S11, S84) are available
as an option for additional compressor protection. On 150
units, each compressor is protected by a crankcase heater.
1−Compressors B1 and B2
All KCA092/150 units use two scroll compressors. Compressor capacity may vary from stage to stage. In all cases,
the capacity of each compressor is added to reach the total
capacity of the unit. See SPECIFICATIONS" and ELECTRICAL DATA" (table of contents) or compressor nameplate
for compressor specifications.
3−Freezestats S49 and S50
Each unit is equipped with a low temperature switch (freezestat) located on a return bend of each evaporator coil. S49
(first circuit) and S50 (second circuit) are located on the
corresponding evaporator coils.
Freezestats are wired in series with compressor contactors.
Each freezestat is a SPST N.C. auto−reset switch which
opens at 29F + 3F (-1.7C + 1.7C) on a temperature drop
and closes at 58F + 4F (14.4C + 2.2C) on a temperature rise. To prevent coil icing, freezestats open during
compressor operation to temporarily disable the respective compressor until the coil temperature rises.
If the freezestats are tripping frequently due to coil icing,
check the airflow/filters, economizer position and unit
charge before allowing unit back in operation. Make sure
to eliminate conditions which might promote evaporator
ice buildup.
4−High Pressure Switches S4 and S7
The high pressure switch is a manual reset SPST N.C. switch
which opens on a pressure rise.
S4 (first circuit) and S7 (second circuit)are located in the
compressor discharge line and wired in series with the respective compressor contactor coils.
When discharge pressure rises to 640 ± 10 psig (4413 ±
69 kPa) (indicating a problem in the system) the switch
opens and the respective compressor is de−energized
(the economizer can continue to operate).
WARNING
Electrical shock hazard. Compressor must be
grounded. Do not operate without protective cover
over terminals. Disconnect power before removing
protective cover. Discharge capacitors before servicing unit. Failure to follow these precautions could
cause electrical shock resulting in injury or death.
5−Low Ambient Switches S11 & S84
(optional)
The low ambient switch is an auto-reset SPST N.O. pressure switch which allows for mechanical cooling operation
at low outdoor temperatures. In all models a switch is located in each liquid line prior to the indoor coil section.
Each compressor is energized by a corresponding compressor contactor.
In the KCA092/150, S11 and S84 are wired in parallel with
outdoor fan relay K10.
NOTE−Refer to the wiring diagram section for specific unit
operation.
When liquid pressure rises to 450 ± 10 psig (3102 ± 69
kPa), the switch closes and the condenser fans are energized. When discharge pressure in both refrigerant circuits
drops to 240 ± 10 psig (1655 ± 69 kPa), the switches open
and the condenser fans are de−energized. This intermittent
fan operation results in higher evaporating temperature allowing the system to operate without icing the evaporator
coil and losing capacity.
If Interlink compressor replacement is necessary, call
1−800−4−LENNOX (1−800−453−6669).
IMPORTANT
Some scroll compressors have an internal vacuum
protector that will unload scrolls when suction
pressure goes below 20 psig. A hissing sound will
be heard when the compressor is running unloaded. Protector will reset when low pressure in
system rises above 40 psig. DO NOT REPLACE
COMPRESSOR.
6−Crankcase Heaters HR1, HR2
150S units use insertion type heaters. Heater HR1 is
installed around compressor B1 and heater HR2 is installed
around compressor B2. Crankcase heater wattage varies
by compressor manufacturer.
Page 20
C−Blower Compartment
The blower compartment in all KCA092/150S units is located
between the evaporator coil and the condenser coil section.
The blower assembly is accessed by disconnecting the blower motor .See Blower Access in the Operation/ Adjustment
section. The blower pulls out as shown in figure 10.
1−Blower Wheels
All KCA092/150 units have one 15 in. x 15 in. (381 mm x 381
mm) blower wheel.
2−Indoor Blower Motor B3
All units use three-phase single-speed blower motors.
CFM adjustments are made by adjusting the motor pulley
(sheave). Motors are equipped with sealed ball bearings.
All motor specifications are listed in the SPECIFICATIONS (table of contents) in the front of this manual.
Units may be equipped with motors manufactured by various manufacturers, therefore electrical FLA and LRA
specifications will vary. See unit rating plate for information specific to your unit.
OPERATION / ADJUSTMENT
Blower Operation
Initiate blower demand at thermostat according to instruc-
tions 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.
Determining Unit CFM
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). Measure
static below roof curb if roof curb is used.
3− Refer to blower tables in BLOWER DATA (table of contents) in the front of this manual. Use static pressure and
RPM readings to determine unit air volume.
BLOWER ASSEMBLY
TO INCREASE BELT TENSION
SIDE VIEW
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.
MOTOR
IMPORTANT − Gap between end of frame and motor
mounting base should be equal at both ends, i.e. parallel along gap.
PULLEY
3− Tighten four bolts securing motor mounting base
to frame.
BLOWER
HOUSING
4− Relieve tension on two adjusting bolts.
MOTOR MOUNTING
BASE
BELT ADJUSTING BOLTS
− TURN CLOCKWISE
TO TIGHTEN BELT
GAP BETWEEN
EDGES SHOULD BE
PARALLEL ON BOTH
ENDS BEFORE
TIGHTENING MOTOR
MOUNTING BASE IN
PLACE
REMOVE TWO SCREWS
TO COMPLETELY SLIDE
BLOWER OUT OF UNIT
ALLEN
SCREW
MOTOR
BLOWER
FRAME
LOOSEN BEFORE
ADJUSTING BELT TENSION
(TWO EACH SIDE)
REMOVE TWO SCREWS ON EACH
SIDE TO SLIDE FRAME PARTIALLY
OUT OF UNIT FOR SERVICE ACCESS
FIGURE 10
Page 21
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 10. 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
Check Belt Tension
Overtensioning belts shortens belt and bearing life. Check
belt tension as follows:
1− Measure span length X. See figure 12.
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 11.
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).
PULLEY ALIGNMENT
ALIGNED
BELT
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.
3− Tighten bolts on side of base.
*No minimum number of turns open when B belt is used on
pulleys 6" O.D. or larger.
BLOWER
PULLEY
To loosen belt tension −
Turn the adjusting bolt to the left, or counterclockwise
to loosen belt tension.
A force below these values indicates an undertensioned belt. A force above these values indicates an
overtensioned belt.
MOTOR
PULLEY
MEASURE BELT TENSION
NOT ALIGNED
FIGURE 11
FORCE
1− Loosen four bolts securing motor base to mounting
frame. See figure 10.
2− To increase belt tension −
Turn adjusting bolt 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.
Page 22
DEFLECTION 1/64" PER INCH OF SPAN
OR 1.5mm PER 100mm OF SPAN
FIGURE 12
D−Optional Electric Heat Components
Table 2 shows electric heat fuse ratings. See Options/Accessories section (see table of contents) for KCA to EHA match−
ups. See Electrical/Electric Heat Data section (see table of
contents) of this manual for electrical ratings and capacities.
All electric heat sections consist of electric heating elements exposed directly to the air stream. See figure 14.
EHA parts arrangement is shown in figures 14 and 15.
Multiple-stage elements are sequenced on and off in response to thermostat demand.
1−Contactors K15, K16
Contactors K15 and K16 are three−pole double−break
contactors located on the electric heat vestibule. All
contactors are equipped with a 24VAC coil. The coils in
the K15 and K16 contactors are energized by a W2
thermostat demand, K9, and DL2. Contactor K15
energizes the first stage heating elements, while K16
energizes the second stage heating elements. On M−volt
units, contactors are CE approved by manufacturer
(Siemens). See figure 5.
2−High Temperature Limits S15 (Primary)
S15 is a SPST N.C. auto-reset thermostat located on
the back panel of the electric heat section below the
heating elements. S15 is the high temperature limit for
the electric heat section. When S15 opens, indicating a
problem in the system, contactor K15 is de-energized.
When K15 is de-energized, first stage and all subsequent stages of heat are de-energized. For
EHA102/150 units, the electric heat section thermostat
is factory set to open at 170_F + 5_F (76_C + 2.8_C) on
a temperature rise and automatically reset at 130_F +
6_F (54.4_C + 3.3_C) on a temperature fall. For
EHA100 units, the electric heat section thermostat is
factory set to open at 160_F + 5_F (71.0_C + 2.8_C) on
a temperature rise and automatically reset at 120_F +
6_F (49.0_C + 3.3_C) on a temperature fall. The thermostat is not adjustable.
3−High Temperature Limit S20, S157, S158, S15, S160 &
S161 (Secondary)
Limits are SPST N.C. manual-reset thermostat . Like
the primary temperature limit, S20 is wired in series
with the first stage contactor coil (K15) and second
stage contactor coil (K16). When S20 opens, contactors (K15, K16) are de-energized. When the contactors
are de-energized, first stage and all subsequent stages
of heat are de-energized. The thermostat is factory set
to open at 220_F + 6_F (104_C + 3.3_C) on a temperature rise and can be manually reset when temperature
falls below 160_F (71.0_C).
4−Terminal Strip TB2
Terminal strip TB2 is used for single point power installations only. TB2 distributes L1, L2 and L3 power to TB3.
Units with multi−point power connections will not use TB2.
5−Terminal Strip TB3
Electric heat line voltage connections are made to
terminal strip TB3 located in the upper left corner of the
electric heat vestibule. TB3 distributes power to the
electric heat components.
6−Heating Elements HE1 through HE6
Heating elements are composed of helix wound bare
nichrome wire exposed directly to the air stream. Three
elements are connected in a three-phase arrangement. The elements in 208/230V units are connected in
a Delta" arrangement. Elements in 460 and 575V units
are connected in Wye" arrangement. Each stage is
energized independently by the corresponding contactors located on the electric heat vestibule panel. Once
energized, heat transfer is instantaneous. High
temperature protection is provided by primary and redundant high temperature limits and overcurrent
protection is provided by fuses.
7−Fuse F3
Fuse F3 are housed in a fuse block which holds three
fuses. Each F3 fuse is connected in series with each leg of
electric heat. Figure 15 and table 2 show the fuses used
with each electric heat section. For simplicity, the service manual labels the fuses F3 − 1, 2 and F4 − 1, 2.
8−Unit Fuse Block F4
Three line voltage fuses F4 provide short circuit and
ground fault protection to all cooling components in the
KCA units with electric heat. The fuses are rated in accordance with the amperage of the cooling components.
ELECTRIC HEAT CONTROL ASSEMBLY
1−Electric Heat Relay K9
All KCA series units with electric heat use an electric heat
relay K9. K9 is a N.O. DPDT pilot relay intended to electrically isolate the unit’s 24V circuit from the electric heat 24V
circuit. K9 is energized by CMC1. K9−1 closes, energizing
timer DL2. K9 is located in the electric heat control assembly. See figure 13.
2−Time Delay DL2
DL2 is a factory−installed solid state timer used in 22.5 to 60
kW electric heat units. DL2 allows staging by providing a
timed−interval between the first and second heating elements. When the timer is energized, the contacts are
delayed for 30 seconds before closing. When the timer is
de−energized, the contacts are delayed 1 second before
opening. DL2 is located in the electric heat control assembly. See figure 13.
Page 23
ELECTRIC HEAT CONTROL ASSEMBLY
ELECTRIC HEAT
CONTROL ASSEMBLY
ELECTRIC HEAT
SECTION
K9
DL2
FIGURE 13
EHA QUANTITY
& SIZE
EHA100−7.5
EHA100−15
EHA100−22.5
EHA100−30
EHA100−45
EHA102−7.5
EHA150−15
EHA360−22.5
EHA150−30
EHA150−45
EHA150−60
TABLE 2
KCA ELECTRIC HEAT SECTION FUSE RATING
FUSE (3 each)
VOLTAGES
F3 − 1
F3 − 2
F3 − 3
F3 − 4
208/230V
25 Amp 250V
−−−−−
−−−−−
−−−−−
460V
15 Amp 600V
−−−−−
−−−−−
−−−−−
575V
10 Amp 600V
−−−−−
−−−−−
−−−−−
208/230V
50 Amp 250V
−−−−−
−−−−−
−−−−−
460V
25 Amp 600V
−−−−−
−−−−−
−−−−−
575V
20 Amp 600V
−−−−−
−−−−−
−−−−−
208/230V
50 Amp250V
−−−−−
−−−−−
25 Amp 250V
460V
25 Amp 600V
−−−−−
−−−−−
15 Amp 600V
575V
20 Amp 600V
−−−−−
−−−−−
10 Amp 600V
208/230V
50 Amp 250V
−−−−−
−−−−−
50 Amp 250V
460V
25 Amp 600V
−−−−−
−−−−−
25 Amp 600V
575V
20 Amp 600V
−−−−−
−−−−−
20 Amp 600V
208/230V
50 Amp 250V
−−−−−
60 Amp 250V
60 Amp 250V
460V
25 Amp 600V
−−−−−
−−−−−
50 Amp 600V
575V
20 Amp 600V
−−−−−
−−−−−
40 Amp 600V
208/230V
25 Amp 250V
−−−−−
−−−−−
−−−−−
460V
15 Amp 600V
−−−−−
−−−−−
−−−−−
575V
10 Amp 600V
−−−−−
−−−−−
−−−−−
208/230V
50 Amp 250V
−−−−−
−−−−−
−−−−−
460V
25 Amp 600V
−−−−−
−−−−−
−−−−−
575V
20 Amp 600V
−−−−−
−−−−−
−−−−−
208/230V
50 Amp 250V
−−−−−
−−−−−
25 Amp 250V
460V
25 Amp 600V
−−−−−
−−−−−
15 Amp 600V
575V
20 Amp 600V
−−−−−
−−−−−
10 Amp 600V
208/230V
50 Amp 250V
−−−−−
−−−−−
50 Amp 250V
460V
25 Amp 600V
−−−−−
−−−−−
25 Amp 600V
575V
20 Amp 600V
−−−−−
−−−−−
20 Amp 600V
208/230V
50 Amp 250V
−−−−−
60 Amp 250V
60 Amp 250V
460V
25 Amp 600V
−−−−−
−−−−−
50 Amp 600V
575V
20 Amp 600V
−−−−−
−−−−−
40 Amp 600V
208/230V
60 Amp 250V
60 Amp 250V
60 Amp 250V
60 Amp 250V
460V
50 Amp 600V
−−−−−
−−−−−
50 Amp 600V
575V
40 Amp 600V
−−−−−
−−−−−
40 Amp 600V
Page 24
EHA 7.5, 15, 22.5, 30, 45, 60KW
ELECTRIC HEAT SECTION PARTS ARRANGEMENT
ELECTRIC HEAT
VESTIBULE
SECONDARY
LIMIT S20
SECONDARY
LIMIT S20
HEATING ELEMENTS
HE1 − HE6
SECONDARY
LIMIT S20
SECONDARY
LIMIT S20
SECONDARY
LIMIT S20
SECONDARY
LIMIT S20
ELECTRIC
HEAT THERMOSTAT
S19
PRIMARY ELECTRIC
HEAT LIMIT
S15
P2
CONTROL WIRE
HARNESS
FIGURE 14
ELECTRIC HEAT VESTIBULE PARTS ARRANGEMENT
TERMINAL STRIP
(TB3)
FUSE F3
F3 - 1
FUSE F3
F3−2
FUSE F4
F4 - 2
FIRST STAGE ELECTRIC
HEAT CONTACTOR K15
SECOND STAGE ELECTRIC
HEAT CONTACTOR K16
FIGURE 15
Page 25
FUSE F4
F4 - 1
II−PLACEMENT AND INSTALLATION
Three Phase Scroll Compressor Voltage Phasing
Make sure the unit is installed in accordance with the
installation instructions and all applicable codes. See
accessories section for conditions requiring use of the
optional roof mounting frame (LARMF18/36 or
LARMFH18/24).
Three phase power supplied to the unit disconnect switch
must be phased sequentially to ensure the scroll compressor and indoor blower rotate in the correct direction.
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.
III−STARTUP − OPERATION
A−Preliminary and Seasonal Checks
1− Observe suction and discharge pressures and blower
rotation on unit start−up.
1− Make sure the unit is installed in accordance with the
installation instructions and applicable codes.
2− Suction pressure must drop, discharge pressure must
rise and blower rotation must match rotation marking.
2− Inspect all electrical wiring, both field and factory installed
for loose connections. Tighten as required. Refer to unit
diagram located on inside of unit compressor access panel.
3− Check to ensure that refrigerant lines are in good
condition and do not rub against the cabinet or other
refrigerant lines.
4− Check voltage at the disconnect switch. Voltage must
be within the range listed on the nameplate. If not, consult the power company and have the voltage corrected before starting the unit.
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 K2 contactor or disconnect switch if
installed. 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.
5− Recheck voltage and amp draw with unit running. If
voltage is not within range listed on unit nameplate,
stop unit and consult power company. Refer to unit
nameplate for maximum rated load amps.
REFRIGERANT CIRCUITS
092/150
(BOTH FANS ARE ENERGIZED
WITH A Y1 DEMAND)
B−Cooling Startup
EVAPORATOR
COIL STAGE 2
1− Initiate first and second stage cooling demands according to instructions provided with thermostat.
2− First−stage thermostat demand will energize compressor 1. Second−stage thermostat demand will energize
compressor 2. 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.
3− Units contain two refrigerant circuits or stages. See figure 16.
2
1
EVAPORATOR
COIL STAGE 1
4− Each refrigerant circuit is separately charged with refrigerant. See unit rating plate for correct amount of
charge.
NOTE − Refer to IV−CHARGING for proper method to check
refrigerant charge.
FIGURE 16
C−Safety or Emergency Shutdown
Turn off power to unit.
Page 26
TABLE 4
KCA102 NORMAL OPERATING PRESSURES
IV−CHARGING
WARNING
Refrigerant can be harmful if it is inhaled. Refrigerant
must be used and recovered responsibly.
Failure to follow this warning may result in personal injury or death.
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:
1− Attach gauge manifolds and operate unit in cooling
mode with economizer disabled until system stabilizes
(approximately five minutes). Make sure outdoor air
dampers are closed.
Outdoor
Coil
Entering
Air Temp
655 F
755 F
855 F
955 F
1055 F
1155 F
4− Apply the outdoor temperature to tables 3 through 6 to
determine normal operating pressures. Pressures are
listed for sea level applications at 80°F dry bulb and 67°F wet
bulb return air.
CIRCUIT 2
DisSuction
charge
+5 psig
+10 psig
270
129
310
131
353
134
399
136
448
139
501
142
TABLE 5
KCA120 NORMAL OPERATING PRESSURES
Outdoor
Coil
Entering
Air Temp
655 F
755 F
855 F
955 F
1055 F
1155 F
CIRCUIT 1
DisSuction
charge
+5 psig
+10 psig
275
135
313
137
355
140
400
142
447
145
499
148
CIRCUIT 2
DisSuction
charge
+5 psig
+10 psig
282
136
323
138
366
141
414
143
464
145
517
148
TABLE 6
KCA150 NORMAL OPERATING PRESSURES
2− Check each system separately with all stages operating.
3− Use a thermometer to accurately measure the outdoor
ambient temperature.
CIRCUIT 1
DisSuction
charge
+5 psig
+10 psig
262
128
299
131
342
134
386
137
434
140
487
143
Outdoor
Coil
Entering
Air Temp
655 F
755 F
855 F
955 F
1055 F
1155 F
CIRCUIT 1
DisSuction
charge
+5 psig
+10 psig
279
132
318
134
360
136
406
138
456
141
508
145
CIRCUIT 2
DisSuction
charge
+5 psig
+10 psig
283
136
323
138
364
139
411
140
462
142
515
145
5− Compare the normal operating pressures to the pressures obtained from the gauges. Minor variations in
these pressures may be expected due to 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.
Charge Verification − Approach Method − AHRI Testing
6− If discharge pressure is high, remove refrigerant from
the system. If discharge pressure is low, add refrigerant
to the system.
Approach Temperature = Liquid temperature minus
ambient temperature.
S Add or remove charge in increments.
S 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
KCA092 NORMAL OPERATING PRESSURES
Outdoor
Coil
Entering
Air Temp
655 F
755 F
855 F
955 F
1055 F
1155 F
CIRCUIT 1
DisSuction
charge
+5 psig
+10 psig
260
130
301
133
343
135
388
138
435
140
481
142
CIRCUIT 2
DisSuction
charge
+5 psig
+10 psig
269
132
311
133
354
136
401
139
449
141
497
144
1− Using the same thermometer, compare liquid temperature (at condenser outlet) to outdoor ambient temperature.
2− Approach temperature should match values shown in
table 7. An approach temperature greater than this value indicates an undercharge. An approach temperature less than this value indicates an overcharge.
3− The approach method is not valid for grossly over or
undercharged systems. Use tables 3 through 6 as a
guide for typical operating pressures.
TABLE 7
APPROACH TEMPERATURE
Liquid Temp. Minus Ambient Temp.
Unit
1st Stage
2nd Stage
092
9°F + 1 (5.0°C + 0.5)
8°F + 1 (4.4°C + 0.5)
102
7°F + 1 (3.9°C + 0.5)
6°F + 1 (3.3°C + 0.5)
120
8°F + 1 (4.4°C + 0.5)
6°F + 1 (3.3°C + 0.5)
150
6°F + 1 (3.3°C + 0.5)
6°F + 1 (3.3°C + 0.5)
Page 27
V− SYSTEMS SERVICE CHECKS
A−Cooling System Service Checks
A−Filters
KGA units are factory charged and require no further adjustment; however, charge should be checked periodically using
the approach method. The approach method compares actual
liquid temperature with the outdoor ambient temperature. See
section IV− CHARGING.
NOTE−When unit is properly charged discharge line pressures should approximate those in tables 3 through 6.
Units are equipped with four 20 X 25 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 17. Filters
must be U.L.C. certified or equivalent for use in Canada.
B−Lubrication
All motors are lubricated at the factory. No further lubrication is required.
REMOVE FILTERS
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.
VI−MAINTENANCE
The unit should be inspected once a year by a qualified service technician.
PULL TO
REMOVE
FILTERS
! 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.
FIGURE 17
C−Evaporator Coil
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 on unit nameplate or
contact your supervisor.
Inspect and clean coil at beginning of each cooling 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.
D−Condenser Coil
Clean condenser coil annually with detergent or commercial
coil cleaner and inspect monthly during the cooling season.
Condenser coils are made of one, two and three 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 18. Flush coils with
water following cleaning.
Note − Remove all screws and gaskets prior to cleaning procedure and replace upon completion.
E−Supply 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 28
CLEAN CONDENSER COIL
TOP VIEW
ENDPLATE IS SECURED
TO MULLION
1−
Remove unit top panel and condenser section access
panel.
2−
Remove screws securing coil end plate to mullion.
3−
Remove clips 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.
EVAPORATOR COIL
BLOWER
CONDENSER
COILS
CONDENSER ACCESS PANEL
FIGURE 18
VII−ACCESSORIES
ASSEMBLED ROOF MOUNTING FRAME
The accessories section describes the application of most of
the optional accessories which can be factory or field installed
to the KCA units. OPTIONAL ACCESSORIES section (see
table of contents) show specific size per unit.
SUPPLY AIR
OPENING
RETURN AIR
OPENING
A−LARMF Mounting Frames
When installing units on a combustible surface for downflow
discharge applications, the Lennox C1CURB roof mounting
frame is used. The roof mounting frames are recommended
in all other applications but not required. If the KCA units are
not mounted on a flat (roof) surface, they MUST be supported under all edges and under the middle of the unit to
prevent sagging. The units MUST be mounted level within
1/16" per linear foot or 5mm per meter in any direction.
The assembled C1CURB mounting frame is shown in figure 19. Refer to the roof mounting frame installation instructions for details of proper assembly and mounting. The roof
mounting frame MUST be squared to the roof and level before mounting. Plenum system MUST be installed before
the unit is set on the mounting frame. Typical roof curbing
and flashing is shown in figure 20. Refer to the roof mounting frame installation instructions for proper plenum
construction and attachment.
B−Transitions
FIGURE 19
TYPICAL FLASHING DETAIL
UNIT BASE
BOTTOM
UNIT BASE RAIL
FIBERGLASS
INSULATION
(Furnished)
COUNTER FLASHING
(Field Supplied)
NAILER STRIP
(Furnished)
Optional supply/return transitions LASRT08/10 is available
for use with the KCA 7.5 ton units and LASRT10/12 is available for the 8.5 and 10 ton units, utilizing optional C1CURB
roof mounting frames. KCA 12.5 ton units will use
LASRT15 with C1CURB roof mounting frame. Transition
must be installed in the C1CURB mounting frame before
mounting the unit to the frame. Refer to the manufacturer’s
instructions included with the transition for detailed installation procedures.
Page 29
CANT STRIP
(Field Supplied)
RIGID INSULATION
(Field Supplied)
ROOF
MOUNTING FRAME
(Extends around entire
perimeter of unit)
FIGURE 20
ROOFING
MATERIAL
LAOAD(M) MOTORIZED OUTDOOR AIR DAMPER
MOTORIZED
DAMPER
COVER PANEL
HORIZONTAL
SUPPLY AIR
OPENING
COMPRESSOR
SECTION
HORIZONTAL
RETURN AIR
OPENING
LOWER PANEL
MANUAL OUTDOOR AIR DAMPER
COVER PANEL
MANUAL DAMPER
HORIZONTAL
SUPPLY AIR
OPENING
COMPRESSOR
SECTION
HORIZONTAL
RETURN AIR
OPENING
LOWER PANEL
FIGURE 21
Page 30
ECONOMIZER
ACCESSORY
PANEL MULLION
ECONOMIZER
DIVIDER PANEL
(Attach with two
provided screws)
BOTTOM OF
COMPRESSOR
SECTION
FLANGED
RETURN AIR
OPENING
FIGURE 22
TABLE 8
C−LAOAD(M) Outdoor Air Dampers
Field or Factory Installed
Dampers will modulate to 55°F
discharge air (RT6) when:
Sensors
Optional manual and motorized outdoor air dampers provide up to 25 percent fresh air for return. Motorized damper
opens to minimum position simultaneously with the blower
during the occupied period and remains closed during the
unoccupied period. Manual damper assembly is manually
operated; damper position is manually set at installation
and remains in that position. See figure 21.
D−Supply and Return Diffusers
Single OA Sensible
OA temperature (S175) is lower
than free cooling setpoint.
Single OA Sensible
OA temperature and humidity (A7)
is lower than free cooling setpoint.
Differential Enthalpy − 1
in OA and 1 in RA
OA temperature and humidity (A7)
is lower than RA temperature and
humidity (A62).
IAQ Sensor
CO2 sensed (A63 ) is higher than
CO2 setpoint.
Optional flush mount diffuser/return FD11 and extended mount
diffuser/return RTD11 are available for use with all KCA units.
Refer to manufacturer’s instructions included with transition for detailed installation procedures.
MIXED AIR SENSOR (R1) LOCATION
R1 MIXED
AIR SENSOR
E−K1ECON20B Economizer
(Field or Factory Installed)
Economizers use outdoor air for free cooling when temperature and/or humidity is suitable. See figure 22.
The mixed air temperature sensor (R1) measures the supply
air sensible temperature. See figure 23. The outdoor air sensible control is the default economizer control. An outdoor air
single sensible sensor, S175, is also provided. See table 8
for outdoor and return air (OA and RA) sensor options. Refer
to instructions provided with sensors for installation.
An IAQ sensor is used when demand control ventilation
(DCV) is specified. Damper minimum position can be set
lower than traditional minimum air requirements resulting in
cost savings. The IAQ sensor allows the A6 to open dampers to traditional ventilation requirements as room occupancy (CO2) increases.
Page 31
FIGURE 23
A6 Enthalpy Control LED’S
TABLE 9
ENTHALPY CONTROL SETPOINTS
A steady green Free Cool LED indicates that outdoor air is
suitable for free cooling.
When an optional IAQ sensor is installed, a steady green
DCV LED indicates that the IAQ reading is higher than setpoint requiring more fresh air. See figure 24.
A6 ENTHALPY CONTROLLER
Control Setting
Free Cooling Setpoint At 50% RH
A
73° F (23° C)
B
70° F (21° C)
C
67° F (19° C)
D
63° F (17° C)
Damper Minimum Position
2V
EXH
Set
10V
EXH
Open
2V
Min
Pos
DCV
Max
10V
DAMPER MINIMUM POSITION
IAQ MAXIMUM
POSITION
1− Set thermostat to occupied mode if the feature is available. Make sure jumper is in place between TB1 terminals R and OC if using a thermostat which does not
have the feature.
(set higher than
minimum position)
IAQ READING IS
ABOVE SETPOINT
DCV
2V
NOTE − A jumper is factory−installed between TB1 R and
OC terminals to maintain occupied status (allowing minimum fresh air). When using an electronic thermostat or
energy management system with an occupied/unoccupied feature, remove jumper.
2− Rotate MIN POS SET potentiometer to approximate
desired fresh air percentage.
DCV
Set
10V
Note − Damper minimum position can be set lower than
traditional minimum air requirements when an IAQ sensor
is specified. Dampers will open to DCV MAX setting (if CO2
is above setpoint) to meet traditional ventilation requirements.
IAQ SETPOINT
Free
Cool
B
C
A
D
OUTDOOR AIR
SUITABLE LED
3− Measure outdoor air temperature. Mark the point on
the bottom line of chart 1 and label the point A" (40_F,
4_C shown).
FREE COOLING SETPOINT;
A=Completely counterclockwise
D=Completely clockwise
4− Measure return air temperature. Mark that point on the
top line of chart 1 and label the point B" (74_F, 23_C
shown).
FIGURE 24
Free Cooling Setpoint
Outdoor air is considered suitable when temperature and
humidity are less than the free cooling setpoints shown in
table 9. Setting A is recommended. See figure 24. At setting A, free cooling will be energized when outdoor air is
approximately 73°F (23°C) and 50% relative humidity. If
indoor air is too warm or humid, lower the setpoint to B. At
setting B, free cooling will be energized at 70°F (21°C) and
50% relative humidity.
When an optional A62 differential sensor is installed, turn
A6 enthalpy control free cooling setpoint potentiometer
completely clockwise to position D".
5− Measure mixed air (outdoor and return air) temperature. Mark that point on the top line of chart 1 and label
point C" (70_F, 21_C shown).
6− Draw a straight line between points A and B.
7− Draw a vertical line through point C.
8− Draw a horizontal line where the two lines meet. Read
the percent of fresh air intake on the side.
9− If fresh air percentage is less than desired, adjust MIN
POS SET potentiometer higher. If fresh air percentage
is more than desired, adjust MIN POS SET potentiometer lower. Repeat steps 3 through 8 until calculation
reads desired fresh air percentage.
Page 32
CHART 1
CALCULATE MINIMUM FRESH AIR PERCENTAGE
MIXED AND RETURN AIR TEMPERATURE
_F
_C
0
−20
−29
−10
−23
0
−18
10
−12
20
−7
30
−1
40
4
50
10
60
16
70
21
C
80
27
90
32
100 _F
38 _C
B
0
10
10
20
20
30
30
40
40
50
50
60
60
70
70
80
80
90
90
A
100
_F −20
_C −29
−10
−23
0
−18
10
−12
20
−7
30
−1
40
4
100
50
10
60
16
70
21
80
27
90
32
100 _F
38 _C
OUTDOOR AIR TEMPERATURE
DCV Set and Max Settings
Adjust settings when an optional IAQ sensor is installed.
Outdoor Air Not Suitable:
During the unoccupied time period dampers are closed.
The DCV SET potentiometer is factory−set at approximately 50% of the potentiometer range. Using a standard
1−2000ppm CO2 sensor, dampers will start to open when
the IAQ sensor reads approximately 1000ppm. Adjust
the DCV SET potentiometer to the approximate setting
specified by the controls contractor. Refer to figure 24.
During the occupied time period a cooling demand will open
dampers to minimum position and mechanical cooling
functions normally.
During the occupied time period dampers will open to DCV
MAX when IAQ reading is above setpoint (regardless of
thermostat demand or outdoor air suitability).
The DCV MAX potentiometer is factory−set at approximately 50% of the potentiometer range or 6VDC. Dampers will open approximately half way when CO2 rises
above setpoint. Adjust the DCV MAX potentiometer to
the approximate setting specified by the controls contractor. Refer to figure 24.
Outdoor Air Suitable:
See table 10 for economizer operation with a standard two−
stage thermostat.
During the occupied period, dampers will open to DCV
MAX when IAQ reading is above setpoint (regardless of
thermostat demand or outdoor air suitability). DCV MAX will
NOT override damper full−open position. When an R1
mixed air sensor for modulating dampers is installed, DCV
MAX may override damper free cooling position when occupancy is high and outdoor air temperatures are low. If R1
senses discharge air temperature below 45_F (7_C),
dampers will move to minimum position until discharge air
temperature rises to 48_F (9_C).
Note − DCV Max must be set higher than economizer minimum position setting for proper demand control ventilation.
Economizer Operation
The occupied time period is determined by the thermostat
or energy management system.
TABLE 10
ECONOMIZER OPERATION − OUTDOOR AIR IS SUITABLE FOR FREE COOLING −− FREE COOL LED ON"
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
THERMOSTAT DEMAND
DAMPER POSITION
MECHANICAL COOLING
UNOCCUPIED
OCCUPIED
OFF
CLOSED
CLOSED
NO
G
CLOSED
MINIMUM
NO
Y1
OPEN*
OPEN*
NO
Y2
OPEN*
OPEN*
STAGE 1
* Dampers will open to maintain 55°F (13°C) supply air when an R1 mixed air sensor is installed.
Page 33
B−Outdoor Air Dampers
F−Gravity Exhaust Dampers
Optional manual and motorized outdoor air dampers provide fresh outdoor air. The motorized damper assembly
opens to minimum position during the occupied time period and remains closed during the unoccupied period.
Manual damper assembly is set at installation and remains in that position.
Dampers are used in downflow (see figure 26) and horizontal (see figure 27) air discharge applications. Horizontal
gravity exhaust dampers are installed in the return air duct.
The dampers must be used any time an economizer and a
power exhaust fan is applied to KCA series units.
Gravity exhaust dampers allow exhaust air to be discharged from the system when an economizer and/or power exhaust is operating. Gravity exhaust dampers also prevent outdoor air infiltration during unit off cycle. See
installation instructions for more detail.
Set damper minimum position in the same manner as
economizer minimum position. Adjust motorized damper
position using the thumbwheel on the damper motor. See
figure 25. Manual damper fresh air intake percentage can
be determined in the same manner.
NOTE− GED is optional except required with power exhaust dampers.
GRAVITY EXHAUST DAMPERS − DOWNFLOW
DAMPER MOTOR
THUMBWHEEL
HOOD TOP
DAMPER
ASSEMBLY
HOOD TOP
SUPPORT
FIGURE 25
FIGURE 26
GRAVITY EXHAUST DAMPERS − HORIZONTAL
RETURN AIR PLENUM
13
(330)
29−1/2
(749)
FIGURE 27
Page 34
6−1/2
(165)
G−Power Exhaust Fan
H−Control Systems
The power exhaust fan (PEF) requires an optional gravity
exhaust damper and economizer and is used in downflow
applications only. See figure 28. The PEF provides exhaust
air pressure relief and also runs when return air dampers
are closed and the supply air blower is operating. See
installation instructions for more detail.
Three different types of control systems may be used with
the KCA series units. All thermostat wiring is connected to
TB1 located in the control area. Each thermostat has additional control options available. See thermostat installation
instructions for more detail.
1− Electro-mechanical thermostat (13F06)
The electro-mechanical thermostat is a two stage heat /
two stage cool thermostat with dual temperature levers.
A non-switching or manual system switch subbase
may be used.
GED AND PEF INSTALLATION
2− Electronic thermostat (see price book)
Any two stage heat / two stage cool electronic thermostat may be used.
P18
GED GRAVITY
EXHAUST
DAMPERS
3− Honeywell T7300 thermostat (60L59)
The Honeywell T7300 thermostat is a programmable, internal or optional remote temperature sensing thermostat. The T7300 provides occupied and unoccupied
changeover control.
PEF POWER
EXHAUST FAN ASSEMBLY
(ORDERED SEPARATELY)
I−Smoke Detectors A171 and A172
FIGURE 28
Power Exhaust Setpoint Adjustment
Locate the A6 enthalpy control in the control area. The EXH
SET potentiometer is factory−set at approximately 50% of
the dial range. See figure 29. Power exhaust fans will be energized 30 seconds after dampers are 50% open. Adjust the
EXH SET potentiometer higher (clockwise toward 10V) to
energize fans when dampers are further open. Adjust the
EXH SET potentiometer lower (counterclockwise toward
2V) to energize fans when dampers are further closed.
(Thirty−second delay allows dampers to partially open before exhaust fan starts.)
A6 ENTHALPY CONTROLLER
2V
EXH
Set
10V
EXH
Open
2V
Photoelectric smoke detectors are a field installed option.
The smoke detectors can be installed in the supply air section (A172), return air section (A171), or in both the supply
and return air section.
J−Drain Pan Overflow Switch S149 (optional)
The overflow switch is used to interrupt cooling operation
when excessive condensate collects in the drain pan. The
N.O. overflow switch is controlled by K220 and DL46 relays, located in the unit control panel. When the overflow
switch closes, 24VAC power is interrupted and after a five−
second delay unit compressors are de−energized. Once
the condensate level drops below the set level, the switch
will open. After a five−minute delay the compressor will be
energized.
ADJUST POWER
EXHAUST FAN
SETPOINT
Min
Pos
DCV
Max
10V
ENERGIZED WHEN
DAMPER POSITION
IS HIGHER THAN
EXHAUST FAN
SETPOINT
DCV
2V
DCV
Set
10V
Free
Cool
B
C
A
D
FIGURE 29
Page 35
VIII−Wiring Diagrams and Sequence of Operation
KCA092/150 UNIT DIAGRAM
24V POWER
TO
L1
P2 IS USED ON KCA UNITS ONLY
IMPORTANT: TO PREVENTMOTOR BURNOUT, NEVER
CONNECTMORETHAN ONEMOTORLEADTO ANY ONE
CONNECTION. TAPE UNUSED MOTOR LEADS
TO
380−420V
N
UNITS
S42 USED ON "M" VOLTAGEUNITS AND UNITS
WITH HIGH EFFICIENCY MOTORS
CONNECT A172 SENSOR TO J261 ON SUPPLY AI R
SMOKE DETECTOR ONLY
S48 OR CB10 MAY BE USED
JUMPER WHEN S11 AND S84 ARE NOT USED
ECONOMIZER
3
BLOWER(G)
HEAT 1(W1)
HEAT 2(W2)
DESCRIPTION
KEY
5
COMPONENT
A42
MONITOR, PHASE PROTECTION
A144
MODULE, VOLTAGE REDUCTION
COOL 1(Y1)
COOL 2 (Y2)
7
K220
A
B
B
K2
2
A
A
K1
L2
460V − 575V
U N I T S
A
K10
A
K3
BLACK
A171
1
L1
T18
220−240V
WHITE
8 6
B
B
B
MODULE, CONTROL SMOKE DETECTION
B1
COMPRESSOR 1
B2
COMPRESSOR 2
B3
MOTOR, BLOWER
B4
MOTOR, OUTDOOR FAN 1
B5
MOTOR, OUTDOOR FAN 2
B10
MOTOR, EXHAUST FAN 1
C1
CAPACITOR, OUTDOOR FAN 1
C2
CAPACITOR, OUTDOOR FAN 2
C6
CAPACITOR, EXHAUST FAN 1
CB8
CIRCUIT, BREAKER T1
DL46
DELAY, OVERFLOW SWITCH
HR1
HEATER COMPRESSOR 1
HR2
HEATER COMPRESSOR 2
J2
JACK, HEAT
J11
JACK, GFI, RECEPTICLE
DISCONNECT ALL POWER BEFORE SERVICING.
J18
JACK, EXHAUST FAN COMPT
J24
JACK, EXHAUST FAN
J35
JACK, TEST
J36
JACK, TEST COOL
J86
JACK, OUTDOOR FANS 1
J132
JACK, BLOWER , EXHAUST FAN MOTOR 1
J250
JACK, SMOKE DETECTOR ONE
J251
JACK, SMOKE DETECTOR ONE
J252
JACK, SMOKE DETECTOR TWO
J253
JACK, SMOKE DETECTOR TWO
J255
JACK, MODULE, CONTROL SMOKE DETECTION
4
T3
K65−1
T3
6
9
7
K65−2
L3
K10−2
K2−1
T3
L3
J11
4
9
6
6
B2
120/ 60/1
SENSOR TWO, SMOKE, SUPPLY AIR
A173
WARNING − ELECTRIC SHOCK HAZARD, CAN CAUSE INJURY
DEATH
OR
UNIT MUST BE GROUNDEDIN ACCORDANCEWITH NATIONAL AND
LOCAL CODES
L3
H
A172
24V COMMON
NOTE − IF ANY WIRE IN THIS APPLIANCEIS REPLACEDIT MUST BE
REPLACEDWITH WIRE OF LIKE SIZE, RATING, TERMINATION AND
INSULATION THICKNESS
2
SENSOR ONE, SMOKE, RETURN AIR
B3
HR2
HR1
7
5
2
3
N
GROUND
P86
PLUG, OUTDOOR FANS 1
P132
PLUG, EXHAUST FAN MOTOR 1
P250
JACK, SMOKE DETECTOR ONE
P251
JACK, SMOKE DETECTOR ONE
P252
JACK, SMOKE DETECTOR TWO
P253
JACK, SMOKE DETECTOR TWO
P255
PLUG, MODULE, CONTROL SMOKE DETECTION
S3
SWITCH, LIMIT LOW COMPRESSOR 1
S4
SWITCH, LIMIT HI PRESS COMP 1
S5
SWITCH, LIMIT HI TEMP COMPRESSOR 1
S7
SWITCH, LIMIT HI PRESS COMP 2
S8
SWITCH, LIMIT HI TEMP COMPRESSOR 2
S11
SWITCH, LOW PRESS, LOW AMBIENT KIT
S30
SWITCH, LIMIT LOW COMPRESSOR 2
S42
SWITCH, OVERLOAD RELAY BLOWER MOTOR
S48
SWITCH, DISCONNECT
S49
SWITCH, FREEZESTAT COMP 1
S50
SWITCH, FREEZESTAT COMP 2
S84
SWITCH, LOW PRESS, LOW AMBIENT KIT COMP 2
S149
SWITCH, OVERFLOW
T1
TRANSFORMER, CONTROL
J261
JACK, SMOKE DETECTOR JUMPER
K1,−1
CONTACTOR, COMPRESSOR 1
K2,−1
CONTACTOR, COMPRESSOR 2
K3, −1
CONTACTOR, BLOWER
K10,−1,2 RELAY, OUTDOOR FAN
K65−1,2
3
2
1
B4
3
2
RELAY, EXHAUST FAN
K220, −1 RELAY, OVERFLOW DELAY
1
B5
DENOTES OPTIONAL COMPONENTS
LINE VOLTAGE FIELD INSTALLED
P2
JACK, HEAT
P18
PLUG, EXHAUST FAN COMPT
P24
PLUG, EXHAUST FAN
P35
JACK, TEST
P36
PLUG, TEST COOL
COOLING
REV. 0.0
Lennox Commercial
Page 36
KCA092/150 Sequence of Operation
Power:
the thermostat. G energizes blower. 24VAC is routed
through TB1 passing N.C. freezestat S49 and optional
N.C. high pressure switch S4. Compressor contactor
K1 is energized. N.O. contacts K1 close energizing
compressor B1.
1− Line voltage from unit disconnect energizes transformer T1. T1 provides 24VAC power to terminal strip TB1.
TB1 provides 24VAC to the unit cooling, heating and
blower controls.
Blower Operation:
2− Indoor thermostat terminal G energizes blower contactor K3 with 24VAC. N.O. K3 closes, energizing blower
B3.
6− Optional N.O. low ambient switch S11 closes to energize condenser fan relay K10. N.O. contacts K10−1 and
K10−2 close energizing condenser fans B4 and B5.
N.C. contacts K10−1 open de−energizing crankcase
heaters HR1 and HR2.
2nd Stage Cooling (compressor B2 is energized)
Economizer Operation:
3− The economizer control module receives a demand
and energizes exhaust fan relay K65 with 24VAC at
50% outside air damper open (adjustable).
4− N.O. K65−1 and N.O. K65−2 both close, energizing exhaust fan motor B10.
1st Stage Cooling (compressor B1)
5− First stage cooling demand Y1 and G are energized by
7− 24VAC is routed through TB1 and proves N.C. freezestat S50 and optional N.C. high pressure switch S7.
Compressor contactor K2 is energized. N.O. K2 contacts close energizing compressor B2.
8− Optional N.O. low ambient switch S84 closes to energizing condenser fan relay K10. N.O. contacts K10−1
and K10−2 close energizing condenser fans B4 and B5.
N.C. contacts K10−1 open de−energizing crankcase
heaters HR1 and HR2.
Page 37
ELECTRONIC OR ELECTROMECHANICAL THERMOSTAT
24V POWER
ECONOMIZER
BLOWER(G)
HEAT 1(W1)
HEAT 2(W2)
COOL 1(Y1)
COOL 2(Y2)
k65
A
B
24V COMMON
24V POWER
COOL 1 (Y1)
KEY
A2
A63
CMC3
J3
K65
P3
R1
RT2
TB1
DESCRIPTION
COMPONENT
SENSOR, ELECTRONIC THERMOSTAT
SENSOR, CO2
CLOCK, TIME
JACK, UNIT ECONOMIZER
RELAY, EXHAUST FAN
PLUG, ECONOMIZER BYPASS
SENSOR, MIXED AIR OR SUPPLY AIR
SENSOR, REMOTE THERMOSTAT
TERMINAL STRIP, CLASS II VOLTAGE
COOL 2 (Y2)
24V COMMON
CONNECTION SCHEME FOR KCA, KGA AND KHA
092 THROUGH 150 UNITS WITHOUT
ECONOMIZER ONLY
REMOVEP3 WHEN ECONOMIZERIS USED, ONLY ON KCA,
KGA AND KHA 180 THROUGH 300 UNITS.
ACCESSORIES
TOUCHSCREEN THERMOSTAT
REV. 2.0
Lennox Commercial
POWER:
1− Terminal strip TB1 energizes thermostat components with 24VAC.
OPERATION:
2− TB1 receives data from the electronic thermostat A2 (Y1, Y2, W1, W2, G, OCP). The 24VAC signal from TB1 energizes the appropriate components for heat or cool demand.
Page 38
ECONOMIZER
SEQUENCE OF OPERATION
POWER:
1− Terminal strip TB1 energizes the economizer components with 24VAC.
OPERATION:
2− Enthalpy sensor A7 and A62 (if differential enthalpy is used) communicates to the economizer control
module A6 when to power the damper motor B7.
3− Economizer control module A6 supplies B7 with 0 − 10 VDC to control the positioning of economizer.
4− The damper actuator provides 2 to 10 VDC position feedback.
Page 39
EHA−7.5, 15, 22.5, 30, 45 & 60kW Y VOLTAGE
KCA SERIES UNITS
5
5
6
9
1
4 11
7 10
Page 40
3
11
EHA−7.5, 15, 22.5, 30, 45 & 60kW G, J VOLTAGE
KCA SERIES UNITS
P2
2
DESCRIPTION
KEY
COMPONENT
DL2
DELAY−ELECTRIC HEAT
F3
FUSE−ELECTRIC HEAT
F4
FUSE−UNIT
F42
FUSE−ELECTRIC HEAT 2
7
4
1
7
6
1
5
K9−1
HE1
ELEMENT−ELECTRIC HEAT 1
HE2
ELEMENT−ELECTRIC HEAT 2
HE3
ELEMENT−ELECTRIC HEAT 3
HE4
ELEMENT−ELECTRIC HEAT 4
J7
JACK−ELECT HT SUB−BUS KIT
K9,−1
RELAY−HEAT
K15,−1
CONTACTOR−ELECTRIC HT 1
K16,−1
CONTACTOR−ELECTRIC HT 2
P2
PLUG−HEAT
P7
PLUG−ELECT HT SUB−BASE KIT
S15
SWITCH LIMIT, PRIMARY, ELECT HT
S19
J7 P7
7
9
8
8
6
5
B
S19
THERMOSTAT−ELECTRIC HEAT LIMIT
S20
SWITCH−LIMIT, SECONDARY ELECT HT
S157
SWITCH LIMIT, SECONDARY ELECT HT 2
S158
SWITCH LIMIT, SECONDARY ELECT HT 3
S159
SWITCH LIMIT, SECONDARY ELECT HT 4
TB2
TERMINAL STRIP−UNIT
TB3
TERMINAL STRIP−ELECTRIC HEAT
3
A
9
5
6
9
A
A
B
B
4
3
11
1
F42
L1
L2
L3
T1
T2
T3
T1
T2
T3
S159
L3
S158
L2
S157
4
L1
7
11
10
HEATING−ELETRIC
REV. 0.0
Lennox Commercial
Page 41
Sequence of Operation −EHA 7.5, 15, 22.5, 30, 45, 60 kW − Y and G, J, M
NOTE: This sequence of operation is for all Electric
Heat kW ratings Y through J voltages. Each step of operation is numbered and can be followed in sequence
on the diagrams. Operation for G, J, and M voltages will
be the same.
HEATING ELEMENTS:
SECOND STAGE HEAT:
2− Heating demand initiates at W1 in thermostat.
3− 24VAC W2 signal is routed through from the thermostat
to TB1. After S15 N.C. primary limit and S20 secondary
limit is proved, the electric heat contactor K15 is energized.
1− Terminal Strip TB3 is energized when the unit disconnect closes. TB3 supplies line voltage to electric heat
elements HE1 through HE7. Each element is protected
by fuse F3.
Page 42