LENNOX LGM-LCM092U Gas and Cooling Packaged Units Instruction Manual

LENNOX LGM-LCM092U Gas and Cooling Packaged Units

Product Information

Specifications

• Model: LGM/LCM092U (7.5 TON), LGM/LCM102U (8.5 TON), LGM/LCM120U (10 TON), LGM/LCM150U (12.5 TON)
• Type: Gas and Cooling Packaged Units
• Part Number: 508116-01
• Dimensions: Please refer to the diagram below for detailed dimensions.

Parts Arrangement

The parts of the product are arranged as shown in the diagram below:

Shipping and Packing List
The product is shipped with the following items:

• Product unit
• Factory-installed accessories (if applicable)
• User manual and instructions

Safety

It is important to follow safety guidelines to prevent property damage, personal injury, or loss of life. The following safety precautions should be taken:

• All installation, adjustment, alteration, service, and maintenance must be performed by a licensed professional HVAC installer or equivalent, service agency, or the gas supplier.
• Before performing any maintenance, ensure proper lock-out and tag-out procedures are followed.
• Disable power to the blower and set all controllers and thermostats to the OFF position before performing maintenance.
• Avoid contact with moving parts and sharp sheet metal edges. Always wear gloves and protective clothing when handling the equipment.

Unit Support

The product unit should be properly supported to ensure stability and safety. Follow the manufacturer’s guidelines for unit support.

Duct Connection
Connect the product unit to the duct system using appropriate duct connections. Ensure proper sealing to prevent air leaks.

Rigging Unit for Lifting
If lifting the product unit is necessary, use the designated lifting holes or forklift slots as indicated in the diagram below. Follow proper rigging procedures and guidelines.

Condensate Drains
Proper condensate drainage is important for the operation and efficiency of the product unit. Install condensate drains as per manufacturer’s instructions.

Connect Gas Piping (Gas Units)
If using a gas unit, connect the gas piping following appropriate guidelines and codes. Ensure proper sealing and leak testing.

Pressure Test Gas Piping (Gas Units)
Before operating a gas unit, it is important to perform a pressure test on the gas piping to ensure there are no leaks. Follow the manufacturer’s instructions for pressure testing.

High Altitude Derate

In high altitude areas, the product unit may require derating. Refer to the manufacturer’s guidelines for derating instructionsspecific to your altitude.

Download Mobile Service App
The product unit is compatible with a mobile service app that allows for remote control and configuration. Follow the steps below to download and set up the app:

1. Use your smartphone to scan the QR code provided in the unit control area or refer to the manual for the QR code.
2. Download and install the mobile service app from the appropriate iOS or Android store.
3. Follow the prompts in the app to pair it with the unit control system and configure the unit.
4. For detailed instructions, refer to the “Download Mobile App” section in the user manual and the Setup Guide provided with the unit.

Electrical Connections – Power Supply
Ensure proper electrical connections for the power supply of the product unit. Follow local electrical codes and guidelines. If unsure, consult a licensed professional.

Electrical Connections – Control Wiring
Connect the control wiring according to the manufacturer’s instructions. Follow proper wiring practices and ensure secure connections.

Blower Operation

The blower is a critical component of the product unit. Follow the manufacturer’s instructions for blower operation, maintenance, and troubleshooting.

Direct Drive Blower Start-Up
If the product unit has a direct drive blower, follow these steps for start-up:

1. Ensure all power to the unit is off.
2. Inspect the blower for any obstructions or damage.
3. If necessary, lubricate the blower motor according to the manufacturer’s instructions.
4. Turn on the power to the unit and set the thermostat to the desired settings.
5. Observe the blower operation for any abnormalities or unusual noises.

Cooling Start-Up

To start the cooling operation of the product unit, follow these steps:

1. Ensure all power to the unit is off.
2. Inspect the cooling components for any obstructions or damage.
3. Check the refrigerant level and make adjustments if necessary.
4. Turn on the power to the unit and set the thermostat to the desired cooling temperature.
5. Observe the cooling operation for any abnormalities or insufficient cooling.

Prognostic & Diagnostic Sensors
The product unit is equipped with prognostic and diagnostic sensors to monitor and detect any issues. These sensors provide valuable information for maintenance and troubleshooting. Refer to the manufacturer’s instructions for details on sensor operation and interpretation of sensor data.

Gas Heat Start-Up (Gas Units)
To start the gas heating operation of the product unit, follow these steps:

1. Ensure all power to the unit is off.
2. Inspect the gas heat components for any obstructions or damage.
3. Check the gas supply and ensure it is connected properly.
4. Turn on the power to the unit and set the thermostat to the desired heating temperature.
5. Observe the gas heating operation for any abnormalities or insufficient heating.

Heating Operation and Adjustments
For heating operation and adjustments, follow the manufacturer’s instructions specific to your product unit model. This may include settings for temperature control, fan speed, and other heating-related parameters.

Electric Heat Start-Up (Cooling Units)

If the product unit has electric heat for cooling operation, follow these steps for start-up:

1. Ensure all power to the unit is off.
2. Inspect the electric heat components for any obstructions or damage.
3. Check the electrical connections for the electric heat elements.
4. Turn on the power to the unit and set the thermostat to the desired cooling temperature.
5. Observe the electric heating operation for any abnormalities or insufficient heating.

SCR Electric Heat Controller (LCM Units)
If your product unit is equipped with an SCR electric heat controller (LCM units), follow the manufacturer’s instructions for operation and adjustments specific to the controller. This may include settings for temperature control, fan speed, and other heating-related parameters.

Cooling Operation

For cooling operation, follow the manufacturer’s instructions specific to your product unit model. This may include settings for temperature control, fan speed, and other cooling-related parameters.

Modulating Hot Gas Reheat Start-Up and Operation
If your product unit has a modulating hot gas reheat system, follow the manufacturer’s instructions for start-up and operation. This system is designed to provide precise control of reheat temperature for optimal comfort and energy efficiency.

Service

For servicing the product unit, refer to the manufacturer’s instructions. Only perform maintenance and repairs that are within your capabilities. If unsure, consult a licensed professional HVAC technician.

Field-Installed Accessories
If you have installed any field accessories in addition to the factory- installed accessories, refer to the manufacturer’s instructions for operation and maintenance of those accessories.

Factory Unit Controller Settings

The factory unit controller settings are pre-configured for optimal performance. Avoid making unnecessary changes to the controller settings unless instructed by the manufacturer or a licensed professional.

FAQ

Q: Can I install the product unit myself?
A: No, installation must be performed by a licensed professional HVAC installer or equivalent, service agency, or the gas supplier.

Q: Where can I download the mobile service app?
A: The mobile service app can be downloaded from the appropriate iOS or Android store. Look for the following icon:

Q: How can I prevent personal injury while handling the equipment?
A: Take care while handling the equipment and always wear gloves and protective clothing. Avoid contact with sharp sheet metal edges.

IMPORTANT

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

INSTALLATION INSTRUCTIONS

LGM/LCM092U (7.5 TON)

LGM/LCM102U (8.5 TON)

LGM/LCM120U (10 TON)

LGM/LCM150U (12.5 TON)

GAS AND COOLING PACKAGED UNITS
508116-01 10/2023 Supersedes 4/2022

Cooling Operation

26

Modulating Hot Gas Reheat Start-Up and Operation 27

Service

28

Field-Installed Accessories

35

Factory Unit Controller Settings

35

WARNING
To prevent serious injury or death:
1- Lock-out. tag-out before performing maintenance.
2- If system power is required (e.g., smoke detector maintenance), disable power to blower, remove fan belt where applicable, and ensure all controllers and thermostats are set to the OFF position before performing maintenance.
3- Always keep hands, hair clothing, jewelery, tools, etc., away from moving parts.

RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCES
Attention!
Use this QR code to download the mobile service app. Follow the prompts to pair the app with the unit control system and configure the unit. Refer to the “Download Mobile App” section in this manual and the Setup Guide provided with this unit. The QR code is also available in the unit control area.

The app can be downloaded from the appropriate iOS or Android store. Look for the following icon.

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

LGM/LCM092, 102, 120, 150 DIMENSIONS in. – Gas heat section shown

6-1/8 (156)
AA

5-5/8 (143) BOTTOM SUPPLY
AIR OPENING
BB

58-1/8 (1476)

6-1/8 (156)

24 (610)

10-3/4

28

(273) 20 (711)

(508)

60-1/8 (1527) BASE
BOTTOM POWER ENTRY 5-1/2 (140) Dia.

27 (686)
BOTTOM RETURN AIR OPENING
EE

CENTER OF GRAVITY
FF

7 (178)

6-5/8 (168)

DD

BOTTOM

CC

7 (178)

CONDENSATE

34-7/8 (886)

101-1/4 BASE (2572)

TOP VIEW

OPTIONAL DISCONNECT (FACTORY INSTALLED)

99-1/4 (2521)

60-1/8 (1527)
END VIEW

46-7/8 (1191) 43-3/8 (1102)
3-1/2 (89)

1 (25) ELECTRIC INLETS
15-1/2 (394)

CONDENSATE DRAIN (FRONT)

GAS SUPPLY INLET

5-3/8 (137)

18-1/2 (470)

FLUE OUTLET

46-7/8 (1191)

34-7/8 (886)
39-7/8 (1013)

FORKLIFT SLOTS (BOTH SIDES) LIFTING HOLES (FOR RIGGING)

101-1/4 (2572)
SIDE VIEW

15-1/2 (394)

1-5/8 (41)

HORIZONTAL SUPPLY AIR
OPENING

HORIZONTAL RETURN AIR
OPENING

30 (762)

12-1/8 (308)

CONDENSATE

6-1/8

DRAIN (BACK)

5-3/8

(156)

(137)

31-1/2

30

Important – Do not install

(800)
66-3/8 (1686)

(762)

horizontal economizers on this opening. Refer to

SIDE VIEW

economizer instructions for proper installation.

(Horizontal Openings)

Page 2

LGM092, 102, 120, 150 PARTS ARRANGEMENT

FILTERS (FOUR – 20 X 25 X 2″)

EVAPORATOR COIL

REHEAT COIL BLOWER (OPTIONAL) (DIRECT DRIVE)

CONDENSER FANS
CONDENSER COIL

COMPRESSOR INVERTER
(BEHIND THE HINGED PANEL)
ECONOMIZER (OPTIONAL)
WIFI ANTENNA

UNIT CONTROLLER
WIRELESS BOARD
COMPRESSORS

GAS VALVE
CONDENSATE DRAIN

COMBUSTION AIR INDUCER
BURNERS

IGNITION CONTROL

LCM092, 102, 120, 150 PARTS ARRANGEMENT

FILTERS (FOUR – 20 X 25 X 2″)

EVAPORATOR COIL

REHEAT COIL (OPTIONAL)

BLOWER (DIRECT DRIVE)

CONDENSER FANS

COMPRESSOR INVERTER
(BEHIND THE HINGED PANEL)
ECONOMIZER (OPTIONAL)
WIFI ANTENNA
UNIT CONTROLLER
WIRELESS BOARD
COMPRESSORS

CONDENSATE DRAIN

ELECTRIC HEAT (OPTIONAL)

CONDENSER COIL

Page 3

Shipping and Packing List
Package 1 of 1 contains:
1 – Assembled unit
Check unit for shipping damage. Receiving party should contact last carrier immediately if shipping damage is found.
General
These instructions are intended as a general guide and do not supersede local codes in any way. Authorities having jurisdiction should be consulted before installation.
The LGM092, 102, 120, & 150 gas/electric packaged rooftop unit is available in 130,000, 180,000, or 240,000 Btuh heating inputs. The LCM092, 102, 120, & 150 cooling packaged rooftop unit is the same basic design as the LGM unit except for the heating section. Optional electric heat is factory- or field-installed in LCM units. Units are equipped with fin/tube condenser coils. Units are available with an optional hot gas reheat coil which provides dehumidifying modes of operation. Refer
to Reheat Operation section.
Units are equipped with direct drive blowers. The blower will operate at lower speeds when demand is low and increase to higher speeds when demand is high. Refer to the Direct Drive Start-Up section.
The following examples show the model numbers of ten ton units with blower options.
LGM/LCM120U4E Single Zone VAV Direct Drive
LGM/LCM120U4P VAV Direct Drive
All units are available using R410A, an ozone-friendly HFC refrigerant. Refer to the Cooling Start-Up section for precautions when installing unit.
Safety
See TABLE 1 for unit clearances.
WARNING
Electric shock hazard and danger of explosion. Can cause injury, death or product or property damage. Turn off gas and electrical power to unit before performing any maintenance or servicing operations on the unit. Follow lighting instructions attached to unit when putting unit back into operation and after service or maintenance.

Optional Outdoor Air Hood

UNIT CLEARANCES

C

B D

A

FIGURE 1

TABLE 1 UNIT CLEARANCES

¹ Unit

A

B

C

D

Top

Clearance in.(mm) in.(mm) in.(mm) in.(mm) Clearance

Service Clearance

60 (1524)

36 (914)

36 (914)

60 (1524)

Unobstructed

Clearance to

36

1

1

1

Unob-

Combustibles (914)

(25)

(25)

(25)

structed

Minimum Operation Clearance

36 (914)

36 (914)

36 (914)

36 (914)

Unobstructed

NOTE – Entire perimeter of unit base requires support when elevated above mounting surface.

¹ Service Clearance – Required for removal of serviceable parts Clearance to Combustibles – Required clearance to combustible material (gas units). On LCM units, see clearance to combustible materials as outlined of neater rating plate. Minimum Operation Clearance – Required clearance for proper unit operation.

NOTICE
Roof Damage!
This system contains both refrigerant and oil. Some rubber roofing material may absorb oil, causing the rubber to swell. Bubbles in the rubber roofing material can cause leaks. Protect the roof surface to avoid exposure to refrigerant and oil during service and installation. Failure to follow this notice could result in damage to roof surface.

IMPORTANT
The Clean Air Act of 1990 bans the intentional 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.

Page 4

Use of this unit as a construction heater or air conditioner is not recommended during any phase of construction. Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.
If this unit has been used for heating or cooling of buildings or structures under construction, the following conditions must be met or the warranty will be void:
· A room thermostat or zone air temperature sensor 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.
· 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.
This appliance is not to be used by persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction.
This appliance should not be used by children. Children should be supervised to ensure they do not play with the appliance.
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 C1CURB7*B roof mounting frame.
NOTE – Securely fasten roof frame to roof per local codes.
CAUTION
To reduce the likelihood of supply / return air by pass and promote a proper seal with the RTU, duct work / duct drops / diffuser assemblies must be supported independently to the building structure.

A-Downflow Discharge Application Roof Mounting with C1CURB7B
1 – The C1CURB7B roof mounting frame must be installed, flashed and sealed in accordance with the instructions provided with the frame.
2 – The C1CURB7B roof mounting frame should be square and level to 1/16″ per linear foot (5mm per linear meter) in any direction.
3 – Duct must be attached to the roof mounting frame and not to the unit; supply and return plenums must be installed before setting the unit.
Installer’s Roof Mounting Frame
Many types of roof frames can be used to install the unit depending upon different roof structures. Items to keep in mind when using the building frame or supports are:
1 – The base is fully enclosed and insulated, so an enclosed frame is not required.
2 – The frames or supports must be constructed with non-combustible materials and should be square and level to 1/16″ per linear foot (5mm per linear meter) in any direction.
3 – Frame or supports must be high enough to prevent any form of moisture from entering unit. Recommended minimum frame height is 14″ (356mm).
4 – Duct must be attached to the roof mounting frame and not to the unit. Supply and return plenums must be installed before setting the unit.
5 – Units require support along all four sides of unit base. Supports must be constructed of steel or suitably treated wood materials.
NOTE – When installing a unit on a combustible surface for downflow discharge applications, an C1CURB7B roof mounting frame is required.

Page 5

B-Horizontal Discharge Applications 1 – Units installed in horizontal airflow applications must use a horizontal conversion kit K1HECK00.
2 – Specified installation clearances must be maintained when installing units. Refer to FIGURE 1.
3 – Top of support slab should be approximately 4″ (102mm) above the finished grade and located so no run-off water from higher ground can collect around the unit.
4 – Units require support along all four sides of unit base. Supports must be constructed of steel or suitably treated wood materials.
Duct Connection
All exterior ducts, joints and openings in roof or building walls must be insulated and weather-proofed with flashing and sealing compounds in accordance with applicable codes. Any duct passing through an unconditioned space must be insulated.
CAUTION
In downflow applications, do not drill or punch holes in base of unit. Leaking in roof may occur if unit base is punctured.

Rigging Unit for Lifting
Rig unit for lifting by attaching four cables to holes in unit base rail. See FIGURE 2.
1 – Detach wooden base protection before rigging. NOTE – Remove all 7 (5 brackets on units with three outdoor fans) base protection brackets before setting unit.
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.)

Condensate Drains
Make drain connection to the 1″ N.P.T. drain coupling provided on unit.
NOTE – The drain pan is made with a glass reinforced engineered plastic capable of withstanding typical joint torque but can be damaged with excessive force. Tighten pipe nipple hand tight and turn an additional quarter turn.

A trap must be installed between drain connection and an open vent for proper condensate removal. See FIGURE 3 or 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 1 and page 2 for condensate drain location.

RIGGING

Unit

*Weight

Lbs.

Kg.

LGM LCM

1401

636

1366

620

*Maximum weight with all available factory-installed accessories.

CAUTION – Do not walk on unit.

IMPORTANT – ALL PANELS MUST BE IN PLACE FOR RIGGING.
LIFTING POINT SHOULD BE DIRECTLY ABOVE CENTER OF GRAVITY

FIGURE 2
CONDENSATE SIDE DRAIN CONNECTION

CAULK AROUND CONDENSATE COUPLING

NOTE – Allow clearance to open doors when installing condensate piping.

Minimum Pitch 1″ (25 mm) per 10′ (3 m) of line

OPEN VENT

UNIT

FIGURE 3

MOUNTING FRAME

Page 6

CONDENSATE BOTTOM DRAIN CONNECTION
UNIT
DRAIN PAN CAULK AROUND CONDENSATE COUPLING
OPEN VENT

MOUNTING FRAME

Minimum Pitch 1″ (25 mm) per 10′
(3 m) of line

FIGURE 4
Units are shipped with the drain coupling facing the front of the unit. Condensate can be drained from the back or bottom of the unit with the following modifications. The unit can be installed in either downflow or horizontal air discharge regardless of condensate drain location.
Rear Drain Connection
1 – Open blower and heat access doors. See FIGURE 5.

FILTER ACCESS DOOR

BLOWER ACCESS DOOR

2 – Remove six screws from filter access door. Refer to FIGURE 6.
UNITS WITH HINGED PANELS
FILTER DOOR
CONDENSATE DRAIN MULLION
REMOVE THREE SCREWS (PER HINGE)
FIGURE 6 3 – Open filter access door hinges and carefully remove
door. 4 – Remove eight screws holding condensate drain
mullion and remove mullion. 5 – Lift front edge of the drain pan (to clear bottom drain
plug) and slide drain pan out of unit. See FIGURE 7.

HEAT ACCESS DOOR CONDENSATE DRAIN MULLION
FIGURE 5

DRAIN PAN
FIGURE 7 6 – Make sure the cap over the unit bottom drain hole
is secure. 7 – Rotate the drain pan until the downward slope is
toward the back of the unit. Slide the drain pan back into the unit. Be careful not to dislodge the cap over the bottom drain hole. 8 – From the back side of the unit, pull the drain pan coupling through the rear condensate opening. 9 – Replace the condensate drain mullion and reinstall eight screws. 10 – Reinstall filter door on hinges.

Page 7

Bottom Drain Connection
1 – Open blower and heat access doors. See FIGURE 5.
2 – Remove six screws from filter access door. Refer to FIGURE 6.
3 – Open filter access door hinges and carefully remove door.
4 – Remove eight screws holding condensate drain mullion and remove mullion.
5 – Lift front edge of the drain pan (to clear bottom drain plug) and slide drain pan out of unit. See FIGURE 7.
6 – Turn the drain pan upside down and drill a pilot hole through the bottom of the drain pan in the center of the coupling. See FIGURE 8.

BOTTOM CONDENSATE DRAIN

CAUTION: Be careful not to damage the coupling threads
when drilling the hole.

DRILL A PILOT HOLE IN CENTER
OF COUPLING

Connect Gas Piping (Gas Units)
Before connecting piping, check with gas company or authorities having jurisdiction for local code requirements. When installing gas supply piping, length of run from gas meter must be considered in determining pipe size for 0.5″ w.c. (.12kPa) maximum pressure drop. Do not use supply pipe smaller than unit gas connection. For natural gas units, operating pressure at the unit gas connection must be a minimum of 4.7″ w.c. (1.17kPa) and a maximum of 10.5″ (2.60kPa) w.c. For LP/propane gas units, operating pressure at the unit gas connection must be a minimum of 10.5″ w.c. (2.61kPa) and a maximum of 13.0″ w.c. (3.23kPa).
When making piping connections a drip leg should be installed on vertical pipe runs to serve as a trap for sediment or condensate. A 1/8″ N.P.T. plugged tap is located on gas valve for test gauge connection. Refer to Heating Start-Up section for tap location. Install a ground joint union between the gas control manifold and the main manual shut-off valve. See FIGURE 9 for gas supply piping entering outside the unit. FIGURE 10 shows bottom gas entry piping through the curb. FIGURE 11 shows bottom gas entry piping through the unit.
Compounds used on threaded joints of gas piping shall be resistant to the action of liquefied petroleum gases.
OUTSIDE OF UNIT GAS PIPE CONNECTION

After drilling the pilot hole, drill a 7/8″ hole from
the inside of the pan.
FIGURE 8
7 – From the inside of the pan, use a Vari-Bit® bit to enlarge the hole to 7/8″. Do not damage coupling threads.
8 – Remove the cap over the unit bottom drain hole.
9 – Slide the drain pan back into the unit.
10 – From the back side of the unit, pull the drain pan coupling through the rear condensate opening.
11 – From the front side of the unit, move the drain pan until the bottom coupling settles into the unit bottom drain opening. Once in place, check to make sure the coupling is still positioned through the rear condensate drain hole.
12 – Use a field-provided 1″ plug to seal side drain connection.
13 – Replace the condensate drain mullion and reinstall eight screws.
14 – Reinstall filter door on hinges.

GROUND JOINT UNION

TO GAS SUPPLY

TO GAS VALVE

GAS PIPING SUPPORT
MANUAL MAIN SHUT-OFF VALVE

DRIP LEG
(REFER TO LOCAL CODES)

FIGURE 9

Page 8

BOTTOM ENTRY GAS PIPING THROUGH THE CURB

MULLION BETWEEN

SOR SECTIONS

4″ NIPPLE

4″ NIPPLE
TO GAS VALVE

GROMMET ALL ELBOWS ARE 3/4″
MANUAL MAIN SHUT-OFF VALVE

5″ NIPPLE
7-1/2″ NIPPLE GROUND JOINT UNION
4″ NIPPLE

TO GAS SUPPLY
10″ NIPPLE ROOF MOUNTING FRAME
FIGURE 10

3-1/2″ NIPPLE
3″ NIPPLE DRIP LEG

BOTTOM GAS ENTRY THROUGH THE UNIT

ALL ELBOWS ARE 3/4″

MULLION BETWEEN

10″ NIPPLE GROMMET

GROMMET 7-1/2″ NIPPLE

SOR SECTIONS 5″ NIPPLE
4″ NIPPLE

4″ NIPPLE

TO GAS VALVE

7″ NIPPLE

TO GAS SUPPLY

GROUND JOINT UNION

ALTERNATE KNOCKOUTS
ROOF MOUNTING FRAME
DRIP LEG

4″ NIPPLE MANUAL MAIN SHUT-OFF VALVE
3-1/2″ NIPPLE
3″ NIPPLE

Pressure Test Gas Piping (Gas Units)
When pressure testing gas lines, the gas valve must be disconnected and isolated. Gas valves can be damaged if subjected to more than 0.5 psig (3.48kPa). See FIGURE 12. NOTE – Codes may require that manual main shut-off valve and union (furnished by installer) be installed in gas line external to unit. Union must be of the ground joint type. After all connections have been made, check all piping connections for gas leaks. Also check existing unit gas connections up to the gas valve; loosening may occur during installation. Use a leak detection solution or other preferred means. Do not use matches candles or other sources of ignition to check for gas leaks. NOTE – In case emergency shut down is required, turn off the main manual shut-off valve and disconnect main power to unit. These devices should be properly labeled by the installer.
PRESSURE TEST GAS LINE
MANUAL MAIN SHUT-OFF VALVE

GAS VALVE

CAP

FIGURE 12

CAUTION
Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use matches, candles, flame or other sources of ignition to check for gas leaks.

WARNING
Danger of explosion. Can cause injury or product or property damage. Do not use matches, candles, flame or other sources of ignition to check for leaks.

FIGURE 11

Page 9

High Altitude Derate
Locate the high altitude conversion sticker in the unit literature bag. Fill out the conversion sticker and affix next to the unit nameplate. High altitude kits are available for field-installation.
Refer to TABLE 2 for high altitude adjustments.

TABLE 2 HIGH ALTITUDE DERATE

Altitude Ft.*

Gas Manifold Pressure

2000-4500

See Unit Nameplate

4500 and Above

Derate 4% / 1000 Ft. above Sea Leavel

*Units installed at 0-2000 feet do not need to be modified.

NOTE – This is the only permissible derate for these units.

Download Mobile Service App
A-Mobile Device Requirements
· Android hardware requires 2GB RAM and a 2Ghz core processor. Tablets are supported.
· Minimum Android 6.0 (Marshmallow) or higher. Recommend Android 10 and Apple products require iOS version 11 or higher.
B-New Installations
Once the app is downloaded, refer to the Setup Guide provided with this unit to pair the app to the unit control system. Follow the setup wizard prompts to configure the unit. See FIGURE 13 for the app menu overview. If a mobile device is unavailable or not pairing, refer to the Unit Controller Setup Guide for start-up instructions.

Electrical Connections – Power Supply
Route field wiring in conduit between bottom power entry disconnect. See FIGURE 14. This does not supersede local codes or authorities having jurisdiction.
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 orange wire (230V) at all control power transformer(s). Reconnect the red wire (208V). Tape the exposed end of the 230V orange wire.
2 – Route power through the bottom power entry area. On gas units or units with electric heat, connect power wiring to TB2. On cooling only units, connect power to F4. If unit contains an optional factoryinstalled circuit breaker or disconnect switch, connect line voltage to CB10 or S48. See unit wiring diagram.

3 – Connect separate 120v wiring to optional GFCI outlet. Route field wiring in conduit between bottom power entry and GFCI. See FIGURE 14.
MOBILE SERVICE APP MENU OVERVIEW

MENU

RTU MENU

SETUP

INSTALL
NETWORK INTEGRATION
TEST AND BALANCE

ALARM HISTORY DATA TRENDING
FACTORY RUNTIMES
SYSTEM DATA / SENSORS / OUTPUTS

SERVICE

COMPONENT TEST
REPORT
ADVANCED CONTROL FIRMWARE UPDATE

SETTINGS
FIGURE 13

RTU OPTION INSTALL

FIELD WIRE ROUTING

SIDE ENTRY KNOCKOUTS

MAKE-UP BOX
OPTIONAL 120V GFI

SEAL WATERTIGHT

RUN FIELD WIRING IN
VIDED CONDUIT
BOTTOM POWER ENTRY
FIGURE 14

Page 10

Electrical Connections – Control Wiring

NOTE – Optional wireless sensors are available for use with this unit. Refer to the instructions provided with each sensor.
CAUTION
Electrostatic discharge can affect electronic components. Take precautions during unit installation and service to protect the electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the unit, the control and the technician at the same electrostatic potential. Neutralize electrostatic charge by touching hands and all tools on an unpainted unit surface, such as the gas valve or blower deck, before performing any service procedure.
A-Thermostat Location
Applied to units in default thermostat control mode only.
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
The Unit Controller will operate the unit from a thermostat or zone sensor based on the System Mode. The default System Mode is the thermostat mode. Refer to the Unit Controller Setup Guide to change the System Mode. Use the mobile service app menu and select Settings > Install.
Thermostat Mode
1 – Route thermostat cable or wires from subbase to control area above compressor (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 mounting panel 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 Unit Controller on the lower side of the controls hat section.
4 – Wire as shown in FIGURE 15 for electromechanical and electronic thermostats. If using other temperature control devices or energy management systems see instructions and wiring diagram provided by manufacturer.
IMPORTANT – Terminal connections at the Unit Controller must be made securely. Loose control wire connections may allow unit to operate but not with proper response to room demand.
Zone Sensor Mode
The Unit Controller will operate heating and cooling based on the Unit Controller internal setpoints and the temperature from the A2 room sensor. An optional Network Control Panel (NCP) can also be used to provide setpoints. A thermostat or return air sensor can be used as a back-up mode. Make room sensor wiring connections as shown in FIGURE 16.
C-Hot Gas Reheat Units Only
1 – Install humidity sensor in accordance with instructions provided with sensor. A DDC input may be used to initiate dehumidification instead of a sensor.
2 – Make wiring connections as shown in FIGURE 15 for Thermostat Mode or FIGURE 16 for Zone Sensor Mode. In addition, connect either a humidity sensor or a dehumidification input. See FIGURE 18 or FIGURE 19 for humidity sensor wiring or FIGURE 17 for dehumidification input wiring.
24 VOLT FIELD WIRING IN THERMOSTAT MODE

P262 J262C

24 V POWER

J297A P297

R

1

A55

10

C

2

B

11

G

3

W1

4

W1

W2

5

W2

12

Y1

6

Y2

7

OCP

8

C

9

10

D

FIGURE 15

Page 11

FIELD WIRING IN ZONE SENSOR MODE (Zone Sensor Mode)

UNIT CONTROLLER

24VAC SENSOR SENSOR IAQ

INPUTS

R C AI1

HUM TMP AI2 C R

J298

A2 SENSOR
FIGURE 16

FIELD WIRING HOT GAS REHEAT UNITS (Using A Dehumidification Switch)

J299

7

R

DEHUMIDIFICATION SWITCH

8

DI-4

9

C

10

Use 24 VAC (R) from any terminal available on J299-2, -5, or -7.
FIGURE 17
Humidity Sensor Cable Applications:
Wire runs of 50 feet (mm) or less:
Use two separate shielded cables containing 20AWG minimum, twisted pair conductors with overall shield. Belden type 8762 or 88760 (plenum) or equivalent. Connect both cable shield drain wires to the Unit Controller as shown in FIGURE 18.
Wire runs of 150 feet (mm) or less:
Use two separate shielded cables containing 18AWG minimum, twisted pair conductors with overall shield. Belden type 8760 or 88760 (plenum) or equivalent. Connect both cable shield drain wires to the Unit Controller as shown in FIGURE 18.

Wire runs over 150 feet (mm)
Use a local, isolated 24VAC transformer such as Lennox cat #18M13 (20VA minimum) to supply power to RH sensor as shown in figure 19. Use two shielded cables containing 20AWG minimum, twisted pair conductors with overall shield. Belden type 8762 or 88760 (plenum) or equivalent.

FIELD WIRING HOT GAS REHEAT UNITS (Using A

Humidity Sensor With Less Than 150 Ft. Wire

NOT CONNECTED

Runs) J298A 1

A55 UNIT CONTROLLER
P298 R

A91 VIN

2

C

B

3

AI1

4

C

5

HUM

GND
DRAIN
VO

6

7

TMP

D

8

AI2

9

C

10

R

NOT

UNUSED

FIGURE 18

FIELD WIRING HOT GAS REHEAT UNITS (Using

A Humidity Sensor With More than 150Ft. Wire

NOT

Runs)

CONNECTED ISOLATED 24V

TRANSFORMER

A55 UNIT

CONTROLLER

J298A 1 P298 R

A91

DRAIN

2

B

VIN

NOT

3

CONNECTED
4 C

5

C AI1
HUM

GND VO

6

7

TMP

D

8

AI2

9

C

10

R

FIGURE 19

Page 12

Blower Operation
Units are equipped with variable speed, direct drive blowers. The installer is able to enter the design-specified supply air CFM into the Unit Controller for optimal efficiency. The Unit Controller calibrates the supply air volume which eliminates the need to manually take duct static measurements. Refer to C-Adjusting Unit CFM Ultra High Efficiency Direct Drive Blowers.
IMPORTANT
Compressor two is the only component that must be checked to ensure proper phasing. Follow “COOLING START-UP” section of installation instructions to en sure proper compressor and blower operation.
The Unit Controller checks the incoming power during start-up. If the voltage or phase is incorrect, the Unit Controller will display an alarm and the unit will not start.
A-Blower Operation
Refer to the Unit Controller Setup Guide to energize blower. Use the mobile service app menu; see SERVICE > TEST.
In thermostat control mode, the Unit Controller will stage the blower between low and high speed. In zone sensor control mode, the Unit Controller will vary (VAV) the blower between low and high speed.
WARNING
1- Make sure that unit is installed in accordance with the installation instructions and applicable codes.
2- Inspect all electrical wiring, both field and factoryinstalled, for loose connections. Tighten as required.
3- Check to ensure that refrigerant lines do not rub against the cabinet or against other refrigerant lines.
4- Check voltage at disconnect switch. Voltage must be within range listed on nameplate. If not, consult power company and have voltage condition corrected before starting unit.
5- Make sure filters are new and in place before start-up.

Initiate blower only (G) 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.
NOTE – Blower operation mode can also be initiated by the mobile service app.
Direct-drive motor may not immediately stop when power is interrupted to the Unit Controller. Disconnect unit power before opening the blower compartment. The Controller’s digital inputs must be used to shut down the blower. See Unit Controller manual for operation sequences.
B-Blower Access
The blower assembly is secured to a sliding frame which allows the blower assembly to be pulled out of the unit. See FIGURE 21.
1 – Loosen the reusable wire tie which secures the controls and high voltage blower wiring to the blower housing. Disconnect the pressure sensor low voltage wire harness.
2 – Remove and retain screws on either side (and on the front for direct drive) of sliding frame. Use the metal handle to pull frame toward outside of unit.
3 – Slide frame back into original position when finished servicing. Reattach the blower wiring in the previous location using the wire tie. Reconnect pressure sensor low voltage wire harness.
4 – Replace retained screws.

Page 13

LOCATION OF STATIC PRESSURE READINGS

INSTALLATIONS WITH DUCTWORK

INSTALLATIONS WITH CEILING DIFFUSERS

ROOFTOP UNIT

ROOFTOP UNIT

RETURN AIR READING LOCATION

SUPPLY TURN
MAIN DUCT RUN

FIRST BRANCH OFF OF MAIN RUN

SUPPLY AIR READING LOCATION

SUPPLY AIR READING LOCATION

FIGURE 20

DIRECT DRIVE BLOWER ASSEMBLY

SUPPLY TURN
DIFFUSER

BLOWER HOUSING

RETURN AIR READING LOCATION

BLOWER MOTOR SECURED TO THIS SIDE OF HOUSING

REMOVE TWO SCREWS ON EACH SIDE TO SLIDE
BLOWER OUT OF UNIT

INLET GRID

FIGURE 21

Page 14

Direct Drive Blower Start-Up
The supply CFM can be adjusted by changing Unit Controller settings. Refer to TABLE 3 for menu paths and default settings. Record any CFM changes on the parameter settings label located on the inside of the compressor access panel.
IMPORTANT
The BLOWER CALIBRATION process starts the in door blower at operational speeds and moves the economizer damper blades. Before starting this process, replace any access panels and close all unit doors except compressor compartment door.

Blower calibration is required only on units that are newly installed or if there is a change in the duct work or air filters after installation. Use the mobile service app to navigate to the SETUP>TEST & BALANCE>BLOWER menu.
After the new CFM values are entered, select START CALIBRATION. The blower calibration status is displayed as a % complete. Upon successful completion, the mobile service app will display CALIBRATION SUCCESS and go back to the blower calibration screen.
IMPORTANT – The default value for Cooling Low CFM is lower than a traditional singe- or two-speed unit. If operating the unit with a 2- or 3-stage controller (2- or 3-stage thermostat, DDC controller, etc.), it is recommended to increase the Cooling Low CFM default value to a suitable level for part load cooling (typically 60% of full load CFM).

TABLE 3 DIRECT DRIVE PARAMETER SETTINGS

Parameter

Factory Setting 092 102 120 150

Field Setting

Description

NOTE – Any changes to Smoke CFM setting must be adjusted before the other CFM settings. Use SETTINGS > RTU OPTIONS > EDIT PARAMETERS = 12

BLOWER SMOKE CFM

3000 3400 4000 5000

CFM Smoke blower speed

SETUP > TEST & BALANCE > BLOWER

BLOWER HEATING HIGH CFM BLOWER COOLING HIGH CFM

3000 2625

3400 2975

4000 3500

5000 4375

CFM Heating blower speed CFM High cooling blower speed

BLOWER COOLING LOW CFM BLOWER VENTILATION CFM

800 800 875 1100 800 800 875 1100

CFM Low cooling blowr speed CFM Ventilation blower speed

SETUP > TEST & BALANCE > DAMPER BLOWER HIGH CFM DAMPER POS % 0% 0% 0% 0%

% Minimum damper position for high speed blower operation.

BLOWER LOW CFM DAMPER POS % 0% 0% 0% 0%

% Minimum damper position for low speed operation.

BLOWER EXHAUST DAMPER POS % 50% 50% 50% SETTINGS > RTU OPTIONS > EDIT PARAMETERS = 216

50%

% Minimum damper position for power exhaust operation.

POWER EXHAUST DEADBAND %

10% 10% 10% 10%

% Deadband % for power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETER = 10 (Applies to Thermostat Mode ONLY)

FREE COOLING STAGE-UP DELAY

300 300 300 300 sec, sec. sec. sec.

sec

Number of seconds to hold indoor blower at low speed before switching to indoor blower at high speed.

Installer – Circle applicable unit model number and record any parameter changes under “Field Setting” column. Settings need to be recorded by installer for use when Unit Controller is replaced or reprogrammed.

Page 15

BLOWER DATA

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.) See page 17 for wet coil and option/accessory air resistance data. See page 17 for minimum air volume required for use with optional electric heat.

Maximum Static Pressure With Gas Heat – 2.0 in. w.g.
Minimum Air Volume Required For Different Gas Heat Sizes: Standard – 2150 cfm; Medium – 2250 cfm; High – 2600 cfm

Total Air Volume
cfm

0.2 RPM Watts

0.4 RPM Watts

Total Static Pressure – in. w.g.

0.6

0.8

1.0

RPM Watts RPM Watts RPM Watts

1.2 RPM Watts

1.4 RPM Watts

1750

759 223 864 298 961 359 1049 420 1128 508 1199 607 1260 704

2000

846 271 943 345 1035 410 1117 488 1189 598 1255 704 1313 804

2250

945 303 1030 391 1111 476 1184 577 1247 697 1310 806 1367 905

2500

1035 366 1109 476 1180 583 1245 688 1306 797 1368 903 1426 1008

2750

1113 476 1182 601 1248 715 1310 809 1371 902 1432 1011 1491 1129

3000

1195 596 1261 718 1324 827 1385 922 1444 1024 1503 1146 1559 1279

3250

1282 711 1346 827 1406 935 1464 1044 1521 1167 1576 1306 1629 1460

3500

1372 821 1432 940 1489 1060 1544 1192 1598 1337 1650 1494 1700 1663

3750

1461 949 1517 1081 1571 1221 1624 1373 1675 1532 1725 1700 1773 1875

4000

1549 1109 1602 1256 1653 1413 1703 1576 1753 1743 1801 1916 1847 2091

4250

1637 1298 1687 1458 1735 1625 1784 1795 1831 1966 1877 2139 1923 2310

4500

1724 1510 1772 1678 1818 1851 1864 2023 1910 2195 1955 2365 2000 2530

4750

1811 1738 1856 1910 1901 2083 1946 2254 1990 2423 2034 2587 2079 2746

5000

1897 1973 1941 2144 1985 2314 2028 2480 2071 2644 2114 2805 2158 2959

5250

1983 2205 2026 2373 2069 2538 2111 2699 2153 2860 2195 3017 – – – – – –

5500

2070 2428 2112 2595 2153 2756 2194 2912 – – – – – – – – – – – – – – – – – –

5750

2156 2643 2197 2809 – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –

Total Air Volume
cfm

1.6 RPM Watts

1.8 RPM Watts

Total Static Pressure – in. w.g.

2.0

2.2

2.4

RPM Watts RPM Watts RPM Watts

2.6 RPM Watts

1750

1316 793 1373 875 1432 963 1491 1064 1548 1175 1604 1300

2000

1368 894 1425 982 1483 1081 1540 1196 1596 1322 1650 1458

2250

1423 1001 1480 1101 1537 1216 1593 1344 1647 1483 1700 1629

2500

1483 1117 1539 1236 1594 1368 1648 1509 1700 1657 1752 1810

2750

1547 1256 1601 1394 1654 1539 1705 1690 1756 1846 1806 2004

3000

1612 1425 1664 1577 1715 1734 1765 1893 1815 2053 1864 2213

3250

1680 1623 1729 1787 1778 1949 1828 2110 1876 2269 1925 2426

3500

1748 1835 1796 2003 1844 2165 1893 2324 1942 2479 1991 2633

3750

1819 2048 1866 2214 1914 2374 1963 2530 2012 2684 2061 2837

4000

1893 2260 1940 2423 1988 2581 2036 2737 2084 2891 2134 3044

4250

1969 2475 2016 2634 2063 2790 2111 2945 2159 3098 – – – – – –

4500

2046 2689 2093 2844 2140 2998 2187 3153 – – – – – – – – – – – –

4750

2124 2900 2170 3053 – – – – – – – – – – – – – – – – – – – – – – – –

5000

2203 3111 – – – – – – – – – – – – – – – – – – – – – – – – – – – – – –

5250

— — — — — — — — — — — —

5500

— — — — — — — — — — — —

Page 16

BLOWER DATA

POWER EXHAUST FAN PERFORMANCE Return Air System Static Pressure in. w.g. 0 0.05 0.10 0.15 0.20 0.25 0.30 0.35

Air Volume Exhausted cfm 3175 2955 2685 2410 2165 1920 1420 1200

MINIMUM AIR VOLUME REQUIRED FOR USE WITH OPTIONAL ELECTRIC HEAT

Electric Heat kW

Minimum cfm

7.5

1750

15

2750

22.5

2750

30

2750

45

2750

60

3500

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

Air

Wet Indoor Coil

Gas Heat Exchanger

Volume

Standard Medium High

cfm 092, 102 120, 150 Heat

Heat Heat

Electric Heat

Econo mizer

Condensor Reheat Coil

1750 0.04 0.04

0.06

0.02

0.02

0.03

0.05

0.02

2000 0.05 0.05

0.07

0.05

0.06

0.03

0.06

0.02

2250 0.06 0.06

0.07

0.07

0.08

0.04

0.08

0.02

2500 0.07 0.07

0.09

0.10

0.11

0.04

0.11

0.03

2750 0.08 0.08

0.09

0.11

0.12

0.05

0.12

0.03

3000 0.10 0.09

0.11

0.12

0.13

0.06

0.13

0.03

3250 0.11 0.10

0.12

0.15

0.16

0.06

0.15

0.04

3500 0.12 0.11

0.12

0.16

0.17

0.09

0.15

0.04

3750 0.14 0.13

0.14

0.19

0.20

0.09

0.15

0.05

4000 0.15 0.14

0.14

0.21

0.22

0.09

0.19

0.05

4250 0.17 0.15

0.14

0.24

0.28

0.13

0.19

0.06

4500 0.19 0.17

0.15

0.26

0.32

0.14

0.22

0.07

4750 0.20 0.18

0.16

0.29

0.37

0.17

0.25

0.07

5000 0.22 0.20

0.16

0.34

0.43

0.20

0.29

0.08

5250 0.24 0.22

0.16

0.37

0.47

0.22

0.32

0.08

5500 0.25 0.23

0.18

0.44

0.54

0.25

0.34

0.09

5750 0.27 0.25

0.19

0.49

0.59

0.31

0.45

0.10

6000 0.29 0.27

0.20

0.54

0.64

0.33

0.52

0.10

MERV 8
0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.03 0.03 0.04 0.04 0.04 0.05 0.06 0.06 0.07 0.07 0.08

Filters MERV 13 MERV 16

0.03

0.05

0.03

0.06

0.04

0.07

0.05

0.08

0.05

0.09

0.06

0.10

0.06

0.11

0.07

0.12

0.08

0.13

0.08

0.14

0.09

0.15

0.09

0.17

0.10

0.18

0.10

0.19

0.11

0.20

0.12

0.22

0.12

0.23

0.13

0.24

Return Air
Adaptor Plate 0.00 0.00 0.00 0.00 0.00 0.02 0.02 0.04 0.07 0.09 0.11 0.12 0.16 0.18 0.19 0.22 0.25 0.27

Page 17

Cooling Start-Up
IMPORTANT – The crankcase heater must be energized for 24 hours before attempting to start compressor. Set thermostat so there is no demand to prevent compressors from cycling. Apply power to unit. A-Start-Up
1 – Initiate full load cooling operation using the following mobile service app menu path:
RTU MENU > SERVICE > COMPONENT TEST > COOLING > COOL 4
2 – Refer to Cooling Operation section for cooling startup.
3 – Units have two refrigerant circuits. See FIGURE 22.
4 – Each refrigerant circuit is charged with R410A refrigerant. See unit rating plate for correct amount of charge.
5 – Refer to Refrigerant Check and Charge section for proper method to check refrigerant charge.
B-R410A Refrigerant
Units charged with R410A refrigerant operate at much higher pressures than R22. The expansion valve and liquid line drier provided with the unit are approved for use with R410A. Do not replace them with components designed for use with R22.
R410A refrigerant is stored in a pink cylinder.
Manifold gauge sets used with systems charged with R410A refrigerant must be capable of handling the higher system operating pressures. The gauges should be rated for use with pressures of 0-800 on the high side and a low side of 30″ vacuum to 250 psi with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psi of pressure with a 4000 psi burst rating.
IMPORTANT
Mineral oils are not compatible with R410A. If oil must be added, it must be a polyol ester oil.
C-Refrigerant Charge and Check
WARNING-Do not exceed nameplate charge under any condition.
This unit is factory charged and should require no further adjustment. If the system requires additional refrigerant, reclaim the charge, evacuate the system, and add required nameplate charge.
NOTE – System charging is not recommended below 60°F (15°C). In temperatures below 60°F (15°C) , the charge must be weighed into the system.
If weighing facilities are not available, or to check the charge, use the following procedure:

REFRIGERANT STAGES TRADITIONAL FIN/TUBE COIL

CONDENSER COIL STAGES 1 & 2

(BOTH FANS ARE ENERGIZED WITH A Y1 DEMAND)

EVAPORATOR COIL STAGE 2

B4 B5

2

1

EVAPORATOR COIL STAGE 1

FIGURE 22

1 – Attach gauge manifolds to discharge and suction lines. With the economizer disabled, operate the unit in cooling mode at high speed using the following mobile service app menu path:

SERVICE > COMPONENT TEST > COOLING > COOL 4
2 – Use a thermometer to accurately measure the outdoor ambient temperature.
3 – Apply the outdoor temperature to TABLE 4 through 11 to determine normal operating pressures. Pressures are listed for sea level applications at 80°F dry bulb and 67°F wet bulb return air.
4 – 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.
5 – If discharge pressure is high, remove refrigerant from the system. If discharge pressure is low, add refrigerant to the system.
· Add or remove charge in increments. · Allow the system to stabilize each time refrigerant is
added or removed. 6 – Use the following subcooling method along with the
normal operating pressures to confirm readings.

Page 18

Outdoor Coil
Entering Air Temp
65° F
75° F
85° F
95° F
105° F
115° F

TABLE 4 581027-01 LGM/LCM092U No Reheat

CIRCUIT 1

CIRCUIT 2

Discharge Suction + Discharge Suction +

+ 10 psig

5 psig

+ 10 psig

5 psig

252

140

269

137

293

143

311

139

335

146

354

142

382

148

403

144

434

150

454

147

490

153

508

150

Outdoor Coil
Entering Air Temp
65° F
75° F
85° F
95° F
105° F
115° F

TABLE 5 581028-01 LGM/LCM092U Reheat

CIRCUIT 1

CIRCUIT 2

Discharge Suction + Discharge Suction +

+ 10 psig

5 psig

+ 10 psig

5 psig

258

140

269

136

301

139

308

137

344

141

349

139

392

143

398

142

445

145

447

144

504

148

501

147

Outdoor Coil
Entering Air Temp
65° F
75° F
85° F
95° F
105° F
115° F

TABLE 6 581029-01 LGM/LCM102U No Reheat

CIRCUIT 1

CIRCUIT 2

Discharge Suction + Discharge Suction +

+ 10 psig

5 psig

+ 10 psig

5 psig

256

140

259

139

294

143

300

141

333

147

341

143

381

149

388

146

433

151

438

149

487

155

491

153

Outdoor Coil
Entering Air Temp
65° F
75° F
85° F
95° F
105° F
115° F

TABLE 7 581030-01 LGM/LCM102U Reheat

CIRCUIT 1

CIRCUIT 2

Discharge Suction + Discharge Suction +

+ 10 psig

5 psig

+ 10 psig

5 psig

264

140

266

137

301

139

300

139

349

141

341

141

399

144

390

144

450

146

440

147

508

149

494

150

Outdoor Coil
Entering Air Temp
65° F
75° F
85° F
95° F
105° F
115° F

TABLE 8 581031-01 LGM/LCM120U No Reheat

CIRCUIT 1

CIRCUIT 2

Discharge Suction + Discharge Suction +

+ 10 psig

5 psig

+ 10 psig

5 psig

258

132

263

131

296

137

302

133

337

139

344

135

383

141

389

137

439

142

438

140

490

145

494

143

Outdoor Coil
Entering Air Temp
65° F
75° F
85° F
95° F
105° F
115° F

TABLE 9 581032-01 LGM/LCM120U Reheat

CIRCUIT 1

CIRCUIT 2

Discharge Suction + Discharge Suction +

+ 10 psig

5 psig

+ 10 psig

5 psig

272

131

255

133

309

135

294

135

350

138

335

137

396

139

381

139

452

141

430

142

503

144

485

145

Outdoor Coil
Entering Air Temp
65° F
75° F
85° F
95° F
105° F
115° F

TABLE 10 581033-01 LGM/LCM150U No Reheat

CIRCUIT 1

CIRCUIT 2

Discharge Suction + Discharge Suction +

+ 10 psig

5 psig

+ 10 psig

5 psig

267

122

270

113

308

128

313

120

355

133

363

127

399

136

407

130

448

139

456

132

503

142

510

136

Outdoor Coil
Entering Air Temp
65° F
75° F
85° F
95° F
105° F
115° F

TABLE 11 581034-01 LGM/LCM150U Reheat

CIRCUIT 1

CIRCUIT 2

Discharge Suction + Discharge Suction +

+ 10 psig

5 psig

+ 10 psig

5 psig

313

123

259

113

353

129

302

121

401

134

351

127

445

137

396

130

493

140

445

133

548

143

499

137

Page 19

Charge Verification – Subcooling Method – AHRI Testing
1 – Attach gauge manifolds to discharge and suction lines. With the economizer disabled, operate the unit in cooling mode at high speed using the following mobile service app menu path:
RTU MENU > SERVICE > COMPONENT TEST > COOLING > COOL 4
2 – Use the liquid line pressure and a PT chart to determine the saturated liquid temperature.
3 – Measure the liquid line temperature at the condenser outlet.
Subcooling Temperature = Liquid Saturated Temperature Minus Liquid Temperature
4 – Refer to TABLE 12 for subcooling temperatures. A subcooling temperature greater than this value indicates an overcharge. A subcooling temperature less than this value indicates an undercharge.

TABLE 12 SUBCOOLING TEMPERATURE

Liquid Temp. Minus Ambient Temp.

Unit

1st Stage

2nd Stage

092

12°F + 1 (6.7°C + 0.5) 15°F + 1 (8.3°C + 0.5)

092 Reheat 17°F + 1 (9.4°C + 0.5) 15°F + 1 (8.3°C + 0.5)

102

11°F + 1 (6.1°C + 0.5) 14°F + 1 (7.7°C + 0.5)

102 Reheat 19°F + 1 (6.7°C + 0.5) 14°F + 1 (7.7°C + 0.5)

120

9°F + 1 (5.0°C + 0.5) 13°F + 1 (7.2°C + 0.5)

120 Reheat 15°F + 1 (8.3°C + 0.5) 8°F + 1 (4.4°C + 0.5)

150

10°F + 1 (5.6°C + 0.5) 11°F + 1 (6.1°C + 0.5)

150 Reheat 22°F + 1 (12°C + 0.5) 8°F + 1 (4.4°C + 0.5)

F-Compressor Controls

See unit wiring diagram to determine which controls are used on each unit.

1 – High Pressure Switch (S4)

The compressor circuit is protected by a high pressure switch which opens at 640 psig + 10 psig (4413 kPa + 70 kPa) and automatically resets at 475 psig + 20 psig (3275kPa + 138 kPa).

2 – Low Pressure Switch (S87, S88)
The compressor circuit is protected by a loss of charge switch. Switch opens at 40 psig + 5 psig (276 + 34 kPa) and automatically resets at 90 psig + 5 psig (621 kPa + 34 kPa).
3 – Crankcase Heater (HR1, HR2)
Compressors have belly band compressor oil heaters which must be on 24 hours before running compressors. Energize by setting thermostat so that there is no cooling demand, to prevent compressor from cycling, and apply power to unit.
4 – Thermal Protector (S5)
The compressors are thermally protected with automatic temperature switches.
5 – Prognostics and Diagnostics Sensors (RT42RT49) Eight thermistors are located on specific points in the refrigeration circuit. The thermistors provide constant temperature feedback to the Unit Controller to protect the compressor. Thermistors take the place of the freezestat and low ambient pressure switch.

Prognostic & Diagnostic Sensors
Units are equipped with eight factory-installed thermistors (RT42 – RT49) located on different points on the refrigerant circuit.
The thermistors provide the Unit Controller with constant temperature readings of four specific locations on the refrigeration circuit. These temperatures are used as feedback in certain modes of unit operation. In addition, the Unit Controller uses these temperatures to initiate alarms such as loss of condenser or evaporator airflow and loss of charge.
Each thermistor must be specifically placed for proper unit operation and to initiate valid alarms. See TABLE 13 for proper locations.

TABLE 13 THERMISTOR LOCATION

RT42, 43, 46, 47

RT44 & RT45

RT48 & 49

FIGURE 23

FIGURE 24

FIGURE 25

Page 20

THERMISTOR LOCATION RT42, 43, 46, 47 (EVAPORATOR COIL VIEW FROM FRONT SIDE OF UNIT)

RT47

RT42

RT46
TXV BULB
RT42/43
SUCTION LINE

RT43

FIGURE 23 Page 21

THERMISTOR LOCATION RT44 & 45 (VIEW FROM FRONT SIDE OF UNIT)

092, 102 CONDENSER COIL

120, 150 CONDENSER COIL

RT44 & 45

RT44 RT45

RT45

RT44

FIGURE 24 Page 22

THERMISTOR LOCATION RT48 & 49 (VIEW FROM FRONT SIDE OF UNIT)

092, 102 CONDENSER COIL

120, 150 CONDENSER COIL

RT48

RT49

FIGURE 25 Page 23

Gas Heat Start-Up (Gas Units)
FOUR YOUR SAFETY READ BEFORE LIGHTING
WARNING
Electric shock hazard. Can cause injury or death. Do not use this unit if any part has been under water. Immediately call a qualified service technician to inspect the unit and to replace any part of the control system and any gas control which has been under water.
WARNING
Danger of explosion. Can cause injury or product or property damage. If over heating occurs or if gas supply fails to shut off, shut off the manual gas valve to the appliance before shutting off electrical supply.
WARNING
Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.
WARNING
SMOKE POTENTIAL The heat exchanger in this unit could be a source of smoke on initial firing. Take precautions with respect to building occupants and property. Vent initial supply air outside when possible. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
WARNING
Danger of explosion. Can cause injury or death. Do not attempt to light manually. Unit has a direct spark ignition system.

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

WARNING
Danger of explosion and fire. Can cause injury or product or property damage. You must follow these instructions exactly.
Gas Valve Operation for Honeywell VR8205Q/VR8305Q and White Rodgers 36H54 (FIGURE 26 and FIGURE 27).

WHITE RODGERS 36H54 GAS VALVE

INLET

Two-Stage

PRESSURE TAP

MANIFOLD PRESSURE

TAP

HIGH FIRE ADJUSTMENT
LOW FIRE ADJUSTMENT

GAS VALVE SWITCH SHOWN IN ON POSITION.
FIGURE 26

HONEYWELL VR8205Q/VR8305Q GAS VALVE

HIGH FIRE ADJUSTMENT

LOW FIRE ADJUSTMENT

MANIFOLD PRESSURE
TAP

INLET PRESSURE
TAP
GAS VALVE KNOB IS SHOWN IN OFF POSITION.
FIGURE 27 1 – Set thermostat to lowest setting. 2 – Turn off all electrical power to appliance. 3 – This appliance is equipped with an ignition device
which automatically lights the burner. Do not try to light the burner by hand. 4 – Open or remove the heat section access panel.

Page 24

5 – Turn gas valve switch to OFF. See FIGURE 26. On Honeywell VR8305Q gas valves, turn the knob on the gas valve clockwise to OFF. Do not force. See figure 27.
6 – Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you do not smell gas, go to the next step.
7 – Turn gas valve switch to ON. See FIGURE 26. On Honeywell VR8305Q gas valves, turn the knob on the gas valve counterclockwise to ON. Do not force. See FIGURE 27.
8 – Close or replace the heat section access panel.
9 – Turn on all electrical power to appliance.
10 – Set thermostat to desired setting.
11 – The ignition sequence will start.
12 – If the appliance does not light the first time (gas line not fully purged), it will attempt up to two more ignitions before locking out.
13 – If lockout occurs, repeat steps 1 through 10.
14 – If the appliance will not operate, follow the instructions “Turning Off Gas to Appliance” and call your service technician or gas supplier.
Turning Off Gas to Unit 1 – If using an electromechanical thermostat, set to the lowest setting.
2 – Before performing any service, turn off all electrical power to the appliance.
3 – Open or remove the heat section access panel.
4 – Turn gas valve switch to OFF. On Honeywell VR8305Q gas valves, turn the knob on the gas valve clockwise to OFF. Do not force.
5 – Close or replace the heat section access panel.
WARNING
Danger of explosion. Can cause injury or death. Do not attempt to light manually. Unit has a direct spark ignition system.
Heating Operation and Adjustments
(Gas Units) A-Heating Sequence of Operation
1 – On a heating demand the combustion air inducer starts immediately.
2 – Combustion air pressure switch proves inducer operation. After a 30-second pre-purge, power is allowed to ignition control. Switch is factory set and requires no adjustment.
3 – Spark ignitor energizes and gas valve solenoid opens.
4 – Spark ignites gas, ignition sensor proves the flame and combustion continues.

5 – If flame is not detected after first ignition trial, ignition control will repeat steps 3 and 4 two more times before locking out the gas valve.
6 – For troubleshooting purposes, an ignition attempt after lock out may be re-established manually. Move thermostat to OFF and return thermostat switch to HEAT position.
B-Limit Controls
Limit controls are factory-set and are not adjustable. The primary limit is located on the blower deck to the right of the blower housing.
C-Heating Adjustment
Main burners are factory-set and do not require adjustment.
The following manifold pressures are listed on the gas valve.
Natural Gas Units – Low Fire – 1.6″ w.c. (not adjustable) Natural Gas Units – High Fire – 3.7″ w.c. LP Gas Units – Low Fire – 5.5″ w.c. (not adjustable) LP Gas Units – High Fire – 10.5″ w.c.
Electric Heat Start-Up (Cooling Units)
Factory or Field-Installed Option
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.
SCR Electric Heat Controller (LCM Units)
Optional factory-installed SCR (A38) will provide small amounts of power to the electric heat elements to efficiently maintain warm duct air temperatures when there is no heating demand. The SCR maintains duct air temperature based on input from a field-provided and installed thermostat (A104) and duct sensor (RT20). SCR is located in the electric heat compartment in front of the elements. Use only with a thermostat.
Use the instructions provided with the thermostat to set DIP switches as follows: S1 On, S2 Off, S3 Off. Use the instructions provided with the duct sensor to install sensor away from electric element radiant heat and in a location where discharge air is a mixed average temperature.
Once power is supplied to unit, zero SCR as follows:
1 – Adjust thermostat (A104) to minimum position.
2 – Use a small screwdriver to slowly turn the ZERO potentiometer on the SCR until the LED turns solid red.
3 – Very slowly adjust the potentiometer the opposite direction until the LED turns off.

Cooling Operation

This is a summary of cooling operation. Refer to the sequence of operation provided in the Engineering Handbook or Service Manual for more detail.
NOTE – Free cooling is locked-out during reheat operation. Refer to hot gas reheat start-up and operation section for details.
A-Two-Stage Thermostat
1 – Economizer With Outdoor Air Suitable
Y1 Demand –
Compressors Off Blower Cooling Low Dampers modulate NOTE – If dampers are at maximum open for five minutes, compressors are energized and blower stays on cooling high.
Y2 Demand –
Compressors Modulate Blower Cooling High Dampers Maximum Open
2 – No Economizer or Outdoor Air Not Suitable
Y1 Demand –
Compressors Modulate Blower Cooling Low Dampers Minimum Position
Y2 Demand –
Compressors Modulate Blower Cooling High Dampers Minimum Position

B-Three-Stage Thermostat
1 – Economizer With Outdoor Air Suitable
Y1 Demand –
Compressors Off Blower Cooling Low Dampers Modulate NOTE – If dampers are at maximum open for five minutes, compressors are energized and blower stays on cooling high.
Y2 Demand –
Compressors Modulate Blower Cooling Intermediate Dampers Maximum Open
Y3 Demand –
Compressors Modulate Blower Cooling High Dampers Maximum Open
C-Room Sensor
1 – Economizer With Outdoor Air Suitable
Compressors Off Blower Modulates Dampers modulate NOTE – If dampers are at maximum open for five minutes, compressors are energized and the blower modulates. 2 – No Economizer or Outdoor Air Not Suitable
Compressors Modulate Blower Modulates Dampers Minimum Position

Page 26

Modulating Hot Gas Reheat Start-Up and Operation
General
Hot gas reheat units provide a dehumidifying mode of operation. These units contain a reheat coil adjacent to and downstream of the evaporator coil. Reheat coil solenoid valve, L14, routes hot discharge gas from the compressor to the reheat coil. Return air pulled across the evaporator coil is cooled and dehumidified; the reheat coil adds heat to supply air. See FIGURE 28 for reheat refrigerant routing and FIGURE 29 for standard refrigerant routing.
L14 Reheat Coil Solenoid Valve
When Unit Controller input (Unit Controller J298-5 or J2998) indicates room conditions require dehumidification, L14 reheat valve is energized (Unit Controller J394-1) and refrigerant is routed to the reheat coil.
Reheat Setpoint
Reheat is factory-set to energize when indoor relative humidity rises above 60% (default).

The reheat setpoint can be adjusted by changing mobile service app Settings – Control menu. A setting of 100% will operate reheat from an energy management system digital output.
The reheat setpoint can also be adjusted using an optional Network Control Panel (NCP). Reheat will terminate when the indoor relative humidity falls 3% (57% default) or the digital output de-energizes. The reheat deadband can be adjusted at Settings – Control menu.
Check-Out
Test hot gas reheat operation using the following procedure.
1 – Make sure reheat is wired as shown in wiring section.
2 – Make sure unit is in local thermostat mode.
3 – Select:
RTU MENU > SERVICE > COMPONENT TEST >
DEHUMIDIFICATION The blower and compressor 1 (reheat) should be operating. DEHUMIDIFIER 1 ON will appear.
4 – Press STOP to discontinue the testing mode. Compressor 1 (reheat) and blower should de-energize.

REHEAT MODE REFRIGERANT ROUTING

FIGURE 28 Page 27

COOLING MODE REFRIGERANT ROUTING

FIGURE 29

Default Reheat Operation

TABLE 14 Reheat Operation – Two Cooling Stages – Default

T’stat and Humidity Demands

Operation

Reheat Only

Compressor 1 Reheat

Reheat & Y1

Compressor 1 & 2 Enhanced Dehumidification at Low CFM

Reheat & Y1 & Y2

Compressor 1 & 2 Enhanced Dehumidification at High CFM

*If there is no reheat demand and outdoor air is suitable, free cooling will operate.

**If there is no reheat demand and outdoor air is suitable, free cooling and compressor 1 will operate.

Service
The unit should be inspected once a year by a qualified service technician.
CAUTION
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

A-Filters
Units are equipped with four 20 X 25 X 2′ filters. Filters should be checked monthly and replaced when necessary with filters of like kind and size. Take note of air flow direction marking on filter frame when reinstalling filters. See FIGURE 30.
NOTE – 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.
C-Burners (Gas Units)
Periodically examine burner flames for proper appearance during the heating season. Before each heating season examine the burners for any deposits or blockage which may have occurred.
Clean burners as follows:
1 – Turn off both electrical power and gas supply to unit.
2 – Remove burner compartment access panel.
3 – Remove screws securing burner assembly to burner support and remove assembly. See figure 31. Clean as necessary.
4 – Locate the ignitor under the left burners. Check ignitor spark gap with appropriately sized twist drills or feeler gauges. See FIGURE 32.

Page 28

REMOVE FILTERS

PULL TO REMOVE FILTERS

GAS VALV
E

FIGURE 30
BURNER BOX ASSEMBLY 240KBTUH SHOWN BURNER ASSEMBLY SECURED WITH MULTIPLE SCREWS

GAS MANIFOLD
FIGURE 31 IGNITOR
SPARK GAP SHOULD BE 1/8″
(3mm)
FIGURE 32

5 – Check the alignment of the ignitor and the sensor as shown in FIGURE 33 and TABLE 15.

TABLE 15

Dimensions

Unit Btuh Input

Length – in. (mm)

Ignitor

Sensor

A

130K

7-3/4 (197)

11 (279)

B

180K

5 (127)

5-1/2 (140)

C

240K

2-1/4 (57)

2-3/4 (70)

6 – Replace burners and screws securing burner.

7 – Replace access panel.

8 – Restore electrical power and gas supply. Follow lighting instructions attached to unit and use inspection port in access panel to check flame.

WARNING
Danger of explosion. Can cause injury or death. Do not overtighten main burner mounting screws. Snug tighten only.
D-Combustion Air Inducer (Gas Units)
A combustion air proving switch checks combustion air inducer operation before allowing power to the gas controller. Gas controller will not operate if inducer is obstructed.
Under normal operating conditions, the combustion air inducer wheel should be checked and cleaned prior to the heating season. However, it should be examined periodically during the heating season to establish an ideal cleaning schedule. With power supply disconnected, the condition of the inducer wheel can be determined by looking through the vent opening.
Clean combustion air inducer as follows:
1 – Shut off power supply and gas to unit.
2 – Disconnect pressure switch air tubing from combustion air inducer port.
3 – Remove and retain screws securing combustion air inducer to flue box. Remove vent connector. See FIGURE 34.
4 – Clean inducer wheel blades with a small brush and wipe off any dust from housing. Clean accumulated dust from front of flue box cover.
5 – Return combustion air inducer motor and vent connector to original location and secure with retained screws. It is recommended that the combustion air inducer gasket be replaced during reassembly.
6 – Clean combustion air inlet louvers on heat access panel using a small brush.

Page 29

IG NIT O R
A B C

IGNITOR AND SENSOR POSITION TOP VIEW

S E NS OR
A B C

S IDE VIE W IGNITOR
Gas Flow

S IDE VIE W S E NS OR
Gas Flow

1-3/8″ (35mm)

1-3/4″ (45mm)

13/16″ (21mm)

BURNER BOX FIGURE 33

3/8″ (10mm)

HEAT EXCHANGER ASSEMBLY
HEAT EXCHANGER
TUBE COMBUSTION AIR INDUCER
VENT CONNECTOR

G-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.
H-Condenser Coil
Clean condenser coil annually with detergent or commercial coil cleaner and inspect monthly during the cooling season. Access panels are provided on front and back of condenser section.
J-Needlepoint Bipolar Ionizer
The ionizer was designed for low maintenance. The device should be checked semi-annually to confirm the brushes are clean for maximum output. The ionizer is located on the blower deck. See FIGURE 36.
BIPOLAR IONIZER

GAS VALVE
BURNER
FIGURE 34
E-Flue Passageway and Flue Box (Gas Units)
1 – Remove combustion air inducer assembly as described in section D.
2 – Remove flue box cover. Clean with a wire brush as required.
3 – Clean tubes with a wire brush.
4 – Reassemble the unit. The flue box cover gasket and combustion air inducer gasket should also be replaced during reassembly.
F-Evaporator 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.

IONIZER ASSEMBLY
FIGURE 35

Page 30

K-UVC Light
When field-installed, use only UVC Light Kit assembly 106882-01 (21A93) with this appliance.
Factory-Installed UVC Light
When the UVC light is factory installed, the lamp is shipped in a foam sleeve. The lamp is attached to the UVC light assembly on the blower deck. See FIGURE 37. Remove the lamp and install into the UVC light assembly as shown in steps 2 through 11.

Annual Lamp Replacement
WARNING
Personal Burn Hazard Personal injury may result from hot lamps. During replacement, allow lamp to cool for 10 minutes be fore removing lamp from fixture. The lamp should be replaced every 12 months, as UVC energy production diminishes over time.
1 – Obtain replacement lamp 101087-01 for your germicidal light model.
2 – Disconnect power to the rooftop unit before servicing the UVC kit.

UVC ASSEMBLY

UVC LAMP UVC ASSEMBLY

DOOR SWITCH

FIGURE 36

ASSEMBLY SECURED WITH 3 SCREWS

Page 31

3 – Open the blower access door. 4 – Remove the screw in wire tie from the UVC
assembly and disconnect the 4-pin connector from the lamp end. 5 – Remove and retain the (3) screws securing the UVC assembly. Carefully slide the complete UVC assembly out through the blower access door. See FIGURE 37.
INSTALL LAMP IN HOLDER CLIPS
UVC Sub-Assembly

BANDS (see Note below)
DETAIL A

SHEET METAL END STOP

LAMP FLANGE

4-PIN CONNECTOR

LAMP

HOLDER CLIPS (2)

NOTE – The bands around the lamp should be evenly spaced as shown in the diagram .

FIGURE 37

6 – Allow 10 minutes before touching the lamps. Then, carefully remove the old lamp from the lamp holder clips.

7 – Wear cotton gloves or use a cotton cloth when handling the new lamp. Place the new lamp in the holder clips of the UVC assembly. Verify that the lamp flange at the connector end is sandwiched between the lamp holder clip and the sheet-metal end stop (see FIGURE 38).

8 – Carefully place the UVC assembly on the blower deck. Line up the mounting holes on the UVC assembly with the mounting holes on the blower deck See FIGURE 37. Use the retained screws provided to attach the UVC assembly in place.

9 – Close the blower access door.

10 – Reconnect power to the rooftop unit.

11 – Open the filter access door and look through the view port in the triangular sheet-metal panel to
verify that the UVC light is on.

If UVC lamp does not come on:
1 – Check Power Wiring: Disconnect 1/4″ QC (quick connects) of the UVC cable near the UVC assembly. With Power ON, use multimeter to test 110-230V at the 1/4″QC quick connects from the control panel.
2 – Check Lamp: Carefully remove the UVC assembly out of the rooftop unit. Use multimeter to test for continuity across each pair of pins at each end of the lamp.
3 – Check Lamp Installation: Make sure that lamp’s pins snap properly into the lamp holder.
LED(s) not illuminated
Power status LED not lit–Check that the lamp unit is connected to the proper power source and is wired correctly.
Lamp status LED(s) not lit
1 – Check that lamp 4-pin connectors are properly engaged.
2 – Ohm-check across the lamp pins to check for continuity of lamp filaments (see FIGURE 40).
Troubleshooting charts are provided to aid in determining the cause of any problems encountered (FIGURE 39 and FIGURE 40).
Lamp Disposal
Hg-LAMP Contains Mercury – Manage in accordance with local, state and federal disposal laws. Refer to www. lamprecycle.org or call 800-953-6669.
Proper Clean-up Technique in Case of Lamp Breakage
Wear protective gloves, eye wear and mask.
Sweep the broken glass and debris into a plastic bag, seal the bag, and dispose of properly. Contact your local waste management office for proper disposal. Do not use a vacuum cleaner. Do not incinerate.
Maintenance
· For all maintenance, contact a qualified HVAC technician.
· Read the maintenance instructions before opening unit panels.
· Unintended use of the unit or damage to the unit housing may result in the escape of dangerous UVC radiation. UVC radiation may, even in small doses, cause harm to the eyes and skin.
· Do not operate units that are obviously damaged. · Do not discard the triangular UVC light shield or any
barriers with an ultraviolet radiation symbol. · Do not override the door interlock switch that inter-
rupts power to the UVC light. · Do not operate the UVC light outside of the unit.

Page 32

DANGER
Ultraviolet (UVC) Radiation hazard. Any exposure will cause significant eye damage and may cause skin damage. DO NOT look into UVC light source. Access panels must be in place during appliance operation.
UVC LIGHT TROUBLESHOOTING – POWER

UVC LAMP NOT OPERATING

POWER LED

LIT?

NO

YES

CHECK LAMP LEDS

DONE

YES

NO LAMP LEDS
LIT?

USE MULTIMETER TO TEST 110-230V AT
BALLAST INPUT LEADS

CORRECT VOLTAGE PRESENT? NO
YES
CHECK POWER
LEDS

FIRST TURN THE POWER OFF

;

CHECK THE WIRING

TURN POWER BACK ON

POWER LED YES LIT NOW?
NO GO TO LAMP LED TROUBLESHOOTING
FIGURE 38

REPLACE BALLAST

LAMP LEDS NOT LIT

UVC LIGHT TROUBLESHOOTING – LAMP

FIRST TURN THE POWER OFF. BE SURE THAT THE 4-PIN
CONNECTORS FOR ALL THE LAMPS ARE PROPERLY ENGAGE.D

TURN POWER ON; CHECK LAMP LEDS

DETAIL A

CALL LENNOX TECH SUPPORT 1-800-453-6669
NO

DONE

LAMPS BLACK ON
ENDS?
YES NO

YES LAMP LEDS LIT?
CHECK FOR CONTINUITY

TWO PAIR, PIN TO PIN ON EACH PAIR (SEE DETAIL A)
CONTINUITY YES PRESENT?
NO
REPLACE LAMPS; TURN POWER ON

LAMP LEDS

YES

LIT?

NO

BANDS

AROUND LAMP

YES

INTACT?

NO

BANDS

NOTE – CHECK FOR CONTINUITY ON THE SETS OF PINS CLOSEST TOGETHER
CHECK FOR CONTINUITY

DETAIL B

FIGURE 39 Page 33

Field-Installed Accessories
When field-installing the following accessories, refer to the latest online installation instructions.

Accessory Economizer Outdoor Air Damper Electric Heat Smoke Detector

TABLE 16
Instruction # 507227-XX 506340-XX 507250-XX 506437-XX

Factory Unit Controller Settings
Use the mobile service app to adjust parameters; menu paths are shown in each table. Refer to the Unit Controller manual provided with each unit.
TABLE 14 through TABLE 20 show blower factory settings. Record any field- adjusted settings in the blank column.
TABLE 21 through TABLE 23 show control options. When applicable, record field- specific information on the label located inside the compressor access panel.
When field installing optional kits and accessories, the Unit Controller must be configured to identify the option before it will function. Refer to FIGURE 41 and FIGURE 42 to determine whether the Unit Controller configuration I.D. must change. To configure the option, use RTU MENU > SETUP > INSTALL menu path. Press NEXT until CONFIGURATION ID 1 or 2 appears depending on the option installed. Change the appropriate character in the configuration I.D. For example, when an economizer is installed using a single enthalpy sensor, change configuration I.D. 1, the second character, to “S”.

TABLE 17

LGM/LCM 092U4E (2-Compressor) Staged Direct Drive

Parameter

Factory Setting

Field Setting

Description

NOTE – Any changes to Smoke CFM setting must be adjusted be fore the other CFM settings. Use SETTINGS > RTU OPTIONS > EDIT PARAMETERS

12

3000 CFM CFM

Blower CFM during smoke detection.

SETUP > TEST & BALANCE (can also use SETTINGS > RTU OPTIONS > BLOWER > SPEEDS)

3000 CFM CFM

Clower CFM during heating.

2625 CFM CFM

Blower CFM during high speed cooling (2 compressor) operation.

300 CFM CFM

Blower CFM during low speed cooling (1 compressor) operation.

800 CFM CFM

Blower CFM during ventilation.

1195 CFM RPM*

Adjust RPM based on unit stattic and blower tables to reach target CFM.

*Once all four blower settings are entered, the target (highest of the heating and cooling settings) CFM will be displayed. Once the RPM is saved for the target CFM, all other blower RPM values are set by the Unit Controller according to the field CFM setting..

SETUP > TEST & BALANCE (can also use SETTINGS > RTU OPTIONS > DAMPER)

0%

%

Damper min. position during LOW blower operation.

0%

%

Damper min. position during HIGH blower operation.

50%

%

Min. damper % for stage 1 power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETERS

Damper minimum position

during G blower operation.

29

101%

% Open

(Setting parameter 29 to “101” disables parameter

29 and passes control to

parameter 9 or 132).

216

10%

%

Deadband % for stage 1 power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETER

Compressor 1 low temp

85

0°F

°F

lockot. Settings lower than

0°F could void warranty.

Compressor 2 low temp

86

0°F

°F

lockout. Settings lower than

0°F could void warranty.

Page 34

TABLE 18

LGM/LCM 102U4E (2-Compressor) Staged Direct Drive

Parameter

Factory Setting

Field Setting

Description

NOTE – Any changes to Smoke CFM setting must be adjusted be fore the other CFM settings. Use SETTINGS > RTU OPTIONS > EDIT PARAMETERS

12

3400 CFM CFM

Blower CFM during smoke detection.

SETUP > TEST & BALANCE (can also use SETTINGS > RTU OPTIONS > BLOWER > SPEEDS)

3400 CFM CFM

Clower CFM during heating.

2675 CFM CFM

Blower CFM during high speed cooling (2 compressor) operation.

800 CFM CFM

Blower CFM during low speed cooling (1 compressor) operation.

800 CFM CFM

Blower CFM during ventilation.

1285 CFM RPM*

Adjust RPM based on unit stattic and blower tables to reach target CFM.

*Once all four blower settings are entered, the target (highest of the heating and cooling settings) CFM will be displayed. Once the RPM is saved for the target CFM, all other blower RPM values are set by the Unit Controller according to the field CFM setting..

SETUP > TEST & BALANCE (can also use SETTINGS > RTU OPTIONS > DAMPER)

0%

%

Damper min. position during LOW blower operation.

0%

%

Damper min. position during HIGH blower operation.

50%

%

Min. damper % for stage 1 power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETERS

Damper minimum position

during G blower operation.

29

101%

% Open

(Setting parameter 29 to “101” disables parameter

29 and passes control to

parameter 9 or 132).

216

10%

%

Deadband % for stage 1 power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETER

Compressor 1 low temp

85

0°F

°F

lockot. Settings lower than

0°F could void warranty.

Compressor 2 low temp

86

0°F

°F

lockout. Settings lower than

0°F could void warranty.

TABLE 19

LGM/LCM 120U4E (2-Compressor) Staged Direct Drive

Parameter

Factory Setting

Field Setting

Description

NOTE – Any changes to Smoke CFM setting must be adjusted be fore the other CFM settings. Use SETTINGS > RTU OPTIONS > EDIT PARAMETERS

12

4000 CFM CFM

Blower CFM during smoke detection.

SETUP > TEST & BALANCE (can also use SETTINGS > RTU OPTIONS > BLOWER > SPEEDS)

4000 CFM CFM

Clower CFM during heating.

3500 CFM CFM

Blower CFM during high speed cooling (2 compressor) operation.

875 CFM CFM

Blower CFM during low speed cooling (1 compressor) operation.

875 CFM CFM

Blower CFM during ventilation.

1425 CFM RPM*

Adjust RPM based on unit stattic and blower tables to reach target CFM.

*Once all four blower settings are entered, the target (highest of the heating and cooling settings) CFM will be displayed. Once the RPM is saved for the target CFM, all other blower RPM values are set by the Unit Controller according to the field CFM setting..

SETUP > TEST & BALANCE (can also use SETTINGS > RTU OPTIONS > DAMPER)

0%

%

Damper min. position during LOW blower operation.

0%

%

Damper min. position during HIGH blower operation.

50%

%

Min. damper % for stage 1 power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETERS

Damper minimum position

during G blower operation.

29

101%

% Open

(Setting parameter 29 to “101” disables parameter

29 and passes control to

parameter 9 or 132).

216

10%

%

Deadband % for stage 1 power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETER

Compressor 1 low temp

85

0°F

°F

lockot. Settings lower than

0°F could void warranty.

Compressor 2 low temp

86

0°F

°F

lockout. Settings lower than

0°F could void warranty.

Page 35

TABLE 20

LGM/LCM 150U4E (2-Compressor) Staged Direct Drive

Parameter

Factory Setting

Field Setting

Description

NOTE – Any changes to Smoke CFM setting must be adjusted be fore the other CFM settings. Use SETTINGS > RTU OPTIONS > EDIT PARAMETERS

12

5000 CFM CFM

Blower CFM during smoke detection.

SETUP > TEST & BALANCE (can also use SETTINGS > RTU OPTIONS > BLOWER > SPEEDS)

5000 CFM CFM

Clower CFM during heating.

4375 CFM CFM

Blower CFM during high speed cooling (2 compressor) operation.

1100 CFM CFM

Blower CFM during low speed cooling (1 compressor) operation.

1100 CFM CFM

Blower CFM during ventilation.

1655 CFM RPM*

Adjust RPM based on unit stattic and blower tables to reach target CFM.

*Once all four blower settings are entered, the target (highest of the heating and cooling settings) CFM will be displayed. Once the RPM is saved for the target CFM, all other blower RPM values are set by the Unit Controller according to the field CFM setting..

SETUP > TEST & BALANCE (can also use SETTINGS > RTU OPTIONS > DAMPER)

0%

%

Damper min. position during LOW blower operation.

0%

%

Damper min. position during HIGH blower operation.

50%

%

Min. damper % for stage 1 power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETERS

Damper minimum position

during G blower operation.

29

101%

% Open

(Setting parameter 29 to “101” disables parameter

29 and passes control to

parameter 9 or 132).

216

10%

%

Deadband % for stage 1 power exhaust operation.

SETTINGS > RTU OPTIONS > EDIT PARAMETER

Compressor 1 low temp

85

0°F

°F

lockot. Settings lower than

0°F could void warranty.

Compressor 2 low temp

86

0°F

°F

lockout. Settings lower than

0°F could void warranty.

TABLE 21 581024-01

Units With Hot Gas Reheat

RTU Menu > Settings “RTU Options” > Dehumidifier

Parameter

Factory Setting

Field Setting

Description

105

7

Factory Setting 7: Reheat mode en abled without prerequisite conditions. Controlled by RH sensor (A91) con nected to input A55_P298_5 and set point set at parameter 106 (default 60%).

TABLE 22 581037-01
Units with LonTalk Settings
Use menu RTU Menu > Network Integration > Network Setup Wiz ard > Set “LONTALK”

TABLE 23 581038-01
Units With BACnet Settings
RTU Menu > Network Integration > Network Setup Wizard > BACnet MS/TP > See BACnet MAC Address
BACNET MAC ADDRESS:
Units With Room Sensor, CPC/LSE Gateway Settings
RTU Menu > Network Integration > Network Setup Wizard > SBUS > Set SBUS Address
LCONN ADDRESS:

Page 36

Configuration ID 1
1 2 3 4 5 6 7 8

Humiditrol [1] Not Installed = N Humiditrol Installed = H
Unconfigured = U
Economizer [2] Not Installed = N Motorized Outdoor Air
Damper Only = M Economizer – Temperature = T
Economizer Global = G Economizer – Single Enthalpy = S
Economizer – Dual Enthalpy = D Unconfigured = U
Power Exhaust [3] Not Installed = N Single-Stage = S
Dual-Stage = D Unconfigured = U
Power Exhaust Control 4] Not Installed = N Damper Position = A A34 Pressure Sensor = C

[8] Outdoor Air Velocity Control
N = Not applicable (for future use) L = Outdoor Air Control Installed
with A24 Sensor set for low range. M = Outdoor Air Control Installed with
A24 Sensor set for medium range. H = Outdoor Air Control Installed with
A24 Sensor set for high range.
[7] Reserved
N = Reserved for future use.
[6] Blower Variable Frequency Drive Bypass
N = Not Installed A = Automatic Bypass M = Manual Bypass U = Unconfigured
[5] Network Module
N = Not Installed L = LonTalk (Lennox)

FIGURE 40 Page 37

Configuration ID 2

1 2 3 4 5 6 7 8 9 10

Air Flow Proving [1] Switch (S52)
Not Installed = N Installed on M4 = C Installed on DDC
Controller = D
Dirty Filter Switch (S27) [2] Not Installed = N Installed on M4 = C Installed on DDC Controller = D
Overflow Switch [3] (S149 / S179)
Not Installed = N Installed = Y
Reserved [4] Reserved = N

[10] Reserved
N = Reserved
[9] Electric Heat (Field-Installed)
N = Not Installed Y = Installed
[8] Load Shedding
N = Not Installed G = Global (P297 – pin 9) 2 = Installed on DI-2 3 = Installed on DI-3
[7] Zone Bypass Damper
N = Not Installed Y = Installed

Phase / Voltage Detection * [5] N = Not Installed 1 = Enabled Internal (Lennox) 2 = External (A42) Phase Detection
on DI-2 3 = External (A42) Phase Detection
on DI-3

[6] IAQ Options
N = Not Installed
1 = UV Lamp Installed
2 = Bipolar Ionizer Installed 3 = UV Lamp and
Bipolar Ionizer Installed

• When phase detection and voltage monitoring is enabled and wired incorrectl y, the system will go into demand hold status and restart after six minutes.

FIGURE 41 Page 38

START-UP REPORT
Job Name:___

Inspections and Checks

Store No.___Start-Up Date:__

Damage?

Yes No

R22 R410A

Address:_____

If yes, reported to:____

City:__State:__ Start-Up Contractor:____ Technician: Model No.: Serial No.:____ RTU No.:____ Catalog No.:__

Verify factory and field-installed accessories.
Check electrical connections. Tighten if necessary.
Supply voltage: L1-L2__L1-L3L2-L3
If unit contains a 208-230/240 volt transformer: Check primary transformer tap Transformer secondary voltage: __

Cooling Checks

Compressor Rotation Ambient Temp.____Return Air Temp.____ Supply Air Temp.____

Compressor Amps

Compressor Volts

Pressures Condenser Fan Amps CC Heater Amps

L1

L2

L3 L1-L2 L1-L3 L2-L3 Disch. Suct. L1

L2

L3

L1

1

2

3

4

Blower Checks

Pulley/Belt Alignment Set Screws Tight

Blower Rotation Belt Tension

Nameplate Amps:_ Volts:___

Motor

Amps L1 L2 L3_____

Volts L1-L2 L1-L3 L2-L3_____

Heating Checks – Gas

Fuel type: Nat. LP Inlet Pressure:_in. w.c. Return Air Temp.:__ Supply Air Temp.:_ Altitude:____ Primary Limits Operate:

CO2%: Gas Valve GV1 GV2

Manifold Pressure

Low Fire

High Fire

Control Type

Heating Checks – Electric

Return Air Temp.:__ Supply Air Temp.:__ Limits Operate:

Amps

L1 L2 L3

L1 L2 L3

1

10

2

11

3

12

4

13

5

14

6

15

7

16

8

17

9

18

Accessory Checks

Power Exhaust Amps

1 _____ 2 ____ None

Min. Pos.

Economizer Operation Motor travel full open/close

Page 39

References

• Lamp Recycle – Environmental Responsiblility Starts Here

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