LENNOX KG036-300S Phase Reversal Protection Kit Instruction Manual

LENNOX KG036-300S Phase Reversal Protection Kit Instruction Manual

Safety

   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 licensed professional HVAC installer or equivalent, service agency, or the gas supplier.

Use of this unit as a construction heater or air condition- er is not recommended during any phase of construction. Very low return air temperatures, harmful vapors and op- eration of the unit with clogged or misplaced filters will damage the unit.
NOTE – On KD dual-fuel units, before making any adjust- ments, set outdoor thermostat setpoint above the outdoor ambient temperature. This will disable heat pump opera- tion and allow gas heat operation.
If this unit has been used for heating or cooling of build- ings or structures under construction, the following condi- tions must be met or the warranty will be void:

• The vent hood must be installed per these installation

• A room thermostat must control the unit. The use of fixed jumpers that will provide continuous heating or cooling is not allowed

• A pre-filter must be installed at the entry to the return air duct.

• The return air duct must be provided and sealed to the unit.

• Return air temperature range between 55°F (13°C) and 80°F (27°C) must be maintained.

• Air filters must be replaced and pre-filter must be removed upon construction completion.

• The 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.
  NOTE – The Commonwealth of Massachusetts stipulates these additional requirements:

• Gas units shall be installed by a licensed plumber or gas fitter only.

• The gas cock must be “T handle” type.
  The unit is certified for installation on noncombustible floors only. However, it may be installed on wood flooring, or on class A, class B, or class C material covered floors when used in horizontal discharge applications or in downflow discharge applications when mounted on an LARMF roof mounting frame.
  Adequate clearance shall be provided around air openings into the vestibule area. Provisions shall be made for proper operation and for combustion air and ventilation air supply. Unit must be adjusted for the temperature rise range and within the allowable external static pressure on furnaces with a duct system as listed on unit nameplate.
  United States
  The unit is ETL/CSA certified for outdoor installations only at the clearances to combustible materials listed on the unit nameplate and in Figure 1, Figure 2 and Figure 3.

1Unit

Clearance

| A

in.(mm)

| B

in.(mm)

| C

in.(mm)

| D

in.(mm)

| Top Clear- ance
---|---|---|---|---|---
Service Clearance| 48

(1219)

| 36 (914)| 36 (914)| 36 (914)| Unobstructed
Clearance to Combustibles| 36 (914)| 1 (25)| 1 (25)| 1 (25)| Unobstructed
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.
Minimum Operation Clearance – Required clearance for proper unit operation

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. Minimum Operation Clearance –** Required clearance for proper unit operation. Installation of the ETL/CSA certified units must conform
with local building codes. In the absence of local codes, units must be installed according to the current National Fuel Gas Code ANSI Z223.1/NFPA 54.
When installed, the unit must be electrically wired and grounded according to local codes or, in the absence of local codes, with the current National Electric Code, ANSI/ NFPA 70.
The current American National Standard (ANSIZ233.1/ NFPA54) National Fuel Gas Code is available from the following address:

American National Standard Institute Inc.
11 West 42nd Street
New York, NY 10036
The current National Electric Code (ANSI/NFPA 70) is available from the following address:
National Fire Protection Association
1 Batterymarch Park
PO Box 9101
Quincy, MA 02269-9101
Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.
Never test for gas leaks with an open flame. Check all connections with a commercially available soap solution made specifically for leak detection.
NOTE – Furnace must be adjusted to obtain a temperature rise (high and low fire) within the range(s) specified on the unit nameplate. Failure to do so may cause erratic limit operation.e

Canada

The unit is CSA International (CSA) certified for combina- tion heating/cooling for outdoor installations and non-res- idential use only at the clearances to combustible materi- als as listed on the unit nameplate.
Installation of CSA international certified units must con- form with current standard CSA B149.1, “Natural Gas and Propane Installation Codes” and applicable local codes. Authorities having jurisdiction should be consulted before installation.
The unit must be wired and electrically grounded accord- ing to local codes or, in the absence of local codes, cur- rent CSA Standard C22.1 Canadian Electrical Code Part

1. Installation of combination heating/cooling units must also conform with current CSA Standard B52 “Mechanical Refrigeration Code.”

**Con ** A manual main shut-off valve must be installed external to the unit when local codes require the installation of such a valve.
Install a ground joint union between the gas control mani- fold and the main manual shut-off valve.
When making piping connections a drip leg should be in- stalled 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. See Figure 4, Figure 5, Figure 6 or Fig- ure 7 for tap location. See Figure 8 for gas supply piping entry through the side of the unit and Figure 9 for gas pip- ing through the bottom of the unit. A kit is required when routing gas supply piping through the bottom of the unit.
Compounds used on threaded joints of gas piping must be

High Alititue Derate

Locate the high altitude conversion sticker in the unit literature bag. Fill out the conversion sticker and affix next to the unit nameplate.
Refer to table 1 for high altitude adjustments

HIGH ALTITUDE DERATE

Pressure Test Gas Piping

Operating pressures at the unit gas connection must be as shown in table 2.

OPERATING PRESSURE AT GAS CONNECTION “w.c

Model

| Natural Gas| LP/ Propane Gas
---|---|---
Min.| Max.| Min| Max.
KG/KD 024-090| 4.5| 10.5| 11| 13
KG/KD 092-300| 4.7| 10.5| 11| 13

When testing the pressure of gas lines, the gas valve must be disconnected and isolated. Gas valves can be damaged if subjected to more than 0.5 psig

Two-Stage Gas Valve Adjustment **** Gas manifold pressures should match pressures shown in table 3. On two stage gas valves, initiate a W2 thermostat demand to check high fire pressure before low fire pres- sure. With high fire operating, reduce the thermostat de- mand to W1 and check the low fire pressure. Refer to the Unit Controller manual to initiate a thermostat demand.

IMPORTANT – Do not set low fire pressure lower than the certified minimum input rating listed in table 3.

Unit

| Natural Gas| Propane (LP)Gas
---|---|---
1st Stage

±0.2

| 2nd Stage

± 0.3.

| 1st Stage

±0.2

| 2nd Stage

± 0.3.

024, 030, 036, 048, 060, 072,

074 Std./Med./High Heat

| ****

NA

| ****

3.5

| ****

NA

| ****

10.5

036, 048, 060, 072, 074,

090 Dual Heat

| ****

2.0

| ****

3.5

| ****

5.9

| ****

10.5

092-300| 1.6| 3.7| 5.5| 10.5

Gas Heat Operation

See the operating instruction plate on the unit for details Proper Gas Flow (Approximate)

1.  Operate unit at least 15 minutes before checking gas flow. Determine the time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) A portable LP gas meter (17Y44) is available for LP applications.
2. Divide the number of seconds by two and compare to the time in table 4. If manifold pressure is correct and rate is incorrect, check gas orifices for proper size and restriction.
3. Remove temporary gas meter if installed.
   NOTE – To obtain accurate reading, shut off all other gas appliances connected to meter.

GAS METER CLOCKING CHART

Natural-1000 btu/cu ft

Typical Gas Heat Schematic

Typical Unit Schematic

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