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2017

WARNING

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

CAUTION

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.

Table Of Contents

Dimensions

Page 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shipping and Packing List

Page 3

. . . . . . . . . . . . . . . . . . . .

General

Page 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Requirements

Page 3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Support

Page 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct Connection

Page 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION
INSTRUCTIONS

KDB024

(2 TON)

KDB036

(3 TON)

KDB048

(4 TON)

KDB060

(5 TON)

ROOFTOP PACKAGED UNITS

507626-01
04/2017
Supersedes 8/2016

Rigging Unit For Lifting

Page 5

. . . . . . . . . . . . . . . . . . . . . . .

Condensate Drains

Page 6

. . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections

Page 9

. . . . . . . . . . . . . . . . . . . . . . .

Unit Power-Up

Page 9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Operation and Adjustments

Page 10

. . . . . . . . . . . .

Defrost Control Board

Page 30

. . . . . . . . . . . . . . . . . . . . . . . .

Service

Page 33

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE

KDB024, 036, 048, 060 PARTS ARRANGEMENT

EVAPORATOR

COIL

CONDENSER

FAN

CONDENSATE

DRAIN

FILTERS

ECONOMIZER

(OPTIONAL)

BLOWER

COMPRESSOR

CONDENSER

COIL

REVERSING

VALVE

GAS VALVE

BURNERS

COMBUSTION

AIR INDUCER

INDOOR

TXV

OUTDOOR

TXV

TB1 LOW VOLTAGE

TERMINAL BLOCK

1
2
3
...
»

Содержание KDB024

Страница 1: ... 3 General Page 3 Requirements Page 3 Unit Support Page 4 Duct Connection Page 5 INSTALLATION INSTRUCTIONS KDB024 2 TON KDB036 3 TON KDB048 4 TON KDB060 5 TON ROOFTOP PACKAGED UNITS 507626 01 04 2017 Supersedes 8 2016 Rigging Unit For Lifting Page 5 Condensate Drains Page 6 Electrical Connections Page 9 Unit Power Up Page 9 Blower Operation and Adjustments Page 10 Defrost Control Board Page 30 Ser...

Страница 2: ...ETURN AIR OPENING BOTTOM CONDENSATE OUTLET BOTTOM POWER ENTRY 3 X 8 76 X 203 25 3 4 654 024 thru 074 38 3 4 984 090 GAS INLET FLUE VENT OUTLET 27 686 15 381 3 1 2 89 98 1 4 2496 060 BASE 26 1 2 673 5 1 2 140 LIFTING HOLES For rigging SIDE VIEW 1 25 35 3 8 899 KDB024 036 43 3 8 1102 KDB048 060 85 1 4 2165 024 thru 036 BASE 96 1 4 2445 048 060 83 1 4 2115 024 036 CONDENSATE OUTLET EITHER SIDE ELECTR...

Страница 3: ...to swell Bubbles in the rubber roofing material can cause leaks Protect the roof surface to avoid exposure to refrigerant and oil during service and installation Failure to follow this notice could result in damage to roof surface The National Electric Code ANSI NFPA No 70 1984 is available from National Fire Protection Association 1 Batterymarch Park PO Box 9101 Quincy MA 02269 9101 UNIT CLEARANC...

Страница 4: ...f 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 C1CURB 1 The C1CURB roof mounting frame must be installed flashed and sealed in accordance with the instructions provided with the frame 2 The C1CURB roof mounting frame should be sq...

Страница 5: ... Directly Above Center Of Gravity CAUTION DO NOT WALK ON UNIT Unit Weight Lbs Kg Maximum weight with all avail able installed accessories 894 406 Horizontal Air Discharge Unit is shipped with panels covering the horizontal supply and return air openings Remove horizontal covers and place over downflow openings for horizontal air discharge See figure 3 Secure in place with sheet metal screws Units ...

Страница 6: ...IDE DRAIN CONNECTION NOTE Allow clearance to open doors when installing condensate piping CAULK AROUND CONDENSATE COUPLING FIGURE 6 UNIT Minimum Pitch 1 25 mm per 10 3 m of line MOUNTING FRAME CONDENSATE BOTTOM DRAIN CONNECTION OPEN VENT CAULK AROUND CONDENSATE COUPLING DRAIN PAN Units are shipped with the drain coupling facing the front of the unit Condensate can be drained from the back or botto...

Страница 7: ...DRAIN DRILL A PILOT HOLE IN CENTER OF COUPLING After drilling the pilot hole drill a 7 8 hole from the inside of the pan CAUTION Be careful not to damage the coupling threads when drilling the hole 9 Use a field provided 1 plug to seal side drain connection 10 Replace the condensate drain mullion and reinstall screws 11 Reinstall access doors Connect Gas Piping Before connecting field provided pip...

Страница 8: ...eans Do not use matches candles or other sources of ignition to check for gas leaks 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 othe sources of ignition to check for gas leaks WARNING Danger of explosion Can cause injury or product or property damage Do not use ma...

Страница 9: ...oltage they must be routed away from line voltage wiring Use wire ties located near the front of the control section to secure thermostat cable Use18 AWG wire for all applications using remotely installed electro mechanical and electronic thermostats 2 Install thermostat assembly in accordance with instructions provided with thermostat 3 Connect thermostat wiring to TB1 terminal board on the lower...

Страница 10: ... toward outside of unit 3 Slide frame back into original position when finished servicing Reattach the blower wiring in the previous location on the blower motor base using the wire tie 4 Replace retained screws on either side of the sliding frame Direct Drive Blowers 1 Loosen the reusable wire tie which secures the controls and high voltage blower wiring to the blower housing 2 Remove and retain ...

Страница 11: ...ic pressure readings can vary if not taken where shown 3 Referring to pages 17 to 22 use static pressure and RPM readings to determine unit CFM Use page 23 when installing units with any of the optional accessories listed 4 The blower RPM can be adjusted at the motor pulley Loosen Allen screw and turn adjustable pulley clockwise to increase CFM Turn counterclockwise to decrease CFM See figure 18 D...

Страница 12: ...n Overtensioning belts shortens belt and bearing life Check belt tension as follows 1 Measure span length X See figure 19 2 Apply perpendicular force to center of span X with enough pressure to deflect belt 1 64 for every inch of span length or 1 5mm per 100mm of span length Example Deflection distance of a 40 span would be 40 64 or 5 8 Example Deflection distance of a 400mm span would be 6mm 3 Me...

Страница 13: ...e in w g Air Volume at Specific Blower Taps cfm Tap 1 Tap 2 Tap 3 Tap 4 Tap 5 DOWNFLOW KDB024H4E 0 0 635 825 918 1121 1336 0 1 547 763 861 1071 1290 0 2 433 699 806 1031 1253 0 3 371 636 749 986 1212 0 4 280 559 677 927 1166 0 5 217 481 605 868 1120 0 6 548 819 1071 0 7 491 773 1029 0 8 442 714 983 0 9 393 653 929 1 0 604 879 HORIZONTAL KDB024H4E 0 0 602 815 908 1096 1302 0 1 509 750 852 1057 1263...

Страница 14: ...Specific Blower Taps cfm Tap 1 Tap 2 Tap 3 Tap 4 Tap 5 DOWNFLOW KDB036H4E 0 0 893 1035 1375 1600 1840 0 1 838 965 1330 1574 1780 0 2 768 895 1277 1543 1748 0 3 705 800 1253 1505 1712 0 4 645 750 1200 1473 1677 0 5 575 690 1150 1435 1638 0 6 1095 1390 1608 0 7 1052 1345 1577 0 8 1004 1302 1528 0 9 950 1260 1491 1 0 900 1218 1455 HORIZONTAL KDB036H4E 0 0 900 1045 1379 1599 1810 0 1 828 970 1305 1549...

Страница 15: ... 5 DOWNFLOW KDB048H4E 0 0 1225 1310 1561 2015 2168 0 1 1167 1254 1514 1995 2143 0 2 1112 1203 1473 1977 2126 0 3 1052 1145 1424 1942 2097 0 4 1000 1098 1387 1917 2078 0 5 939 1040 1343 1888 2049 0 6 894 996 1300 1854 2020 0 7 840 941 1250 1819 1991 0 8 780 883 1201 1787 1952 0 9 734 839 1159 1749 1914 1 0 681 784 1115 1704 1856 HORIZONTAL KDB048H4E 0 0 1185 1265 1504 1983 2120 0 1 1130 1213 1467 1...

Страница 16: ...NFLOW KDB060H4E 0 0 1351 1405 1801 1982 2339 0 1 1303 1359 1769 1956 2310 0 2 1254 1314 1736 1928 2281 0 3 1206 1268 1703 1900 2253 0 4 1158 1222 1669 1870 2224 0 5 1109 1177 1634 1838 2195 0 6 1061 1131 1598 1806 2166 0 7 1012 1085 1561 1772 2137 0 8 964 1040 1524 1736 2108 0 9 915 994 1486 1700 2080 1 0 867 949 1446 1662 2051 HORIZONTAL KDB60H4E 0 0 1329 1353 1728 1886 2206 0 1 1284 1320 1708 18...

Страница 17: ... 34 971 0 36 1200 560 0 21 625 0 25 689 0 28 755 0 30 820 0 32 879 0 34 932 0 37 983 0 40 1300 591 0 24 654 0 28 716 0 31 779 0 33 841 0 35 897 0 38 948 0 41 996 0 44 1400 631 0 26 690 0 30 748 0 34 807 0 36 864 0 39 916 0 42 964 0 46 1011 0 49 1500 676 0 28 729 0 33 782 0 36 835 0 40 887 0 43 935 0 47 981 0 50 1028 0 54 Air Volume cfm External Static in w g 0 90 1 00 1 10 1 20 1 30 1 40 1 50 1 60...

Страница 18: ... 0 33 959 0 36 1200 567 0 19 633 0 22 700 0 24 768 0 27 833 0 30 884 0 33 928 0 37 974 0 40 1300 599 0 22 664 0 25 729 0 28 793 0 30 853 0 33 902 0 37 945 0 41 990 0 44 1400 634 0 26 697 0 29 758 0 31 819 0 34 875 0 38 921 0 42 964 0 46 1008 0 49 1500 669 0 30 730 0 33 789 0 36 846 0 39 897 0 42 941 0 47 983 0 51 1028 0 54 Air Volume cfm External Static in w g 0 90 1 00 1 10 1 20 1 30 1 40 1 50 1 ...

Страница 19: ... 33 754 0 37 806 0 41 867 0 43 927 0 45 976 0 48 1014 0 51 1700 708 0 30 754 0 34 800 0 38 846 0 42 898 0 46 949 0 49 992 0 53 1028 0 57 1800 764 0 31 804 0 36 844 0 40 884 0 45 927 0 49 970 0 54 1008 0 58 1044 0 63 1900 812 0 34 847 0 39 881 0 44 916 0 49 953 0 54 990 0 59 1025 0 64 1061 0 69 2000 857 0 42 889 0 47 920 0 52 952 0 57 986 0 62 1020 0 68 1055 0 73 1091 0 77 Air Volume cfm External S...

Страница 20: ...50 0 31 792 0 35 836 0 39 880 0 43 924 0 47 968 0 51 1007 0 55 1043 0 59 1800 799 0 35 837 0 39 875 0 43 913 0 48 952 0 52 990 0 56 1026 0 61 1061 0 65 1900 840 0 40 873 0 45 907 0 49 941 0 54 976 0 58 1011 0 63 1045 0 67 1080 0 72 2000 883 0 48 913 0 53 944 0 57 976 0 62 1009 0 67 1043 0 71 1078 0 76 1112 0 8 Air Volume cfm External Static in w g 0 90 1 00 1 10 1 20 1 30 1 40 1 50 1 60 RPM BHP RP...

Страница 21: ...4 940 0 59 973 0 70 1006 0 70 1041 0 75 1076 0 80 1112 0 85 2200 897 0 55 929 0 61 961 0 66 994 0 78 1028 0 78 1063 0 83 1099 0 89 1134 0 93 2300 918 0 62 950 0 68 983 0 74 1017 0 86 1052 0 86 1087 0 92 1122 0 97 1157 1 02 2400 941 0 70 974 0 77 1008 0 83 1042 0 96 1077 0 96 1111 1 01 1146 1 06 1181 1 11 Air Volume cfm External Static in w g 0 90 1 00 1 10 1 20 1 30 1 40 1 50 1 60 RPM BHP RPM BHP ...

Страница 22: ... 0 75 1067 0 79 1101 0 84 1135 0 88 2200 930 0 64 960 0 68 991 0 73 1024 0 78 1058 0 83 1092 0 88 1126 0 92 1160 0 96 2300 954 0 72 985 0 77 1017 0 82 1051 0 87 1085 0 92 1119 0 96 1152 1 00 1186 1 04 2400 981 0 81 1013 0 86 1046 0 91 1079 0 96 1113 1 00 1180 1 05 1180 1 09 1213 1 13 Air Volume cfm External Static in w g 0 90 1 00 1 10 1 20 1 30 1 40 1 50 1 60 RPM BHP RPM BHP RPM BHP RPM BHP RPM B...

Страница 23: ...ide 2 Ends Open All Ends Sides Open 800 0 15 0 13 0 11 0 11 1000 0 19 0 16 0 14 0 14 1200 0 25 0 20 0 17 0 17 1400 0 33 0 26 0 20 0 20 1600 0 43 0 32 0 20 0 24 1800 0 56 0 40 0 30 0 30 2000 0 73 0 50 0 36 0 36 2200 0 95 0 63 0 44 0 44 BLOWER DATA BELT DRIVE KIT SPECIFICATIONS Model No Motor HP No of Speeds Drive Kits and RPM Range Nominal Maximum A01 A02 A03 A05 A06 A07 036 0 75 0 86 2 low 449 673...

Страница 24: ...thermostat or temperature control device to initiate a first stage heating demand 2 A first stage heating demand W1 will energize compressors 1 and the outdoor fan Note L1 reversing valve is de energized in the heating mode Cooling 1 Initiate first and second stage cooling demands according to instructions provided with thermostat See table 4 for operation 2 Units contain one refrigerant circuit o...

Страница 25: ...IMPORTANT Charge unit in standard cooling mode 1 Make sure outdoor coil is clean Attach gauge manifolds and operate unit at full CFM in cooling mode with economizer disabled until system stabilizes approximately five minutes Make sure all outdoor air dampers are closed 2 Compare the normal operating pressures see table 5 through 8 to the pressures obtained from the gauges Check unit components if ...

Страница 26: ... 130 476 142 240 142 278 144 321 146 370 149 425 151 483 157 247 163 286 165 330 168 378 170 431 173 491 TABLE 7 KDB048H Normal Operating Pressures Outdoor Coil Entering Air Temperature 65 F 75 F 85 F 95 F 105 F 115 F Suct psig Disc psig Suct psig Disc psig Suct psig Disc psig Suct psig Disc psig Suct psig Disc psig Suct psig Disc psig 107 234 109 272 110 314 112 363 116 409 117 462 115 242 117 27...

Страница 27: ...re F Suction Pressure psig Outdoor Temperature F KDB 024H Charging Curves 115 105 95 85 75 65 180 130 60 70 80 90 100 110 120 110 120 130 140 150 160 170 Liquid Temperature F Suction Pressure psig Outdoor Temperature F KDB 036H Charging Curves 115 105 95 85 75 65 180 130 60 ...

Страница 28: ...ature F Suction Pressure psig Outdoor Temperature F KDB 048H Charging Curves 115 105 95 85 75 65 130 100 70 80 90 100 110 120 110 120 130 140 150 160 170 Liquid Temperature F Suction Pressure psig Outdoor Temperature F KDB 060H Charging Curves 115 105 95 85 75 65 130 100 ...

Страница 29: ...he defrost control which cycles defrost The ambient sensor is located on the inside of the corner mullion on the back of the outdoor coil section The coil sensor is located on a return bend on the front of the outdoor coil 5 Defrost Controls CMC1 Gas heat is energized during defrost to maintain discharge air temperature 100269 Series Time Temperature When the liquid line temperature drops below 42...

Страница 30: ...st switch on 100269 series defrost control boards The defrost control uses input from a coil and an ambient temperature sensor on 100135 series defrost control boards Defrost Test Option A TEST option is provided for troubleshooting The TEST mode may be started any time the unit is in the heating mode and the defrost thermostat is closed or jumpered If the timing jumper is in the TEST position at ...

Страница 31: ... 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...

Страница 32: ...s valve solenoid opens 13 Spark ignites gas ignition sensor proves the flame and combustion continues 14 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 15 For troubleshooting purposes an ignition attempt after lock out may be re established manually Move thermostat to OFF and return thermostat switch to...

Страница 33: ... bi flow filter drier if replacement is necessary order another of like design FIGURE 24 REMOVE FILTERS PULL TO REMOVE FILTERS E Indoor Coil Inspect and clean coil at beginning of each cooling and heating season Clean using mild detergent or commercial coil cleanser Flush coil and condensate drain with water taking care not to get insulation filters and return air ducts wet F Outdoor Coil Clean co...

Страница 34: ...ten main burner mounting screws Snug tighten only 7 Restore electrical power and gas supply Follow lighting instructions attached to unit and use inspection port in access panel to check flame H Combustion Air Inducer 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 nor...

Страница 35: ...ended that the combustion air inducer gasket be replaced during reassembly 17 Clean combustion air inlet louvers on heat access panel using a small brush 18 Replace mullion J Flue Passageway and Flue Box 1 Remove combustion air inducer assembly as described in section J 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 co...

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