Lennox KG Series User manual

Page 1
INSTALLATION INSTRUCTIONS FOR OUTDOOR AIR DAMPERS
USED WITH KG/KC/KH/LGH/LCH/ZG/ZC/ZH 024-090 UNITS
506882-02
4/2017
Supersedes 11/2016
©2017
OUTDOOR AIR DAMPERS
OUTDOOR AIR DAMPERS
Note - Disregard shipping and packing list and installation
sections when dampers are factory-installed.
Shipping and Packing List
Package 1 of 1 contains:
1- Outdoor air damper (OAD) assembly
1- Hood pivot bracket (15D17, 15D19)
1- Bag assembly containing (15D17, 15D19):
1-P160/J160 jumper harness
1-J39/P39 harness (15D19)
#10 self-drilling screws (15D19)
2-Wiring diagrams (15D17)
3-Wiring diagrams (15D19)
1- Outdoor air hood carton containing:
1-Hood top (15D18, 15D20)
2-Hood sides (left and right)
1-Hood front filter bracket
1-Filter
1-Bottom filter bracket (15D17, 15D19)
1-Bag assembly containing:
#10 sheet metal screws
1-#10 - 32 X 1/2” screw (15D17, 15D19)
Foam tape (15D18, 15D20)
Check parts for shipping damage. Receiving party should
contact last carrier immediately if shipping damage is found.
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, service agency, or the
gas supplier
Application
Optional outdoor air dampers provide fresh outdoor air.
See table 1 for usage.
C1DAMP21A-1 and Z1DAMP21A-2
Motorized Dampers:
Electro-mechanical units (KC/KG/KH/ZC/ZG/ZH) -
The damper opens to a set position when the blower is
operating. To operate the damper only during the
occupied time period, an optional thermostat or energy
management system must be installed that provides an
occupied signal to the unit's thermostat connection.
Units equipped with an M3 A55 Unit Controller (LC/LG) -
The damper opens to a set position when the blower is
operating and an occupied signal is provided to the Unit
Controller.
C1DAMP11A-2 & Z1DAMP11A-2
Manual Dampers:
Damper is manually operated; damper position is
manually set at installation and remains in that position.
TABLE 1
Unit Type LB # Cat. #
LCH/LGH 036–072
KC/KG/KH 024-090 Motorized 613924-07 15D17
LCH/LGH 036–072
KC/KG/KH 024-090 Manual 613924-08 15D18
ZC/ZG/ZH 036-060 Motorized 613924-09 15D19
ZC/ZG/ZH 036-060 Manual 613924-10 15D20
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.

Page 2
Install Motorized Damper Assembly
LGH/LCH/KG/KC/KH Units
1- Disconnect all power to unit.
2- On LGH/LCH/KG/KC/KH units equipped with
factory-installed dampers, go to Outdoor Air Hood -
Motorized Damper section.
3- Remove and retain five screws securing end panel to
the unit. See figure 1. Remove and discard end panel.
4- Remove and retain two screws securing the hood top
to the damper assembly (provided in kit). Remove
hood top and retain. See figure 3.
5- Install damper assembly in unit; insert top of panel
first. Secure bottom of assembly with screws retained
from previous panel.
FIGURE 1
LGH/LCH/KG/KC/KH UNIT
FILTER
ACCESS PANEL
UNIT END
PANEL
BLOWER
ACCESS PANEL
J3/P3 BEHIND
THIS PANEL
Install Motorized Damper Assembly
ZG/ZC/ZH Units
1- Disconnect all power to unit.
2- Remove and discard unit back panel. Retain screws and
two door brackets which secure panel. See figure 2.
3- Remove filter access panel. Retain panel and
screws.
4- Install damper assembly (provided in kit) in unit. Hold
door brackets in place and secure damper assembly
and brackets to unit with retained screws.
5- Secure the bottom of the assembly with retained
screws.
FIGURE 2
ZG/ZC/ZH UNIT
UNIT BACK
PANEL
FILTER ACCESS PANEL
J3/P3 BEHIND
THIS PANEL
DOOR
BRACKETS
MOTORIZED OUTDOOR AIR DAMPER - LGH/LCH/KG/KC/KH
DAMPER
ASSEMBLY
UNIT
FILTER
ACCESS
PANEL
FIT TOP OF
PANEL UNDER
UNIT TOP FLANGE
FIGURE 3
REMOVE AND RE
TAIN TWO SCREWS
AND HOOD TOP

Page 3
Wiring Harnesses - J/P3, P4, J/P39, J/P160
1- Remove the filter access panel and locate the unit
connection J3/P3.
2- Remove P3 jumper plug and discard.
3- Locate the following harnesses provided in kit:
KG/KC/KH Units - P160/J160
ZG/ZC/ZH Units - P160/J160 and P39/J39
Note - LGH/LCH units do not require kit harnesses.
4- Make harness connections as shown in figure 4, 5, or 6.
5- Discard unused harnesses.
6- Replace the filter access panel.
CONNECT P4 MOTORIZED DAMPER PLUG
TO J3 UNIT JACK
J3 P4
DISCONNECT P3 JUMPER PLUG
FROM J3 UNIT JACK
J3 P3
TO
UNIT DISCARD P3
TO
UNIT B7
DAMPER
MOTOR
FIGURE 4
WIRING HARNESS CONNECTIONS
LGH/LCH UNITS
DISCONNECT P3 JUMPER PLUG
FROM J3 UNIT JACK
J3 P3
TO
UNIT DISCARD P3
CONNECT J/P160 KIT HARNESS BETWEEN J3 AND P4
J3 P160
TO
UNIT J160 P4 B7
DAMPER
MOTOR
FIGURE 5
J3 P160 J160 P4 B7
WIRING HARNESS CONNECTIONS
KG/KC/KH UNITS
WIRING HARNESS CONNECTIONS
ZG/ZC/ZH UNITS
DISCONNECT P3 JUMPER PLUG
FROM J3 UNIT JACK
J3 P3
TO
UNIT DISCARD P3
FIGURE 6
CONNECT J/P39 AND J/P160 KIT HARNESSES
BETWEEN J3 AND P4
J3 P39
TO
UNIT J160 P4 B7B7J39 P160P160
Actuator DIP Switch Setting -
KG/KC/KH/ZG/ZC/ZH Units Only
1- Remove and retain horizontal return panel and
screws.
2- Open the damper motor DIP switch access cover and
adjust the setting. See figure 7.
3- Replace damper motor access cover and horizontal
return panel.
FIGURE 7
INTERLINK DAMPER MOTOR -
(KG/KC/KH/ZG/ZC/ZH)
RETAINER
CLIP
DAMPER
STOP
DIP SWITCH
ACCESS COVER
MOVE STOP THIS
DIRECTION FOR LESS
OUTDOOR AIR
FACTORY-
INSTALLED SETTING
CHANGE TO
THIS SETTING

Page 4
Wiring Diagrams
LGH/LCH/KG/KC/KH Units -
Affix the applicable wiring diagram on the inside of the
control compartment access panel. Position diagram to
the right of the “C” control section wiring diagram.
LGH/LCH units use the diagram showing A55 in the key
list. KG/KC/KH units use the diagram showing J160/P160
in the key list. Discard the unused diagram.
ZG/ZC/ZH Units -
Affix the appropriate wiring diagram on the inside of the
control compartment access panel. Discard the other two
diagrams.
Outdoor Air Hood - Motorized Damper
Outdoor air hood carton is shipped in the return air section
when the dampers are factory-installed.
On LGH/LCH/KG/KC/KH units equipped with
factory-installed dampers, go to step 3-.
1- LC/LG/KG/KC/KH Only -
Slide the top edge of hood pivot bracket between the
unit cabinet top flange and the outdoor air assembly.
See figure 9. Secure pivot bracket using retained end
panel screws. Install, but do not tighten, the screws.
ZG/ZC/ZH Only -
Align four holes in hood pivot bracket with the dimples
above opening in lower panel. Use self-drilling
screws, provided, to install the hood pivot bracket, but
do not tighten the screws. See figure 8.
2- Position the hood top V-channel under the
corresponding V-channel on hood pivot bracket.
Slide hood from left to right until it is properly
positioned. See figure 9.
3- Factory-Installed Dampers Only - Remove screws
securing hood to unit. Lift hood upward allowing the
hood to slide from left to right.
4- Secure left hood side to the hood top and to the
cabinet using the provided screws. See figure 11.
5- Secure the right hood side to the hood top. Do not
secure the right hood side to cabinet. See figure 12.
6- Align the two holes on the left hood side with the two
holes in the bottom filter bracket. Secure using
provided screws. See figure 11.
7- Secure bottom filter bracket to the right hood side as
shown in figure 12.
8- Secure right hood side to cabinet using provided
screws. See figure 12.
FIGURE 8
ZG/ZC/ZH PIVOT BRACKET
HOOD PIVOT
BRACKET
FILTER ACCESS
PANEL
DAMPER
ASSEMBLY
FIGURE 9
OUTDOOR AIR HOOD - LGH/LCH/KG/KC/KH SHOWN
UNIT TOP
FLANGE
HOOD PIVOT
BRACKET
HOOD TOP
LEFT HOOD
SIDE
INSERT THREAD
FORMING SCREW
HOOD TOP
FILTER BRACKET
FILTER
BOTTOM FILTER
BRACKET
HOOD
TOP
UNIT TOP
FLANGE
HOOD PIVOT
BRACKET
OUTDOOR AIR
DAMPER ASSEMBLY
ON SHORTER UNITS
FILLER PANEL ON
TALLER UNITS

Page 5
9- Slide filter into the slot on the bottom filter bracket.
Make sure arrows on filter match airflow direction.
Secure the hood top filter bracket to the hood top
using the thread forming screw provided. See
figure 11.
10- Tighten hood pivot bracket screws.
11- Seal the locations shown in figures 11 and 12 with
caulk.
12- LGH/LCH/KG/KC/KH Only -
Locate the two retained screws removed from the
hood top in figure 3. Install screws into the two open
holes on the unit end panel below the assembled
hood. See figure 10.
FIGURE 11
OUTDOOR AIR HOOD
LGH/LCH/KG/KC/KH SHOWN
LEFT
HOOD SIDE
INSERT
THREAD
FORMING
SCREW
HOLES FOR
BOTTOM
FILTER
BRACKET
HOOD TOP
FILTER
BRACKET
DAMPER
ASSEMBLY
SEAL
WITH
CAULK
HOOD
PIVOT
BRACKET
UNIT TOP
PANEL
HOOD
TOP
INSTALL RETAINED SCREWS
IN OPEN HOLES ON LGH/
LCH/KG/KC/KH UNITS
FIGURE 12
OUTDOOR AIR HOOD
LGH/LCH/KG/KC/KH SHOWN
HOLES FOR
BOTTOM
FILTER
BRACKET
SEAL WITH
CAULK
DAMPER
ASSEMBLY
HOOD
TOP
HOOD PIVOT
BRACKET
RIGHT
HOOD
SIDE

Page 6
Install Manual Damper
1- Disconnect all power to the unit.
2- On LGH/LCH/KG/KC/KH units equipped with
factory-installed dampers, go to Outdoor Air Hood -
Motorized Damper section.
LGH/LCH/KG/KC/KH Units
3- Remove and retain screws securing end panel to the
unit. See figure 1. Remove and discard end panel.
4- Insert top of damper assembly. See figure 14. Secure
the bottom of the assembly using retained screws.
Secure the top of the assembly with retained screws.
ZG/ZC/ZH Units
1- Disconnect all power to the unit.
2- Remove and discard unit back panel. Retain screws and
two door brackets which secure panel. See figure 2.
3- Remove filter access panel. Retain panel and screws.
4- Position retained brackets on damper assembly and
install below filter access panel. Secure damper
assembly and brackets to unit using retained screws.
See figure 13.
5- Secure the bottom of the assembly with retained
screws.
6- Replace filter access panel.
FIGURE 13
MANUAL OUTDOOR AIR DAMPER - ZG/ZC/ZH
DAMPER
ASSEMBLY
LOOSEN FOUR
SCREWS TO
SLIDE DAMPER
FILTER ACCESS
PANEL
MANUAL OUTDOOR AIR DAMPER - LGH/LCH/KG/KC/KH
DAMPER
ASSEMBLY
UNIT
FILTER
ACCESS
PANEL
FIT TOP OF
PANEL UNDER
UNIT TOP FLANGE
FIGURE 14
SECURE BOTTOM
SCREWS FIRST
LOOSEN FOUR
SCREWS TO
SLIDE DAMPER

Page 7
Outdoor Air Hood - Manual Damper
Hood is shipped in the return air section when the
dampers are factory-installed.
1- Assemble hood as shown in figure 15.
2- Install mist eliminator filter as shown in figure 16.
Make sure arrows on filter match airflow.
3- Secure hood to unit as shown in figure 17.
4- Install kit screws into the two open holes on the end
panel below the hood. See figure 17.
HOOD TOP
ASSEMBLE HOOD
HOOD
SIDE (2)
HOOD FRONT
POSITION HOOD TOP
FLANGE ON TOP OF
HOOD FRONT
FIGURE 15
ÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂ
ÂÂÂÂÂÂÂÂ
HOOD
INSERT MIST ELIMINATOR FILTER
FILTER
MAKE SURE ARROWS ON
MIST ELIMINATOR FILTER
MATCH AIRFLOW DIRECTION
FIGURE 16
HOOD
INSTALL HOOD
UNIT
APPLY FOAM
TAPE TO INSIDE
OF FLANGES
FIGURE 17
INSTALL KIT SCREWS INTO
OPEN HOLES ON LGH/LCH/
KG/KC/KH UNITS

Page 8
Determine Outdoor Air Percentage
Outdoor air percentage can be estimated in the same
manner for both manual and motorized dampers.
Measure outdoor air temperatures according to the
following steps and calculate the outdoor air percentage.
For motorized dampers, refer to unit specific damper
adjustment details following these steps.
1- Measure outdoor air temperature. Mark the point on
the bottom line of chart 1 and label the point “A” (40°F,
4°C shown).
2- Measure return air temperature. Mark that point on
the top line of chart 1 and label the point “B” (74°F,
23°C shown).
3- Measure mixed air (outdoor and return air)
temperature. Mark that point on the top line of chart
1 and label point “C” (70°F, 21°C shown).
4- Draw a straight line between points A and B.
5- Draw a vertical line through point C.
6- Draw a horizontal line where the two lines meet. Read
the percent of outdoor air intake on the side.
7- If outdoor air percentage is less or more than desired,
increase or decrease minimum damper position.
Then, repeat steps 2 through 7 until calculation reads
desired outdoor air percentage.
-20
-29
-10
-23
0
-18
10
-12
20
-7
30
-1
40
4
50
10
60
16
70
21
80
27
90
32
100
38
0
10
30
40
50
60
70
80
90
100
20
OUTDOOR AIR TEMPERATURE
0
10
30
40
50
60
70
80
90
100
20
MIXED AND RETURN AIR TEMPERATURE
CHART 1
CALCULATE MINIMUM OUTDOOR AIR PERCENTAGE
A
BC
_F
_C
_F
_C
-20
-29
-10
-23
0
-18
10
-12
20
-7
30
-1
40
4
50
10
60
16
70
21
80
27
90
32
100
38
_F
_C
_F
_C

Page 9
Damper Minimum Position Adjustments
Units Equipped With M2 and M3 Unit Controllers
The damper minimum position or positions are
adjusted using the Unit Controller input screen. For a
unit equipped with more than 1 blower speed, the unit
should initially be run on highest speed.
1- Field-Installed Dampers Only -
Use one of the following menus to enable the
motorized damper function on the Unit Controller.
M3 Unit Controller -
SETUP > INSTALL
Navigate through the various screens until
CONFIGURATION ID 1 appears. Enable set position 2 to
M (motorized outdoor air damper only).
M2 Unit Controller -
SETTINGS > INSTALL > NEW M2 > DAMPER > MOAD
2- Use one of the following menu paths to set the
minimum damper position.
M3 Unit Controller -
SETUP > TEST & BALANCE > DAMPER > MIN
DAMPER POSITION BLOWER ON HIGH=.%
M2 Unit Controller -
SETTINGS > SETPOINTS > DAMPER > MIN OCP
BLOWER HIGH
3- Use the Determine Outdoor Air Percentage section to
verify the minimum damper air percentage.
4- Units Equipped With Two Blower Speeds -
Use one of the following menu paths to set the low
speed minimum damper position.
M3 Unit Controller -
SETUP > TEST & BALANCE > DAMPER > MIN
DAMPER POSITION BLOWER ON LOW=.%
M2 Unit Controller -
SETTINGS > SETPOINTS > DAMPER > MIN OCP
BLOWER LOW
5- Use the Determine Outdoor Air Percentage section to
verify the low speed minimum damper air
percentage.
Note - For additional details, refer to Unit Controller
manual shipped with unit.
Units Not Equipped With A Unit Controller
The damper motor stop is preset to provide 100%
outdoor air and is adjustable in fixed increments. For
units supporting more than 1 blower speed, the
damper minimum set point should be determined with
the blower operating at the highest speed.
1- To reduce the outdoor air percentage, remove
retainer clip and adjust damper stop in the clockwise
direction. Replace the retainer clip securing the stop
arm in the new position. See figure 7.
2- Power the damper open by providing a blower and
occupied demand to the unit thermostat connections.
3- Use the Determine Outdoor Air Percentage section to
verify the minimum damper air percentage.
4- Repeat steps 1 through 3 until calculation reads
desired outdoor air percentage. Remove the
blower and occupied demand signals before
adjusting damper stop.

Page 10
Minimum Damper Position Range
The motorized outdoor air damper operation is optimized
as shown in the shaded area of Chart 2. Unit operation
during minimum damper position above this curve
increases the potential for rain being drawn into the unit.
1- Remove the metal mesh filter from the hood.
Measure the static pressure differential between the
return compartment (through horizontal return air
panel is recommended) and outside the unit.
Operate the unit with the damper open to minimum
position. Record the single blower speed pressure
differential in table 2.
2- Units With More Than One Blower Speed -
Repeat the static pressure measurement at each
blower speed and minimum set point combination.
Record the multiple blower speed pressure
differential in table 2.
3- Read the damper percentage open.
Units Equipped With Unit Controller -
The damper percentage open was entered into the
Unit Controller.
Units Not Equipped With Unit Controller -
Operate the unit with the damper open to minimum
position. Measure the voltage between pins 7 and 9
from the damper motor plug P4. Calculate the
percentage open from the formula:
% Open = [(Measure voltage - 2.5) / 7.0] X 100
4- Plot the damper % open and static pressure drop on
Chart 2. Plot additional blower speeds in the same
manner.
5- Replace the metal mesh filter.
TABLE 2
Single Blower Speed Multiple Blower Speed
Static Pressure Differential - “w.c. Damper % Open Static Pressure Differential - “w.c. Damper % Open
CHART 2
OPTIMAL OUTDOOR AIR OPERATION
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
0 100 200 300 400 500 600 700 800 900
Measured Static Pressure Drop Across Damper (inch w.c.)
Measured Airflow Through Damper (CFM)
20% 25% 33%
40%
46%
53%
67%
80%
100%