installation, start-up and
service instructions
580D
SINGLE PACKAGE ROOFTOP
GAS HEATING/ELECTRIC COOLING UNITS
Sizes 090-150
71/2 to 121/2 Tons
Cancels: II 580D-90-4
II 580D-90-5
7/15/00
IMPORTANT — READ BEFORE INSTALLING
1. Read and become familiar with these installation instructions before installing this unit (Fig. 1).
2. Be sure the installation conforms to all applicable
local and national codes.
3. These instructions contain important information for
the proper maintenance and repair of this equipment.
Retain these instructions for future use.
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1,2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
I. Locate the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
II. Unit Duct Connections . . . . . . . . . . . . . . . . . . . . . . . 5
III. Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IV. Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,21
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-31
I. Heating Section Start-Up and Adjustments . . . . . 21
II. Cooling Section Start-Up and Adjustments . . . . . 24
III. Indoor Airflow and Airflow Adjustments . . . . . . . . 26
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 31,32
I. Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-37
I. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
II. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
III. Condenser Fan Adjustment . . . . . . . . . . . . . . . . . . 32
IV. Blower Belt Adjustment . . . . . . . . . . . . . . . . . . . . . 32
V. Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 33
VI. Main Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
VII. Flue Gas Passageways . . . . . . . . . . . . . . . . . . . . . . 36
VIII. Combustion-Air Blower . . . . . . . . . . . . . . . . . . . . . . 36
IX. Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
X. Burner Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
XI. Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . 36
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .38-45
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1
SAFETY CONSIDERATIONS
WARNING: Improper installation, adjustment,
alteration, service, maintenance, or use can cause carbon
monoxide poisoning, explosion, fire, electric shock, or
other occurrences which may cause injury or property
damage. Consult a qualified installer, service agency, or
the gas supplier for information or assistance. The qualified installer or agency must use only factory-authorized
kits or accessories when modifying this product.
Fig. 1 — Typical Unit
Recognize safety information. This is the safety-alert symbol (
). When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words — DANGER, WARNING, and
CAUTION. These words are used with the safety-alert symbol. Danger identifies the most serious hazards which will
result in severe personal injury or death. Warning indicates
a condition that could result in personal injury. Caution is
used to identify unsafe practices which would result in minor
personal injury or product and property damage.
WARNING: Disconnect gas piping from unit when
leak testing at pressure greater than 1/2 psig. Pressures
greater than 1/2 psig will cause gas valve damage
resulting in hazardous condition. If gas valve is ever
subjected to pressure greater than 1/2 psig, it must be
replaced before use. When pressure testing fieldsupplied gas piping at pressures of 1/2 psig or less, a
unit connected to such piping must be isolated by manually closing the gas valve.
WARNING: Before performing service or maintenance operations on unit, turn off main power switch
to unit and install lockout tag. Electrical shock could
cause personal injury.
1. The power supply (volts, hertz, and phase) must correspond to that specified on unit rating plate.
2. The electrical supply provided by the utility must be
sufficient to handle load imposed by this unit.
3. Locate connections for gas inlet, electrical inlets, condensate drain, duct connections, and required clearances before setting unit in place. Refer to Locate the
Unit section on page 2 and Fig. 2-4 for locations.
4. Locate the unit where the vent hood will be a minimum of 4 ft from openable windows or doors.
5. This installation must conform with local building
codes and with NFGC (National Fuel Gas Code);
ANSI (American National Standards Institute)
Z223.1-1988 (Canada, CAN/CGA [Canadian Gas
Association] B149.1, [2]-M86); or NFPA (National
Fire Protection Association) 54-1988 TIA-54-84-1.
Refer to Provincial and local plumbing or wastewater
codes and other applicable local codes.
6. Approved for outdoor installation only on wood flooring or on class A, B, or C roof covering materials.
INSTALLATION
Unit is shipped in the vertical airflow configuration (see
Fig. 1). To convert to horizontal discharge, remove horizontal
duct opening covers. Using the same screws, install covers
with insulation-side down (facing outside) on the unit on vertical duct openings. Seals around duct openings must be
tight.
These units are equipped with an energy-saving, automatic,
electric direct-spark ignition system that does not have a
continuously burning pilot. All units are manufactured with
natural gas controls.
These units are designed for a minimum continuous returnair temperature of 50 F (dry bulb) or an intermittent operation down to 45 F (dry bulb), such as when used with a night
setback thermostat.
All units can be connected into existing duct systems that are
properly sized and designed to handle an airflow of 300 to
500 cfm per each 12,000 Btuh of rated cooling capacity.
NOTE: When installing any accessory item, see the manufacturer’s installation instructions packaged with the accessory. A qualified agency must use factory-authorized kits or
accessories when modifying this unit.
I. LOCATE THE UNIT
A. Clearance
Maintain clearance around and above unit to provide minimum distance from combustible materials, proper airflow,
and service access (see Fig. 2 and 3).
Minimum clearance to combustibles is 48 in. on flue side
(18 in. with accessory flue discharge deflector), 0 in. on all
other sides.
Minimum clearance on all sides to block walls or any other
grounded surface is 42 inches.
Minimum clearance of 36 in. should be provided on side with
outdoor-air intake, if unit is so equipped.
Minimum distance between unit and other electrically live
parts is 48 inches.
Do not install unit in an indoor location. Do not locate unit
air inlets near exhaust vents or other sources of contaminated air.
Be sure that unit is installed so that snow will not block the
combustion intake or flue outlet.
Although unit is weatherproof, guard against water from
higher level runoff and overhangs.
Slab-mounted units should be at least 4 in. above the highest
expected water, flood, and runoff levels. Do not use the unit if
it has been under water.
Locate mechanical draft system flue assembly at least 48 in.
from any opening through which combustion products could
enter the building, and at least 24 in. from an adjacent building. When unit is located adjacent to public walkways, flue
assembly must be at least 7 ft above grade.
Flue gas can deteriorate building materials. Orient unit so
that flue gas will not affect building materials.
Adequate combustion-air space must be provided for proper
operation of this equipment. Be sure that installation complies with all local codes.
Flue vent discharge must have a minimum horizontal clearance of 4 ft from electric and gas meters, gas regulators, and
gas relief equipment.
B. Roof Curb Mount
Assemble and install accessory roof curb in accordance with
instructions shipped with curb (see Fig. 4). Install insulation, cant strips, roofing felt, and counter flashing as shown.
Ductwork must be attached to curb. If gas, electric power, or
control power is to be routed through the curb, attach the
utility connection plates to the roof curb in accordance with
the accessory installation instructions. Accessory electric
and gas utility connection plates must be installed before
unit is in place on roof curb.
NOTE: If thru-the-bottom power and gas connections are
used, refer to the accessory installation instructions for
information on installation. Refer to Fig. 3 for drilling holes
in basepan.
42”
12”
42”
36”
IMPORTANT: The gasketing of the unit to the roof curb is
critical for watertightness. Install gasket with the roof curb
as shown in Fig. 4. Improperly applied gasket can also result
in air or water leaks and poor unit performance.
Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are shown in Fig. 5.
42”
C. Slab Mount (Horizontal Units Only)
48”
SERVICE CLEARNCE
OPERATIONAL CLEARANCE
Provide a level concrete slab that extends a minimum of 6 in.
beyond unit cabinet. Install a 6 in. gravel apron in front of
condenser coil air inlet to prevent grass and foliage from obstructing airflow.
NOTE: Horizontal units may be installed on a roof curb if
required.
Fig. 2 — Service and Operational Clearances
—2 —
—3 —
469
476
1035
1050
120
150
44
Lb
— 14 NPT Condensate Drain
4″
3/
1/ ″
2
3/ ″
4
2″ Dia [51] Power Supply Knockout
F
G
28
Kg
228
225
191
103
102
87
CORNER
WEIGHT
(A)
Lb
Kg
189 86
195
192
163
88
87
74
CORNER
WEIGHT
(B)
Lb Kg
161 73
NOTES:
1. Dimensions in [ ] are in millimeters.
2.
Center of gravity.
3.
Direction of airflow.
4. On vertical discharge units, ductwork to be attached to accessory roof curb
only. For horizontal discharge units field-supplied flanges should be attached to
horizontal discharge openings, and all ductwork should be attached to the
flanges.
5. Minimum clearance (local codes or jurisdiction may prevail):
a. Between unit (flue side) and combustible surfaces, 48 in. (18 in. with
accessory flue discharge deflector).
b. Bottom of unit to combustible surfaces (when not using curb) 1 inch. Bottom of base rail to combustible surfaces (when not using curb) 0 inches.
c. Condenser coil, for proper airflow, 36 in. one side, 12 in. the other. The
side getting the greater clearance is optional.
d. Overhead, 60 in. to assure proper condenser fan operation.
e. Between units, control box side, 42 in. per NEC (National Electrical
Code).
f. Between unit and ungrounded surfaces, control box side, 36 in. per
NEC.
g. Between unit and block or concrete walls and other grounded surfaces,
control box side, 42 in. per NEC.
h. Horizontal supply and return end, 0 inches.
6. With the exception of the clearance for the condenser coil and combustion side
as stated in Notes 5a, b, and c, a removable fence or barricade requires no
clearance.
7. Units may be installed on combustible floors made from wood or Class A, B, or
C roof covering material if set on base rail.
8. The vertical center of gravity is 1′-7″ [483] for 090 and 102, 1′-11″ [584] for 120
and 150 up from the bottom of the base rail.
— 14 NPT Gas Connection 580D090-102, low heat units.
— 14 NPT Gas Connection All other units.
Dia [22] Field Control Wiring Hole
8″
7/
E
13/4″ Dia [44] Charging Port Hole
C
D
13/8″ Dia [35] Field Power Supply Hole
21/2″ Dia [64] Power Supply Knockout
B
62
Lb
ECONOMI$ER
WEIGHT
A
20
Kg
DURABLADE
ECON. WEIGHT
CONNECTION SIZES
399
880
STANDARD
UNIT
WEIGHT
Lb
Kg
870
395
102
090
UNIT
580D
289
285
242
131
129
110
CORNER
WEIGHT
(C)
Lb
Kg
239 109
338
333
284
153
151
129
CORNER
WEIGHT
(D)
Lb
Kg
280 127
1013
759
378
3-37/8
2-57/8
1-27/8
4-15/16
4-15/16
3-55/16
ft-in.
3-55/16
‘‘J’’
1253
1253
1050
mm
1050
3-03/8
3-03/8
2-911/16
ft-in.
2-911/16
‘‘K’’
924
924
856
mm
856
Fig. 3 — Base Unit Dimensions
mm
378
ft-in.
1-27/8
‘‘H’’
2-107/16
2-107/16
2- 27/16
ft-in.
2- 27/16
‘‘L’’
875
875
672
mm
672
24 V
Power*
Power*
Gas
Gas
WIRE
USE
REQUIRED
HOLE
SIZES
(MAX.)
7/ ″ [22.2]
8
11/8″ [28.4]
13/4″ [44.4]
11/4″ [31.8]
15/8″ [41.3]
*Select either 3/4″or 11/4″ for power, depending on
wire size.
1/ ″
2
3/ ″
4
11/4″
(003) 1/2″ FPT
(004) 3/4″ FPT
THREADED
CONDUIT
SIZE
BOTTOM POWER CHART, THESE HOLES
REQUIRED FOR USE WITH ACCESSORY
PACKAGES CRBTMPWR001A00, 3A00 (1/2″, 3/4″)
OR
CRBTMPWR002A00, 4A00 (1/2″, 11/4″)
“B”
“C”
“D” ALT
DRAIN
HOLE
“E”
GAS
“F”
POWER
“G”
CONTROL
3/ ″
4
3/ ″
4
[19] NPT
2′-87/16″ 1′-1015/16″
[827]
[583]
13/4″
[44.5]
[19] NPT
11/4″
[31.7]
3/ ″
4
1/ ″
2
[12.7] NPT [19] NPT
3/ ″
4
[19] NPT
11/4″
[31.7]
2″
[12.7]
1/
1/
2″
CONNECTOR
PACKAGE
ACCESSORY
CRBTMPWR001A00
CRBTMPWR002A00
CRBTMPWR003A00
[12.7]
CRBTMPWR004A00
ROOF CURB
ACCESSORY
CRRFCURB003A00
CRRFCURB004A00
“A”
UNIT SIZE
580D
1′-2″ [356]
2′-0″ [610]
090-150
NOTES:
1. Roof curb accessory is shipped unassembled.
2. Insulated panels.
3. Dimensions in [ ] are in millimeters.
4. Roof curb: galvanized steel.
5. Attach ductwork to curb (flanges of duct rest on
curb).
6. Service clearance 4 ft on each side.
7.
Direction of airflow.
8. Connector packages CRBTMPWR001A00 and
002A00 are for thru-the-curb connections.
Packages CRBTMPWR003A00 and 004A00
are for thru-the-bottom connections.
Fig. 4 — Roof Curb Dimensions
—4 —
A minimum clearance is not required around ductwork. Cabinet return-air static shall not exceed –0.35 in. wg with
Durablade and EconoMi$er economizer or –0.45 in. wg without economizer.
NOTE: Connection must be made to roof curb before unit is
set in place.
III. RIG AND PLACE UNIT
Inspect unit for transportation damage. File any claim with
transportation agency. Keep unit upright and do not drop.
Spreader bars are not required if top crating is left on unit.
Rollers may be used to move unit across a roof. Level by
using unit frame as a reference. See Table 1 and Fig. 6 for
additional information. Operating weight is shown in Fig. 6.
Lifting holes are provided in base rails as shown in Fig. 6.
Refer to rigging instructions on unit.
IMPORTANT: Unit has forklift protection skids (wood runners located behind forklift slots), be sure to remove forklift
protection skids from under unit before setting unit in place.
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
A-B
0.5
B-C
1.0
A-C
1.0
Fig. 5 — Unit Leveling Tolerances
II. UNIT DUCT CONNECTIONS
A properly positioned unit will have the following clearances
between unit and roof curb: 1/4-in. clearance between roof
curb and base rails on each side, 35/16-in. at duct end of unit;
1/ -in. clearance between roof curb and condenser section
4
end. See Fig. 4, Views A-A and C-C.
On vertical units, secure all ducts to roof curb and building
structure. Do not connect ductwork to unit. On horizontal
units, duct flanges should be attached to horizontal openings
and all ductwork should be secured to flanges.
If a plenum return is used on a vertical unit, the return
should be ducted through the roof deck to comply with applicable fire codes.
UNIT
580D
090
102
120
150
OPERATING
WEIGHT
Lb
Kg
870
395
880
399
1035
469
1050
476
‘‘A’’
‘‘B’’
‘‘C’’
in.
mm
in.
mm
87.38
2219
40.25
1022
in.
41.31
41.31
49.31
49.31
mm
1050
1050
1253
1253
NOTES:
1. Dimension in ( ) is in millimeters.
2. Hook rigging shackles through holes in base rail, as shown in detail ‘‘A.’’ Holes in base rails are
centered around the unit center of gravity. Use wooden top skid when rigging to prevent rigging
straps from damaging unit.
3. Weights do not include economizer. See Table 1 for economizer weights.
CAUTION: All panels must be in place when rigging.
Fig. 6 — Rigging Details
—5 —
Table 1 — Physical Data
UNIT 580D
NOMINAL CAPACITY (tons)
OPERATING WEIGHT (lb)
Unit
Durablade Economizer
EconoMi$er Economizer
Roof Curb*
COMPRESSOR
Quantity
Oil (oz)
REFRIGERANT TYPE
Operating Charge (lb-oz)
Circuit 1
Circuit 2
CONDENSER COIL
Rows...Fins/in.
Total Face Area (sq ft)
CONDENSER FAN
Nominal Cfm
Quantity...Diameter (in.)
Motor Hp...Rpm
Watts Input (Total)
EVAPORATOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
EVAPORATOR FAN
Quantity...Size (in.)
Type Drive
Nominal
Maximum Continuous Bhp
Motor Frame Size
Fan Rpm Range
Motor Bearing Type
Maximum Allowable Rpm
Motor Pulley Pitch Diameter
Min/Max (in.)
Nominal Motor Shaft Diameter (in.)
Fan Pulley Pitch Diameter (in.)
Belt, Quantity...Type...Length (in.)
Pulley Center Line Distance (in.)
Speed Change per Full Turn of
Movable Pulley Flange (rpm)
Movable Pulley Maximum Full Turns
From Closed Position
Factory Setting
Factory Speed Setting (rpm)
090
71/2
102
81/2
120
10
150
12
870
44
62
143
Reciprocating
2
50 ea
880
44
62
143
Reciprocating
2
50 ea
1035
44
62
143
Reciprocating
2
54 ea
1050
44
62
143
Scroll
2
54 ea
R-22
4-13
4-14
1...17
20.50
6500
2...22
1/ ...1100
4
600
3...15
8.0
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
1...15 x 15
1...15 x 15
Belt
—
3000
3000
2.40
—
56
—
590-840
685-935
Ball
2100
2.4/3.4
2.8/3.8
5/
8
—
7.0
7.0
1...A...48
1...A...51
16.75-19.25
16.75-19.25
50
50
5
5
5
5
590
685
1
Medium
Heat
195
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Fan Shaft Diameter at Pulley (in.)
FURNACE SECTION
Rollout Switch Cutout Temp (F)†
Burner Orifice Diameter (in. ...drill size)
Natural Gas
Liquid Propane**
Thermostat Heat Anticipator Setting (amps)
208/230 v Stage 1
Stage 2
460 v Stage 1
Stage 2
Gas Input (Btuh) Stage 1
Stage 2
Efficiency (Steady Stage) (%)
Temperature Rise Range
Manifold Pressure (in. wg)
Natural Gas
Liquid Propane**
Gas Valve Quantity
Field Gas Connection Size (in.)
HIGH-PRESSURE SWITCH (psig)††
Standard Compressor Internal Relief (Differential)
Cutout
Reset (Auto.)
LOW-PRESSURE/LOSS-OF-CHARGE SWITCH (psig)††
Cutout
Reset (Auto.)
FREEZE-PROTECTION THERMOSTAT (F)††
Opens
Closes
OUTDOOR-AIR INLET SCREENS
Quantity...Size (in.)
RETURN-AIR FILTERS
Quantity...Size (in.)
Low
Heat
195
High
Heat
195
6-2
7-3
9-8
7-13
Enhanced Copper Tubes, Aluminum Lanced Fins
2...17
2...17
18.00
20.47
Propeller Type
6500
7000
2...22
2...22
1/ ...1100
1/ ...1100
4
4
600
600
Enchanced Copper Tubes, Aluminum Double-Wavy Fins
3...15
3...15
8.0
10.0
Centrifugal Type
1...15 x 15
1...15 x 15
—
1...15 x 15
Belt
Belt
—
Belt
3400
4000
—
4000
2.40
2.40
—
2.90
56
56
—
56
685-935
685-935
—
835-1085
Ball
Ball
2100
2100
2.8/3.8
2.8/3.8
—
3.4/4.4
5/
5/
8
8
7/
—
8
7.0
7.0
—
7.0
1...A...51
1...A...51
—
1...A...57
16.75-19.25
15.85-17.50
—
15.85-17.50
50
50
—
50
5
5
—
5
5
5
—
5
685
685
—
835
1
1
Low
Medium
High
Low
Medium
Heat
Heat
Heat
Heat
Heat
195
195
195
195
195
8-10
8-6
2...17
25.00
7000
2...22
1/ ...1100
4
600
4...15
11.1
High
Heat
195
1...15 x 15
1...15 x 15
Belt
Belt
5000
5000
3.70
5.25
56
56
860-1080
900-1260
Ball
2100
4.0/5.0
3.1/4.1
7/
8
7/
8
8.0
5.9
1...A...51
1...BX...46
15.85-17.50
15.85-17.50
44
60
5
6
5
6
860
900
1
Low
Medium
Heat
Heat
195
195
.120...31 .120...31 .120...31 .120...31 .120...31 .120...31 .120...31 .120...31
.096...41 .096...41 .096...41 .096...41 .096...41 .096...41 .096...41 .096...41
.129...30
.102...38
.120...31 .120...30
.096...41 .102...38
.14
.20
.14
.20
125,000
—
80
20-50
.14
.20
.14
.20
120,000
180,000
80
35-65
.14
.20
.14
.20
180,000
220,000
80
45-75
.14
.20
.14
.20
125,000
—
80
20-50
.14
.20
.14
.20
120,000
180,000
80
35-65
.14
.20
.14
.20
180,000
220,000
80
45-75
.14
.20
.14
.20
120,000
180,000
80
35-65
.14
.20
.14
.20
180,000
220,000
80
35-65
.14
.20
.14
.20
2000,000
250,000
80
40-70
.14
.20
.14
.20
180,000
220,000
80
35-65
.14
.20
.14
.20
200,000
250,000
80
40-70
3.5
3.5
1
1/
2
3.5
3.5
1
3/
4
3.5
3.5
1
3/
4
3.5
3.5
1
1/
2
3.5
3.5
1
3/
4
3.5
3.5
1
3/
4
3.5
3.5
1
3/
4
3.5
3.5
1
3/
4
3.5
3.5
1
3/
4
3.5
3.5
1
3/
4
3.5
3.5
1
3/
4
450 ± 50
428
320
500 ± 50
428
320
7±3
22 ± 7
30 ± 5
45 ± 5
Cleanable
1...20 x 25 x 1
1...16 x 25 x 1
Throwaway
4...16 x 20 x 2
4...16 x 20 x 2
LEGEND
Bhp — Brake Horsepower
*Weight of 14-in. roof curb.
†Rollout switch is manual reset.
**Indicates a FIOP (Factory-Installed Option).
††Requires an optional or accessory controls upgrade kit.
—6 —
4...20 x 20 x 2
4...20 x 20 x 2
IV. FIELD CONNECTIONS
A. External Trap Condensate Drain
The unit’s 3/4-in. condensate drain connections are located
on the bottom and side of the unit. Unit discharge connections do not determine the use of drain connections; either
drain connection can be used with vertical or horizontal
applications.
When using the standard side drain connection, make sure
the plug in the alternate bottom connection is tight before
installing the unit.
To use the bottom drain connection for a roof curb installation, relocate the factory-installed plug from the bottom connection to the side connection. See Fig. 7. The piping for the
condensate drain and external trap can be completed after
the unit is in place.
All units must have an external trap for condensate drainage. Install a trap at least 4-in. deep and protect against
freeze-up. See Fig. 8. If drain line is installed downstream
from the external trap, pitch the line away from the unit at 1
in. per 10 ft of run. Do not use a pipe size smaller than the
unit connection (3/4-in.).
C. Gas Piping (Fig. 10)
The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2- or
3/ -in. FPT gas inlet on the manual shutoff or gas valve.
4
Install a separate gas supply line that runs directly from the
meter to the heating section. Refer to NFGC for gas pipe sizing. Do not use cast iron pipe. Check the local utility for recommendations concerning existing lines. Choose a supply
pipe that is large enough to keep the pressure loss as low as
practical. Never use pipe smaller than the 1/2-in. FPT gas
inlet on the unit gas valve. See Table 1 for specific unit pipe
size.
For natural gas applications, the gas pressure at unit gas
connection must not be less than 4 in. wg or greater than
13 in. wg while the unit is operating. For liquid propane
applications, the gas pressure must not be less than 5 in. wg
or greater than 13 in. wg at the unit connection.
When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to NFGC ANSI
Z223.1-1988 (in Canada, CAN/CGA B149.1, [2]-M86) or
NFPA 54-1988 in the absence of local building codes. Adhere
to the following pertinent recommendations:
NOTE: When installing gas piping to gas valve inlet, use
properly sized back-up wrench on gas valve inlet flange flats.
1. Avoid low spots in long runs of pipe. Grade all pipe
1/ inch in every 15 ft to prevent traps. Grade all hori4
zontal runs downward to risers. Use risers to connect
to heating section and to meter.
2. Protect all segments of piping system against physical and thermal damage. Support all piping with
appropriate straps, hangers, etc. Use a minimum of
one hanger every 6 ft. For pipe sizes larger than
1/ -in., follow recommendations of national codes.
2
3. Apply joint compound (pipe dope) sparingly and only
to male threads of joint when making pipe connections. Use only pipe dope that is resistant to action of
liquefied petroleum gases as specified by local and/or
national codes. Never use Teflon coated tape.
4. Install sediment trap in riser leading to heating section. This drip leg functions as a trap for dirt and condensate. Install trap where condensate cannot freeze.
Install this sediment trap by connecting a piping tee
to riser leading to heating section, so that straightthrough section of tee is vertical (see Fig. 11). Then,
connect capped nipple into lower end of tee. Extend
capped nipple below level of gas controls.
DRAIN PLUG
NOTE: Drain plug is shown in factory-installed position.
Fig. 7 — Condensate Drain Pan
NOTE: Trap should be deep enough to offset maximum unit static difference. A 4-in. trap is recommended.
Fig. 8 — External Trap Condensate Drain
B. Install Flue Hood
Flue hood is shipped screwed to the burner compartment
access panel. Remove from shipping location and, using
screws provided, install flue hood and screen in location
shown in Fig. 3 and 9.
Fig. 9 — Flue Hood Details
—7 —
5. Install an accessible, external, manual main shutoff
valve in gas supply pipe within 6 ft of heating section.
6. Install ground-joint union close to heating section
between unit manual shutoff and external manual
main shutoff valve.
7. Pressure-test all gas piping in accordance with local
and national plumbing and gas codes before connecting piping to unit.
8. If thru-the-bottom power connections are used refer
to the accessory installation instructions for information on power wiring. Refer to Fig. 3 for drilling holes
in basepan.
NOTE: When pressure testing the gas supply system after
the gas supply piping has been connected to the unit gas
valve, the supply piping must be disconnected from the gas
valve during any pressure testing of the piping systems at
test pressure in excess of 0.5 psig. When pressure testing the
gas supply piping system at test pressures equal to or less
than 0.5 psig, the unit heating section must be isolated from
the gas piping system by closing the external main manual
shutoff valve and slightly opening the ground-joint union.
LEGEND
NFGC — National Fuel Gas Code
*Field supplied.
STEEL PIPE
NOMINAL
DIAMETER
(in.)
1/
2
3/ or 1
4
11/4 or Larger
NOTE: Follow all local codes.
SPACING OF SUPPORTS
X DIMENSIONS
(ft)
6
8
10
Fig. 10 — Gas Piping Guide
(With Accessory Utility Connection Package)
CAUTION: Unstable operation may occur when
the gas valve and manifold assembly are forced out of
position while connecting improperly routed rigid gas
piping to the gas valve. Use a backup wrench when
making connection to avoid strain on, or distortion of,
the gas control piping.
CAUTION: If a flexible conductor is required or
allowed by the authority having jurisdiction, black iron
pipe shall be installed at the gas valve and extend a
minimum of 9 in. outside the unit casing.
DANGER: never use a match or other open flame
when checking for gas leaks. Never purge gas line into
combustion chamber. Failure to adhere to this warning
could result in an explosion causing personal injury or
death.
9. Check for gas leaks at all field- and factory-installed
gas lines after all piping connections have been
completed. Use soap-and-water solution (or method
specified by local codes and/or regulations).
Liquid Propane (LP)
Units are shipped for use with natural gas, but may be fieldconverted for use with liquid propane with accessory LP Kit.
All LP gas equipment must conform to NFPA safety
standards.
The LP gas pressure at the unit must be between 5.0 in. wg
and 13.0 in. wg under full load. Maintaining proper gas pressure depends on:
1. Vaporization rate. (Vaporization rate is determined
by the temperature of the LP and the level of LP in
the tank.)
2. Proper pressure regulation. (Two-stage regulation is
more cost effective and more efficient than singlestage regulation.)
3. Pressure drop in lines between regulators and
between the second-stage regulator and the appliance. Pipe size is determined by the length of the pipe
run and the total load of all appliances.
—8 —
Fig. 11 — Sediment Trap
Contact your LP gas supplier or regulator manufacturer for
further details regarding tank sizing, recommended regulator settings, and pipe sizing.
Special pipe compound must be used when assembling piping for LP gas, as white lead or commercial compounds will
be dissolved easily. Use a shellac-based compound suitable
for use with LP.
E. Electrical Connections
WARNING: The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the
possibility of personal injury if an electrical fault
should occur. This ground may consist of electrical wire
connected to the unit ground lug in the control compartment, or conduit approved for electrical ground
when installed in accordance with the NEC (National
Electrical Code) ANSI/NFPA, latest edition, (in Canada, Canadian Electrical Code CSA [Canadian Standards Association] C22.1) and local electrical codes. Do
not use gas piping as an electrical ground. Failure to
adhere to this warning could result in personal injury.
D. Field Duct Connections
NOTE: The design and installation of the duct system must
be in accordance with the standards of the NFPA for
the installation of nonresidence-type air conditioning and
ventilating systems, NFPA No. 90A or residence-type, NFPA
No. 90B; and/or local codes and ordinances.
Adhere to the following criteria when selecting, sizing, and
installing the duct system:
1. Remove appropriate panels from unit to obtain either
horizontal or vertical discharge. If units are installed
in horizontal discharge applications, remove vertical
discharge duct covers, save screws, and install covers
on vertical duct openings.
CAUTION: Failure to adhere to the following electrical connection procedures could result in damage to
the unit being installed:
2. Select and size ductwork, supply-air registers, and
return-air grilles according to ASHRAE (American
Society of Heating, Refrigeration and Air Conditioning Engineers) recommendations.
CAUTION: When drilling the duct system fastening holes into the side of the unit for duct flanges, use
extreme care not to puncture the coil or coil tubes. See
Fig. 12.
3. Use flexible transition between rigid ductwork and
unit to prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use
suitable gaskets to ensure weather- and airtight seal.
4. When horizontal return is used, install external,
field-supplied air filters in return-air ductwork where
they are easily accessible for service. Recommended
filter sizes are shown in Table 1.
5. Size all ductwork for maximum required airflow
(either heating or cooling) for unit being installed.
Avoid abrupt duct size increases or decreases.
6. Adequately insulate and weatherproof all ductwork
located outdoors. Insulate ducts passing through
unconditioned space, and use vapor barrier in accordance with latest issue of SMACNA (Sheet Metal and
Air Conditioning Contractors National Association)
and ACCA (Air Conditioning Contractors of America)
minimum installation standards for heating and airconditioning systems. Secure all ducts to building
structure.
7. Flash, weatherproof, and vibration isolate all openings in building structure in accordance with local
codes and good building practices.
NOTE: If accessory thru-the-bottom connections are
used, refer to the accessory installation instructions for
installation.
Fig. 12 — Location of Coil Area Not to be Drilled
Field Power Supply (Fig. 13 and 14)
1. Make all electrical connections in accordance with
NEC ANSI/NFPA, latest edition, and local electrical
codes governing such wiring. In Canada, all electrical
connections must be in accordance with CSA Standard C22.1 Canadian Electrical Code Part 1 and
applicable local codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit.
Maximum wire size is no. 2 AWG (American Wire
Gage).
3. Voltage to compressor terminals during operation
must be within voltage range indicated on unit nameplate (also see Table 2). On 3-phase units, voltages
between phases must be balanced within 2% and
the current within 10%. Use the formula shown in
Table 2, Note 2 to determine the percent voltage
imbalance. Operation on improper line voltage or
excessive phase imbalance constitutes abuse and may
cause damage to electrical components. Such operation would invalidate any applicable warranty.
4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires
are run in same conduit as high-voltage wires.
5. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit, etc.
—9 —
NOTE: If accessory thru-the-bottom connections are
used, refer to the accessory installation instructions for
installation.
High-Voltage Connections (Fig. 13)
panel. Be sure that disconnect box and horizontal ducts do
not cover the unit rating plate.
The unit must have a separate electrical service with a fieldsupplied, waterproof, fused disconnect switch mounted at, or
within sight from, the unit. Refer to the unit rating plate for
maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing. Table 2 shows recommended
wire sizes based on rating plate data.
1. Connect ground lead to chassis ground connection
when using separate ground wire.
Proceed as follows to complete the high-voltage connections
to the unit:
2. Pigtails are provided for field power connection. Use
factory-supplied splices or UL (Underwriters’ Laboratories) approved copper connector. Install conduit
connectors in side panel power supply knockout openings indicated in Fig. 3. Route power lines through
connector to unit control box.
The field-supplied disconnect switchbox may be mounted on
the unit over the high-voltage inlet hole in the control corner
Table 2 — Electrical Data
UNIT
580D
NOMINAL
VOLTAGE
102
Tons)
254
14.0
91.0
1/
4
1.4
414
508
6.4
42.0
1/
4
0.7
518
632
5.2
39.0
1/
4
0.7
1/
4
1/
4
1/
4
1.4
FLA
5.8
5.8
2.6
2.6
2.6
2.6
5.8
0.7
2.6
0.7
2.6
187
254
16.0
137.0
414
508
8.3
69.0
575-3-60
Std
518
632
6.4
58.0
460-3-60
208/230-3-60
460-3-60
575-3-60
FLA —
HACR —
IFM —
LRA —
MCA —
MOCP—
NEC —
OFM —
RLA —
187
Std
575-3-60
150
(121/2 Tons)
OFM
(ea)
Hp
FLA
460-3-60
208/230-3-60
120
(10 Tons)
COMPR
(ea)
RLA
LRA
208/230-3-60
460-3-60
575-3-60
(81/2
VOLTAGE
RANGE
Min
Max
Std
Alt
Std
Alt
Std
Alt
Std
208/230-3-60
090
(71/2 Tons)
IFM
TYPE
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
Std
Alt
187
254
15.8
130.0
1/
4
1.4
414
508
7.9
64.0
1/
4
0.7
518
632
6.6
52.0
1/
4
0.7
187
254
23.0
146.0
1/
4
1.4
414
508
10.4
73.0
1/
4
0.7
518
632
8.3
58.4
1/
4
0.7
LEGEND
Full Load Amps
Heating, Air Conditioning and Refrigeration
Indoor (Evaporator) Fan Motor
Locked Rotor Amps
Minimum Circuit Amps
Maximum Overcurrent Protection
National Electrical Code
Outdoor (Condenser) Fan Motor
Rated Load Amps
IFM
5.8
7.5
2.6
3.4
2.6
3.4
10.6
15.0
4.8
7.4
4.8
7.4
COMBUSTION
FAN MOTOR
FLA
POWER SUPPLY
DISCONNECT
SIZE*
FLA
LRA
42/42
229/229
42/42
229/229
19
108
19
108
16
97
16
97
41/41
321/321
.6
MCA
40.1/40.1
40.1/40.1
18.4
18.4
14.9
14.9
44.6/44.6
MOCP†
45/45
45/45
20
20
20
20
50/50
.3
22.7
25
24
.3
17.6
20
18
135
44.2/44.2
45.9/45.9
21.8
22.6
18.9
19.7
65.2/65.2
69.6/69.6
29.6
32.2
23.6
25.7
50/50
50/50
25
25
25
25
80/80
80/80
35
35
30
30
46/46
48/48
23
24
20
21
68/68
73/73
31
34
25
27
307/307
326/326
152
191
126
166
383/383
406/406
192
203
154
163
.6
.3
.3
.6
.3
.3
.6
.3
.3
162
Example: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
Average Voltage =
=
*Used to determine minimum disconnect per NEC.
†Fuse or HACR circuit breaker.
NOTES:
1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker.
Canadian units may be fuse or circuit breaker.
2. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is
greater than 2%. Use the following formula to determine the percent
of voltage imbalance.
% Voltage Imbalance
max voltage deviation from average voltage
= 100 x
average voltage
452 + 464 + 455
3
1371
3
= 457
NOTE: The 575-v 48TJ008-014 units are UL, Canada only.
Determine maximum deviation from average voltage.
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
% Voltage Imbalance = 100 x
7
457
= 1.53%
This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%
IMPORTANT: If the supply voltage phase imbalance is more than 2%,
contact your local electric utility company immediately.
—10—
—11—
BM
C
CAP
CM
FS
IFC
IGC
—
—
—
—
—
—
—
LED
NEC
OFC
RT
TB
TRAN
—
—
—
—
—
—
LEGEND
Light-Emitting Diode
National Electrical Code
Outdoor (Condenser) Fan Contactor
24 v Power to Integrated Gas Unit Controller
Terminal Block
Transformer
Fig. 13 — Field Wiring Connections
Blower (Evaporator Fan) Motor
Contactor
Capacitor
Combustion Motor
Flame Sense
Indoor (Evaporator) Fan Contactor
Integrated Gas Unit Controller
Pass control wires through the hole provided in the corner
post; then feed wires through the raceway built into the corner post to the 24-v barrier located on the left side of the control box (see Fig. 15). The raceway provides the UL required
clearance between high- and low-voltage wiring.
Connect thermostat wires to pigtails of low-voltage circuit in
low-voltage section on control box using terminal strip.
Heat Anticipator Setting
The room thermostat heat anticipator must be adjusted correctly to ensure proper heating performance. Set the heat
anticipator, using an ammeter to determine the exact
required setting.
NOTE: For thermostat selection purposes, use .14 amp for
the approximate required setting. For units with two-stage
gas valves, set heat anticipator stage 2 at .20 amp. See
Table 1 for further clarification.
LEGEND
Failure to make a proper heat anticipator adjustment may
result in improper operation, discomfort to the occupants of
the conditioned space, and inefficient energy utilization;
however, the required setting may be changed slightly to provide a greater degree of comfort for a particular installation.
AHA — Adjustable Heat Anticipator TH — Thermostat-Heating
CC — Cooling Compensator
Field Wiring
TC — Thermostat-Cooling
Factory Wiring
Fig. 14 — Low-Voltage Connections
F. Accessory Installation
Any required accessories should be installed on the unit at
this time. Refer to Table 3 for available accessories. Control
wiring information is provided in the unit wiring book.
Special Procedures for 208-V Operation
DANGER: Make sure that the power supply to the
unit is switched OFF and lockout tag is installed before
making any wiring changes. Electrical shock can cause
personal injury or death.
For operation on 208 v:
Remove black wire with 1/4-in. female spade connector from
the 230-volt male spade transformer and connect to 200 volt
1/ -in. spade of transformer.
4
Control Voltage Connections
Install a factory-approved room thermostat. Locate the thermostat on an inside wall in the space to be conditioned where
it will not be subjected to either a cooling or heating source
or direct exposure to sunlight. Mount the thermostat 4 to 5 ft
above the floor.
NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated
wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG insulated wire (35 C minimum). For over 75 ft, use no. 14 AWG
insulated wire (35 C minimum). All wire larger than
18 AWG cannot be connected directly to the thermostat and
will require a junction box and splice at the thermostat.
—12—
Fig. 15 — Field Control Wiring Raceway
Table 3 — Accessory List
ACCESSORY
Roof Curb (14 in.)
Roof Curb (24 in.)
Low Ambient Controls
Condenser Coil Hail Guard Assembly
LP (Liquid Propane) Kit
Manual Outdoor-Air Damper
Two-Position Damper
Durablade Economizer
EconoMi$er
Power Exhaust
Time Guard® II 5-Minute Recycle Timer*
Controls Upgrade Package
Solid-State Enthalpy Control
Differential Enthalpy Control
Flue Hood Protector Assembly
Flue Discharge Deflector
Low Nox Kit
Condenser Coil Grille
OUTDOOR
AIR OPENING
PANEL
3 SCREWS
(SIDE)
*See unit wiring book for proper installation instructions.
NOTE: Two Time Guard II timers are required.
Fig. 16 — Damper Panel with Outdoor-Air
Damper Installed
G. Optional Outdoor-Air Damper Installation
The outdoor-air hood and screen are attached to the basepan
at the bottom of the unit for shipping.
Assembly:
1. Determine quantity of ventilation required for building. Record amount for use in Step 8.
2. Remove filter access panel. Remove and save outdoorair opening panel and screws. See Fig. 16.
3. Separate hood and screen from basepan by removing
the 6 screws and brackets securing them. Save all
screws and discard brackets.
4. Replace outdoor-air opening panel and filter access
panel.
5. Place hood on front of outdoor-air opening access
panel. See Fig. 17 for hood details. Secure top of hood
with the 6 screws removed in Step 3. See Fig. 18.
6. Remove and save screws from sides of the manual
outdoor-air damper assembly.
7. Align screw holes on hood with screw holes on side of
manual outdoor-air damper assembly. See Fig. 17 and
18. Secure hood with screws from Step 6.
8. For proper quantity of ventilation air, adjust minimum position setting of the damper blade by adjusting the manual outdoor-air adjustment screws on the
front of the damper blade. See Fig. 16. Slide blade
vertically until it is in the appropriate position determined by Fig. 19. Tighten screws.
9. Remove and save screws currently on sides of hood.
Insert screen. Secure screen to hood using the screws.
See Fig. 18.
H. Optional Durablade Economizer Installation
The optional economizer hood assembly is packaged and
shipped in the filter section. Damper blades and control
boards are installed at the factory and the economizer is
shipped in the vertical discharge position.
NOTE: Horizontal discharge block-off plate is shipped with
the air hood package. If unit is to be used for vertical discharge application, discard this plate.
Fig. 17 — Outdoor-Air Hood Details
SCREW
HOLES
(TOP)
HOOD
SCREEN
LOCATION
(SCREEN
NOT SHOWN)
Fig. 18 — Outdoor-Air Hood
—13—
Adjust minimum position setting by loosening the
screws on the position setting bracket. See Fig. 27.
Slide bracket until the top screw is in the position
determined by Fig. 26. Tighten screws.
8. Remove tape from outdoor-air thermostat (OAT). Fasten OAT to inside of hood using screws and speed
clips provided. See Fig. 28. Make sure OAT terminals
are positioned up.
9. Replace outdoor-air opening panel using screws from
Step 2. Replace filter access panel. Ensure the filter
access panel slides along the tracks and is securely
engaged.
Fig. 19 — Position Setting
Assembly
1. Determine if ventilation air is required in building. If
so, determine the minimum amount to be supplied by
each unit and record quantity of ventilation air
needed for use in Step 7.
2. Remove filter access panel by raising panel and
swinging panel outward. Panel is now disengaged
from track and can be removed. No tools are required
to remove filter access panel. Remove outdoor-air
opening panel. Save panels and screws. See Fig. 20.
Remove optional outdoor-air damper hood package
from filter section.
3. Assemble outdoor-air hood top and side plates as
shown in Fig. 21. Install seal strips on hoop top and
sides. Put aside screen retainer and retainer screw
for later assembly. Do not attach hood to unit at this
time.
Fig. 20 — Panel Locations
4. On 120 and 150 units, install vertical discharge
block-off plate on right side over return air duct opening. See Fig. 22.
Remove screw and discard from barometric relief
damper.
NOTE: Be sure to engage rear economizer flange under tabs
at rear of vertical return-air opening.
5. To convert to horizontal discharge application:
a. Rotate the economizer 90 degrees until the economizer motor faces the condenser section (see
Fig. 23).
b. Rotate the barometric relief damper hinge
90 degrees. Barometric relief damper should open
vertically to operate properly.
c. Install horizontal discharge block-off plate over the
opening on the access panel. (Block-off plate
MUST be installed before installing hood assembly.) See Fig. 24.
6. Insert economizer plug into economizer harness.
Remove tape and screw from barometric relief
damper. See Fig. 25.
7. If ventilation air is not required, proceed to Step 8. If
ventilation air is required, determine the minimum
position setting for required airflow. See Fig. 26.
—14—
Fig. 21 — Outdoor-Air Hood Details
ECONOMIZER
MOTOR
ECONOMIZER
CONTROL BOARD
WIRING
HARNESS
BAROMETRIC
RELIEF
DAMPER
SHIPPING
SCREW
ECONOMIZER
MOUNTING
SCREWS
Fig. 22 — Vertical Discharge Block-Off Plate
(Sizes 120,150 Only
Fig. 25 — Durablade Economizer Installed in Unit
ECONOMIZER
CONTROL
BOARD
BAROMETRIC
RELIEF
DAMPER
ECONOMIZER
PLUG
SHIPPING
SCREW
EXAMPLE:
Given — Negative Pressure . . . . . . . . . . . . . . . . . . . . . 0.1 in. wg
Outdoor Air . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 cfm
Determine — Setting =6
ECONOMIZER
MOTOR
Fig. 26 — Durablade Economizer Minimum
Position Setting
7
6
5
4
3
2
1
0
Fig. 23 — Horizontal Durablade Economizer
Installation (90 Degree Rotation)
8
BLOCK-OFF PLATE
9
Fig. 24 — Horizontal Discharge Block-Off Plate
Fig. 27 — Durablade Economizer Minimum Position
Damper Setting
—15—
12. Connect OAT per Fig. 29.
13. Slide outdoor-air inlet screen into screen track on
hood side plate. Slip screen clasp over screens to hold
screens together. While holding screens in place, fasten screen retainer to hood using screws provided.
NOTE: Refer to Fig. 30 for economizer barometric relief
damper characteristics.
Fig. 29 — Wiring Connections for Outdoor-Air
Thermostat
OAT
(TERMINALS ARE UP)
TOP
UNIT
OUTSIDE AIR
SCREEN
ENTHALPY
CONTROL
REV. B
B
C
MINIMUM
POSITION
SO
D
TR
S
OPEN
4
2
5
3
T1
P1
1
T
P
HOOD
Fig. 30 — Durablade Economizer Barometric Relief Damper
Characteristics
TR
C
24VAC
2
TR1
1
3 mA MIN. AT 11 VDC
B A
ENTHALPY CONTROL
3
D
CW–SETPOINTS–CCW
198818A
RUSH AT 24VAC
CONTACT RATINGS: 1.5A RUN, 3.5A IN
°F
CONTACTS SHOWN IN HIGH ENTHALPY
OR UNPOWERED STATE
OUTDOOR TEMP.
% 90
H
DAMPER
U 70
CLOSED
M
I 60
DAMPER
D
OPEN
I 30
T
Y 10
50 55 60 65 70 75 80 85
I. Optional EconoMi$er Economizer Installation
See Fig. 31 for EconoMi$er component locations.
ECONOMI$ER
PLUG
97-3672
CONTROLLER
GEAR-DRIVEN
DAMPER
ACTUATOR
REV.
Fig. 28 — Outdoor-Air Thermostat/Enthalpy
Control Installation
OUTDOOR AIR
TEMPERATURE
SENSOR
10. Fasten hood top and side plate assembly to outdoorair opening panel with screws provided.
11. Place knob supplied with economizer on OAT. See
Fig. 28. Set for 3° F below indoor room thermostat
setting. If accessory enthalpy control (EC) is used in
place of OAT, see instructions shipped with EC for
installation and adjustment. See Fig. 28.
—16—
BAROMETRIC
RELIEF DAMPERS
Fig. 31 — EconoMi$er Component Locations
1. To remove the existing unit filter access panel, raise
the panel and swing the bottom outward. The panel is
now disengaged from the track and can be removed.
Remove the indoor coil access panel and discard. See
Fig. 32.
Controller should be mounted in vertical position as
shown in Fig. 31.
2. Assemble the hood assembly as follows:
Remove the EconoMi$er hood from its packaging.
Locate the outdoor air opening panel. See Fig. 33.
Remove the hood assembly shipping brackets located
on the back (sloped) side of the EconoMi$er assembly.
These brackets are used to retain the hood assembly
during shipping only.
3. Install the 1/8 x 3/4 in. seal strip on the exhaust air
hood side panels and the bottom bracket. Assemble
the exhaust air hood to the outdoor air opening panel
as shown in Fig. 33, using the screws provided. Do
not attach hood assembly to unit at this time.
4. Install the 1/8 x 3/4 in. seal strip on the outdoor air
hood top and side panels. Assemble the outdoor air
hood to the outdoor air opening panel as shown in
Fig. 34, using the screws provided. Do not attach hood
assembly to the unit at this time.
5. Slide the outdoor air inlet screens into the screen
track on the hood side panels. While holding the
screens in place, fasten the screen retainer to the
hood using the screws provided. Repeat the process
for the barometric exhaust air screen. Do not attach
completed (Fig. 35) hood assembly to unit at this time.
OUTDOOR AIR
OPENING PANEL
EXHAUST AIR
HOOD TOP
SCREEN
RETAINER
EXHAUST AIR
HOOD SIDES
SEAL STRIP
EXHAUST AIR SCREEN
EXHAUST AIR
BOTTOM BRACKET
Fig. 33 — Exhaust Air Hood Assembly
OUTDOOR AIR
OPENING
PANEL
SEAL STRIP
OUTDOOR AIR
HOOD TOP
SCREEN
RETAINER
OUTDOOR AIR
INLET
SCREENS
SEAL STRIP
ASSEMBLED
EXHAUST HOOD
OUTDOOR AIR
HOOD SIDES
Fig. 34 — Outdoor Air Hood Assembly
6. Install the return air block-off plate over the return
air duct opening. See Fig. 36.
7. Slide the EconoMi$er assembly into the rooftop unit.
See Fig. 37 and 38.
Fig. 35 — Completed Hood Assembly
BLOWER
RETURN AIR
BLOCK-OFF
PLATE
FILTER
OUTDOOR AIR
BLOCK-OFF PLATE
OUTDOOR-AIR
OPENING PANEL
FILTER ACCESS
PANEL
ECONOMI$ER
Fig. 32 — Typical Access Panel Locations
Fig. 36 — Return Air Block-Off Plate Installation
—17—
NOTE: Be sure to engage rear EconoMi$er flange under tabs
in return air opening of the unit base. See Fig. 37.
8. Install the outdoor air block-off plate, then secure the
EconoMi$er with the screws provided. See Fig. 36
and 38.
9. Remove and discard the 12-pin jumper plug from the
unit wiring harness located in the upper left corner
and insert the EconoMi$er plug into the unit wiring
harness. Refer to wiring diagram Fig. 39 and 40. Also
refer to Fig. 41 if installing an accessory power
exhaust.
10. Install the complete hood assembly on the unit and
secure using the screws provided.
11. Remove the indoor fan motor access panel.
12. Mount the supply air temperature sensor to the lower
left portion of the indoor blower housing with the two
(2) screws provided (see Fig. 42). Connect the violet
and pink wires to the corresponding connections on
the supply air temperature sensor. Replace the indoor
fan motor access panel.
CO2 Control Setup
If a CO2 sensor is not being used, proceed to the next section.
If a CO2 sensor is being used, perform the following:
1. Determine the value at which you want the minimum
position of the dampers to begin opening to allow a
greater amount of outdoor air to enter. The range is
800 to 1,400 ppm.
2. Locate the CO2 SP (PPM) potentiometer and adjust
to the desired set point. See Fig. 43.
UNIT FILTER
RACK
ECONOMIZER
UNIT BASE
ECONOMIZER REAR
FLANGE
Fig. 37 — Rear EconoMi$er Flange Installation
WIRING HARNESS
OUTDOOR AIR
BLOCK-OFF PLATE
OAT — Outdoor Air Thermostat
Fig. 39 — EconoMi$er Wiring
—18—
ECONOMIZER CLIP
HVAC UNIT
Fig. 38 — EconoMi$er Installed
BROWN
ECONOMI$ER
CONTROLLER
VIOLET
OAT
WHITE
RED
COM
OAH
-15 V
BROWN
RAT
VIOLET
WHITE
COM
RAH
RED
+15 V
TEMP
TEMP
COM
OUT
PWR
OUTDOOR
AIR
SENSOR
TEMP
TEMP
COM
OUT
PWR
RETURN
AIR
SENSOR
SUPPLY AIR
TEMPERATURE
SENSOR
MOUNTING
LOCATION
SUPPLY AIR
TEMPERATURE
SENSOR
CO2 SENSOR
24
V+
COM VAC
CO2 (+)
CO2 COM
DAT
COM
REM POT
COM
LED
COM
Fig. 42 — Supply Air Sensor Placement
SUPPLY AIR
TEMPERATURE SENSOR
PINK
TEMP
VIOLET
TEMP
Fig. 40 — EconoMi$er Sensor Wiring
RED
GRAY
H1
H2
X4
X2 X3
RED YEL BLU GRAY
HT01AH850
(460 VAC)
HT01AH859
(575 VAC)
TO FUSED
DISCONNECT
X1
H1
H3 H2
H4
X4
X2 X3
X1
SECONDARY
230VAC
SECONDARY
230VAC
FIELD SUPPLIED
WIRING
BLACK
OR
BLACK
COMPRESSOR 1
CONTACTOR
11
LT. BLUE
21
230VAC
BROWN
23
13
FAN 1
C1
GREEN/
YELLOW
4-PIN
CONNECTOR
PLUG
2 x 4 IN.
HANDY BOX
BLACK L1
1
BLUE
L2 2
GREEN GND
3
4
3
6
9
2
5
8
1
4
7
B
BLACK
R1
24 VAC
A
BLUE
L1
1
L2
2
GND
3
4
230 VAC
1 PHASE
3-PIN
CONNECTOR
PLUG
ORANGE
1
YELLOW
2
BROWN
BLACK
BLACK
BLUE
LT. BLUE
GREEN
BROWN
FAN 2
3
6
9
2
5
8
4
7
C1
GREEN/
YELLOW
1
BLUE
Fig. 41 — Wiring Diagram for Power Exhaust System
—19—
B
BLACK
R2
24 VAC
A
3
Mechanical Cooling Lockout
Determine the outdoor-air temperature at which you want
the mechanical cooling (compressors) to be disabled. Locate
the mechanical cooling lockout (MECH CLG LOCKOUT)
potentiometer. To disable this feature, turn the potentiometer counterclockwise (CCW) to the OFF position. Otherwise,
set the value between 10 and 60 F. Mechanical cooling will
not operate when the outdoor air temperature is below this
value. See Fig. 43.
Dry Bulb Changeover Set Up
NOTE: The EconoMi$er begins operation three minutes after
power up.
WARNING: Personal Injury Hazard. Avoid possible
injury by keeping fingers away from damper blades.
See Fig. 44 for barometric relief damper characteristics.
Determine the dry bulb changeover set point from Table 4.
The settings are A, B, C and D. Locate the ECON SP potentiometer and set the dry bulb changeover set point. See
Fig. 43. When the OAT is above this set point, the damper is
limited to minimum position setting.
Fig. 43 — EconoMi$er Control Adjustment
Potentiometers (Factory Settings)
SETTINGS
Dry Bulb (°F)
Single Enthalpy* (Btu/lb)
Differential Temperature*
(°F, Not Adjustable)
Differential Enthalpy*
(Btu/lb, Not Adjustable)
A
73
27
B
69
25
C
66
24
D
63
22
2
2
2
2
1
1
1
1
*Field-installed accessory.
If a potentiometer fails, its setting will default to the values
in Table 5.
0.5
0.4
0.3
0.2
0.1
0
0
Table 5 — Default Potentiometer Settings
POTENTIOMETER
CO2 SP (PPM)
MECH CLG LOCKOUT
ECON SP
MIN POS (%)
STATIC PRESSURE (IN.WG)
Table 4 — Changeover Set Points
400
800
1200
1600
2000
2400
FLOW (CUBIC FEET/MINUTE)
DEFAULT SETTING
1,000
47°
D
20
Fig. 44 — Barometric Relief Capacity
PRE-START-UP
Ventilation Air (Minimum Position Set Up)
If ventilation air is not required, proceed to Step 5. If ventilation air is required, perform the following:
1. The indoor fan must be on to set the ventilation air.
Either put the thermostat in the continuous fan mode
or jumper the R and G terminals at the rooftop unit
connection board.
2. Locate the minimum position (MIN POS) potentiometer. Turn the potentiometer full CCW to fully close
the outdoor air dampers. Turn the potentiometer
gradually clockwise (CW) to the desired position. See
Fig. 43.
3. Replace the filter access panel. See Fig. 32. Ensure
the filter access panel slides along the tracks and is
securely engaged.
WARNING: Failure to observe the following warnings could result in serious personal injury:
1. Follow recognized safety practices and wear
protective goggles when checking or servicing
refrigerant system.
2. Do not operate compressor or provide any electric power to unit unless compressor terminal
cover is in place and secured.
3. Do not remove compressor terminal cover until
all electrical sources have been disconnected
and lockout tags installed.
4. Relieve all pressure from system before touching or disturbing anything inside terminal box
if refrigerant leak is suspected around compressor terminals.
the
5. Never attempt to repair soldered connection
while refrigerant system is under pressure.
a. Calculate % of outside air using the following
formula.
6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective
goggles and proceed as follows:
4. Calculate the
EconoMi$er.
minimum
airflow
across
% Outdoor air through EconoMi$er
Mixture Temp –
Return Air Temp
% Outdoor air =
Outdoor Temp –
Return Air Temp
a. Shut off gas supply and then electrical power
to unit.
b. Divide total CFM by percentage outdoor air, this
gives outdoor air volume in CFM.
5. Turn on base unit power.
—20—
b. Relieve all pressure from system.
c. Cut component-connecting tubing with tubing cutter and remove component from unit.
d. Carefully unsweat remaining tubing stubs
when necessary. Oil can ignite when exposed
to torch flame.
Proceed as follows to inspect and prepare the unit for initial
start-up:
1. Remove all access panels.
2. Read and follow instructions on all WARNING, CAUTION, and INFORMATION labels attached to or
shipped with unit.
3. Make the following inspections:
a. Inspect for shipping and handling damages such
as broken lines, loose parts, disconnected wires,
etc.
b. Inspect for oil at all refrigerant tubing connections
and on unit base. Detecting oil generally indicates
a refrigerant leak. Leak-test all refrigerant tubing
connections using electronic leak detector, halide
torch, or liquid-soap solution. If refrigerant leak is
detected, see Service, Refrigerant Leaks section on
page 33.
c. Inspect all field- and factory-wiring connections.
Be sure that connections are completed and tight.
Ensure that no electrical wiring is in contact with
refrigerant tubing or sharp edges.
d. Inspect coil fins. If damaged during shipping and
handling, carefully straighten fins with a fin comb.
4. Verify the following conditions:
DANGER: Do not purge gas supply into the combustion chamber. Do not use a match or other open
flame to check for gas leaks. Failure to adhere to this
warning could result in an explosion causing personal
injury or death.
a. Make sure that gas supply has been purged, and
that all gas piping has been checked for leaks.
b. Make sure that condenser-fan blade is correctly
positioned in fan orifice. Blades should clear fan
motor.
c. Make sure that air filters are in place.
d. Make sure that condensate drain pan and trap are
filled with water to ensure proper drainage.
e. Make sure that all tools and miscellaneous loose
parts have been removed.
5. Compressors are internally spring mounted. Do not
loosen or remove compressor holddown bolts. On size
150 units, remove the tiedown bands that hold the
compressors together.
6. Each unit system has 4 Schrader-type gage ports: one
on the suction line, one on the liquid line and two on
the compressor discharge line. Be sure that caps on
the ports are tight.
High Flow Valves
Located on the compressor hot gas and suction tubes are
High Flow Valves. Large black plastic caps distinguish these
valves with o-rings located inside the caps. These valves cannot be accessed for service in the field. Ensure the plastic
caps are in place and tight or the possibility of refrigerant
leakage could occur.
Unit is now ready for initial start-up.
START-UP
I. HEATING SECTION START-UP AND ADJUSTMENTS
CAUTION: Complete the required procedures
given in Pre-Start-Up section on page 20 before starting unit.
Do not jumper any safety devices when operating the unit.
Ensure that burner orifices are aligned properly. Unstable
operation may occur when the burner orifices in the manifold are misaligned.
Follow the lighting instructions on the heating section operation label (located inside the burner access door) to start the
heating section.
NOTE: When lighting the unit for the first time, perform the
following additional steps: If the gas supply pipe was not
purged before connecting the unit, it will be full of air. It is
recommended that the ground joint union be loosened and
the supply line be allowed to purge until the odor of gas is
detected. Never purge gas lines into a combustion chamber.
Immediately upon detection of gas odor, retighten the union.
Allow 5 minutes to elapse, then light unit in accordance with
Checking Heating Control Operation section below.
A. Checking Heating Control Operation
Start and check the unit for proper heating control operation
as follows: (Also see furnace lighting instructions located
inside the burner access panel.)
1. Turn on unit electrical supply and manual gas valve.
2. Set system switch selector at HEAT position and fan
switch at AUTO. or ON position. Set heating temperature lever above room temperature.
3. The induced-draft motor will start immediately.
4. After a call for heating, the main burners should light
within 5 seconds. If the burner does not light, then
there is a 22-second delay before another 5-second
try. If the burner still does not light, the time delay is
repeated. If the burner does not light within 15 minutes there is a lockout. To reset the control, break the
24-v power to W1. See note.
NOTE: The default value for the evaporator-fan motor ON/
OFF delay is 45 seconds. The Integrated Gas Unit Controller
(IGC) modifies this value when abnormal limit switch cycles
occur. Based upon unit operating conditions, the ON delay
can be reduced to 0 seconds and the OFF delay can be
extended to 180 seconds.
When one flash of LED is observed, the evaporator-fan ON/
OFF delay has been modified. If the limit switch trips at the
start of the heating cycle during the evaporator ON delay,
the time period of the ON delay for the next cycle will be 5
seconds less than the time at which the switch tripped.
EXAMPLE: If the limit switch trips at 30 seconds, the evaporator-fan ON delay for the next cycle will occur at 25 seconds.
To prevent short-cycling, a 5-second reduction will only occur
if a minimum of 10 minutes has elapsed since the last call for
heating.
The evaporator-fan OFF delay can also be modified. Once the
call for heating has ended, there is a 10 minute period during which the modification can occur. If the limit switch trips
during this period, the evaporator-fan OFF delay will
increase by 15 seconds. A maximum of 9 trips can occur,
extending the evaporator-fan OFF delay to 180 seconds. To
restore the original default value, reset the power to the
unit.
5. The evaporator fan will turn on 45 seconds after a
call for heating.
6. The evaporator fan will turn off 45 seconds after thermostat temperature has been satisfied.
7. Adjust airflow to obtain a temperature rise within
the range specified on the unit nameplate.
To shut off unit, set system selector switch at OFF position
or set heating selector lever below room temperature.
—21—
4. Turn on gas to unit.
5. Record number of seconds for gas-meter test dial to
make one revolution.
6. Divide number of seconds in Step 5 into 3600 (number of seconds in one hour).
7. Multiply result of Step 6 by the number of cubic ft
shown for one revolution of test dial to obtain cubic ft
of gas flow per hour.
B. Gas Input
Check gas input and manifold pressure in “HIGH FIRE”
(W1 and W2 energized at gas valve) after unit start-up (see
Table 6). If adjustment is required, proceed as follows:
CAUTION: These units are designed to consume
the rated gas inputs using the fixed orifices at specified manifold pressures as shown in Table 6.
DO NOT REDRILL THE ORIFICES UNDER ANY
CIRCUMSTANCES.
8. Multiply result of Step 7 by Btu heating value of gas
to obtain total measured input in Btuh. Compare this
value with heating input shown in Table 1. (Consult
the local gas supplier if the heating value of gas is not
known.)
EXAMPLE: Assume that the size of test dial is one cubic ft,
one revolution takes 30 seconds and the heating value of the
gas is 1045 Btu/ft3.
The rated gas inputs shown in Table 6 are for altitudes from
sea level up to 2000 ft above sea level. These inputs are
based on natural gas with a heating value of 1050 Btu/ft3
at 0.65 specific gravity, or LP (liquid propane) gas with a
heating value of 2500 Btu/ft3 at 1.5 specific gravity. For
elevations above 2000 ft, reduce input 4% for each 1000 ft
above sea level. When the gas supply being used has a different heating value or specific gravity, refer to national and
local codes, or contact your distributor or branch to determine the required orifice size. Refer to Table 7 for the correct
orifice to use at high altitudes. Kits are available from your
distributor.
Proceed as follows:
1. 30 seconds to complete one revolution
2. 3600 ÷ 30 = 120
3. 120 x 1 = 120 ft3 of gas flow/hr
4. 120 x 1045 = 125,400 Btuh input
If the desired gas input is 125,000 Btuh, only a minor change
in the manifold pressure is required.
Observe manifold pressure and proceed as follows to adjust
gas input:
1. Remove cover screw over regulator adjustment screw
on gas valve. See Fig. 45.
2. Turn regulator adjustment screw clockwise to
increase gas input, or counterclockwise to decrease
input. Manifold pressure must be between 3.2 and
3.8 in. wg.
C. Adjusting Gas Input
The gas input to the unit is determined by measuring the
gas flow at the meter or by measuring the manifold pressure.
Measuring the gas flow at the meter is recommended for natural gas units. The manifold pressure must be measured to
determine the input of LP gas units.
NOTE: When observing manifold pressure on 2-stage units,
set unit for high fire.
Measuring Gas Flow at Meter Method — Natural Gas Units
Minor adjustment can be made by changing the manifold
pressure. The manifold pressure must be maintained
between 3.2 and 3.8 in. wg (when measured under high fire
on 2-stage units). If larger adjustments are required, change
main burner orifices following the recommendations of
national and local codes.
NOTE: All other appliances that use the same meter must be
turned off when gas flow is measured at the meter. Proceed
as follows:
WARNING: Unsafe operation of the unit may
result if manifold pressure is outside this range. Personal injury or unit damage may result.
3. Replace cover screw cap on gas valve.
4. Turn off gas supply to unit.
5. Remove manometer from pressure tap.
6. Replace pipe plug on gas valve or manifold.
1. Turn off gas supply to unit.
2. Remove pipe plug on outlet of gas valve or on
manifold.
3. Connect manometer.
7. Turn on gas to unit.
8. Check for leaks.
Table 6 — Rated Gas Inputs at Indicated Manifold Pressures
UNIT
580D090-150
580D120, 150
NUMBER
OF
ORIFICES
3
4
5
5
GAS SUPPLY PRESSURE
(in. wg)
Natural
Propane
MANIFOLD
PRESSURE
(in. wg)*
Min
Max
Min
Max
Natural
Propane
4.0
4.0
4.0
4.0
13.0
13.0
13.0
13.0
5.0
5.0
5.0
5.0
13.0
13.0
13.0
13.0
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
LEGEND
LP — Liquid Propane
*Manifold pressure shown is for second stage of heat when energized.
†Maximum heating input based on altitudes from sea level up to 2000 ft above sea level.
For altitudes above 2000 ft, reduce input rating 4% for each 1000 ft above sea level. In
Canada, from 2000 ft above sea level to 4500 ft above sea level, derate the unit 10%.
**When a 580D unit is converted to LP, the burners must be modified with accessory LP kit.
††580D090,102 only.
¶580D090-120 only.
—22—
NATURAL GAS
Orifice
Drill
Size
31
31
31
30
Heating
Input
(Btuh)†
125,000††
180,000¶
220,000
250,000
LIQUID
PROPANE**
Orifice
Heating
Drill
Input
Size
(Btuh)†
41
125,000††
41
180,000¶
41
220,000
38
250,000
D. Check Burner Flame
Observe the unit heating operation, and watch the burner
flames through the access door to see if they are light blue in
appearance, and that the flames are approximately the same
for each burner. See Fig. 46.
E. Airflow and Temperature Rise
The heating section of each side of the unit is designed and
approved for heating operation within the temperature rise
range stamped on the unit rating plate. Temperature rise
range is also found in Table 1.
ELEVATION
(FT)
0-2,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
11,000
12,000
13,000
14,000
Fig. 45 — Burner Tray Details
The heating operation airflow must produce a temperature
rise that falls within the approved range.
Table 7 — Altitude Compensation*
Refer to Section III, Indoor Airflow and Airflow Adjustments
on page 26 of this section to adjust heating airflow.
125,000, 180,000,
AND 220,000 BTUH
NOMINAL INPUT
Natural
Liquid
Gas
Propane
Orifice
Orifice
Size†
Size†
31
41
32
42
32
42
32
42
33
43
34
43
35
44
36
44
37
45
38
46
39
47
40
47
41
48
42
48
F. Safety Check of Limit Control
250,000 BTUH
NOMINAL
INPUT
Natural
Liquid
Gas
Propane
Orifice
Orifice
Size†
Size†
30
38
30
39
31
40
32
41
33
42
34
43
35
43
36
44
37
44
38
45
39
45
40
46
41
47
42
47
Limit control is located on the deck next to the indoor-air
blower. The control shuts off the gas supply if the unit
overheats.
The recommended method of checking this limit control is to
gradually block off the return air after the unit has been
operating in heating for a period of at least 5 minutes. As
soon as the limit control functions, the return-air opening
should be unblocked to permit normal air circulation. By
using this method to check the limit control, it can be established that the limit is functioning properly and the unit will
‘‘fail-safe’’ if there is a restricted circulating-air supply or
motor failure. If the limit control does not function during
this test, the cause must be determined and corrected.
G. Heating Sequence of Operation
Heating, Units Without Economizer
*As the height above sea level increases, there is less oxygen per
cubic foot of air. Therefore, heat input rate should be reduced at higher
altitudes.
†Orifices available through your local distributor.
Measuring Manifold Pressure — LP Gas Units
The main burner orifices on an LP gas unit are sized for the
unit rated input when the manifold pressure is 3.5 in. wg.
Proceed as follows to adjust gas input on an LP gas unit:
1. Turn off gas to unit.
2. Remove pipe plug on outlet of gas valve or on
manifold.
3. Connect manometer.
When the thermostat calls for heating, terminal W1 is energized. In order to prevent thermostat short-cycling, the unit
is locked into the Heating mode for at least one minute when
W1 is energized. The induced-draft motor is energized and
the burner ignition sequence begins. The indoor (evaporator)
fan motor (IFM) is energized 45 seconds after a flame is
ignited. On units equipped for two stages of heat, when additional heat is needed, W2 is energized and the high-fire solenoid on the main gas valve (MGV) is energized. When the
thermostat is satisfied and W1 is deenergized, the IFM stops
after a 45-second time-off delay.
Heating, Units With Economizer
When the thermostat calls for heating, terminal W1 is energized. In order to prevent thermostat short-cycling, the unit
is locked into the Heating mode for at least one minute when
4. Turn on gas to unit and ensure gas valve operation in
second stage.
5. Remove cover screw over regulator adjustment screw
on gas valve. See Fig. 45.
6. Adjust regulator adjustment screw for a manifold
pressure reading of 3.5 in. wg (when observed under
high fire on 2-stage units). Turn adjusting screw
clockwise to increase manifold pressure, or counterclockwise to decrease manifold pressure.
7. Replace cover screw.
8. Turn off gas to unit.
9. Remove manometer from pressure tap.
10. Replace pipe plug on gas valve or manifold.
11. Turn on gas to unit.
12. Check for leaks.
Fig. 46 — Monoport Burners
—23—
W1 is energized. The induced-draft motor is energized and
the burner ignition sequence begins. The indoor (evaporator)
fan motor (IFM) is energized 45 seconds after a flame is
ignited and the damper moves to the minimum position. On
units equipped for two stages of heat, when additional heat
is needed, W2 is energized and the high-fire solenoid on the
main gas valve (MGV) is energized. When the thermostat
is satisfied and W1 is deenergized, the IFM stops after a
45-second time-off delay. The economizer damper then moves
to the fully closed position. When using continuous fan, the
damper will remain in the minimum position.
H. Limit Switches
Heating limit switches (LS) close the gas valve and the Integrated Gas Unit Controller (IGC) if the leaving-air temperature exceeds the maximum allowable temperature.
Normally closed LS completes a circuit to the gas valve.
Should the leaving-air temperature rise above the maximum
allowable temperature, LS opens instantly, closing the gas
valves and stopping gas flow to the burners. The inducer
motor and evaporator motor are energized to cool heat
exchanger. The combustion blower motor stops.
When the air temperature at LS drops to the low-temperature setting of the LS, the switch closes and completes the
gas valve circuit. The electric-spark ignition system cycles
and the unit returns to normal heating operation.
I. Rollout Switch
The rollout switch (RS) is a temperature-actuated automatic
reset switch which closes the main gas valve in the event of
flame rollout. The switch is located above the main burners
on the internal wind baffle. When the temperature at RS
reaches the maximum allowable temperature, the control
circuit trips, closing the gas valves and stopping gas flow to
the burners. The inducer motor and evaporator-fan motor
are energized when RS trips. Although the rollout switch has
an automatic reset, the Integrated Gas Unit Controller (IGC)
locks out the unit when a trip occurs and does not allow the
burners to ignite until the unit disconnect is reset. If the
switch cycles again, shut down the unit and call for service.
II. COOLING SECTION START-UP AND ADJUSTMENTS
CAUTION: Complete the required procedures
given in the Pre-Start-Up section on page 20 before
starting the unit.
3. When using an autochangeover room thermostat,
place both SYSTEM and FAN switches in AUTO.
positions. Observe that unit operates in heating mode
when temperature control is set to ‘‘call for heating’’
(above room temperature) and operates in cooling
mode when temperature control is set to ‘‘call for cooling’’ (below room temperature).
B. Checking and Adjusting Refrigerant Charge
The refrigerant system is fully charged with R-22 refrigerant, tested, and factory-sealed.
NOTE: Adjustment of the refrigerant charge is not required
unless the unit is suspected of not having the proper R-22
charge. This unit uses charging charts to determine proper
charge. See Refrigerant Charge section on page 33 for further details.
C. Unit Controls
All compressors have the following internal-protection
controls:
1. High-Pressure Relief Valve — This valve (internal to
the compressor) opens when the pressure differential
between the low and high side becomes excessive and
will automatically reset when pressure returns to
normal.
2. Compressor Overload — This overload interrupts
power to the compressor when either the current or
internal temperature becomes excessive, and automatically resets when the internal temperature drops
to a safe level. This overload may require up to
60 minutes (or longer) to reset; therefore, if the internal overload is suspected of being open, disconnect
the electrical power to the unit and check the circuit
through the overload with an ohmmeter or continuity
tester.
D. Compressor Rotation
On 3-phase units with scroll compressors, it is important to
be certain compressor is rotating in the proper direction. To
determine whether or not compressor is rotating in the
proper direction:
1. Connect service gages to suction and discharge pressure fittings.
2. Energize the compressor.
3. The suction pressure should drop and the discharge
pressure should rise, as is normal on any start-up.
Do not jumper any safety devices when operating the
unit.
If the suction pressure does not drop and the discharge pressure does not rise to normal levels:
Do not operate the compressor when the outdoor temperature is below 25 F.
1. Note that the evaporator fan is probably also rotating
in the wrong direction.
Do not rapid-cycle the compressor. Allow 5 minutes
between ‘‘on’’ cycles to prevent compressor damage.
2. Turn off power to the unit and tag disconnect.
3. Reverse any two of the unit power leads.
A. Checking Cooling Control Operation
Start and check the unit for proper cooling control operation
as follows:
1. Place room thermostat SYSTEM switch in OFF position. Observe that fan motor starts when FAN switch
is placed in ON position and shuts down when FAN
switch is placed in AUTO. position.
2. Place SYSTEM switch in COOL position and FAN
switch in AUTO. position. Set cooling control below
room temperature. Observe that compressor, condenser fan, and evaporator-fan motors start. Observe
that cooling cycle shuts down when control setting is
satisfied.
4. Reapply power to the unit.
The suction and discharge pressure levels should now move
to their normal start-up levels.
NOTE: When the compressor is rotating in the wrong direction, the unit makes an elevated level of noise and does not
provide cooling.
E. Cooling Sequence of Operation
Without Economizer
When thermostat calls for cooling, terminals G and Y1 are
energized. The indoor (evaporator) fan contactor (IFC) compressor contactor no. 1 (C1) and outdoor (condenser) fan contactor (OFC) are energized and indoor (evaporator) fan motor
—24—
(IFM), compressor no. 1, and condenser fan start. The outdoor
(condenser) fan motors (OFM) run continuously while unit is
cooling. If the thermostat calls for a second stage of cooling by
energizing Y2, compressor con-tactor no. 2 (C2) is energized
and compressor no. 2 starts. When the thermostat is satisfied,
C1 and C2 are deenergized and the compressor and OFM shut
off. After a 30-second delay, the IFM shuts off. If the thermostat fan selector switch is in the ON position, the IFM will run
continuously.
With Durablade Economizer
When the outdoor-air temperature is above the OAT (outdoorair thermostat) setting and the room thermostat calls for cooling, compressor contactor no. 1 is energized to start compressor no. 1 and outdoor fan contactor (OFC) energizes starting
the condenser fan. The evaporator-fan motor is energized and
the economizer damper moves to the minimum position. After
the thermostat is satisfied, there is a 30-second delay before
the evaporator fan turns off. Upon a further call for cooling,
compressor contactor no. 2 will be energized, starting compressor no. 2. After the thermostat is satisfied, the damper
moves to the fully closed position when using an auto. fan or
to the minimum position when using a continuous fan.
When the outdoor-air temperature is below the OAT setting and
the thermostat calls for cooling, the economizer dampers move
to the minimum position. If the supply-air temperature is above
57 F, contact T2 on the supply-air thermostat (SAT) will close.
The damper continues to open until it reaches the fully open
position or until the supply-air temperature drops below 52 F.
When the supply-air temperature falls to between 57 F and
52 F, contactor T2 and T1 on the SAT will open and the
damper will remain at an intermediate open position. If the
supply-air temperature falls below 52 F, contactor T1 on the
SAT will close. The damper will modulate closed until it
reaches the minimum position or until the supply-air temperature is above 52 F. When the thermostat is satisfied, the
damper will move to the fully closed position when using an
auto. fan or to the minimum position when using a continuous
fan.
If the outdoor air alone cannot satisfy the cooling requirements
of the conditioned space, economizer cooling is integrated with
mechanical cooling, providing a second-stage cooling. Compressor no. 1 and the condenser fan will be energized and the position of the economizer damper will be determined by the
supply-air temperature. Compressor no. 2 is locked out.
When the second stage of cooling is satisfied, the compressor
and condenser-fan motor will be deenergized. The damper
position will be determined by the supply-air temperature.
When the first stage of cooling is satisfied, there is a
30-second delay before the evaporator fan shuts off. The
damper moves to the fully closed position when using an
auto. fan or the minimum position when using a continuous
fan.
Additional information on economizer operation is provided
in the Ventilation Sequence section on page 31.
Cooling, Units with EconoMi$er
When the Outdoor Air Temperature (OAT) is above the
ECON SP set point and the room thermostat calls for
Stage 1 cooling (R to G + Y1), the indoor-fan motor (IFM) is
energized and the EconoMi$er damper modulates to minimum position. The compressor contactor OFC are energized
to start the compressor and outdoor-fan motor (OFM). After
the thermostat is satisfied, the damper modulates to the
fully closed position when the IFM is deenergized.
When the OAT is below the ECON SP setting and the room
thermostat calls for Stage 1 cooling (R to G + Y1), the
EconoMi$er modulates to the minimum position when the
IFM is energized. The EconoMi$er provides Stage 1 of cooling
by modulating the return and outdoor-air dampers to maintain a 55 F supply air set point. If the supply-air temperature
(SAT) is greater than 57 F, the EconoMi$er modulates open,
allowing a greater amount of outdoor air to enter the unit. If
the SAT drops below 53 F, the outdoor-air damper modulates
closed to reduce the amount of outdoor air. When the SAT is
between 53 and 57 F, the EconoMi$er maintains its position.
If outdoor air alone cannot satisfy the cooling requirements
of the conditioned space, and the OAT is above the MECH
CLG LOCKOUT set point, the EconoMi$er integrates free
cooling with mechanical cooling. This is accomplished by the
strategies below.
NOTE: Compressors have a two-minute Minimum On, Minimum Off, and Interstage delay timer.
1. If Y1 is energized, and the room thermostat calls for
Y2 (2-stage thermostat), the compressor number 1
and OFM are energized. The position of the
EconoMi$er damper is maintained at its current
value.
2. If Y1 is energized for more then 20 minutes, and Y2 is
not energized (whether or not a 2-stage thermostat is
used), compressor no. 1 and OFM are energized. The
position of the EconoMi$er damper is maintained at
its current value.
3. If Y1 is energized, and compressor no. 1 is already
energized (see Step 2) and the room thermostat calls
for Y2, compressor no. 1 continues to operate. If Y2
remains energized for more than 20 minutes, compressor no. 2 is energized.
NOTE: Compressor no. 2 cannot be energized unless there is
a signal for Y2 from the space thermostat.
4. If compressor no. 2 is energized, and the Y2 signal
from the thermostat is satisfied, compressor no. 1 and
2 are deenergized. Re-asserting Y2 will start compressor no. 1 and (after a 20-minute interstage delay)
compressor no. 2.
5. If compressor no. 1 is energized and the thermostat is
satisfied, compressor no. 1, the OFM, and IFM are
deenergized and the EconoMi$er modulates closed.
When the OAT is below the MECH CLG LOCKOUT set
point, the compressors remain off.
Time Guard® II Device
If the unit is equipped with accessory Time Guard II recycle
timer, the unit will delay 5 minutes between compressor
starts.
Controls Kit
Loss-of-Charge Switch (LPS) — When the refrigerant liquid
line pressure drops below 7 psig, the LPS opens 24-v power to
the compressor contactor and stops the compressor. When the
pressure reaches 22 psig, the switch resets and the compressor is allowed to come back on.
High-Pressure Switch (HPS) — When the refrigerant highside pressure reaches 428 psig, the HPS opens 24-v power to
the compressor contactor and stops the compressor. When
the pressure drops to 320 psig, the switch resets and the
compressor is allowed to restart.
Freeze Protection Thermostat (FPT) — When the evaporator
coil leaving-refrigerant temperature drops below 30 F, the
FPT opens 24-v power to the compressor contactor and stops
the compressor. When the leaving refrigerant temperature
warms to 45 F, the switch resets and the compressor is
allowed to restart.
—25—
III. INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS
CAUTION: For cooling operation, the recommended airflow is 300 to 500 cfm per each 12,000 Btuh
of rated cooling capacity. For heating operation, the airflow must produce a temperature rise that falls within
the range stamped on the unit rating plate.
Adjust evaporator-fan RPM to meet jobsite conditions and
temperature rise in Table 1. Table 8 shows fan rpm at motor
pulley settings. Table 9 shows motor performance. Refer to
Tables 10-17 to determine fan speed settings.
A. Belt Drive Motors
Fan motor pulleys are factory set for speed shown in Table 1.
NOTE: Before adjusting fan speed, make sure the new fan
speed will provide an air-temperature rise range as shown in
Table 1.
To change fan speed:
1. Shut off unit power supply and tag disconnect.
Fig. 48 — Typical Belt-Drive Motor Mounting
for Sizes 102, 150
2. Loosen belt by loosening fan motor mounting nuts.
See Fig. 47 and 48.
3. Loosen movable pulley flange setscrew (see Fig. 49).
4. Screw movable flange toward fixed flange to increase
RPM and away from fixed flange to decrease RPM.
Increasing fan speed increases load on motor. Do not
exceed maximum speed specified in Table 1.
5. Set movable flange at nearest keyway of pulley hub
and tighten setscrew. (See Table 1 for speed change
for each full turn of pulley flange.)
To align fan and motor pulleys:
1. Loosen fan pulley setscrews.
2. Slide fan pulley along fan shaft.
3. Make angular alignment by loosening motor from
mounting.
Fig. 49 — Evaporator-Fan Pulley Adjustment
To adjust belt tension:
1. Loosen fan-motor nuts.
2. Sizes 090, 102:
Slide motor mounting plate away from fan scroll for
proper belt tension (1/2-in. deflection with 8 to 10 lb.
of force).
Sizes 120, 150:
Slide motor mounting plate downward to tighten belt
tension (1/2-in. deflection with 8 to 10 lb. of force).
3. Tighten nuts.
4. Adjust bolt and nut on motor to secure motor in fixed
position.
5. Verify pulleys are in correct alignment.
Fig. 47 — Typical Belt-Drive Motor Mounting
for Sizes 090, 102
Table 8 — Fan Rpm at Motor Pulley Settings*
UNIT
580D
090†
090**
102†
120†
120††
150†
150††
0
840
935
935
935
1085
1080
1260
815
910
910
910
1060
1060
1220
*Approximate rpm shown.
†Indicates standard motor and drive.
1
790
885
885
885
1035
1035
1185
1
765
860
860
860
1010
1015
1155
2
740
835
835
835
985
990
1130
MOTOR PULLEY TURNS OPEN
2
3
3
715
690
665
810
785
760
810
785
760
810
785
760
960
935
910
970
950
925
1100
1075
1045
4
640
735
735
735
885
905
1015
**Indicates alternate drive.
††Indicates alternate motor and drive.
—26—
4
615
710
710
710
860
880
990
5
590
685
685
685
835
860
960
5
—
—
—
—
—
—
930
6
—
—
—
—
—
—
900
Table 9 — Motor Data
UNIT
580D
EVAPORATORFAN MOTOR
MAXIMUM
CONTINUOUS
BHP*
MAXIMUM
OPERATING
WATTS*
090
Std
2.40
2120
102
Std
2.40
2120
Std
2.40
2120
Alt
2.90
2615
Std
3.70
3313
Alt
5.25
4400
120
150
UNIT
VOLTAGE
MAXIMUM
AMP DRAW
208/230
460
575
208/230
460
575
208/230
460
575
208/230
460
575
208/230
460
575
208/230
460
575
6.7
3.0
3.0
6.7
3.0
3.0
6.7
3.0
3.0
8.6
3.9
3.9
12.2
5.5
5.5
17.3
8.5
8.5
LEGEND
Bhp — Brake Horsepower
*Extensive motor and electrical testing on these units ensures that the full horsepower and watts range
of the motors can be utilized with confidence. Using your fan motors up to the ratings shown in this
table will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
Table 10 — 580D090 Air Delivery, Vertical Discharge Units
AIRFLOW
(Cfm)
2200
2250
2350
2400
2500
2550
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3750
3800
3900
4000
4100
4200
4250
4300
Rpm
499
507
513
528
542
550
557
573
588
604
620
636
652
668
684
701
717
733
742
750
767
783
800
817
826
834
0.2
Watts
524
547
562
600
646
669
692
747
803
867
932
1006
1089
1173
1258
1361
1465
1569
1630
1683
1805
1927
2067
2197
2275
2343
Rpm
580
586
592
606
619
627
634
648
662
676
690
704
718
732
747
762
777
792
800
807
822
838
854
869
877
885
0.4
Watts
677
700
723
779
835
867
891
956
1022
1089
1165
1241
1327
1413
1508
1613
1718
1831
1892
1954
2076
2206
2343
2479
2554
2629
STANDARD BELT DRIVE MOTOR AND ALTERNATE BELT DRIVE
External Static Pressure (in. wg)
0.6
0.8
0.9
1.0
1.2
Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts
652
867
717
1056
748
1165
779
1275
839
1578
843
1604
658
891
722
1097
752
1199
783
1301
846
1630
663
916
727
1131
756
1224
786
1327
853
1665
674
965
738
1199
766
1301
795
1404
859
1718
686
1022
748
1258
777
1370
806
1491
864
1761
692
1056
754
1292
783
1413
812
1543
868
1805
698
1089
759
1327
787
1456
816
1587
878
1910
711
1156
770
1404
798
1534
827
1665
889
2023
723
1233
782
1473
809
1613
837
1753
848
1840
900
2128
737
1318
794
1560
821
1700
849
1927
910
2223
750
1404
806
1648
832
1788
844
1884
870
2023
920
2326
764
1499
818
1744
856
1980
882
2119
931
2428
778
1595
831
1849
844
1954
869
2093
894
2232
942
2537
793
1700
857
2076
882
2206
907
2343
954
2645
807
1805
871
2188
895
2326
919
2462
966
2751
821
1910
885
2317
908
2453
932
2587
978
2870
835
2023
849
2136
899
2445
922
2579
945
2718
990
2987
856
2197
907
2512
929
2653
952
2719
997
3055
863
2257
914
2571
936
2847
958
2854
1003
3114
877
2386
928
2702
950
2979
972
2987
1015
3244
891
2512
942
2839
964
3187
986
3121
1028
3373
905
2645
956
2971
978
3244
1000
3251
1042
3495
920
2783
970
3099
992
3258
1015
3380
1055
3614
928
2854
977
3165
999
3306
1022
3445
1062
3676
935
2925
984
3230
1006
3313
1029
3508
1069
3728
NOTES:
1. Boldface indicates a field-supplied drive is required. (See Note 8.)
2.
indicates an alternate drive is required.
3.
indicates a field-supplied motor and drive are required.
4.
indicates maximum usable watts of a factory-supplied motor.
5. Maximum usable watts input is 2120. Extensive motor and electrical testing
on these units ensures that the full range of the motor can be utilized with
confidence. Using your fan motors up to the wattage ratings shown will not
result in nuisance tripping or premature motor failure. Unit warranty will not be
affected. For additional information on motor performance, refer to Table 9.
—27—
Rpm
905
908
910
912
919
920
921
928
937
947
958
968
979
989
1000
1011
1022
1034
1040
1045
1057
1070
1082
1095
1102
1108
1.4
Watts
1954
1989
2015
2041
2093
2110
2136
2162
2266
2377
2504
2620
2735
2839
2948
3062
3165
3272
3333
3387
3495
3603
3713
3811
3860
3906
Rpm
951
955
959
967
971
974
976
983
986
993
1002
1012
1023
1034
1044
1054
1065
1076
1082
1087
1098
1110
1122
1134
1140
1147
1.6
Watts
2266
2283
2300
2360
2403
2428
2445
2529
2554
2637
2751
2870
3002
3121
3237
3340
3445
3544
3609
3643
3733
3820
3902
3971
4006
4036
6. Values include losses for filters, unit casing, and wet coils.
7. Use of a field-supplied motor may affect wire sizing. Contact your representative to verify.
8. Standard motor drive range: 590 to 840 rpm. Alternate motor drive range:
685 to 935 rpm. All other rpms require field-supplied drive.
9. To convert watts to bhp:
watts input x motor efficiency
bhp =
746
Motor efficiency = .80
Table 11 — 580D102 Air Delivery, Vertical Discharge Units
AIRFLOW
(Cfm)
2200
2250
2300
2400
2500
2550
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3750
3800
3900
4000
4100
4200
4250
4300
Rpm
499
507
513
528
542
550
557
573
588
604
620
636
652
668
684
701
717
733
742
750
767
783
800
817
826
834
0.2
Watts
524
547
562
600
646
669
692
747
803
867
932
1006
1089
1173
1258
1361
1465
1569
1630
1683
1805
1927
2067
2197
2275
2343
Rpm
580
586
592
606
619
627
634
648
662
676
690
704
718
732
747
762
777
792
800
807
822
838
854
869
877
885
0.4
Watts
677
700
723
779
835
867
891
956
1022
1089
1165
1241
1327
1413
1508
1613
1718
1831
1892
1954
2076
2206
2343
2479
2554
2629
Rpm
652
658
663
674
686
692
698
711
723
737
750
764
778
793
807
821
835
849
856
863
877
891
905
920
928
935
0.6
Watts
867
891
916
965
1022
1056
1089
1156
1233
1318
1404
1499
1595
1700
1805
1910
2023
2136
2197
2257
2386
2512
2645
2783
2854
2925
STANDARD BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.8
0.9
1.0
Rpm Watts Rpm Watts Rpm Watts
717
1056
748
1165
779
1275
722
1097
752
1199
783
1301
727
1131
756
1224
786
1327
738
1199
766
1301
795
1404
748
1258
777
1370
806
1491
754
1292
783
1413
812
1543
759
1327
787
1456
816
1587
770
1404
798
1534
827
1665
782
1473
809
1613
837
1753
794
1560
821
1700
848
1840
806
1648
832
1788
849
1927
818
1744
844
1884
870
2023
831
1849
856
1980
882
2119
844
1954
869
2093
894
2232
882
2206
907
2343
857
2076
871
2188
895
2326
919
2462
885
2317
908
2453
932
2587
899
2445
922
2579
945
2718
907
2512
929
2653
952
2719
914
2571
936
2847
958
2854
928
2702
930
2979
972
2987
942
2839
964
3187
986
3121
956
2971
978
3244
1000
3251
970
3099
992
3258
1015
3380
977
3165
999
3306
1022
3445
984
3230
1006
3313
1029
3508
NOTES:
1. Boldface indicates a field-supplied drive is required. (See Note 7.)
2.
indicates a field-supplied motor and drive are required.
3.
indicates maximum usable watts of a factory-supplied motor.
4. Maximum usable watts input is 2120. Extensive motor and electrical testing
on these units ensures that the full range of the motor can be utilized with
confidence. Using your fan motors up to the wattage ratings shown will not
result in nuisance tripping or premature motor failure. Unit warranty will not be
affected. For additional information on motor performance, refer to Table 9.
5. Values include losses for filters, unit casing, and wet coils.
Rpm
839
843
846
853
859
864
868
878
889
900
910
920
931
942
954
966
978
990
997
1003
1015
1028
1042
1055
1062
1069
1.2
Watts
1578
1604
1630
1665
1718
1761
1805
1910
2023
2128
2223
2326
2428
2537
2645
2751
2870
2987
3055
3114
3244
3373
3495
3614
3676
3728
Rpm
905
908
910
912
919
920
921
928
937
947
958
968
979
989
1000
1011
1022
1034
1040
1045
1057
1070
1082
1095
1102
1108
1.4
Watts
1954
1989
2015
2041
2093
2110
2136
2162
2266
2377
2504
2620
2735
2839
2948
3062
3165
3272
3333
3387
3495
3603
3713
3811
3860
3906
Rpm
951
955
959
967
971
974
976
983
986
993
1002
1012
1023
1034
1044
1054
1065
1076
1082
1087
1098
1110
1122
1134
1140
1147
1.6
Watts
2266
2283
2300
2360
2403
2428
2445
2529
2554
2637
2751
2870
3002
3121
3237
3340
3445
3544
3609
3643
3733
3820
3902
3971
4006
4036
6. Use of a field-supplied motor may affect wire sizing. Contact your representative to verify.
7. Standard motor drive range: 685 to 935 rpm. All other rpms require fieldsupplied drive.
8. To convert watts to bhp:
bhp =
watts input x motor efficiency
746
Motor efficiency = .80
Table 12 — 580D120 Air Delivery, Vertical Discharge Units
AIRFLOW
(Cfm)
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
4100
4200
4300
4400
4500
4600
4700
4800
4900
5000
Rpm
552
565
578
591
605
619
633
648
662
677
692
707
722
737
752
768
783
799
814
—
—
0.2
Watts
661
708
763
818
883
948
1022
1106
1190
1284
1378
1482
1595
1718
1840
1980
2119
2309
2469
—
—
Rpm
632
644
656
668
680
691
703
714
726
738
750
762
775
787
800
814
827
841
855
868
883
0.4
Watts
810
859
916
973
1047
1106
1173
1241
1310
1387
1473
1560
1656
1761
1875
1989
2110
2291
2424
2578
2735
Rpm
701
711
723
734
745
755
766
777
789
801
813
825
837
848
860
871
883
894
906
918
931
0.6
Watts
956
1014
1081
1148
1216
1284
1353
1430
1526
1613
1718
1814
1910
2006
2110
2265
2380
2496
2624
2754
2904
STANDARD AND ALTERNATE BELT DRIVE MOTORS
External Static Pressure (in. wg)
0.8
1.0
1.2
1.4
Rpm Watts Rpm Watts Rpm Watts Rpm Watts
761
1097
816 1216
871 1370
918 1482
722
1173
825 1292
879 1447
928 1478
937 1745
782
1241
835 1378
887 1517
946 1828
793
1310
845 1465
895 1595
953 1912
803
1387
856 1552
904 1691
961 1997
813
1465
867 1648
914 1796
970 2099
824
1543
877 1744
924 1901
980 2212
835
1639
887 1831
935 2015
946 2169
989 2326
846
1726
897 1927
956 2282 1000 2460
857
1823
908 2023
967 2397 1010 2587
868
1919
918 2119
929 2282
977 2505 1021 2726
878
2015
941 2397
987 2624 1032 2866
889
2119
900
2273
952 2523
999 2744 1042 3010
912
2397
962 2642 1008 2885 1054 3158
924
2523
973 2772 1019 3029 1067 3325
937
2661
983 2904 1030 3155 1079 3497
949
2800
994 3049 1042 3296 1092 3678
961
2952 1003 3186 1052 3440 1105 3866
972
3088 1013 3333 1063 3589 1119 4061
985
3226 1024 3489 1075 3741 1133 4263
NOTES:
1. Boldface indicates a field-supplied drive is required. (See Note 8.)
2.
6.
7.
indicates an alternate motor and drive is required.
3.
indicates a field-supplied motor and drive are required.
4.
indicates maximum usable watts of a factory-supplied motor.
5. Maximum usable watts input is 2120 with a standard motor and 2615 with an
alternate motor. Extensive motor and electrical testing on these units ensures
that the full range of the motor can be utilized with confidence. Using your fan
motors up to the wattage ratings shown will not result in nuisance tripping or
8.
9.
1.6
Watts
1736
1778
1861
1963
2074
2177
2282
2380
2487
2624
2763
2914
2971
3141
3276
3414
3555
3700
3848
3999
4154
Rpm
1010
1018
1026
1032
1041
1051
1061
1069
1077
1085
1093
1102
1110
1118
1126
1134
1142
1150
1158
1166
1174
1.8
Watts
1903
1971
2048
2099
2203
2318
2451
2587
2698
2819
2933
3097
3244
3396
3553
3715
3883
4056
4235
4419
4608
Rpm
1063
1070
1075
1080
1083
1090
1099
1109
1118
1127
1142
1155
1169
1185
1201
1219
1237
1257
1277
1299
1322
2.0
Watts
2221
2265
2318
2380
2389
2469
2596
2735
2895
3049
3187
3373
3576
3794
4029
4281
4548
4832
5133
5449
5782
premature motor failure. Unit warranty will not be affected. For additional
information on motor performance, refer to Table 9.
Values include losses for filters, unit casing, and wet coils.
Use of a field-supplied motor may affect wire sizing. Contact your representative to verify.
Standard motor drive range: 685 to 935 rpm. Alternate motor drive range:
835 to 1085 rpm. All other rpms require field-supplied drive.
To convert watts to bhp:
watts input x motor efficiency
bhp =
746
Motor efficiency = .80
—28—
Rpm
967
973
981
991
1000
1009
1017
1024
1033
1042
1052
1062
1072
1081
1091
1101
1111
1122
1132
1143
1154
Table 13 — 580D150 Air Delivery, Vertical Discharge Units
STANDARD AND ALTERNATE BELT DRIVE MOTORS
External Static Pressure (in. wg)
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts
3700
729 1259
790 1440
847 1615
902 1845
955 2044 1008 2272 1060 2494 1108 2719 1152 2919 1190 3092
3800
745 1340
805 1531
861 1700
915 1940
967 2149 1019 2378 1070 2620 1118 2846 1163 3074 1203 3267
3900
761 1423
820 1624
875 1802
928 2044
979 2272 1029 2494 1079 2737 1128 2983 1173 3221 1214 3433
4000
777 1514
836 1725
889 1914
941 2140
991 2387 1040 2620 1089 2873 1137 3120 1183 3368 1225 3590
4100
793 1615
851 1836
904 2027
955 2246 1004 2512 1052 2746 1100 3001 1147 3267 1193 3525 1236 3767
4200
810 1717
867 1948
918 2149
968 2361 1017 2638 1064 2882 1110 3138 1157 3414 1202 3674 1245 3943
4300
826 1828
883 2070
933 2272
982 2485 1030 2773 1076 3037 1121 3285 1167 3562 1212 3841 1255 4111
4400
842 1940
898 2193
948 2405
996 2611 1043 2901 1088 3184 1133 3442 1178 3720 1222 3999 1265 4279
4500
859 2061
914 2316
962 2539 1010 2755 1056 3037 1101 3341 1144 3590 1188 3878 1232 4167 1274 4456
4600
876 2184
930 2459
977 2683 1024 2910 1070 3175 1114 3498 1157 3767 1199 4046 1242 4344 1284 4642
4700
892 2316
945 2593
992 2837 1039 3065 1083 3322 1126 3655 1169 3943 1210 4223 1252 4521 1294 4828
4800
—
—
909 2468
961 2737 1008 3001 1053 3230 1097 3479 1140 3822 1181 4130 1222 4400 1263 4707
4900
—
—
926 2611
977 2891 1024 3166 1068 3405 1111 3646 1153 3971 1194 4307 1234 4605 1274 4893
5000
—
—
942 2773
993 3047 1039 3341 1080 3581 1125 3822 1166 4139 1207 4493 1247 4800 1286 5097
5100
—
—
—
—
959 2937 1009 3221 1055 3516 1097 3767 1139 4018 1180 4316 1220 4689 1259 5004
5200
—
—
—
—
976 3101 1025 3387 1071 3702 1112 3962 1153 4214 1194 4503 1233 4874 1272 5207
5300
—
—
—
—
—
—
993 3285 1041 3572 1086 3897 1127 4158 1168 4428 1208 4698 1246 5060
5400
—
—
—
—
—
—
—
—
1010 3470 1057 3757 1102 4093 1142 4372 1182 4642 1221 4902
5500
—
—
—
—
—
—
—
—
1027 3655 1073 3953 1118 4298 1157 4586 1197 4856 1235 5115
5600
1043 3860 1090 4158 1133 4512 1173 4810 1211 5087
—
—
—
—
—
—
—
—
—
—
5700
1060 4065 1106 4363 1149 4726 1189 5032
—
—
—
—
—
—
—
—
—
—
—
—
5800
1077 4279 1122 4586 1165 4939
—
—
—
—
—
—
—
—
—
—
—
—
—
—
5900
1094 4503 1139 4810 1181 5170
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6000
1111 4726 1155 5032
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6100
1128 4967
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6200
1145 5207
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
NOTES:
6. Values include losses for filters, unit casing, and wet coils.
7. Use of a field-supplied motor may affect wire sizing. Contact your representa1. Boldface indicates a field-supplied drive is required. (See Note 8.)
tive to verify.
2.
indicates an alternate motor and drive are required.
8. Standard motor drive range: 860 to 1080 rpm. Alternate motor drive range:
900 to 1260 rpm. All other rpms require field-supplied drive.
3.
indicates a field-supplied motor and drive are required.
9. To convert watts to bhp:
4.
indicates maximum usable watts of a factory-supplied motor.
watts input x motor efficiency
5. Maximum usable watts input is 3775 with a standard motor and 4400 with an
bhp =
746
alternate motor. Extensive motor and electrical testing on these units ensures
that the full range of the motor can be utilized with confidence. Using your fan
Motor efficiency = .85 (Std)
motors up to the wattage ratings shown will not result in nuisance tripping or
.87 (Alt)
premature motor failure. Unit warranty will not be affected. For additional
information on motor performance, refer to Table 9.
AIRFLOW
(Cfm)
Table 14 — 580D090 Air Delivery, Horizontal Discharge Units
STANDARD BELT DRIVE MOTOR AND ALTERNATE BELT DRIVE
External Static Pressure (in. wg)
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
Rpm
Watts
Rpm
Watts
Rpm
Watts
Rpm
Watts
Rpm
Watts
Rpm
Watts
Rpm
Watts
Rpm
Watts
2200
506
539
586
692
898
1954
935
2275
656
875
718
1064
776
1275
838
1578
2250
514
562
841
1604
902
1989
939
2292
593
723
662
907
724
1097
781
1318
2300
521
577
843
1621
905
2015
943
2309
600
747
668
932
730
1131
786
1335
2400
536
623
849
1665
910
2041
952
2411
613
795
680
989
741
1199
796
1413
2500
551
669
859
1735
912
2050
963
2470
626
859
693
1056
753
1275
808
1499
2550
559
692
864
1779
915
2067
968
2479
634
891
700
1089
759
1318
814
1543
2600
567
716
869
1823
918
2093
973
2487
641
916
706
1123
764
1353
819
1587
2700
582
779
880
1919
927
2180
976
2495
655
981
719
1199
776
1430
831
1674
2800
842
1770
892
2023
938
2275
983
2562
598
835
670
1056
732
1275
789
1517
2900
854
1866
903
2136
949
2386
993
2653
614
899
684
1123
745
1361
802
1604
3000
866
1971
915
2240
961
2504
1003
2767
630
973
690
1207
759
1147
815
1700
3100
878
2076
926
2352
972
2629
1016
2886
646
1047
714
1292
773
1543
828
1805
3200
841
1910
891
2188
938
2470
983
2743
1026
3002
662
1131
729
1378
787
1648
3300
854
2023
904
2300
950
2587
995
2870
—
—
679
1216
744
1473
801
1753
3400
867
2136
917
2420
963
2710
1007
2987
—
—
695
1310
759
1578
816
1858
3500
881
2257
930
2546
976
2831
—
—
—
—
712
1413
774
1683
830
1971
3600
845
2093
895
2386
943
2670
988
2956
—
—
—
—
729
1517
790
1796
3700
860
2223
909
2521
956
2807
—
—
—
—
—
—
745
1630
805
1919
3750
868
2283
917
2587
963
2870
—
—
—
—
—
—
754
1691
813
1980
3800
875
2343
924
2653
970
2933
—
—
—
—
—
—
762
1753
821
2041
3900
836
2171
890
2479
938
2783
—
—
—
—
—
—
—
—
779
1875
4000
852
2300
905
2612
953
2925
—
—
—
—
—
—
—
—
796
2006
4100
813
2136
868
2445
920
2751
—
—
—
—
—
—
—
—
—
—
4200
830
2283
884
2587
935
2894
—
—
—
—
—
—
—
—
—
—
4250
839
2360
890
2661
—
—
—
—
—
—
—
—
—
—
—
—
4300
847
2428
900
2735
—
—
—
—
—
—
—
—
—
—
—
—
NOTES:
result in nuisance tripping or premature motor failure. Unit warranty will not be
affected. For additional information on motor performance, refer to Table 9.
1. Boldface indicates a field-supplied drive is required. (See Note 8.)
6. Values include losses for filters, unit casing, and wet coils.
2.
indicates an alternate drive is required.
7. Use of a field-supplied motor may affect wire sizing. Contact your representative to verify.
3.
indicates a field-supplied motor and drive are required.
8. Standard motor drive range: 590 to 840 rpm. Alternate motor drive range:
4.
indicates maximum usable watts of a factory-supplied motor.
685 to 935 rpm. All other rpms require field-supplied drive.
5. Maximum usable watts input is 2120. Extensive motor and electrical testing
9. To convert watts to bhp:
on these units ensures that the full range of the motor can be utilized with
watts input x motor efficiency
bhp =
confidence. Using your fan motors up to the wattage ratings shown will not
746
Motor efficiency = .80
AIRFLOW
(Cfm)
—29—
Table 15 — 580D102 Air Delivery, Horizontal Discharge Units
AIRFLOW
(Cfm)
2200
2250
2300
2400
2500
2550
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3750
3800
3900
4000
4100
4200
4250
4300
Rpm
506
514
521
536
551
559
567
582
598
614
630
646
662
679
695
712
729
745
754
762
779
796
813
830
839
847
0.2
Watts
539
562
577
623
669
692
716
779
835
899
973
1047
1131
1216
1310
1413
1517
1630
1691
1753
1875
2006
2136
2283
2360
2428
Rpm
586
593
600
613
626
634
641
655
670
684
690
714
729
744
759
774
790
805
813
821
836
852
868
884
890
900
0.4
Watts
692
723
747
795
859
891
916
981
1056
1123
1207
1292
1378
1473
1578
1683
1796
1919
1980
2041
2171
2300
2445
2587
2661
2735
Rpm
656
662
668
680
693
700
706
719
732
745
759
773
787
801
816
830
845
860
868
875
890
905
920
935
—
—
0.6
Watts
875
907
932
989
1056
1089
1123
1199
1275
1361
1417
1543
1648
1753
1858
1971
2093
2223
2283
2343
2479
2612
2751
2894
—
—
STANDARD BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.8
1.0
Rpm
Watts
Rpm
Watts
718
1064
776
1275
724
1097
781
1318
730
1131
786
1335
741
1199
796
1413
753
1275
808
1499
759
1318
814
1543
764
1353
819
1587
776
1430
831
1674
789
1517
842
1770
802
1604
854
1866
815
1700
866
1971
828
1805
878
2076
891
2188
841
1910
854
2023
904
2300
867
2136
917
2420
881
2257
930
2546
895
2386
943
2670
909
2521
956
2807
917
2587
963
2870
924
2653
970
2933
938
2783
—
—
953
2925
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
NOTES:
1. Boldface indicates a field-supplied drive is required. (See Note 7.)
2.
indicates a field-supplied motor and drive are required.
3.
indicates maximum usable watts of a factory-supplied motor.
4. Maximum usable watts input is 2120. Extensive motor and electrical testing
on these units ensures that the full range of the motor can be utilized with
confidence. Using your fan motors up to the wattage ratings shown will not
result in nuisance tripping or premature motor failure. Unit warranty will not be
affected. For additional information on motor performance, refer to Table 9.
Rpm
838
841
843
849
859
864
869
880
892
903
915
926
938
950
963
976
988
—
—
—
—
—
—
—
—
—
1.2
Watts
1578
1604
1621
1665
1735
1779
1823
1919
2023
2136
2240
2352
2470
2587
2710
2831
2956
—
—
—
—
—
—
—
—
—
Rpm
898
902
905
910
912
915
918
927
938
949
961
972
983
995
1007
—
—
—
—
—
—
—
—
—
—
—
1.4
Watts
1954
1989
2015
2041
2050
2067
2093
2180
2275
2386
2504
2629
2743
2870
2987
—
—
—
—
—
—
—
—
—
—
—
Rpm
935
939
943
952
963
968
973
976
983
993
1003
1016
1026
—
—
—
—
—
—
—
—
—
—
—
—
—
1.6
Watts
2275
2292
2309
2411
2470
2479
2487
2495
2562
2653
2767
2886
3002
—
—
—
—
—
—
—
—
—
—
—
—
—
5. Values include losses for filters, unit casing, and wet coils.
6. Use of a field-supplied motor may affect wire sizing. Contact your representative to verify.
7. Standard motor drive range: 685 to 935 rpm. All other rpms require fieldsupplied drive.
8. To convert watts to bhp:
watts input x motor efficiency
bhp =
746
Motor efficiency = .80
Table 16 — 580D120 Air Delivery, Horizontal Discharge Units
AIRFLOW
(Cfm)
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
4100
4200
4300
4400
4500
4600
4700
4800
4900
5000
0.2
0.4
0.6
Rpm Watts Rpm Watts Rpm Watts
592
723 661
859 722
989
607
779 676
924 734 1056
622
835 690
989 746 1123
638
899 705 1056 759 1190
653
965 719 1131 772 1275
669 1039 733 1207 786 1361
684 1114 747 1284 800 1456
700 1190 760 1370 814 1552
715 1275 774 1456 828 1648
731 1370 787 1543 843 1753
747 1456 801 1639 857 1858
763 1560 816 1744 872 1971
778 1665 831 1884 886 2084
794 1770 846 1971 900 2256
810 1884 861 2093 913 2380
826 2006 876 2273 927 2505
842 2177 892 2406 940 2633
858 2300 907 2551 954 2782
874 2433 922 2698 968 2933
890 2578 938 2857 984 3063
906 2735 953 3020 998 3216
STANDARD AND ALTERNATE BELT DRIVE MOTORS
External Static Pressure (in. wg)
0.8
1.0
1.2
1.4
Rpm Watts Rpm Watts Rpm Watts Rpm Watts
779 1131
829 1267
880 1404
924 1534
935 1695
791 1199
840 1344
890 1491
946 1786
803 1275
852 1422
900 1569
957 1878
815 1353
864 1508
910 1665
967 1971
826 1439
876 1604
921 1753
976 2074
838 1526
888 1691
933 1858
945 2014
986 2177
850 1613
900 1796
957 2117
998 2291
863 1700
912 1892
969 2230 1010 2406
875 1805
924 1997
936 2151
981 2344 1022 2533
888 1910
948 2265
993 2469 1034 2670
902 2032
916 2203
960 2380 1005 2596 1046 2810
929 2326
972 2505 1016 2735 1058 2952
943 2460
985 2642 1028 2866 1072 3117
958 2605
999 2791 1040 3010 1088 3276
973 2744 1012 2952 1053 3167 1099 3440
987 2904 1024 3117 1065 3321 1113 3611
1002 3068 1037 3275 1077 3481 1127 3789
1018 3232 1050 3439 1089 3646 1142 3973
1034 3406 1063 3609 1101 3816 1157 4163
1050 3588 1077 3785 1114 3991 1173 4360
NOTES:
1. Boldface indicates a field-supplied drive is required. (See Note 8.)
2.
indicates an alternate motor and drive are required.
6.
7.
3.
indicates a field-supplied motor and drive are required.
8.
4.
indicates maximum usable watts of a factory-supplied motor.
5. Maximum usable watts input is 2120 with a standard motor and 2615 with an
alternate motor. Extensive motor and electrical testing on these units ensures
that the full range of the motor can be utilized with confidence. Using your fan
motors up to the wattage ratings shown will not result in nuisance tripping or
—30—
9.
1.6
Rpm Watts
970 1736
977 1828
987 1920
998 2022
1009 2125
1020 2238
1030 2353
1039 2469
1049 2587
1060 2726
1072 2866
1084 3010
1094 3155
1106 3311
1117 3473
1128 3642
1140 3817
1152 3997
1163 4184
1175 4377
1187 4576
1.8
Rpm Watts
1019 1828
1026 1971
1029 2065
1037 2169
1047 2282
1058 2397
1069 2523
1081 2651
1091 2782
1100 2923
1110 3068
1121 3213
1132 3369
1142 3531
1153 3698
1163 3871
1174 4049
1184 4233
1195 4422
1205 4617
1216 4818
2.0
Rpm Watts
1066 2082
1070 2203
1075 2265
1082 2326
1087 2433
1095 2560
1106 2688
1117 2829
1128 2981
1143 3144
1158 3332
1174 3535
1192 3753
1211 3987
1231 4235
1253 4498
1276 4775
1300 5068
1325 5376
1352 5698
1381 6036
premature motor failure. Unit warranty will not be affected. For additional
information on motor performance, refer to Table 9.
Values include losses for filters, unit casing, and wet coils.
Use of a field-supplied motor may affect wire sizing. Contact your representative to verify.
Standard motor drive range: 685 to 935 rpm. Alternate motor drive range:
835 to 1085 rpm. All other rpms require field-supplied drive.
To convert watts to bhp:
watts input x motor efficiency
bhp =
746
Motor efficiency = .80
Table 17 — 580D150 Air Delivery, Horizontal Discharge Units
STANDARD AND ALTERNATE BELT DRIVE MOTORS
External Static Pressure (in. wg)
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts Rpm Watts
3700
677 1129
748 1316
810 1498
869 1700
928 1940
984 2166 1036 2387 1080 2548 1114 2737 1135 2828
3800
691 1194
761 1390
822 1582
880 1776
937 2035
993 2272 1046 2503 1092 2719 1129 2901 1156 3028
3900
705 1267
773 1473
834 1674
891 1862
947 2131 1002 2370 1055 2620 1102 2855 1143 3056 1174 3212
4000
720 1349
786 1548
847 1768
902 1957
957 2228 1011 2485 1064 2737 1112 2983 1155 3212 1190 3405
4100
734 1423
800 1641
860 1871
914 2061
967 2316 1021 2593 1072 2855 1121 3120 1165 3368 1203 3581
4200
749 1506
813 1725
873 1974
926 2175
978 2414 1030 2710 1081 2983 1130 3258 1175 3516 1215 3757
4300
764 1598
826 1828
886 2079
938 2290
989 2521 1040 2837 1090 3111 1139 3396 1185 3664 1226 3925
4400
779 1691
840 1931
899 2193
951 2414 1000 2638 1050 2955 1100 3248 1148 3535 1194 3822 1236 4093
4500
793 1785
854 2035
912 2307
963 2548 1012 2755 1061 3065 1109 3387 1157 3674 1203 3981 1246 4260
4600
808 1888
868 2158
925 2459
975 2674 1024 2901 1071 3184 1119 3525 1166 3832 1212 4130 1255 4437
4700
822 2000
882 2281
937 2548
988 2819 1036 3056 1082 3313 1129 3674 1175 3990 1221 4298 1264 4605
4800
837 2114
896 2414
950 2674 1001 2964 1048 3212 1093 3461 1139 3813 1185 4148 1230 4456 1273 4782
4900
852 2237
910 2548
963 2810 1014 3111 1060 3368 1105 3609 1150 3943 1194 4307 1239 4633 1282 4958
5000
867 2361
924 2683
977 2946 1027 3267 1073 3535 1117 3776 1161 4093 1204 4475 1248 4810 1291 5133
5100
—
—
882 2485
938 2828
990 3092 1040 3424 1085 3702 1129 3962 1172 4251 1214 4642 1257 4995
5200
—
—
896 2629
952 2973 1003 3248 1053 3590 1098 3869 1141 4148 1183 4419 1225 4791 1267 5170
5300
—
—
—
—
911 2773
967 3129 1017 3405 1066 3757 1111 4055 1153 4335 1194 4596 1236 4958
5400
—
—
—
—
926 2919
981 3294 1030 3572 1079 3916 1124 4270 1166 4531 1206 4791 1247 5124
5500
—
—
—
—
—
—
940 3074
995 3461 1044 3748 1092 4093 1137 4437 1178 4726 1218 4958
5600
—
—
—
—
—
—
955 3239 1010 3627 1058 3943 1105 4270 1150 4633 1190 4930 1230 5124
5700
—
—
—
—
—
—
—
—
970 3405 1024 3804 1072 4139 1118 4456 1163 4837 1203 5143
5800
—
—
—
—
—
—
—
—
—
—
985 3581 1039 3981 1086 4335 1131 4652 1176 5041
5900
—
—
—
—
—
—
—
—
—
—
—
—
1000 3757 1053 4167 1100 4540 1144 4856
6000
1015 3953 1068 4363 1114 4754 1158 5060
—
—
—
—
—
—
—
—
—
—
—
—
6100
1030 4139 1083 4558 1128 4967
—
—
—
—
—
—
—
—
—
—
—
—
—
—
6200
1046 4344 1097 4763 1142 5180
—
—
—
—
—
—
—
—
—
—
—
—
—
—
NOTES:
6. Values include losses for filters, unit casing, and wet coils.
7. Use of a field-supplied motor may affect wire sizing. Contact your representa1. Boldface indicates a field-supplied drive is required. (See Note 8.)
tive to verify.
2.
indicates an alternate motor and drive are required.
8. Standard motor drive range: 860 to 1080 rpm. Alternate motor drive range:
900 to 1260 rpm. All other rpms require field-supplied drive.
3.
indicates a field-supplied motor and drive are required.
9. To convert watts to bhp:
4.
indicates maximum usable watts of a factory-supplied motor.
watts input x motor efficiency
bhp =
5. Maximum usable watts input is 3775 with a standard motor and 4400 with an
746
alternate motor. Extensive motor and electrical testing on these units ensures
Motor efficiency = .80 (Std)
that the full range of the motor can be utilized with confidence. Using your fan
.87 (Alt)
motors up to the wattage ratings shown will not result in nuisance tripping or
premature motor failure. Unit warranty will not be affected. For additional
information on motor performance, refer to Table 9.
AIRFLOW
(Cfm)
B. Ventilation Sequence
If unit is equipped with an Durablade economizer or twoposition damper, the damper will open to the minimum position whenever the evaporator fan runs.
The damper motor will be energized with 24-vdc power and
damper will drive open until SW3 on the damper is deactivated. The damper motor will stop and damper will remain
in the minimum ventilation position until the evaporator fan
is shut off. When the evaporator fan is shut off, the damper
motor is again energized and the damper runs closed until
SW2 is activated and the damper motor turns off.
CARE AND MAINTENANCE
To ensure continuing high performance and to minimize the
possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This combination heating/cooling unit should be inspected at least once
each year by a qualified service person.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
The minimum maintenance requirements for this equipment
are as follows:
1. Inspect air filters each month. Clean or replace when
necessary.
2. Inspect cooling coil, drain pan, and condensate drain each
cooling season for cleanliness. Clean when necessary.
3. Inspect blower motor and wheel for cleanliness.
Inspect belts, and belt tension each heating and cooling season. Clean, adjust or replace when necessary.
4. Check electrical connections for tightness and controls for proper operation each heating and cooling
season. Service when necessary.
5. Check and inspect heating section before each heating season. Clean and adjust when necessary.
6. Check and clean vent screen if needed.
WARNING: The ability to perform maintenance on
this equipment properly requires certain expertise,
mechanical skills, tools, and equipment. If you do not
possess these, do not attempt to perform any maintenance on this equipment other than those procedures
recommended in the User’s Manual. FAILURE TO
HEED THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY AND POSSIBLE DAMAGE TO THIS EQUIPMENT.
WARNING: Failure to follow these warnings could
result in serious personal injury:
1. Turn off gas supply, then turn off electrical
power to the unit before performing any maintenance or service on the unit.
2. Use extreme caution when removing panels and
parts. As with any mechanical equipment, personal injury can result from sharp edges, etc.
3. Never place anything combustible either on, or
in contact with, the unit.
4. Should overheating occur, or the gas supply fail to
shut off, shut off the external main manual gas
valve to the unit, then shut off the electrical supply.
—31—
4. Remove screws securing coil to center post.
5. Remove fastener holding coil sections together at
return end of condenser coil. Carefully separate the
outer coil section 3 to 4 in. from the inner coil section.
See Fig. 52.
6. Use a water hose or other suitable equipment to flush
down between the 2 coil sections to remove dirt and
debris. Clean the outer surfaces with a stiff brush in
the normal manner.
7. Secure inner and outer coil rows together with a fieldsupplied fastener.
8. Reposition the outer coil section and remove the coil
corner post from between the top panel and center
post.
I. AIR FILTER
CAUTION: Never operate the unit without a suitable air filter in the return-air duct system. Always
replace the filter with the same dimensional size and
type as originally installed. See Table 1 for recommended filter sizes.
Inspect air filters at least once each month, and replace
(throwaway-type) or clean (cleanable-type) at least twice
during each heating and cooling season and whenever the filters become clogged with dust and lint.
Replace filters when necessary with the same dimensional
size and type as originally provided.
SERVICE
9. Reinstall the coil corner post and replace all screws.
CAUTION: When servicing unit, shut off all electrical power to unit to avoid shock hazard or injury
from rotating parts.
II. LUBRICATION
I. CLEANING
Inspect unit interior at the beginning of each heating and
cooling season or more frequently as operating conditions
require.
A. Evaporator Coil
1. Turn unit power off and tag disconnect. Remove
evaporator coil access panel.
2. If economizer is installed, remove economizer by disconnecting Molex plug and economizer mounting
screws. Refer to Accessory Economizer Installation
Instructions or Optional Economizer Installation sections on pages 13 and 16 for further details.
3. Slide filters out of unit.
4. Clean coil using a commercial coil cleaner or dishwasher detergent in a pressurized spray canister.
Wash both sides of coil and flush with clean water.
For best results, backflush toward return-air section
to remove foreign material. Caution should be taken
as to not overflow the evaporator drain condensate
pan.
5. Flush condensate pan after completion.
A. Compressors
Each compressor is charged with correct amount of oil at the
factory.
B. Fan-Motor Bearings
Fan-motor bearings are of the permanently lubricated type.
No further lubrication is required. No lubrication of condenser-or evaporator-fan motors is required.
III. CONDENSER FAN ADJUSTMENT (Fig. 53)
1. Shut off unit power supply and tag disconnect.
2. Remove condenser-fan assembly (grille, motor, motor
cover, and fan).
3. Loosen fan hub setscrews.
4. Adjust fan height as shown in Fig. 53.
5. Tighten setscrews.
6. Replace condenser-fan assembly.
IV. BLOWER BELT ADJUSTMENT
Inspect blower belt for wear and proper belt tension, and
pulley alignment at the beginning of each heating and air
conditioning season.
6. Reinstall economizer and filters.
7. Reconnect wiring.
8. Replace access panels.
B. Condenser Coil
Inspect coil monthly. Clean condenser coil annually, and as
required by location and outdoor-air conditions.
One-Row Coils
Wash coil with commercial cleaner. Clean outer surfaces
with a stiff brush in the normal manner. It is not necessary
to remove top panel.
Two-Row Coils
Clean coil as follows:
1. Turn off unit power and tag disconnect.
2. Remove top panel screws on condenser end of unit.
3. Remove condenser coil corner post. See Fig. 50. To
hold top panel open, place coil corner post between
top panel and center post. See Fig. 51.
—32—
Fig. 50 — Cleaning Condenser Coil
V. REFRIGERANT CHARGE
A. Checking and Adjustment Refrigerant Charge
The refrigerant system is fully charged with R-22 refrigerant, tested, and factory-sealed. Unit must operate in Cooling
mode a minimum of 10 minutes before checking charge.
NOTE: Adjustment of the refrigerant charge is not required
unless the unit is suspected of not having the proper R-22
charge.
A superheat charging chart is attached to the outside of the
service access panel. The chart includes the required suction
line temperature at given suction line pressures and outdoor
ambient temperatures.
An accurate superheat, thermocouple- or thermistor-type
thermometer and a gage manifold are required when using
the superheat charging method for evaluating the unit
charge. Do not use mercury or small dial-type thermosmeters
because they are not adequate for this type of measurement.
Fig. 52 — Separating Coil Sections
CAUTION: When evaluating the refrigerant
charge, an indicated adjustment to the specified factory charge must always be very minimal. If a substantial adjustment is indicated, an abnormal condition
exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils.
Proceed as follows:
1. Remove caps from low- and high-pressure service
fittings.
2. Using hoses with valve core depressors, attach
low- and high-pressure gage hoses to low- and highpressure service fittings, respectively.
3. Start unit in Cooling mode and let unit run 10 minutes until system pressures stabilize.
4. Measure and record the following:
a. Outdoor ambient-air temperature (F db).
b. Evaporator inlet-air temperature (F db).
c. Suction-tube temperature (F) at low-side service
fitting.
d. Suction (low-side) pressure (psig).
5. Using “Cooling Charging Charts” compare outdoorair temperature (F db) with the suction line pressure
(psig) to determine desired system operating suction
line temperature. See Fig. 54-57.
6. Compare actual suction-tube temperature with
desired suction-tube temperature. Using a tolerance
of ±3° F, add refrigerant if actual temperature is
more than 3° F higher than proper suction-tube temperature, or remove refrigerant if actual temperature
is more than 3° F lower than required suction-tube
temperature.
UNIT
VOLTAGE
208/230 v
460 and 575 v
FAN HEIGHT
‘‘A’’ (in.)
2.75
3.50
Fig. 53 — Condenser Fan Adjustment
B. To Use Cooling Charging Charts
This method is to be used in Cooling mode only.
Take the outdoor ambient temperature and read the suction
pressure gage. Refer to appropriate chart to determine what
suction temperature should be. If suction temperature is
high, add refrigerant. If suction temperature is low, carefully
reclaim some of the charge. Recheck the suction pressure as
charge is adjusted.
EXAMPLE: (Fig. 57, Circuit No. 1)
Outdoor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 F
Suction Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 psig
Suction Temperature should be . . . . . . . . . . . . . . . . . . . 58 F
(Suction Temperature may vary ± 5 F.)
C. Refrigerant Leaks
Proceed as follows to repair a refrigerant leak and to charge
the unit:
1. Locate leak and ensure that refrigerant system pressure has been relieved.
2. Repair leak following accepted practices.
NOTE: Install a filter drier in the liquid line whenever the
system has been opened for repair. Install filter drier where
strainer assembly is located.
3. Add a small charge of R-22 refrigerant vapor to system and leak-test unit.
4. Evacuate refrigerant system to 500 microns if additional leaks are not found.
5. Charge unit with R-22 refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit rating
plate for required charge. Be sure to add extra refrigerant to compensate for internal volume of filter drier.
Fig. 51 — Propping Up Top Panel
—33—
Fig. 54 — Cooling Charging Chart; 580D090
Fig. 55 — Cooling Charging Chart; 580D102
—34—
CIRCUIT NO. 2
CIRCUIT NO. 1
Fig. 56 — Cooling Charging Chart; 580D120
Fig. 57 — Cooling Charging Chart; 580D150
—35—
Table 18 — LED Error Code Description*
VI. MAIN BURNERS
At the beginning of each heating season, inspect for deterioration or blockage due to corrosion or other causes. Observe
the main burner flames and adjust if necessary.
LED INDICATION
ON
OFF
1 Flash†
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
VII. FLUE GAS PASSAGEWAYS
To inspect the flue collector box and upper areas of the heat
exchanger:
1. Remove the combustion blower wheel and motor
assembly according to directions in Combustion-Air
Blower section below.
2. Remove the flue cover to inspect the heat exchanger.
3. Clean all surfaces as required using a wire brush.
VIII. COMBUSTION-AIR BLOWER
Clean seasonally to assure proper airflow and heating efficiency. Inspect blower wheel every fall and periodically during heating season. For the first heating season, inspect
blower wheel bimonthly to determine proper cleaning
frequency.
To inspect blower wheel, shine a flashlight into draft hood
opening. If cleaning is required, remove motor and wheel as
follows:
1. Slide burner access panel out.
ERROR CODE DESCRIPTION
Normal Operation
Hardware Failure
Evaporator Fan On/Off Delay Modified
Limit Switch Fault
Flame Sense Fault
4 Consecutive Limit Switch Faults
Ignition Lockout Fault
Induced-Draft Motor Fault
Rollout Switch Fault
Internal Control Fault
LEGEND
LED — Light-Emitting Diode
*A 3 second pause exists between LED error code flashes. If more
than one error code exists, all applicable codes will be displayed in
numerical sequence.
†Indicates a code that is not an error. The unit will continue to operate
when this code is displayed.
NOTE: Refer to Tables 19-22 for additional troubleshooting information.
A. Removal and Replacement of Gas Train (See Fig. 58)
CAUTION: When servicing gas train, do not hit or
plug orifice spuds.
2. Remove the 6 screws that attach induced-draft motor
housing to vestibule plate (Fig. 58).
3. The blower wheel can be cleaned at this point. If
additional cleaning is required, continue with Steps 4
and 5.
4. To remove blower, remove 2 setscrews.
1. Shut off manual gas valve.
2. Shut off power to unit and tag disconnect.
3. Slide out burner compartment side panel.
4. Disconnect gas piping at unit gas valve.
5. To remove motor, remove 4 screws that hold blower
housing to motor mounting plate. Remove the motor
cooling fan by removing one setscrew. Then remove
nuts that hold motor to mounting plate.
6. To reinstall, reverse the procedure outlined above.
5. Remove wires connected to gas valve. Mark each
wire.
6. Remove wires from ignitor and sensor.
7. Remove the two screws that attach the burner rack to
the vestibule plate.
8. Slide the burner tray out of the unit (Fig. 45).
IX. LIMIT SWITCH
Remove blower access panel (see Fig. 3). Limit switch is
located on the fan deck.
9. To reinstall, reverse the procedure outlined above.
B. Cleaning and Adjustment
X. BURNER IGNITION
1. Remove burner rack from unit as described above.
2. Inspect burners and if dirty, remove burners from
rack.
3. Using a soft brush, clean burners and cross-over port
as required.
4. Adjust spark gap. See Fig. 59.
Unit is equipped with a direct-spark ignition, 100% lockout
system. Integrated Gas Unit Controller (IGC) is located in
the control box (Fig. 15). The IGC contains a self-diagnostic
LED (light-emitting diode). During service, refer to the label
on the control box cover or Table 18 for an explanation of
LED error code descriptions.
A single LED on the IGC provides a visual display of operational or sequential problems when the power supply is
uninterrupted. When a break in power occurs, the IGC
will be reset (resulting in a loss of fault history. The indoor
(evaporator) fan ON/OFF times will also be reset. The LED
error code can be observed through the viewport.
If lockout occurs, unit may be reset by interrupting the
power supply to unit for at least 5 seconds.
5. Reinstall burners on rack.
6. Reinstall burner rack as described above.
XI. REPLACEMENT PARTS
A complete list of replacement parts may be obtained from
your distributor upon request.
—36—
ROLLOUT
SWITCH
FLUE VENT
BURNER
SECTION
VESTIBULE
PLATE
INDUCEDDRAFT
MOTOR
BLOWER
HOUSING
MANIFOLD
PRESSURE
TAP
GAS VALVE
Fig. 58 — Burner Section Details
125,000 BTUH INPUT
580D090,102
125,000/180,000 BTUH INPUT
580D090,102,120
180,000/220,000 BTUH INPUT
200,000/250,000 BTUH INPUT
580D090,102,120,150
Fig. 59 — Spark Gap Adjustment
—37—
TROUBLESHOOTING
Table 19 — Cooling Service Analysis
PROBLEM
Compressor and
condenser fan will not
start.
Compressor will not start
but condenser fan runs.
Compressor cycles
(other than normally
satisfying thermostat).
Compressor makes
excessive noise
(580D150 scroll only).
Compressor operates
continuously.
Excessive head pressure.
Head pressure too low.
Excessive suction
pressure.
Suction pressure too low.
Compressor no. 2 will
not run.
Evaporator fan
will not shut off.
CAUSE
Power failure.
Fuse blown or circuit breaker tripped.
Defective thermostat, contactor, transformer
or control relay.
Insufficient line voltage.
Incorrect or faulty wiring.
Thermostat setting too high.
Faulty wiring or loose connections in
compressor circuit.
Compressor motor burned out, seized,
or internal overload open.
Defective run/start capacitor, overload,
start relay.
One leg of 3-phase power dead.
Refrigerant overcharge or undercharge.
Defective compressor.
Insufficient line voltage.
Blocked condenser.
Defective run/start capacitor, overload, or
start relay.
Defective thermostat.
Faulty condenser-fan motor or capacitor.
Restriction in refrigerant system.
Compressor rotating in wrong direction.
Dirty air filter.
Unit undersized for load.
Thermostat set too low.
Low refrigerant charge.
Leaking valves in compressor.
Air in system.
REMEDY
Call power company.
Replace fuse or reset circuit breaker.
Replace component.
Determine cause and correct.
Check wiring diagram and rewire correctly.
Lower thermostat setting below room
temperature.
Check wiring and repair or replace.
Determine cause. Replace compressor.
Determine cause and replace.
Replace fuse or reset circuit breaker.
Determine cause.
Recover refrigerant, evacuate system, and
recharge to nameplate specifications.
Replace and determine cause.
Determine cause and correct.
Determine cause and correct.
Determine cause and replace.
Replace thermostat.
Replace.
Locate restriction and remove.
Reverse the 3-phase power leads as described
on page 24.
Temperature too low in conditioned area.
Field-installed filter drier restricted.
Unit in economizer mode.
Replace filter.
Decrease load or increase unit size.
Reset thermostat.
Locate leak; repair and recharge.
Replace compressor.
Recover refrigerant, evacuate system, and
recharge.
Clean coil or remove restriction.
Replace filter.
Clean coil.
Recover excess refrigerant.
Recover refrigerant, evacuate system, and
recharge.
Determine cause and correct.
Check for leaks; repair and recharge.
Replace compressor.
Remove restriction.
Check for source and eliminate.
Replace compressor.
Recover excess refrigerant.
Replace filter.
Check for leaks; repair and recharge.
Remove source of restriction.
Increase air quantity. Check filter and replace if
necessary.
Reset thermostat.
Replace.
Proper operation; no remedy necessary.
Time off delay not finished.
Wait for 30 second off delay.
Condenser coil dirty or restricted.
Dirty air filter.
Dirty condenser coil.
Refrigerant overcharged.
Air in system.
Condenser air restricted or air short-cycling.
Low refrigerant charge.
Compressor valves leaking.
Restriction in liquid tube.
High heat load.
Compressor valves leaking.
Refrigerant overcharged.
Dirty air filter.
Low refrigerant charge.
Metering device or low side restricted.
Insufficient evaporator airflow.
—38—
Table 20 — Heating Service Analysis
PROBLEM
Burners will not ignite.
CAUSE
Misaligned spark electrodes.
No gas at main burners.
REMEDY
Check flame ignition and sensor electrode positioning. Adjust as needed.
Check gas line for air, purge as necessary. After purging gas line
of air, allow gas to dissipate for at least 5 minutes before attempting
to relight unit.
Check gas valve.
Water in gas line.
Drain water and install drip leg to trap water.
No power to furnace.
Check power supply, fuses, wiring, and circuit breaker.
No 24 v power supply to control circuit.
Check transformer. Transformers with internal overcurrent
protection require a cool down period before resetting.
Miswired or loose connections.
Check all wiring and wire nut connections.
Burned-out heat anticipator in thermostat. Replace thermostat.
Broken thermostat wires.
Run continuity check. Replace wires, if necessary.
Inadequate heating.
Dirty air filter.
Clean or replace filter as necessary.
Gas input to unit too low.
Check gas pressure at manifold. Clock gas meter for input. If too
low, increase manifold pressure, or replace with correct orifices.
Unit undersized for application.
Replace with proper unit or add additional unit.
Restricted airflow.
Clean filter, replace filter, or remove any restrictions.
Blower speed too low.
Use high speed tap, increase fan speed, or install optional
blower, as suitable for individual units.
Limit switch cycles main burners.
Check rotation of blower, thermostat heat anticipator settings,
and temperature rise of unit. Adjust as needed.
Too much outdoor air.
Adjust minimum position.
Check economizer operation.
Poor flame characteristics. Incomplete combustion (lack of
Check all screws around flue outlets and burner compartment.
combustion air) results in:
Tighten as necessary.
Aldehyde odors, CO, sooting flame, or
Cracked heat exchanger.
floating flame.
Overfired unit — reduce input, change orifices, or adjust gas line
or manifold pressure.
Check vent for restriction. Clean as necessary.
Check orifice to burner alignment.
Burners will not turn off.
Unit is locked into Heating mode for
Wait until mandatory one minute time period has elapsed or
a one minute minimum.
reset power to unit.
—39—
Table 21 — LED Error Code Service Analysis
PROBLEM
Hardware failure.
(LED OFF)
CAUSE
Loss of power to control module (IGC).
Fan ON/OFF delay
modified (LED/
FLASH)
High limit switch opens during heat
exchanger warm-up period before fan-on
delay expires.
Limit switch opens within three minutes
after blower-off delay timing in Heating mode.
High temperature limit switch is open.
Limit switch fault.
(LED 2 flashes)
Flame sense fault.
(LED 3 flashes)
4 consecutive limit
switch faults.
(LED 4 flashes)
Ignition lockout.
(LED 5 flashes)
REMEDY
Check 5 amp fuse on IGC, power to unit, 24-v circuit breaker,
and transformer. Units without a 24-v circuit breaker have an
internal overload in the 24-v transformer. If the overload trips,
allow 10 minutes for automatic reset.
Ensure unit is fired on rate and temperature rise is correct.
The IGC sensed flame that should not be present.
Inadequate airflow to unit.
Unit unsuccessfully attempted ignition for 15 minutes.
Induced-draft motor fault. IGC does not sense that induced-draft motor is
(LED 6 flashes)
operating.
Rollout switch fault.
(LED 7 flashes)
Rollout switch has opened.
Internal control fault.
(LED 8 flashes)
Microprocessor has sensed an error in the
software or hardware.
WARNING: If the IGC must be replaced, be sure to
ground yourself to dissipate any electrical charge that may be
present before handling new control board. The IGC is sensitive
to static electricity and may be damaged if the necessary precautions are not taken.
Ensure unit’s external static pressure is within application
guidelines.
Check the operation of the indoor (evaporator) fan motor. Ensure that the supply-air temperature rise is in accordance with
the range on the unit nameplate.
Reset unit. If problem persists, replace control board.
Check operation of indoor (evaporator) fan motor and that
supply-air temperature rise agrees with range on unit nameplate information.
Check ignitor and flame sensor electrode spacing, gaps, etc.
Ensure that flame sense and ignition wires are properly terminated. Verify that unit is obtaining proper amount of gas.
Check for proper voltage. If motor is operating, check the
speed sensor plug/IGC Terminal J2 connection. Proper
connection: PIN 1 — White, PIN 2 — Red, PIN 3 — Black.
Rollout switch will automatically reset, but IGC will continue to
lock out unit. Check gas valve operation. Ensure that induceddraft blower wheel is properly secured to motor shaft.
Reset unit at unit disconnect.
If error code is not cleared by resetting unit power, replace the
IGC.
IMPORTANT: Refer to Table 20 — Heating Service Analysis for additional troubleshooting analysis.
LEGEND
IGC — Integrated Gas Unit Controller
LED — Light-Emitting Diode
—40—
Table 22 — Durablade Economizer Service Analysis
PROBLEM
Damper does not open.
CAUSE
Indoor (evaporator) fan is off.
No power to economizer motor.
Economizer motor failure.
Economizer operation limited
to minimum position.
OAT or EC set too high.
Verify economizer control board
is correctly wired and works
properly.
Check SAT.
REMEDY
1. Check to ensure that 24 vac is present at terminal C1
on the IFC or that 24 vac is present at the IFO terminal.
Check whether 24 vac is present at PL6-1 (red wire)
and/or PL6-3 (black wire). If 24 vac is not present,
check wiring (see unit label diagram).
2. Check proper thermostat connection to G on the connection board.
1. Check that SW3 is properly making contact with the
damper blade. Check that SW1 is in the NC (normally
closed) position.
2. Check diode D18. If diode is not functioning properly,
replace economizer control board.
3. Confirm that the economizer control board is grounded
properly at PL6-4 (brown wire) and at brown terminal
of the economizer control board (brown wire). The
economizer motor must also be grounded properly at
the negative motor terminal (brown wire).
4. Verify SW1 and SW3 are working and wired properly
(see unit label diagram).
5. Check for 24 vac input at both PL6-1 (red wire) and
PL6-3 (black wire). If 24 vac not present, check unit
wiring (see unit label diagram). If 24 vac is found in
both places, check for 24 vac at the yellow terminal of
the economizer control board (yellow wire). If 24 vac
power is not present, replace the economizer control
board.
If the indoor (evaporator) fan and economizer motor are
energized, verify that there is a minimum of 18 vdc at the
positive motor terminal. If the motor is not operating, replace the motor.
1. Set at correct temperature (3 F below indoor space
temperature).
2. Check OAT or EC by setting above outdoor temperature
or humidly level. If the OAT or EC switches do not
close, replace OAT or EC.
1. Perform the following tests when OAT or EC is closed,
Y1 is called for and damper is at minimum position.
Confirm 24 vac on gray terminal of the economizer control board (gray wire). If 24 vac is not present, check
wiring (see unit label diagram).
2. Verify that SW1 and SW3 are wired correctly and working properly (see unit label diagram).
3. Check to ensure that 24 vac exists at PL6-2 (blue
wire). If 24 vac is not present, check wiring (see unit
wiring label diagram).
4. Check 24 vac output at PL6-10 (white wire). If 24 vac
is not present, replace economizer control board.
1. After verifying that the OAT and EC settings and the
economizer control board wiring are correct, check to
ensure that the 24 vac terminal of the SAT has 24 vac
(white wire). If OAT, EC, and control board are functioning and wired properly and no 24 vac exists, check wiring (see unit label diagram).
2. If supply-air temperature is greater than 57 F, 24 vac
should be found at terminal T2 on the SAT (pink wire). If
24 vac is not present, replace SAT.
(Table continued on page 42.)
—41—
Table 22 — Durablade Economizer Service Analysis (cont)
PROBLEM
Damper does not close.
CAUSE
Incorrect wiring of economizer.
Verify economizer control board
is functioning properly.
Check SAT.
Economizer motor failure.
Economizer damper does not
close on power loss.
C1
EC
IFC
IFO
OAT
PL
SAT
SW
—
—
—
—
—
—
—
—
Verify that close-on-power-loss
and economizer control board
are functioning properly.
LEGEND
Common Power
Enthalpy Control
Indoor (Evaporator) Fan Contactor
Indoor (Evaporator) Fan On
Outdoor-Air Thermostat
Plug
Supply-Air Thermostat
Economizer Position Switch
—42—
REMEDY
1. Verify that SW2 and SW4 are wired and working properly (see unit label diagram).
2. Check diode D18. If diode is not functioning properly,
replace economizer control board.
1. After verifying that the wiring is correct, modulate the
damper to the minimum position. Remove the calls
for G.
2. If the damper does not move, check for 24 vac at PL6-1
(red wire). If 24 vac is not present, check wiring (see
unit label diagram).
3. If damper still does not move, check for 24 vac at blue
terminal of economizer control board (blue wire). If
24 vac is not present, replace the economizer circuit
board.
1. After verifying that the wiring is correct and the economizer control board is functioning properly, place the
OAT or EC switch in the closed position. Place a call for
Y1 and open the damper to the fully open position.
Confirm that the 24 vac terminal of the SAT has 24 vac
(white wire). If 24 vac is not present, check wiring (see
unit label diagram).
2. If supply-air temperature is less than 52 F, 24 vac
should be found at terminal T1 on the SAT (violet wire).
If 24 vac not found, replace SAT.
If economizer control board and SAT are functioning properly, verify that there is a minimum of 18 vdc at the positive motor terminal. If a minimum of 18 vdc is present and
the motor is still not operating, replace the motor.
1. Check voltage potential across batteries. If lower than
14 vdc, replace close-on-power-loss power supply
(9-v alkaline batteries). It is recommended that you
check this emergency power supply on a regular basis
or whenever the filters are changed.
2. If the close-on-power-loss and economizer control
board are functioning properly, check for 14 vdc or
higher at the blue terminal of the economizer control
board (blue wire) when power is disconnected from
unit. If 14 vdc is not present, replace the control
board.
Table 23 — EconoMi$er Economizer Service Analysis
PROBLEM
Damper does not
open.
CAUSE
Indoor (Evaporator) Fan is
Off.
No power to EconoMi$er
controller.
No power to G Terminal.
Controller fault.
Thermostat fault.
Actuator Fault.
EconoMi$er
operation limited
to minimum
position.
Damper position
less than minimum
position set point.
Damper does not
return to minimum
position.
Damper does not
close on power
loss
Minimum position set
incorrectly.
EconoMi$er changeover
set point set too high or
too low.
Supply air temperature
sensor faulty.
OAT sensor faulty.
Supply air low limit
strategy controlling.
CO2 ventilation strategy
controlling.
Damper travel is
restricted.
REMEDY
Check to ensure that 24 vac is present at Terminal C1 (Common Power)
on the IFC (Indoor [Evaporator] Fan contactor) or that 24 vac is present at
the IFO (Indoor [Evaporator] Fan On) terminal. Check whether 24 vac is
present at PL (Plug) 6-1 (red wire) and/or PL6-3 (black wire). If 24 vac is
not present, check wiring (see unit label diagram).
Check proper thermostat connection to G on the connection board.
Check to ensure that 24 vac is present across Terminals 24 VAC and
24V COM on the EconoMi$er control. If 24 vac is not present, check
wiring (see unit label diagram). If 24 vac is present, STATUS light should
be on constantly.
If IFM is on, check to ensure 24 vac is present on G Terminal of the
EconoMi$er controller. If 24 vac is not present, check wiring (see unit
label diagram).
If STATUS light is flashing on flash, the EconoMi$er controller is
experiencing a fault condition. Cycle power to the controller. If condition
continues, replace the EconoMi$er controller.
If STATUS light is flashing two flashes, the EconoMi$er controller senses
the thermostat is wired incorrectly. Check wiring between the thermostat
and the connection board in the electrical panel. The fault condition is
caused by Y2 being energized before Y1.
Check the wiring between the EconoMi$er controller and the actuator.
Hold CONFIG button between three and ten seconds to verify the
actuator’s operation. (This process takes three minutes to complete.)
Verify that the MIN POS (%) is set greater than zero. Adjust
MIN POS (%) to 100% to verify operation, and then set to correct setting.
Set at correct value. See Table 4.
If STATUS light is flashing four flashes, the supply air temperature
sensor is faulty. Check wiring or replace sensor.
If STATUS light is flashing five flashes, the OAT sensor is faulty. Check
wiring or replace sensor.
The supply-air temperature is less than 45 F, causing the minimum
position to decrease. Refer to the Start-Up instructions. Verify correct
setting of MIN POS (%). If correct, EconoMi$er is operating correctly.
If a CO2 sensor is being used, and the damper position is greater than
minimum position, the ventilation control strategy is controlling. Refer to
the Start-Up instructions. EconoMi$er is operating correctly.
Check to ensure the damper is not blocked.
LEGEND
IFM — Indoor (Evaporator) Fan Motor
OAT — Outdoor-Air Temperature
—43—
LEGEND FOR FIG. 60
IMPORTANT: Refer to unit wiring label for actual unit wiring information.
AHA —
BR
—
C
—
CAP —
CB
—
CC
—
COMP —
CR
—
D
—
EC
—
ECON —
EPS —
EQUIP—
ER
—
FPT —
GND —
GVR —
HPS —
HS
—
HV
—
I
—
IDM —
IFC
—
Adjustable Heat Anticipator
Blower Relay
Contactor, Compressor
Capacitor
Circuit Breaker
Cooling Compensator
Compressor Motor
Combustion Relay
Diode
Enthalpy Control
Economizer
Emergency Power Supply
Equipment
Economizer Relay
Freeze-Protection Thermostat
Ground
Gas Valve Relay
High-Pressure Switch
Hall Effect Sensor
High Voltage
Ignitor
Induced-Draft Motor
Indoor (Evaporator) Fan Contactor
IFM —
IGC —
LED —
LPS —
LS
—
MGV —
MTR —
OAT —
OFC —
OFM —
PL
—
QT
—
R
—
RS
—
SAT —
SEN —
SW1 —
SW2 —
SW3 —
SW4 —
TC
—
TH
—
TRAN —
Indoor (Evaporator) Fan Motor
Integrated Gas Unit Controller
Light-Emitting Diode
Low-Pressure/Loss-of-Charge Switch
Limit Switch
Main Gas Valve
Motor
Outdoor-Air Thermostat
Outdoor-Fan Contactor
Outdoor-Fan Motor
Plug Assembly
Quadruple Terminal
Relay
Rollout Switch
Supply-Air Thermostat
Sensor
Switch Fully Open
Switch Fully Closed
Switch Minimum Vent Position
Switch Maximum Vent Position
Thermostat-Cooling
Thermostat-Heating
Transformer
—44—
Field Splice
Marked Wire
Terminal (Marked)
Terminal (Unmarked)
Terminal Block
Splice
Splice (Marked)
Factory Wiring
Field Control Wiring
Field Power Wiring
Accessory or Optional Wiring
To indicate common potential only;
not to represent wiring.
NOTES:
1. If any of the original wire furnished must be
replaced, it must be replaced with Type 90 C
wire or its equivalent.
2. Three-phase motors are protected under primary single phasing conditions.
3. Thermostat: HH07AT170, 172, 174 and P2722783
Subbase: HH93AZ176, 178 and P272-1882,
1883
4. Set heat anticipator for first stage at 0.14 amp,
second stage at 0.2 amp.
5. Use copper conductors only.
6. TRAN is wired for 230 v unit. If unit is to be run
with 208 v power supply, disconnect BLK wire
from 230 v tap (RED) and connect to 200 v
tap (BLU). Insulate end of 230 v tap.
Fig. 60 — Typical Wring Schematic and Component Arrangement
—45—
Copyright 2000 Bryant Heating & Cooling Systems
CATALOG NO. 5358-005
START-UP CHECKLIST
(Remove and Use in Job File)
I. PRELIMINARY INFORMATION:
MODEL NO.: _________________________________
SERIAL NO.: ______________________________________
DATE: _______________________________________
TECHNICIAN: _____________________________________
UNIT NO.: ____________________________________
JOB LOCATION: ___________________________________
JOB NAME: _______________________________________
VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
REMOVE ALL SHIPPING TIEDOWN BANDS ON COMPRESSOR (SIZE 150 ONLY) PER INSTALLATION
INSTRUCTIONS
VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS
CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS
CHECK GAS PIPING FOR LEAKS
CHECK THAT INDOOR- AIR FILTERS ARE CLEAN AND IN PLACE
VERIFY THAT UNIT INSTALLATION IS LEVEL
CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW
TIGHTNESS
ENSURE BELT TENSION AND BLOWER PULLEYS ARE PROPERLY ALIGNED
CUT ALONG DOTTED LINE
II. PRE-START-UP (insert checkmark in box as each item is completed)
III. START-UP:
ELECTRICAL
SUPPLY VOLTAGE
L1-L2
_________
L2-L3
__________
L3-L1
__________
COMPRESSOR AMPS
L1
_________
L2
__________
L3
__________
INDOOR-FAN AMPS
L1
_________
L2
__________
L3
__________
OUTDOOR-AIR TEMPERATURE
_________
DB
RETURN-AIR TEMPERATURE
_________
DB
_________
WB
COOLING SUPPLY AIR
_________
DB
_________
WB
GAS HEAT SUPPLY AIR
_________
DB
PRESSURES
GAS INLET PRESSURE
_________
IN. WG
GAS MANIFOLD PRESSURE
_________
IN. WG (HI FIRE)
REFRIGERANT SUCTION
_________
PSIG — CIRCUIT NO. 1 _________
PSIG — CIRCUIT NO. 2
REFRIGERANT DISCHARGE
_________
PSIG — CIRCUIT NO. 1 _________
PSIG — CIRCUIT NO. 2
VERIFY REFRIGERANT CHARGE USING CHARGING TABLES
VERIFY THAT 3-PHASE SCROLL COMPRESSOR IS ROTATING IN CORRECT DIRECTION (580D150 SCROLL
UNITS ONLY)
Copyright 2000 Bryant Heating & Cooling Systems
CL-1
CATALOG NO. 5358-005
CUT ALONG DOTTED LINE
TEMPERATURES