Bryant 580D 090-150 rooftop gas heating/electric cooling unit Installation, start-up and service instructions
The Bryant 580D 090-150 rooftop gas heating/electric cooling unit provides heating and cooling for your building. It is designed for a minimum return air temperature of 50 degrees Fahrenheit (dry bulb) and an intermittent operation down to 45 degrees Fahrenheit (dry bulb). The unit includes an energy-saving, automatic, electric direct-spark ignition system that does not require a continuously burning pilot. It features a variable-speed blower motor for quiet operation and efficiency. The unit requires an external trap for condensate drainage. It also includes a variety of safety features, such as a rollout switch and a high-pressure switch.
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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 ">

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Key features
- Energy-saving automatic electric direct-spark ignition system
- Variable-speed blower motor
- External trap for condensate drainage
- Rollout switch
- High-pressure switch