Instruction manual | Brother SV-100B eBook Reader User Manual

604D-- - A
LEGACYt 13 SEER
SINGLE-- PACKAGED HEAT PUMP SYSTEM
WITH PURONR (R-- 410A) REFRIGERANT
SINGLE AND THREE PHASE
NOMINAL 2-- 5 TONS (SIZES 24--60)
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
NOTE: Installer: Make sure the Owner’s Manual and Service
Instructions are left with the unit after installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1--2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
RECEIVING AND INSTALLATION . . . . . . . . . . . . . . . . . 2--10
Check Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Identify Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspect Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Provide Unit Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Slab Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Provide Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rigging/Lifting of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Select and Install Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge Units . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Provide for Condensate Disposal . . . . . . . . . . . . . . . . . . . . . . 9
Install Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . 9
High--Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . 9
Special Procedures for 208--V Operation . . . . . . . . . . . . . . 10
Control Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . 10
Standard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transformer Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessory Electric Heaters Installation . . . . . . . . . . . . . . . 10
PRE--START--UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
START--UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--22
Checking Cooling & Heating Control Operation . . . . . . . . 18
Check for Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . 18
Start--Up Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
604D----A Sequence of Operation . . . . . . . . . . . . . . . . . . . 19
Checking & Adjusting Refrigerant Charge . . . . . . . . . . . . 19
Indoor Airflow & Airflow Adjustments . . . . . . . . . . . . . . 19
Continuous Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . 20
Defrost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quiet Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--28
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Indoor Blower and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Outdoor Coil, Indoor Coil, & Condensate Drain Pan . . . . . . 23
Outdoor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical Controls and Wiring . . . . . . . . . . . . . . . . . . . . . . . 26
Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Metering Devices-- TXV & Piston . . . . . . . . . . . . . . . . . . . . 27
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Loss of Charge Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Copeland Scroll compressor (Puron Refrigerant) . . . . . . . . . 27
Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
A09034
Fig. 1 -- Unit 604D----A
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Servicing Systems on Roofs with Synthetic Materials . . . . 27
Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PuronR (R--410A) Refrigerant Charging . . . . . . . . . . . . . 28
System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Loss of Charge Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check Defrost Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 28
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
START--UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
VERTICAL ECONOMIZER . . . . . . . . . . . . . . . . . . . . . . . 32--50
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Small Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32--33
Large Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36--38
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39--48
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SAFETY CONSIDERATIONS
Installation and servicing of this equipment can be hazardous due
to mechanical and electrical components. Only trained and
qualified personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance functions such
as cleaning and replacing air filters. All other operations must be
performed by trained service personnel. When working on this
equipment, observe precautions in the literature, on tags, and on
labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have a fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes, the
current editions of the National Electrical Code (NEC) NFPA 70.
1
In Canada refer to the current editions of the Canadian electrical
Code CSA C22.1.
.
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 these
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 signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
604D -- -- A
!
WARNING
Step 2 — Provide Unit Support
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be
more than one disconnect switch. Turn off accessory heater
power switch if applicable.
WARNING
!
FIRE,
EXPLOSION,
HAZARD
ELECTRICAL
SHOCK
Failure to follow this warning could result in personal
injury, death or property damage.
A qualified installer or agency must use only
factory--authorized kits or accessories when modifying this
product.
CAUTION
!
nearest equipment distributor if any item is missing. To prevent
loss or damage, leave all parts in original packages until
installation.
If the unit is to be mounted on a curb in a downflow application,
review Step 5 to determine which method is to be used to remove
the downflow panels before rigging and lifting into place. The
panel removal process may require the unit to be on the ground.
IMPORTANT: The unit must be secured to the curb by installing
screws through the bottom of the curb flange and into the unit base
rails. When installing large base units onto the common curb, the
screws must be installed before allowing the full weight of the unit
to rest on the curb. A minimum of six screws are required for large
base units. Failure to secure unit properly could result in an
unstable unit. See Warning near Rigging/Lifting information and
accessory curb instructions for more details.
CUT HAZARD
Failure to follow this caution may result in personal injury.
When removing access panels (see Fig. 20) or performing
maintenance functions inside your unit, be aware of sharp
sheet metal parts and screws. Although special care is taken
to reduce sharp edges to a minimum, be extremely careful
when handling parts or reaching into the unit.
Roof Curb
Install accessory roof curb in accordance with instructions shipped
with curb (See Fig. 4). Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical
for a watertight seal. Install gasketing material supplied with the
roof curb. Improperly applied gasketing also can result in air leaks
and poor unit performance.
Curb should be level to within 1/4 in. (6 mm) (See Fig. 6). This is
necessary for unit drain to function properly. Refer to accessory
roof curb installation instructions for additional information as
required.
Installation on older “G” series roof curbs.
Two accessory kits are available to aid in installing a new “G”
series unit on an old “G” roof curb.
1. Accessory kit number CPADCURB001A00, (small chassis)
and accessory kit number CPADCURB002A00, (large
chassis) includes roof curb adapter and gaskets for the
perimeter seal and duct openings. No additional
modifications to the curb are required when using this kit.
2. An alternative to the adapter curb is to modify the existing
curb by removing the outer horizontal flange and use
accessory kit number CPGSKTKIT001A00 which includes
spacer blocks (for easy alignment to existing curb) and
gaskets for the perimeter seal and duct openings. This kit is
used when existing curb is modified by removing outer
horizontal flange.
!
INTRODUCTION
UNIT/STRUCTURAL DAMAGE HAZARD
The 604D----A heat pump is fully self--contained and designed for
outdoor installation. (See Fig. 1.) Standard units are shipped in a
horizontal--discharge configuration for installation on a
groundlevel slab. Standard units can be converted to downflow
(vertical) discharge configurations for rooftop applications.
RECEIVING AND INSTALLATION
Step 1 — Check Equipment
Identify Unit
The unit model number and serial number are stamped on the unit
identification plate. Check this information against shipping
papers.
Inspect Shipment
Inspect for shipping damage before removing packaging materials.
If unit appears to be damaged or is torn loose from its anchorage,
have it examined by transportation inspectors before removal.
Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in transit.
Check all items against shipping list. Immediately notify the
CAUTION
Failure to follow this caution may result in property damage.
Ensure there is sufficient clearance for saw blade when cutting
the outer horizontal flange of the roof curb so there is no
damage to the roof or flashing.
Slab Mount
Place the unit on a solid, level concrete pad that is a minimum of 4
in. (102 mm) thick with 2 in. (51 mm) above grade (See Fig. 8).
The slab should extend approximately 2 in. (51 mm) beyond the
casing on all 4 sides of the unit. Do not secure the unit to the slab
except when required by local codes.
Step 3 — Provide Clearances
The required minimum service clearances are shown in Fig. 2 and
3. Adequate ventilation and outdoor air must be provided. The
outdoor fan draws air through the outdoor coil and discharges it
through the top fan grille. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
corner or under an overhead obstruction. The minimum clearance
2
INSPECTION
Prior to initial use, and at monthly intervals, all rigging shackles,
clevis pins, and straps should be visually inspected for any damage,
evidence of wear, structural deformation, or cracks. Particular
attention should be paid to excessive wear at hoist hooking points and
load support areas. Materials showing any kind of wear in these areas
must not be used and should be discarded.
!
WARNING
UNIT FALLING HAZARD
Step 4 — Rig and Place Unit
Failure to follow this warning could result in personal injury
or death.
Rigging and handling of this equipment can be hazardous for many
reasons due to the installation location (roofs, elevated structures,
etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
Never stand beneath rigged units or lift over people.
!
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment, and
any other safety precautions that might apply.
WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
Training for operators of the lifting equipment should include, but not
be limited to, the following:
1. Application of the lifter to the load, and adjustment of the lifts
to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting kit,
such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
When straps are taut, the clevis should be a minimum of 36 in.
(914 mm) above the unit top cover.
3
604D -- -- A
under a partial overhang (such as a normal house overhang) is 48
in. (1219 mm) above the unit top. The maximum horizontal
extension of a partial overhang must not exceed 48 in. (1219 mm).
IMPORTANT: Do not restrict outdoor airflow. An air restriction
at either the outdoor--air inlet or the fan discharge may be
detrimental to compressor life.
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting or other combustible materials. Slab--mounted units
should be at least 4 in. (102 mm) above the highest expected water
and runoff levels. Do not use unit if it has been under water.
604D -- -- A
A09471
Fig. 2 -- 604D----A24--36 Unit Dimensions
4
604D -- -- A
A09472
Fig. 3 -- 604D----A42--60 Unit Dimensions
5
Dashed lines show cross support
location for large basepan units.
B
G
HVAC unit
basepan
HVAC unit
base rails
C
Sealing
Gasket
Roofcurb
A
Anchor screw
H
F
Wood nailer*
Flashing field
supplied
Roofcurb*
Insulation
(field supplied)
Roofing material
field supplied
604D -- -- A
E
D
Cant strip
field supplied
A09413
SMALL/COMMON CURB
*Provided with roofcurb
A09090
ROOF CURB DETAIL
B
C
SUPPLY
AIR
SMALL
BASE
UNIT
RETURN
AIR
LARGE
BASE
UNIT
G
H
F A
E
D
UNIT PLACEMENT ON
COMMON CURB
A09415
LARGE CURB
A09094
SMALL OR LARGE BASE UNIT
A09414
UNIT
SIZE
CATALOG
NUMBER
A
IN. (mm)
Small
or
Large
CPRFCURB010A00
11 (279)
CPRFCURB011A00
14 (356)
CPRFCURB012A00
CPRFCURB013A00
11 (279)
14 (356)
Large
B
(small/common
base)
IN. (mm)*
B
(large base)
IN. (mm)*
C
IN. (mm)
D
IN. (mm)
14 (356)
16 (406)
47.8
(1214)
10 (254)
14 (356)
E
IN. (mm)
32.4
(822)
43.9
(1116)
F
IN. (mm)
G
IN. (mm)
30.6 (778)
2.7 (69)
42.2 (1072)
H
IN. (mm)
46.1
(1170)
* Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small and large basepan units. The cross supports must be located based on
whether the unit is a small basepan or a large basepan.
NOTES:
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
3. Roof curb is made of 16--gauge steel.
4. Attach ductwork to curb (flanges of duct rest on curb).
5. Insulated panels: 1--in. (25.4 mm) thick fiberglass 1 lb. density.
Fig. 4 -- Roof Curb Dimensions
6
CAUTION - NOTICE TO RIGGERS
PRUDENCE - AVIS AUX MANIPULATEUR
ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.
PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.
Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition
DUCTS
SEAL STRIP MUST BE IN
PLACE BEFORE PLACING
UNIT ON ROOF CURB
UNIT HEIGHT
HAUTEUR D'UNITÉ
604D -- -- A
MINIMUM HEIGHT: 36" (914.4 mm)
HAUTEUR MINIMUM
BANDE SCELLANT DOIT ÊTRE
EN PLACE AVANT DE PLACER
L'UNITÉ SUR LA BASE DE TOIT
DETAIL A
VOIR DÉTAIL A
SEE DETAIL A
VOIR DÉTAIL A
50CY502286 2.0
A09051
CORNER WEIGHTS (SMALL CABINET)
24
30
lb
kg
lb
kg
lb
Unit
Rigging
Weight
327
148
340
154
343
*For 460 Volt units add 14 lb (6.35 kg) to the rigging weight.
NOTE: See dimensional drawing for corner weights.
36
Unit
kg
156
Rigging
Weight
CORNER WEIGHTS (LARGE CABINET)
42
48
lb
kg
lb
kg
419
190
429
195
60
lb
kg
454
206
Fig. 5 -- Rigging Weights
Rigging/Lifting of Unit (See Fig. 5.)
!
WARNING
UNIT FALLING HAZARD
A
Failure to follow this warning could result in personal injury
or death.
2. Attach shackles, clevis pins, and straps to the base rails of the
unit. Be sure materials are rated to hold the weight of the unit.
(See Fig. 5).
3. Attach a clevis of sufficient strength in the middle of the straps.
Adjust the clevis location to ensure unit is lifted level with the
ground.
After the unit is placed on the roof curb or mounting pad, remove the
top skid.
MAXIMUM ALLOWABLE
DIFFERENCE in. (mm)
B
Large base units must be secured to common curb before
allowing full weight of unit to rest on curb. Install screws
through curb into unit base rails while rigging crane is still
supporting unit.
Lifting holes are provided in base rails as shown in Fig. 2 and 3.
1. Leave top shipping skid on the unit for use as a spreader bar
to prevent the rigging straps from damaging the unit. If the
skid is not available, use a spreader bar of sufficient length to
protect the unit from damage.
C
A-B
B-C
A-C
1/4 (6.35)
1/4 (6.35)
1/4 (6.35)
A07925
Fig. 6 -- Unit Leveling Tolerances
Step 5 — Select and Install Ductwork
The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
non--residence type air conditioning and ventilating systems,
NFPA 90A or residence--type, NFPA 90B and/or local codes and
ordinances.
Select and size ductwork, supply--air registers, and return air grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supply-- and return--air openings
on the side of the unit.
7
!
WARNING
PERSONAL
INJURY
OPERATION HAZARD
AND
ELECTRICAL
Failure to follow this warning could result in personal
injury or death.
604D -- -- A
For vertical supply and return units, tools or parts could
drop into ductwork Install a 90 degree turn in the return
ductwork between the unit and the conditioned space. If a
90 degree elbow cannot be installed, then a grille of
sufficient strength and density should be installed to prevent
objects from falling into the conditioned space. Units with
electric heaters require 90 degree elbow in supply duct.
When designing and installing ductwork, consider the following:
1. All units should have field--supplied filters or accessory
filter rack installed in the return--air side of the unit.
Recommended sizes for filters are shown in Table 1.
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
ensure weather tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
connector between ductwork and unit discharge connection. If
flexible duct is used, insert a sheet metal sleeve inside duct. Heat
resistant duct connector (or sheet metal sleeve) must extend 24--in.
(610 mm) from electric heater element.
3. Size ductwork for cooling air quantity (cfm). The minimum
air quantity for proper electric heater operation is listed in
Table 2. Heater limit switches may trip at air quantities
below those recommended.
4. Seal, insulate, and weatherproof all external ductwork. Seal,
insulate and cover with a vapor barrier all ductwork passing
through conditioned spaces. Follow latest Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA) and Air Conditioning Contractors Association
(ACCA) minimum installation standards for residential
heating and air conditioning systems.
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration--isolate duct openings in wall or roof
according to good construction practices.
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge Units
!
WARNING
ELECTRICAL SHOCK HAZARD
Horizontal Duct Covers
A09061
Basepan
Downflow
(Vertical)
Supply
Knockout
Basepan
Downflow
(Vertical)
Return
Knockout
Fig. 7 -- Supply and Return Duct Openings
A09088
CAUTION
!
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Collect ALL screws that were removed. DO NOT leave screws
on rooftop as permanent damage to the roof may occur.
To remove downflow return and supply knockout covers, break
front and right side connections tabs with a screwdriver and
hammer. Push cover down to break rear and left side tabs.
NOTE: These panels are held in place with tabs similar to an
electrical knockout. Reinstall horizontal duct covers (Fig. 7)
shipped on unit from factory. Insure openings are air and
watertight.
NOTE: The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of non
residence--type air conditioning and ventilating systems, NFPA
90A or residence--type, NFPA 90B; and/or local codes and
ordinances.
Failure to follow this warning could result in personal injury
or death.
OPTIONAL
RETURN
AIR
OPENING
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be more
than one disconnect switch.
1. Open all electrical disconnects and install lockout tag before
starting any service work.
2. Remove horizontal (metal) ductcovers to access vertical
(downflow) discharge duct knockouts in unit basepan. (See
Fig. 7.)
3. After completing unit conversion, perform all safety checks
and power up unit.
OPTIONAL
SUPPLY
AIR
OPENING
2˝
(50.8mm)
EVAP. COIL
COND. COIL
A07926
Fig. 8 -- Slab Mounting Detail
8
High-- Voltage Connections
NOTE: Ensure that condensate--water disposal methods comply
with local codes, restrictions, and practices.
The 604D----A units dispose of condensate through a 3/4 in. NPT
female fitting that exits on the compressor end of the unit.
Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground
level installations. Install a field--supplied 2--in. (51 mm)
condensate trap at end of condensate connection to ensure proper
drainage. Make sure that the outlet of the trap is at least 1 in. (25
mm) lower than the drain--pan condensate connection to prevent
the pan from overflowing. Prime the trap with water. When using a
gravel apron, make sure it slopes away from the unit.
If the installation requires draining the condensate water away from
the unit, install a field--supplied 2 --in. (51mm) trap at the
condensate connection to ensure proper drainage. Condensate trap
is available as an accessory or is field--supplied. Make sure that the
outlet of the trap is at least 1 in. (25 mm) lower than the unit
drain--pan condensate connection to prevent the pan from
overflowing. Connect a drain trough using a minimum of
field--supplied 3/4--in. PVC or field--supplied 3/4--in. copper pipe
at outlet end of the 2--in. (51 mm) trap. (See Fig. 10) Do not
undersize the tube. Pitch the drain trough downward at a slope of at
least 1 in. (25 mm) every 10 ft (3 m) of horizontal run. Be sure to
check the drain trough for leaks. Prime the trap at the beginning of
the cooling season start--up.
The unit must have a separate electrical service with a
field--supplied, waterproof disconnect switch mounted at, or within
sight from the unit. Refer to the unit rating plate, NEC and local
codes for maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.
The field--supplied disconnect may be mounted on the unit over
the high--voltage inlet hole when the standard power and
low--voltage entry points are used. See Fig. 2 and 3 for acceptable
location. Remove high voltage knockout.
See unit wiring label (Fig. 11--13) and Fig. 9 for reference when
making high voltage connections. Proceed as follows to complete
the high--voltage connections to the unit.
Single phase units:
1. Run the high--voltage (L1, L2) and ground lead into the
control box.
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the line side
of the contactor.
HIGH VOLTAGE
POWER LEADS
(SEE UNIT WIRING
LABEL)
3-PHASE SHOWN
1-PHASE USES
TWO POWER
EQUIP GR
LEADS
Step 7 — Install Electrical Connections
!
CAUTION
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
The unit cabinet must have an uninterrupted, unbroken
electrical ground. This ground may consist of an electrical
wire connected to the unit ground screw in the control
compartment, or conduit approved for electrical ground when
installed in accordance with NEC,NFPA 70 National Fire
Protection Association (latest edition) (in Canada, Canadian
Electrical Code CSA C22.1) and local electrical codes.
FIELD-SUPPLIED
FUSED DISCONNECT
CONTROL BOX
WHT(W1)
VIO (W2)
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the unit
being installed.
1. Make all electrical connections in accordance with NEC
NFPA 70 (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. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high--voltage power to unit is within
operating voltage range indicated on unit rating plate. On
3--phase units, ensure phases are balanced within 2
percent. Consult local power company for correction of
improper voltage and/or phase imbalance.
4. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit,
etc.
POWER
SUPPLY
YEL(Y)
GRN(G)
LOW-VOLTAGE
POWER LEADS
(SEE UNIT )
WIRING LABEL
RED(R)
BRN(C)
ORN(O)
BLU(DH)
GRA(Y2)
W1
W2
Y
G
R
THERMOSTAT
(TYPICAL)
C
O
DH
3-Phase
Only
SPLICE BOX
A09071
Fig. 9 -- High-- and Control--Voltage Connections
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L2 to yellow wire on connection 23 of
the compressor contactor.
Three--phase units:
1. Run the high--voltage (L1, L2, L3) and ground lead into the
control box.
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the line side
of the contactor.
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L3 to yellow wire on connection 13 of
the compressor contactor.
6. Connect field wire L2 to blue wire from compressor.
9
604D -- -- A
Step 6 — Provide for Condensate Disposal
Special Procedures for 208-- V Operation
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. With disconnect
switch open, move black wire from transformer (3/16 in.)
terminal marked 230 to terminal marked 200. This retaps
transformer to primary voltage of 208 vac.
604D -- -- A
Control Voltage Connections
NOTE: Do not use any type of power--stealing thermostat. Unit
control problems may result.
Use no. 18 American Wire Gage (AWG) color--coded, insulated
(35°C minimum) wires to make the control voltage connections
between the thermostat and the unit. If the thermostat is located
more than 100 ft (30.5 m) from the unit (as measured along the
control voltage wires), use no. 16 AWG color--coded, insulated
(35° C minimum) wires.
If an accessory electric heater is installed, low voltage leads from
heater must be connected to factory supplied control leads from
Indoor Fan Board P4 connector. Factory wires are provided for
electric heat staging W1 and W2 (W2 and W3 on IFB). If room
thermostat has only one stage of supplemental heat, connect white
and violet wires shown in Fig. 9 to second stage heat field wire.
Some electric heaters have four control wires (plus common wire).
Consult unit wiring diagram and electric heater wiring diagram for
additional details.
Transformer Protection
The transformer is of the energy--limiting type. It is set to withstand
a 30--second overload or shorted secondary condition. If an
overload or short is present, correct overload condition and check
for blower fuse on Interface Fan Board. Replace fuse as required
with correct size and rating.
Accessory Electric Heaters Installation
Electric heaters may be installed with the 604D----A units per
instructions supplied with electric heater package. See unit rating
plate for factory--approved electric heater kits.
TRAP
OUTLET
1-in. (25 mm) min.
Standard Connections
Locate the eight (nine on 3--phase) low voltage thermostat leads in
24 volt splice box. See Fig. 9 for connection diagram. Run the
low--voltage leads from the thermostat, through the control wiring
inlet hole grommet (Fig. 2 and 3), and into the low--voltage splice
box. Provide a drip loop before running wires through panel.
Secure and strain relief all wires so that they do not interfere with
operation of unit. A gray wire is standard on 3--phase units for
connection to an economizer.
2-in. (51 mm) min.
A09052
Fig. 10 -- Condensate Trap
10
604D --- --- A24
2
327
148
604D --- --- A30
2.5
340
154
8.3
3.8
10.2
4.6
604D --- --- A36
3
343
156
604D --- --- A42
3.5
419
190
1
SCROLL COMPRESSOR
R---410A
7.9
10.0
3.6
4.5
TXV
604D --- --- A48
4
429
195
604D --- --- A60
5
454
206
9.6
4.4
12.3
5.6
0.038 (Left OD Coil)
0.040 (Right OD Coil)
ORIFICE OD (in.)
0.032 (2)
0.035 (2)
0.037 (2)
0.046 (2)
0.052 (2)
.97/1.02
(mm)
.81
.89
.94
1.2
1.3
OUTDOOR COIL
2...21
2...21
2...21
2...21
2...21
2...21
Rows... Fins/in.
11.9
11.9
11.9
13.6
13.6
17.5
face area (sq. ft.)
OUTDOOR FAN
2000
2700
2700
3100
3100
3500
Nominal Airflow (CFM)
24
24
24
26
26
26
Diameter Motor HP (RPM)
1/5 (810)
1/5 (810)
1/5 (810)
1/5 (810)
1/5 (810)
1/5 (810)
INDOOR COIL
3...17
3...17
3...17
3...17
3...17
3...17
Rows... Fins/in.
3.7
3.7
3.7
4.7
4.7
5.7
face area (sq. ft.)
INDOOR BLOWER
800
1000
1200
1400
1600
1800
Nominal Cooling Airflow (CFM)
10x10
10x10
11x10
11x10
11x10
11x10
Size (in.)
254x254
254x254
279x254
279x254
279x254
279x254
(mm)
1/2
1/2
3/4
3/4
1.0
1.0
Motor (HP)
HIGH --- PRESSURE SWITCH (psig)
650±15
Cutout
420±25
Reset (Auto)
LOSS--- OF--- CHARGE/LOW --- PRESSURE
20±5
SWITCH
45±10
(Liquid Line) (psig)
20±5
Cutout
45±10
Reset (Auto)
RETURN--- AIR FILTERS*{
20x20x1
20x24x1
24x30x1
24x36x1
throwaway (in.)
508x508x25
508x610x25
610x762x25
610x914x25
(mm)
*Required filter sizes shown are based on the larger of the AHRI (Air Conditioning, Heating and Refrigeration Institute) rated cooling airflow or the heating airflow
velocity of 300 ft/minute for throwaway type or 450 ft/minute for high ---capacity type. Air filter pressure drop for non ---standard filters must not exceed 0.08 IN.
W.C.
{ If using accessory filter rack refer to the filter rack installation instructions for correct filter size and quantity.
} For 460 volt units, add 14 lb (6.4 kg) to the weight.
Table 2 – Minimum Airflow for Reliable Electric Heater Operation (CFM)
SIZE
AIRFLOW (CFM)
604D-- - A24
800
604D-- - A30
1025
604D-- - A36
1250
11
604D-- - A42
1400
604D-- - A48
1710
604D-- - A60
1800
604D -- -- A
Table 1 – Physical Data -- Unit 604D----A
UNIT SIZE
NOMINAL CAPACITY (ton)
SHIPPING WEIGHT} (lb)
(kg)
COMPRESSOR QUANTITY
TYPE
REFRIGERANT
Refrigerant (R --- 410A) Quantity (lb)
Quantity (kg)
METERING DEVICE ID
604D -- -- A
A10197
Fig. 11 -- Connection Wiring Schematics 208/230--1--60
12
604D -- -- A
A10197
Fig. 11 Cont. -- Ladder Wiring Schematics 208/230--1--60
13
604D -- -- A
A10194
Fig. 12 -- Connection Wiring Schematics -- 208/230--3--60
14
604D -- -- A
A10194
Fig. 12 Cont. -- Ladder Wiring Schematics -- 208/230--3--60
15
604D -- -- A
A10195
Fig. 13 -- Connection Wiring Diagram 460--3--60
16
604D -- -- A
A10195
Fig. 13 Cont. -- Ladder Wiring Diagram 460--3--60
17
PRE--START--UP
!
WARNING
604D -- -- A
FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
1. Follow recognized safety practices and wear protective
goggles when checking or servicing refrigerant system.
2. Relieve and recover all refrigerant from system before
touching or disturbing compressor plug if refrigerant
leak is suspected around compressor terminals.
3. Do not remove compressor plug until all electrical
sources are disconnected and tagged.
4. Never attempt to repair soldered connection while
refrigerant system is under pressure.
5. 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:
a. Shut off electrical power to unit and install lockout
tag.
b. Relieve and reclaim all refrigerant from system
using both high-- and low--pressure ports.
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.
Use the Start--Up Checklist supplied at the end of this book and
proceed as follows to inspect and prepare the unit for initial
start--up:
1. Remove all access panels (see Fig. 20).
2. Read and follow instructions on all DANGER, 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, or
liquid--soap solution. If a refrigerant leak is detected, see
following Check for Refrigerant Leaks section.
c. Inspect all field and factory--wiring connections. Be sure
that connections are completed and tight. Ensure wires
do not touch refrigerant tubing or sharp sheet metal
edges.
d. Inspect coil fins. If damaged during shipping and
handling, carefully straighten fins with a fin comb.
4. Verify the following conditions:
a. Make sure that outdoor--fan blade is correctly positioned
in fan orifice.
b. Make sure that air filter(s) is in place.
c. Make sure that condensate drain pan and trap are filled
with water to ensure proper drainage.
d. Make sure that all tools and miscellaneous loose parts
have been removed.
5. Each unit system has 2 Schrader--type ports, one low--side
Schrader fitting located on the suction line, and one
high--side Schrader fitting located on the compressor
discharge line. Be sure that caps on the ports are tight.
START--UP
Checking Cooling and Heating Control Operation
Start and check the unit for proper control operation as follows:
(1.) Place room thermostat SYSTEM switch or MODE
control in OFF position. Observe that blower
motor starts when FAN mode is placed in FAN ON
position and shuts down when FAN MODE switch
is placed in AUTO position.
(2.) Thermostat:
When the room temperature rises to a point that is
slightly above the cooling control setting of the
thermostat, the thermostat completes the circuit
between thermostat terminal R to terminals Y, O
and G.These completed circuits through the
thermostat connect contactor coil (C) (through unit
wire Y) and Indoor Fan board (through unit wire
G) across the 24--v. secondary of transformer
(TRAN).
(3.) Place system switch or MODE control in HEAT
position. Set control above room temperature.
Observe that compressor, outdoor fan, and indoor
blower motors start. Observe that heating cycle
shuts down when control setting is satisfied.
(4.) When using an automatic changeover room
thermostat place both SYSTEM or MODE control
and FAN mode switches in AUTO positions.
Observe that unit operates in Cooling mode when
temperature control is set to “call for Cooling”
(below room temperature), and unit operates in
Heating mode when temperature control is set to
“call for Heating” (above room temperature).
NOTE: Once the compressor has started and then has stopped, it
should not be started again until 5 minutes have elapsed. The
defrost board has a built--in 5 minute delay between cycles. The 5
minute compressor delay also applies to heat pump heating mode.
Step 1 — Check for Refrigerant Leaks
Proceed as follows to locate and repair a refrigerant leak and to
charge the unit:
1. Locate leak and make sure that refrigerant system pressure
has been relieved and reclaimed from both high-- and
low--pressure ports.
2. Repair leak following Refrigerant Service procedures.
NOTE: Install a bi--flow filter drier whenever the system has been
opened for repair.
3. Add a small charge of R--410A refrigerant vapor to system
and leak--test unit.
4. Recover refrigerant from refrigerant system and evacuate to
500 microns if no additional leaks are not found.
5. Charge unit with Puron (R--410A) refrigerant, using an
electronic scale. Refer to unit rating plate for required
charge.
Step 2 — Start--Up Adjustments
Complete the required procedures given in the Pre--Start--Up
section before starting the unit. Do not jumper any safety devices
when operating the unit. Do not operate the unit in Cooling mode
when the outdoor temperature is below 40_F (4_C) (unless
accessory low--ambient kit is installed).
IMPORTANT: Three--phase, scroll compressors are direction
oriented. Unit must be checked to ensure proper compressor
3--phase power lead orientation. If not corrected within 5 minutes,
the internal protector will shut off the compressor. The 3--phase
power leads to the unit must be reversed to correct rotation. When
turning backwards, the difference between compressor suction and
discharge pressures may be near zero.
18
a. CONTINUOUS FAN
(1.) Thermostat closes circuit R to G energizing the
blower motor for continuous fan.
b. COOLING MODE
(1.) If indoor temperature is above temperature set
point, thermostat closes circuits R to G, R to Y and
R to O--The unit delivers cooling airflow.
c. ELECTRIC HEATING MODE
(1.) Thermostat closes circuit R to W/W1, or W2 and R
to G. There are no on or off delays.
d. HEAT PUMP HEATING MODE
(1.) Thermostat closes circuits R to G and R to Y. The
compressor, indoor and outdoor fans are energized.
e. HEAT PUMP HEATING WITH AUXILIARY
ELECTRIC HEAT
(1.) Thermostat closes circuits R to G, R to Y and R to
W/W1 or W2. The compressor, indoor and outdoor
fans are energized, as well as the electric heat
relays.
f. DEFROST MODE
The defrost mode is automatically energized by the
defrost board during heating mode. The defrost board
energizes “O” (reversing valve) and “W2” (electric
heat). It also de--energizes the outdoor fan. When defrost
is complete, unit will return to heating mode. If room
thermostat is satisfied during defrost, unit will shut
down and restart in defrost on next call for heat.
(psig) to determine desired system operating liquid line
temperature (See Fig. 17).
6. Compare actual liquid line temperature with desired liquid
line temperature. Using a tolerance of ±2°F (±1.1°C), add
refrigerant if actual temperature is more than 2°F (1.1°C)
higher than proper liquid line temperature, or remove
refrigerant if actual temperature is more than 2°F (1.1°C)
lower than required liquid line temperature.
NOTE:
If the problem causing the inaccurate readings is a
refrigerant leak, refer to Check for Refrigerant Leaks section.
Indoor Airflow and Airflow Adjustments
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage.
For cooling operation, the recommended airflow is 350 to
450 cfm for 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.
NOTE: Be sure that all supply--and return--air grilles are open,
free from obstructions, and adjusted properly.
!
WARNING
ELECTRICAL SHOCK HAZARD
Checking and Adjusting Refrigerant Charge
The refrigerant system is fully charged with Puron (R--410A)
refrigerant and is tested and factory sealed.
NOTE:
Adjustment of the refrigerant charge is not required
unless the unit is suspected of not having the proper Puron
(R--410A) charge.
A subcooling charging chart is attached to the inside of the
compressor access panel (see Fig. 20). The chart includes the
required liquid line temperature at given discharge line pressures
and outdoor ambient temperatures.
An accurate thermocouple-- or thermistor--type thermometer, and a
gauge manifold are required when using the subcooling charging
method for evaluating the unit charge. Do not use mercury or small
dial--type thermometers because they are not adequate for this type
of measurement.
NOTE: Allow system to operate for a minimum of 15 minutes
before checking or adjusting refrigerant charge.
IMPORTANT: 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 gauge hoses to low-- and high--pressure
service fittings, respectively.
3. Start unit and let run until system pressures stabilize.
4. Measure and record the following:
a. Outdoor ambient--air temperature (°F [°C] db).
b. Liquid line temperature (°F [°C]) at TXV.
c. Discharge (high--side) pressure (psig).
d. Suction (low--side) pressure (psig) (for reference only).
5. Using Cooling Charging Charts compare outdoor--air
temperature (°F [°C] db) with the discharge line pressure
CAUTION
Failure to follow this warning could result in personal
injury or death.
Disconnect electrical power to the unit and install lockout
tag before changing blower speed.
This unit has independent fan speeds for gas heating and cooling.
In addition, this unit has the field-selectable capability to run two
different cooling fan speeds: A normal cooling fan speed (350~400
CFM/Ton) and an enhanced dehumidification fan speed (As low as
320 CFM/Ton) for use with either a dehumidistat or a thermostat
that supports dehumidification.
The cooling speed is marked “LOW” on the interface fan board
(IFB) (See. Fig. 15) . The factory-shipped settings are noted in
Table 4. There are 4 additional speed tap wires available for use in
either electric heating or cooling (For color coding on the indoor
fan motor leads, see Table 3). The additional 4 speed tap wires are
shipped loose with vinyl caps and are located in the control box,
near the interface fan board (IFB) (See Fig. 15).
Single Cooling Fan Speed Set-up (Dehumidification
feature not used)
To change cooling speed:
1. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 3 for color coding). Add the wet coil
pressure drop in Table 5 to the system static to determine the
correct cooling airflow speed in Table 4 that will deliver the
nominal cooling airflow as listed in Table 1 for each size.
2. Remove the current speed tap wire from the “LOW”
terminal on the interface fan board (IFB) (See Fig. 15) and
place vinyl cap over the connector on the wire.
3. Connect the desired speed tap wire to the “LOW” terminal
on the interface fan board (IFB).
NOTE: If accessory electric heat is installed, and the
electric heat fan speed is chosen to be the same as the
normal cooling fan speed, the dry airflow must meet or
exceed the minimum airflow speed specified in Table 2 for
the specific size unit.
19
604D -- -- A
604D-- - A Sequence of Operation
604D -- -- A
Two Cooling Fan Speeds Set-up (Dehumidification
feature used)
IMPORTANT: Dehumidification control must open control
circuit on humidity rise above set point.
Use of the dehumidification cooling fan speed requires use of
either a 24 VAC dehumidistat or a thermostat which includes
control of a 24 VAC dehumidistat connection. In either case, the
dehumidification control must open the control circuit on humidity
rise above the dehumidification set point. Dehumidification
controls are available with the reverse logic; these must not be
used.
1. Using Fig. 15, move the two pin DEHUM jumper from the
“STD” position to the “DEHUM” position.
2. Remove fan speed tap wire from the “LOW” terminal on
the interface fan board (IFB) (See Fig. 15).
3. Determine correct normal cooling fan speed for unit and
application. Add the wet coil pressure drop in Table 5 to
the system static to determine the correct cooling airflow
speed in Table 4 that will deliver the nominal cooling
airflow as listed in Table 1 for each size.
NOTE: If accessory electric heat is installed, the dry
airflow must meet or exceed the minimum airflow speed
specified in Table 2 for the specific size unit. The electric
heat fan speed will be the same as the normal cooling fan
speed.
4. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 3 for color coding) for the normal cooling
fan speed and place desired speed tap wire on “HIGH” on
the interface board.
5. Refer to airflow tables (Table 4) to determine allowable
speeds for the dehumidification cooling fan speed. In Table
4, speeds that are not allowed for dehumidification cooling
are shaded.
6. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 3 for color coding) for the dehumidification
cooling fan speed and place desired speed tap wire on the
“LOW” connection on the interface board (IFB). Verify
that static pressure is in the acceptable range for the speed
tap to be used for dehumidification cooling.
7. Use any spare vinyl plugs to cap any unused speed tap
wires.
Table 3 – Color Coding for Indoor Fan Motor Leads
Black = High Speed
Orange = Med--High Speed
Red = Med Speed
Pink = Med--Low Speed
Blue = Low Speed
Single Speed Cooling With Higher Electric Heat Speed
This unit can also be configured to operate with single speed
cooling and a higher speed for an accessory electric heater.
1. Using Fig. 15, move the two pin DEHUM jumper from the
“STD” position to the “DEHUM” position.
2. See Table 2 for minimum airflow for electric heat operation.
Add electric heater and filter pressure drop to duct system
static pressure to determine total external static pressure.
3. Select speed tap from Table 4 that will achieve required
airflow from Table 2.
4. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 3 for color coding).
5. Connect the desired speed tap wire to the “HIGH” terminal
on the interface fan board (IFB).
!
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit component
damage or improper operation.
To use this mode, a speed connection must be made on the
“HIGH” terminal that meets or exceeds the minimum
airflow found in Table 2.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Disconnect electrical power to the unit and install lockout
tag before changing blower speed.
Continuous Fan Operation
When the DEHUM feature is not used, the continuous fan speed
will be the same as cooling fan speed. When the DEHUM feature
is used, the continuous fan will operate on IFB “LOW” speed
when the DH control lead is not energized, or IFB “HIGH” speed
when the DH lead is energized (see Fig. 15).
20
INDOOR COIL
OUTDOOR COIL
ACCUMULATOR
TXV in Metering
Position
HP S
Bypass
Position
LEGEND
HPS – High Pressure Switch
LCS – Loss of Charge Switch
Accurater® Metering De vice
Arrow indicates direction of flo w
C03011
Fig. 14 -- Typical Heat Pump Operation, Cooling Mode
QC5
LOW
COM
QC4
QC3
KL
KZ
09 0L0
08
ALO
R13 C8
R11
C
Q1
D2
QC1
Q3
C4
AL2
RL
G1
01
3AMP
C9
QCR
24VAC/R
07
DCR
CDM/C
STD
DEHUM
HIGH
G2
QIL
Z2
06
04
A7
R9
AB A15
C0
F1
Z1
U1
R4
C3
RL4
D5 D3
C7
JWZ
P3
JW5
R2
R3 R5 R6
P2
QCB
JW3
SDL
P4
Y
R
W2 Y
C
W3 W3 W2 W2 C
JW4
SSTZ-8
P1
Y1
W3 W2 Y2
DH G Y
C
R
A09059
Fig. 15 -- Interface Fan Board (IFB)
INDOOR COIL
OUTDOOR COIL
LCS
COMPRESSOR
ACCUMULATOR
TXV in Bypass
Position
HP S
Metering
Position
LEGEND
HPS – High Pressure Switch
LCS – Loss of Charge Switch
Accurater®Metering De vice
Arrow indicates direction of flo w
C03012
Fig. 16 -- Typical Heat Pump Operation, Heating Mode
21
604D -- -- A
COMPRESSOR
LCS
Step 3 — Defrost Control
!
Quiet Shift
Quiet Shift is a field--selectable defrost mode, which will eliminate
occasional noise that could be heard at the start of defrost cycle and
restarting of heating cycle. It is selected by placing DIP switch 3
(on defrost board) in ON position.
When Quiet Shift switch is placed in ON position, and a defrost is
initiated, the following sequence of operation will occur. Reversing
valve will energize, outdoor fan will turn off, compressor will turn
off for 30 sec and then turn back on to complete defrost. At the
start of heating after conclusion of defrost reversing valve will
de--energize, compressor will turn off for another 30 sec, and the
outdoor fan will stay off for 40 sec, before starting in the Heating
mode.
ELECTRICAL SHOCK HAZARD
Failure to follow these warnings could result in personal
injury or death:
1. Turn off electrical power to the unit and install a lockout
tag before performing any maintenance or service on this
unit.
2. Use extreme caution when removing panels and parts.
3. Never place anything combustible either on or in contact
with the unit.
!
604D -- -- A
Defrost
The defrost control is a time/temperature control which includes a
field--selectable time period (DIP switch 1 and 2 on the board)
between defrost cycles of 30, 60, 90, or 120 minutes (factory set at
60 minutes). To initiate a forced defrost, two options are available
depending on the status of the defrost thermostat.
If defrost thermostat is closed, speed--up pins (J1) must be shorted
by placing a flat head screw driver in between for 5 sec and
releasing, to observe a complete defrost cycle. When the Quiet
Shift switch is selected, compressor will be turned off for two 30
sec intervals during this complete defrost cycle, as explained
previously. When Quiet Shift switch is in factory default OFF
position, a normal and complete defrost cycle will be observed.
If defrost thermostat is in open position, and speedup pins are
shorted (with a flat head screw driver) for 5 sec and released, a
short defrost cycle will be observed (actual length is dependent
upon the selected Quiet Shift position). When Quiet Shift switch is
in ON position, the length of defrost is 1 minute (30 sec
compressor off period followed by 30 sec of defrost with
compressor operation). On return to heating operation, compressor
will again turn off for an additional 30 sec and the outdoor fan for
40 sec. When the Quiet Shift is in OFF position, only a brief 30
sec. cycle will be observed.
NOTE: Unit will remain in defrost until defrost thermostat
reopens at approximately 65_F (18_C) coil temperature at liquid
line or remainder of defrost cycle time.
MAINTENANCE
To ensure continuing high performance, and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment. This heat pump unit should
be inspected at least once each year by a qualified service person.
To troubleshoot unit, refer to Table 9.
NOTE: TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
!
WARNING
PERSONAL INJURY AND UNIT DAMAGE HAZARD
Failure to follow this warning could result in personal injury
or death and unit component damage.
The ability to properly perform maintenance on this
equipment 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 Owner’s Manual.
WARNING
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
When removing access panels (see Fig. 20) or performing
maintenance functions inside your unit, be aware of sharp
sheet metal parts and screws. Although special care is taken
to reduce sharp edges to a minimum, be extremely careful
when handling parts or reaching into the unit.
!
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper
operation.
Errors made when reconnecting wires may cause improper
and dangerous operation. Label all wires prior to
disconnecting when servicing.
The minimum maintenance requirements for this equipment are as
follows:
1. Inspect air filter(s) each month. Clean or replace when
necessary.
2. Inspect indoor coil, drain pan, and condensate drain each
cooling season for cleanliness. Clean when necessary.
3. Inspect blower motor and wheel for cleanliness each
cooling season. Clean when necessary.
4. Check electrical connections for tightness and controls for
proper operation each cooling season. Service when
necessary.
Step 1 — Air Filter
IMPORTANT: 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 filter(s) at least once each month and replace
(throwaway--type) or clean (cleanable--type) at least twice during
each cooling season and twice during the heating season, or
whenever the filter becomes clogged with dust and lint.
Indoor Blower and Motor
NOTE: All motors are pre--lubricated. Do not attempt to lubricate
these motors.
NOTE: 460 volt units have a stepdown autotransformer that
supplies approximately 230 volts to a nominal 230 volt indoor
blower motor.
For longer life, operating economy, and continuing efficiency,
clean accumulated dirt and grease from the blower wheel and
motor annually.
22
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Disconnect and install lockout tag on electrical power to the
unit before cleaning and lubricating the blower motor and
wheel.
To clean the blower motor and wheel:
1. Remove and disassemble blower assembly as follows:
a. Remove blower access panel (see Fig. 20).
b. Disconnect 5 pin plug and 4 pin plug from indoor
blower motor. Remove capacitor if required.
c. On all units remove blower assembly from unit.
Remove screws securing blower to blower partition and
slide assembly out. Be careful not to tear insulation in
blower compartment.
d. Ensure proper reassembly by marking blower wheel and
motor in relation to blower housing before disassembly.
e. Loosen setscrew(s) that secures wheel to motor shaft,
remove screws that secure motor mount brackets to
housing, and slide motor and motor mount out of
housing.
2. Remove and clean blower wheel as follows:
a. Ensure proper reassembly by marking wheel orientation.
b. Lift wheel from housing. When handling and/or
cleaning blower wheel, be sure not to disturb balance
weights (clips) on blower wheel vanes.
c. Remove caked--on dirt from wheel and housing with a
brush. Remove lint and/or dirt accumulations from
wheel and housing with vacuum cleaner, using soft
brush attachment. Remove grease and oil with mild
solvent.
d. Reassemble wheel into housing.
e. Reassemble motor into housing. Be sure setscrews are
tightened on motor shaft flats and not on round part of
shaft. Reinstall blower into unit. Reinstall capacitor if
required.
f. Connect 5 pin plug and 4 pin plug to indoor blower
motor.
g. Reinstall blower access panel (see Fig. 20).
3. Restore electrical power to unit. Start unit and check for
proper blower rotation and motor speeds during cooling
cycles.
Step 2 — Outdoor Coil, Indoor Coil, and
Condensate Drain Pan
Inspect the condenser coil, evaporator coil, and condensate drain
pan at least once each year.
The coils are easily cleaned when dry; therefore, inspect and clean
the coils either before or after each cooling season. Remove all
obstructions, including weeds and shrubs, that interfere with the
airflow through the condenser coil.
Straighten bent fins with a fin comb. If coated with dirt or lint,
clean the coils with a vacuum cleaner, using the soft brush
attachment. Be careful not to bend the fins. If coated with oil or
grease, clean the coils with a mild detergent--and--water solution.
Rinse coils with clear water, using a garden hose. Be careful not to
splash water on motors, insulation, wiring, or air filter(s). For best
results, spray condenser coil fins from inside to outside the unit. On
units with an outer and inner condenser coil, be sure to clean
between the coils. Be sure to flush all dirt and debris from the unit
base.
Inspect the drain pan and condensate drain line when inspecting
the coils. Clean the drain pan and condensate drain by removing all
foreign matter from the pan. Flush the pan and drain trough with
clear water. Do not splash water on the insulation, motor, wiring, or
air filter(s). If the drain trough is restricted, clear it with a plumbers
snake or similar probe device.
Step 3 — Outdoor Fan
Keep the condenser fan free from all obstructions to ensure
proper cooling operation. Never place articles on top of the
unit. Damage to unit may result.
1. Remove 6 screws holding outdoor grille and motor to top
cover.
2. Turn motor/grille assembly upside down on top cover to
expose fan blade.
3. Inspect the fan blades for cracks or bends.
4. If fan needs to be removed, loosen setscrew and slide fan off
motor shaft.
5. When replacing fan blade, position blade back to same position as before.
6. Ensure that setscrew engages the flat area on the motor shaft
when tightening.
7. Replace grille.
23
604D -- -- A
!
Table 4 – Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -- Unit 604D----A24--60 Series A
EXTERNAL STATIC PRESSURE (IN. W.C.)
MOTOR
WIRE
SPEED
COLOR
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
Blue
CFM
754
650
538
429
--- --- ----- --- ----- --- --Med---Low
Pink
CFM
851
777
675
591
475
--- --- ----- --- --604D --- ---A24
Medium1
Red
CFM
941
851
774
684
576
479
--- --- --Med---High
Orange
CFM
1009
917
840
759
667
577
447
High
Black
CFM
1241
1167
1111
1036
969
881
818
Low
Blue
CFM
741
638
547
415
--- --- ----- --- ----- --- --Med---Low
Pink
CFM
973
887
823
733
665
538
451
604D --- ---A30
Medium
Red
CFM
1088
1023
954
881
800
723
658
1
Med---High
Orange
CFM
1140
1064
996
915
840
758
687
High
Black
CFM
1202
1140
1082
1015
961
881
810
Low
Blue
CFM
1234
1168
1093
1021
961
894
825
Med---Low
Pink
CFM
1290
1223
1154
1090
1027
977
894
604D --- ---A36
Medium1
Red
CFM
1354
1290
1226
1158
1102
1046
981
Med---High
Orange
CFM
1606
1546
1489
1430
1371
1316
1258
High
Black
CFM
1630
1580
1517
1463
1407
1339
1277
Low
Blue
CFM
1295
1234
1182
1126
1075
1016
955
Med---Low
Pink
CFM
1345
1282
1235
1194
1140
1095
1027
604D --- ---A42
Medium
Red
CFM
1505
1452
1413
1358
1323
1282
1234
Med---High1
Orange
CFM
1545
1492
1449
1411
1362
1313
1278
High
Black
CFM
1705
1643
1607
1568
1518
1483
1448
Low
Blue
CFM
1402
1351
1311
1263
1224
1172
1136
Med---Low
Pink
CFM
1457
1404
1367
1318
1284
1233
1197
604D --- ---A48
Medium1
Red
CFM
1736
1695
1642
1601
1553
1512
1465
Med---High
Orange
CFM
2149
2111
2062
2026
1980
1945
1905
High
Black
CFM
2344
2306
2259
2203
2141
2070
1991
Low
Blue
CFM
1445
1389
1341
1281
1236
1189
1139
Med---Low
Pink
CFM
1678
1635
1602
1558
1513
1474
1438
604D --- ---A60
Medium1
Red
CFM
1927
1893
1858
1824
1791
1759
1720
Med---High
Orange
CFM
2131
2088
2065
2013
1982
1941
1888
High
Black
CFM
2461
2409
2339
2286
2192
2140
2062
* Air delivery values are without air filter and are for dry coil (See 604D --- ---A Wet Coil Pressure Drop Table).
1 Factory ---shipped cooling speed
NOTE: Deduct field---supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting.
Shaded areas indicate speed/static combinations that are not permitted for dehumidification speed.
604D -- -- A
UNIT
0.8
--- --- ----- --- ----- --- ----- --- --731
--- --- ----- --- --563
564
732
759
828
918
1208
1210
898
974
1169
1231
1404
1080
1144
1427
1864
1902
1072
1404
1689
1860
1968
0.9
--- --- ----- --- ----- --- ----- --- --640
--- --- ----- --- --461
480
631
687
762
843
1140
1131
857
921
1130
1188
1360
1041
1104
1381
1793
1803
1027
1349
1640
1785
1874
Table 5 – 604D----A Wet Coil Pressure Drop (IN. W.C.)
UNIT SIZE
500
24
30
36
42
48
60
600
0.06
700
0.07
800
0.08
0.12
900
0.09
0.15
STANDARD CFM (S.C.F.M)
1100
1200
1300
1400
1000
0.1
0.19
0.07
0.23
0.11
0.27
0.18
0.04
0.26
0.07
1500
1600
1700
1800
1900
2000
0.15
0.14
0.21
0.17
0.1
0.22
0.17
0.28
0.23
0.31
0.36
0.35
0.1
0.11
Table 6 – Wet Coil Air Delivery (CFM) -- Downflow -- High Speed with 1--in. (25 mm) Filter and Economizer
UNIT SIZE
0.1
1333
1612
2166
2298
36
42
48
60
0.2
1289
1569
2085
2239
0.3
1256
1527
2002
2180
EXTERNAL STATIC PRESSURE (IN. W.C.)
0.4
1214
1481
1919
2110
0.5
1152
1451
1798
2044
0.6
1118
1393
1709
1951
0.7
1076
1351
1582
1862
0.8
1035
1317
1467
1777
0.9
997
1278
1270
1697
1.0
950
1242
988
1591
Table 7 – Filter Pressure Drop Table (IN. W.C.)
500
600
700
800
900
1000
1100
1200
1300
CFM
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
20X20X1
(508X508X25)
0.05
0.07
0.08
0.1
0.12
0.13
0.14
0.15
—
—
—
—
—
—
—
—
—
—
—
20X24X1
(508X610x25)
—
—
—
.09
.10
.11
.13
.14
.15
.16
—
—
—
—
—
—
—
—
—
24X30X1
(610X762x25)
—
—
—
0.04
0.05
0.06
0.07
0.07
0.08
0.09
0.1
—
—
—
—
—
—
—
—
24X36X1
(610X914X25)
—
—
—
—
—
—
—
0.06
0.07
0.07
0.08
0.09
0.09
0.10
0.11
0.12
0.13
0.14
0.14
FILTER SIZE
in. (mm)
Table 8 – Electric Heat Pressure Drop Table (IN. W.C.)
Small Cabinet: 24--36 cfm
5kw
7.5 kw
10 kw
15 kw
20 kw
500
0.00
0.00
0.00
0.00
0.00
600
0.00
0.00
0.00
0.00
0.00
700
0.00
0.00
0.00
0.00
0.02
800
0.00
0.00
0.00
0.02
0.04
900
0.00
0.00
0.00
0.04
0.06
1000
0.00
0.00
0.02
0.06
0.08
1100
0.00
0.02
0.04
0.08
0.09
1200
0.00
0.03
0.06
0.10
0.11
1300
0.02
0.05
0.07
0.12
0.13
1400
0.04
0.07
0.09
0.14
0.15
1500
0.06
0.08
0.10
0.16
0.17
1600
0.07
0.09
0.11
0.18
0.19
Electric Heat Pressure Drop Table (IN. W.C.)
Large Cabinet 42--60 cfm
5kw
7.5 kw
10 kw
15 kw
20 kw
1100
0.00
0.00
0.00
0.00
0.02
1200
0.00
0.00
0.00
0.02
0.03
1300
0.00
0.01
0.01
0.03
0.04
1400
0.01
0.02
0.02
0.04
0.05
1500
0.02
0.03
0.03
0.05
0.06
1600
0.03
0.04
0.04
0.06
0.07
1700
0.04
0.05
0.05
0.07
0.08
1800
0.05
0.06
0.06
0.08
0.09
24
1900
0.06
0.07
0.07
0.09
0.10
2000
0.07
0.08
0.08
0.10
0.11
2100
0.08
0.09
0.09
0.11
0.12
2200
0.09
0.10
0.10
0.12
0.13
2300
0.10
0.11
0.11
0.13
0.14
2400
0.11
0.12
0.12
0.14
0.15
2500
0.12
0.13
0.13
0.15
0.16
604D -- -- A
A09070
Fig. 17 -- Cooling Charging Table--Subcooling
25
T1
Y
P1
30
30
60
120
60
P3
ON
DFT
QUIET
SHIFT
90
INTERVAL TIMER OFF
J1
SPEEDUP
604D -- -- A
OF1
DFT
OF2
T2 C C O
O R W2 Y C
Speedup
Pins
Quiet
Shift
Defrost interval
DIP switches
A08020
Fig. 18 -- Defrost Control
Step 4 — Electrical Controls and Wiring
Inspect and check the electrical controls and wiring annually. Be
sure to turn off the electrical power to the unit.
Remove access panels (see Fig. 20) to locate all the electrical
controls and wiring. Check all electrical connections for tightness.
Tighten all screw connections. If any discolored or burned
connections are noticed, disassemble the connection, clean all the
parts, restrip the wire end and reassemble the connection properly
and securely.
After inspecting the electrical controls and wiring, replace all the
panels. Start the unit, and observe at least one complete cooling
cycle to ensure proper operation. If discrepancies are observed in
operating cycle, or if a suspected malfunction has occurred, check
each electrical component with the proper electrical
instrumentation. Refer to the unit wiring label when making these
checkouts.
Step 5 — Refrigerant Circuit
Inspect all refrigerant tubing connections and the unit base for oil
accumulation annually. Detecting oil generally indicates a
refrigerant leak.
If oil is detected or if low performance is suspected, leak--test all
refrigerant tubing using an electronic leak detector, or liquid--soap
solution. If a refrigerant leak is detected, refer to Check for
Refrigerant Leaks section.
If no refrigerant leaks are found and low performance is suspected,
refer to Checking and Adjusting Refrigerant Charge section.
C99097
Fig. 19 -- Refrigerant Circuit
26
High pressure may be caused by a dirty outdoor coil, failed fan
motor, or outdoor air recirculation.
To check switch:
1. Turn off all power to unit.
2. Disconnect leads on switch.
3. Apply ohm meter leads across switch. You should have
continuity on a good switch.
Step 11 — Copeland Scroll Compressor (Puron
Refrigerant)
The compressor used in this product is specifically designed to
operate with Puron (R--410A) refrigerant and cannot be
interchanged.
COMPRESSOR
ACCESS PANEL
BLOWER
ACCESS
PANEL
EXPLOSION HAZARD
CONTROL
ACCESS
PANEL
Failure to follow this warning could result in personal injury,
death or property damage.
Wear safety glasses and gloves when handling refrigerants.
Keep torches and other ignition sources away from refrigerant
and oils.
A09207
Fig. 20 -- Unit Access Panels
Step 6 — Indoor Airflow
The heating and/or cooling airflow does not require checking
unless improper performance is suspected. If a problem exists, be
sure that all supply--air and return--air grilles are open and free
from obstructions, and that the air filter is clean. When necessary,
refer to Indoor Airflow and Airflow Adjustments section to check
the system airflow.
Step 7 — Metering Devices--TXV & Piston
This unit uses 2 types of metering devices. The outdoor metering
device is a fixed orifice and is contained in the brass hex--body in
each liquid line feeding the outdoor coils. The indoor metering
device is a TXV type device.
Step 8 — Pressure Switches
Pressure switches are protective devices wired into control circuit
(low voltage). They shut off compressor if abnormally high or low
pressures are present in the refrigeration circuit. These pressure
switches are specifically designed to operate with Puron (R--410A)
systems. R--22 pressure switches must not be used as replacements
for the Puron (R--410A) system.
The scroll compressor pumps refrigerant throughout the system by
the interaction of a stationary and an orbiting scroll. The scroll
compressor has no dynamic suction or discharge valves, and it is
more tolerant of stresses caused by debris, liquid slugging, and
flooded starts. The compressor is equipped with an internal
pressure relief port. The pressure relief port is a safety device,
designed to protect against extreme high pressure. The relief port
has an operating range between 550 and 625 psig differential
pressure.
Step 12 — Refrigerant System
This step covers the refrigerant system of the 604D----A, including
the compressor oil needed, servicing systems on roofs containing
synthetic materials, the filter drier and refrigerant charging.
Refrigerant
!
NOTE: Because these switches are attached to refrigeration
system under pressure, it is not advisable to remove this device for
troubleshooting unless you are reasonably certain that a problem
exists. If switch must be removed, remove and recover all system
charge so that pressure gauges read 0 psi. Never open system
without breaking vacuum with dry nitrogen.
Step 10 — High--Pressure Switch
The high--pressure switch is located in the discharge line and
protects against excessive condenser coil pressure. It opens at 650
psig.
WARNING
PROPERTY HAZARD, PERSONAL INJURY OR
ENVIRONMENTAL HAZARD
Step 9 — Loss of Charge Switch
This switch is located on the liquid line and protects against low
suction pressures caused by such events as loss of charge, low
airflow across indoor coil, dirty filters, etc. It opens on a pressure
drop at about 20 psig. If system pressure is above this, switch
should be closed. To check switch:
1. Turn off all power to unit.
2. Disconnect leads on switch.
3. Apply ohm meter leads across switch. You should have
continuity on a good switch.
WARNING
Failure to follow this warning could result in property damage
or personal injury or death.
This system uses Puron (R--410A) refrigerant which has
higher operating pressures than R--22 and other refrigerants.
No other refrigerant may be used in this system. Gauge set,
hoses, and recovery system must be designed to handle Puron.
If you are unsure consult the equipment manufacturer.
Compressor Oil
The Copeland scroll compressor uses 3MAF POE oil. If additional
oil is needed, use Uniqema RL32--3MAF. If this oil is not
available, use Copeland Ultra 32 CC or Mobil Arctic EAL22 CC.
This oil is extremely hygroscopic, meaning it absorbs water
readily. POE oils can absorb 15 times as much water as other oils
designed to HCFC and CFC refrigerants. Take all necessary
precautions to avoid exposure of the oil to the atmosphere.
Servicing Systems on Roofs with Synthetic Materials
POE (polyolester) compressor lubricants are known to cause long
term damage to some synthetic roofing materials. Exposure, even if
immediately cleaned up, may cause embrittlement (leading to
cracking) to occur in one year or more. When performing any
service that may risk exposure of compressor oil to the roof, take
appropriate precautions to protect roofing. Procedures which risk
oil leakage include, but are not limited to, compressor replacement,
27
604D -- -- A
!
604D -- -- A
repairing refrigerant leaks, replacing refrigerant components such
as filter drier, pressure switch, metering device, coil, accumulator,
or reversing valve.
Synthetic Roof Precautionary Procedure
1. Cover extended roof working area with an impermeable
polyethylene (plastic) drip cloth or tarp. Cover an
approximate 10x10 ft (3x3 m) area.
2. Cover area in front of the unit service panel with a terry
cloth shop towel to absorb lubricant spills and prevent
run--offs, and protect drop cloth from tears caused by tools
or components.
3. Place terry cloth shop towel inside unit immediately under
component(s) to be serviced and prevent lubricant run--offs
through the louvered openings in the unit base.
4. Perform required service.
5. Remove and dispose of any oil contaminated material per
local codes.
NOTE: Because these switches are attached to refrigeration
system under pressure, it is not advisable to remove this device for
troubleshooting unless you are reasonably certain that a problem
exists. If switch must be removed, remove and recover all system
charge so that pressure gauges read 0 psi. Never open system
without breaking vacuum with dry nitrogen.
Check Defrost Thermostat
The defrost thermostat signals heat pump that conditions are right
for defrost or that conditions have changed to terminate defrost. It
is a thermally actuated switch clamped to outdoor coil to sense its
temperature. Normal temperature range is closed at 32_  3_F (0
 1.7_C) and open at 65_  5_F (18  2.8_C).
NOTE: The defrost thermostat is usually located on the lowest
liquid leaving circuit of the left condenser coil.
FEEDER TUBE
STUB TUBE
Liquid Line Filter Drier
The biflow filter drier is specifically designed to operate with
Puron. Use only factory--authorized components. Filter drier must
be replaced whenever the refrigerant system is opened. When
removing a filter drier, use a tubing cutter to cut the drier from the
system. Do not unsweat a filter drier from the system. Heat from
unsweating will release moisture and contaminants from drier into
system.
DEFROST
THERMOSTAT
Puron (R-- 410A) Refrigerant Charging
Refer to unit information plate and charging chart. Some R--410A
refrigerant cylinders contain a dip tube to allow liquid refrigerant to
flow from cylinder in upright position. For cylinders equipped
with a dip tube, charge Puron units with cylinder in upright
position and a commercial metering device in manifold hose.
Charge refrigerant into suction--line.
Step 13 — System Information
Loss of Charge Switch
The loss of charge switch is a protective device wired into control
circuit (low voltage). It shuts off the compressor if abnormally low
pressures are present in the refrigeration circuit.
C99029
Fig. 21 -- Defrost Thermostat
TROUBLESHOOTING
Refer to the Cooling and Heating Troubleshooting Chart (Table 9)
for troubleshooting information.
START--UP CHECKLIST
Use the Start--Up Checklist.
28
PURONR (R--410A) QUICK REFERENCE GUIDE
Puron refrigerant operates at 50--70 percent higher pressures than R--22. Be sure that servicing equipment and replacement
components are designed to operate with Puron
S Puron refrigerant cylinders are rose colored.
S
S
S
Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose when
S
Manifold sets should be minimum 700 psig high side and 180 psig low side with 550 psig low--side retard.
S
Use hoses with minimum700 psig service pressure rating.
S
Leak detectors should be designed to detect HFC refrigerant.
S
Puron, as with other HFCs, is only compatible with POE oils.
S
Vacuum pumps will not remove moisture from oil.
S
Do not use liquid--line filter driers with rated working pressures less than 600 psig.
S
Do not leave Puron suction line filter driers in line longer than 72 hours.
S
Do not install a suction--line filter drier in liquid line.
S
POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
S
POE oils may cause damage to certain plastics and roofing materials.
S
Wrap all filter driers and service valves with wet cloth when brazing.
S
A factory approved liquid--line filter drier is required on every unit.
S
Do NOT use an R--22 TXV.
S
Never open system to atmosphere while it is under a vacuum.
S
When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and replace filter
driers. Evacuate to 500 microns prior to recharging.
S
Do not vent Puron into the atmosphere.
S
Observe all warnings, cautions, and bold text.
S
All indoor coils must be installed with a hard shutoff Puron TXV metering device.
29
604D -- -- A
charging into suction line with compressor operating
Table 9 – Troubleshooting Chart
SYMPTOM
Compressor and condenser fan will not start.
CAUSE
Power failure
Fuse blown or circuit breaker tripped
Defective contactor, transformer, or high--pressure,
loss--of--charge or low--pressure switch
Insufficient line voltage
Incorrect or faulty wiring
Thermostat setting too high
Compressor will not start but condenser fan
runs
Faulty wiring or loose connections in compressor circuit
Compressor motor burned out, seized, or
internal overload open
Defective run/start capacitor, overload, start relay
604D -- -- A
One leg of 3--phase power dead
Three--phase scroll compressor
makes excessive noise, and there may be a
low pressure differential.
Scroll compressor is rotating in the wrong direction
Refrigerant overcharge or undercharge
Compressor cycles (other than normally satisfying thermostat).
Compressor operates continuously
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
Dirty air filter
Unit undersized for load
Thermostat set too low
Low refrigerant charge
Mechanical damage in compressor
Air in system
Excessive head pressure
Condenser coil dirty or restricted
Dirty air filter
Dirty condenser coil
Refrigerant overcharged
Air in system
Head pressure too low
Excessive suction pressure
Suction pressure too low
Condenser air restricted or air short--cycling
Low refrigerant charge
Compressor IPR leaking
Restriction in liquid tube
High heat load
Compressor IPR leaking
Refrigerant overcharged
Dirty air filter
Low refrigerant charge
Metering device or low side restricted
Insufficient evaporator airflow
Temperature too low in conditioned area
Outdoor ambient below 55°F (12.7°C)
Filter drier restricted
30
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
Correct the direction of rotation by reversing the
3--phase power leads to the unit.
Recover refrigerant, evacuate system, and recharge to capacities shown on rating plate
Replace and determine cause
Determine cause and correct
Determine cause and correct
Determine cause and replace
Replace thermostat
Replace
Locate restriction and remove
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–replace if necessary
Reset thermostat
Install low--ambient kit
Replace filter
START--UP CHECKLIST
(Remove and Store in Job Files)
II. PRESTART--UP (Insert check mark in box as each item is completed)
( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS
( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS
( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE
( ) VERIFY THAT UNIT INSTALLATION IS LEVEL
( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS
III. START--UP
ELECTRICAL
SUPPLY VOLTAGE
COMPRESSOR AMPS
INDOOR (EVAPORATOR) FAN AMPS
TEMPERATURES
OUTDOOR (CONDENSER) AIR TEMPERATURE
DB
RETURN--AIR TEMPERATURE
DB
WB
COOLING SUPPLY AIR
DB
WB
HEAT PUMP SUPPLY AIR __________________
ELECTRIC HEAT SUPPLY AIR_______________
PRESSURES
REFRIGERANT SUCTION
PSIG, SUCTION LINE TEMP*
REFRIGERANT DISCHARGE
PSIG, LIQUID TEMP{
( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS
* Measured at suction inlet to compressor
{ Measured at liquid line leaving condenser.
31
604D -- -- A
I. PRELIMINARY INFORMATION
MODEL NO.:
SERIAL NO.:
DATE:
TECHNICIAN:
604D -- -- A
VERTICAL ECONOMIZER
(FACTORY INSTALLED OPTION)
GENERAL
Economizers are recommended for only commercial packaged
products that have X13 motors. The Economizer system utilizes
the latest technology available for integrating the use of free
cooling with mechanical cooling for rooftop units. The solid state
control system optimizes energy consumption, zone comfort, and
equipment cycling by operating the compressors when the outdoor
air temperature is too warm, integrating the compressor with
outdoor air when free cooling is available, and locking out the
compressor when outdoor air temperature is too cold. Demand
ventilation is supported.
The Economizer system utilizes gear--drive technology with a
direct--mount spring return actuator that will close upon loss of
power. The Economizer system comes standard with an outdoor air
temperature sensor, a supply air temperature sensor, and low
temperature compressor lockout switch. Indoor enthalpy, outdoor
enthalpy, and CO2 sensors are available for field installation.
Barometric relief dampers provide natural building pressurization
control. Barometric relief dampers are built into the design and are
standard. See Table 10 for Hood Package contents. See Table 11
for sensor usage.
Table 10 – Package Contents
SMALL CHASSIS
(Sizes 30 and 36)
LARGE CHASSIS
(Sizes 42, 48, and 60)
Qty
Content Description
Qty
Content Description
1
Hood Side, Right
1
Hood Side, Right
1
Hood Side, Left
1
Hood Side, Left
2
Angle, Filter
2
Angle, Filter
1
Aluminum Filter
(20--- 1/2” x 16--- 1/2 x 1”)
(521 x 419 x 25 mm)
1
Aluminum Filter
(20--- 1/2” x 16--- 1/2 x 1”)
(521 x 419 x 25 mm)
18
Screws
(#10 --- 14 x 5/8” w/Seal
Washer)
18
Screws
(#10 --- 14 x 5/8” w/Seal
Washer)
2
Screws
(#8 --- 18 x 3/4” Type B Pan
Head)
2
Screws
(#8 --- 18 x 3/4” Type B Pan
Head)
1
Bracket, Sensor
Table 11 – Economizer Sensor Usage
APPLICATION
ECONOMIZER WITH OUTDOOR AIR DRY BULB
SENSOR
Accessories Required
Outdoor Air Dry Bulb
None, The outdoor air dry bulb sensor is factory
installed.
Single Enthalpy
HH57AC078
Differential Enthalpy
HH57AC078 and CRENTDIF004A00*
CO2 for DCV Control
Using a Wall--- Mounted
CO2 Sensor
33ZCSENC02 or CGCDXSEN004A00
CO2 for DCV Control
Using a Duct--Mounted CO2 Sensor
33ZCSENC02 or
CGCDXSEN004A00{
and 33ZCASPCO2 or
CGCDXASP00100**
or
ACCESSORIES
The economizer has several field--installed accessories available to
optimize performance. Refer to Table 12 for authorized parts.
Table 12 – Accessory List
DESCRIPTION
PART NUMBER
Outdoor Air Enthalpy Sensor
HH57AC078
Indoor Air Enthalpy Sensor
CRENTDIF004A00
Return Air CO2 Sensor (4--- 20 mA)
CRCBDIOX005A00
CO2 Room Sensor (4--- 20 mA)
33ZCSENX02 Or
CGCDXSEN004A00
Aspirator Box for duct Mount CO2 Sensor
(4--- 20 mA)
33ZCASPC02 Or
CGCDXASP001A00
Space Temperature and CO2 Room
Sensor with Override (4--- 20mA)
33ZCT55C02
Space Temperature and CO2 Room
Sensor with Override and Set Point
(4--- 20mA)
33ZCT56C02
Heat Pump Relay Package
CPRLYKIT001A00
INSTALLATION
Small Chassis
To install the Vertical Economizer on the small chassis perform the
following procedure:
1. Turn off unit power supply and install lockout tag.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be more
than one disconnect switch. Turn off accessory heater
power switch if applicable.
2. Remove economizer hood top panel from the return side of
the unit. See Fig. 22. Keep screws and panel next to the
unit.
3. Open economizer hood package found on the top skid.
4. Remove red shipping tape that attaches the outside air
temperature (OAT) sensor to the economizer assembly.
Using two #8 fasteners, found in the hood package, attach
the OAT sensor to the economizer according to Fig. 23.
NOTE: See label attached to economizer for OAT installing
details.
5. Remove horizontal return duct cover panel and cut the wire
ties that hold the hood divider to the economizer assembly.
Slide hood divider off from the two slots holding it in place
and place next to the unit. See Fig. 24.
CRCBDIOX005A00{ {
*CRENTDIF004A00 accessory is used on many different base units. As
such, these kits may contain parts that will not be needed for installation.
{33ZCSENCO2 and CGCDXSEN004A00 are accessory CO2 sensors.
**33ZCASPC02 AND CGCDXASP00100 are accessory aspirator boxes
required for duct---mounted applications.
{{CRCBDIOX005A00 is an accessory that contains both 33ZCSENCO2
AND 33ZVASPC02 accessories.
32
OAT Sensor
Table 13 – Filter Part Number
Hood Top
Panel
DESCRIPTION
A09689
Fig. 22 -- Economizer Hood Top Panel Removal
Indoor Coil Air Filter
OAT Sensor
A09690
Fig. 23 -- Oat Sensor Installed
12 x 20 x 1
(304.8 x 508 x 25.4 mm)
PART NUMBER
KH01AA312
NOTE: The economizer control settings and the filters are
accessible through the filter access door.
13. Economizer controls are set to a standard factory setting.
Nevertheless, you can adjust these settings through the filter
access door. Review the settings in the Operation section:
(2.) The standard economizer controller has a factory
setting of “C” for the outdoor air temperature
changeover and 63_F (17_C) for the supply air
(mixed air) temperature sensor. The outdoor air
temperature changeover setting is adjusted on the
sensor by setting the dip switches on the sensor.
The ABCD potentiometer on the economizer
control should be set to the “D” position.
(3.) The low ambient compressor lockout switch setting
is fixed at 42_F (5.6_C).
(4.) The minimum position for the outdoor air damper
can be configured at the controller. When not using
a CO2 sensor, the DCV Max potentiometer must be
completely closed (CCW) for the Minimum Position potentiometer to function correctly.
(5.) Settings for the optional outdoor enthalpy sensor,
indoor enthalpy sensor, and CO2 sensor can also be
configured at the controller.
14. Replace the filter access panel. Screw in place ensuring all
seams are air and watertight.
15. Install all economizer accessories then power HVAC unit
and test cycle economizer.
33
604D -- -- A
6. Replace horizontal return duct cover panel. Screw in place
ensuring all seams are air and watertight.
7. Install the 2 angle filter brackets to the right and left hood
side panels respectively with the #10 screws provided. See
Fig. 25.
8. Assemble hood according to Fig. 26 screwing together with
provided #10 sheet metal screws.
9. Install assembled hood over the economizer opening in the
replacement return chamber panel. See Fig. 27. Screw in
place through pre-punched holes. Make sure all seams are
air and watertight.
NOTE: The two wires that connect to the outside air temperature
sensor (OAT) should remain accessible.
10. Connect the outside air temperature sensor (OAT) to the
economizer per wiring diagram.
11. Open the filter clips on the inside of the hood top. Insert the
aluminum filter into the hood and close the clips to hold in
place. See Fig. 28.
12. To replace 12 x 20 x1 (304.8mm x 508mm x 25.4mm) air
filters, open the filter access door (horizontal return duct
cover panel), remove old filters and install new disposable
filters in filter rack. See Table 13 for filter part number.
604D -- -- A
Hood
Divider
(Removed)
Hood
Divider
Horizontal
Return
Duct Cover
Panel
A09691
Fig. 24 -- Horizontal Return Duct Cover Panel Removal
Right Hood
Side Panel
Left Hood
Side Panel
Filter Angle Bracket
Filter Angle Bracket
A09692
Fig. 25 -- Filter Angle Bracket Installation
34
Hood Top Panel
Hood Divider
Left Hood
Side Panel
A09693
Fig. 26 -- Economizer Hood Assembly
Filter Clips
Aluminum
Filter
A09694
Fig. 27 -- Economizer Hood Installation
A09695
Fig. 28 -- Filter Installation (See Through View)
35
604D -- -- A
Right Hood
Side Panel
Large Chassis
To install the Vertical Economizer on the large chassis perform the
following procedure:
1. Turn off unit power supply and install lockout tag.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
604D -- -- A
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be more
than one disconnect switch. Turn off accessory heater
power switch if applicable.
7. Install the 2 angle filter brackets to the right and left hood
side panels respectively with the #10 screws provided. See
Fig. 32.
8. Assemble hood according to Fig. 33 screwing together
with provided #10 sheet metal screws.
9. Install assembled hood over the economizer opening in the
replacement return chamber panel. See Fig. 34. Screw in
place through pre-punched holes. Make sure all seams are
air and watertight.
NOTE: The two wires that connect to the outside air temperature
sensor (OAT) should remain accessible.
10. Connect the outside air temperature sensor (OAT) to the
economizer per wiring diagram.
2. Remove economizer hood top panel from the return side of
the unit. See Fig. 29. Keep screws and panel next to the
unit.
3. Remove red shipping tape that attaches the outside air
temperature (OAT) sensor to the economizer assembly and
place sensor next to the unit.
4. Remove horizontal return duct cover panel and cut the wire
ties that hold the hood divider to the economizer assembly.
Slide hood divider off from the two slots holding it in place
and place next to the unit. See Fig. 30.
5. Replace horizontal return duct cover panel. Screw in place
ensuring all seams are air and watertight.
6. Open economizer hood package found on the top skid.
Mount OAT sensor to its assigned bracket by screwing
together with provided two #8 fasteners. Afterwards install
OAT sensor to the right side hood panel with the provided
#10 screws. See Fig. 31.
Filter Access
Panel
Hoop Top
Panel
OAT Sensor
A09696
Fig. 29 -- Economizer Hood Top Panel Removal
Hood Divider
(Removed)
Horizontal
Return Duct
Cover Panel
Hood
Divider
A09697
Fig. 30 -- Horizontal Return Duct Cover Panel and Hood Divider Removal
36
Left Hood
Side Panel
Filter Angle
Bracket
Right Hood
Side Panel
Filter Angle Bracket
Left Hood Side
Right Hood Side
A09699
Fig. 32 -- Filter Angle Bracket Installation
37
604D -- -- A
A09698
Fig. 31 -- OAT Bracket Installation
Right Hood
Side Panel
Hood Top Panel
Left Hood
Side Panel
604D -- -- A
Hood
Divider
A09700
Fig. 33 -- Hood Assembly
NOTE: The economizer control settings and the filters are
accessible through the filter access door.
Table 14 – Filter Part Number
DESCRIPTION
Straight Indoor
Coil Air Filter
Bent Indoor
Coil Air Filter
PART NUMBER
14 x 24 x 1
(355.6 x 609.6 x 25.4 mm)
KH01AA314
16 x 24 x 1
(406.4 x 609.6 x 25.4 mm)
KH01AA316
16 x 24 x 1
(406.4 x 609.6 x 25.4 mm)
KH01AA316
18 x 24 x 1
(457.2 x 609.5 x 25.4 mm)
KH01AA318
13. Economizer controls are set to a standard factory setting.
Nevertheless, you can adjust these settings through the filter
access door. Review the settings in the Operation section:
(1.) The standard economizer controller has a factory
setting of “C” for the outdoor air temperature
changeover and 63_F (17_C) for the supply air
(mixed air) temperature sensor. The outdoor air
temperature changeover setting is adjusted on the
sensor by setting the dip switches on the sensor.
The ABCD potentiometer on the economizer
control should be set to the “D” position.
(2.) The low ambient compressor lockout switch setting
is fixed at 42_F (5.6_C).
(3.) The minimum position for the outdoor air damper
can be configured at the controller. When not using
a CO2 sensor, the DCV Max potentiometer must be
completely closed (CCS) for the Minimum Position potentiometer to function correctly.
(4.) Settings for the optional outdoor enthalpy sensor,
indoor enthalpy sensor, and CO2 sensor can also be
configured at the controller.
14. Replace the filter access panel. Screw in place ensuring all
seams are air and watertight.
15. Install all economizer accessories then power HVAC unit
and test cycle economizer.
A09701
Fig. 34 -- Economizer Hood Installation
11. Open the filter clips on the inside of the hood top. Insert the
aluminum filter into the hood and close the clips to hold in
place. See Fig. 35.
12. To replace air filters, open filter access door remove old
filters and install new disposable filters in filter rack. See
Table 14 for filter part numbers.
IMPORTANT: On the the bent coil (See Fig. 36 to determine coil
type) filter rack, the 18 x 24 x 1 (257.2mm x 609.6mm x25.4mm)
filter must be installed through the filter access door first then
install the 16 x 24 x 1 (406.4mm x 609.6mm x 25.4mm) filter.
38
CONFIGURATION
Filter
Clips
Aluminum
Filter
OUTDOOR AIR TEMPERATURE (OAT) SENSOR— The
outdoor air temperature sensor (HH57AC080) is a 10 to 20mA
device used to measure the outdoor--air temperature. The outdoor--air
temperature is used to determine when the Economizer can be used
for free cooling. The operating range of temperature measurement is
40 to 100_F (4.4 to 37.8_C). The sensor has 8 selectable temperature
changeover setpoints. The temperature changeover is set using 3 dip
switches on the sensor. The ABCD potentiometer on the controller
should be set to the “D” position. See Fig. 39.
SUPPLY AIR TEMPERATURE (SAT) SENSOR—The supply
air temperature sensor is a 3 KΩ thermistor located at the inlet of the
indoor fan. See Fig. 37. The operating range of temperature
measurement is 0_ to 158_F (--17.8_ to 70_C). See Table 15 for
sensor temperature/resistance values. The temperature sensor looks
like an eyelet terminal with wires running to it. The sensor is located
in the “crimp end” and is sealed from moisture.
Table 15 – Supply Air Sensor Temperature/Resistance Values
A09704
Fig. 35 -- Filter Installation (See through view)
Evaporator
Coil
RIGHT SIDE
Top filter
rack
Screw
(Note 4 and 5)
TEMPERATURE
(_F)
CELSIUS (_C)
RESISTANCE (OHMS)
--- 22
--- 30
53,010
--- 4
--- 20
29,091
14
--- 10
16,590
32
0
9,795
50
10
5,970
68
20
3,747
77
25
3,000
86
30
2,416
104
40
1,597
122
50
1,080
140
60
746
158
70
525
Supply Air Temperature
Sensor (SAT)
Bottom
filter rack
BENT COIL
Indoor
Blower
Top filter
rack
Evaporator
Coil
A09707
Bottom
filter rack
Fig. 37 -- SAT Location
STRAIGHT COIL
A09714
Fig. 36 -- Indoor Coil with Filter Rack
39
604D -- -- A
Economizer Standard Sensors
604D -- -- A
LOW TEMPERATURE COMPRESSOR LOCKOUT
SWITCH—The Economizer is equipped with a low ambient
temperature lockout switch located in the outdoor airstream which is
used to lock out the compressors below a 42_F (5.6_C) ambient
temperature.
Economizer Control Modes—Determine the Economizer control
mode before set up of the control. Some modes of operation may
require different sensors. Refer to Table 11. The Economizer is
supplied from the factory with a supply air temperature sensor, a
low temperature compressor lockout switch, and an outdoor air
temperature sensor. This allows for operation of the Economizer
with outdoor air dry bulb changeover control. Additional
accessories can be added to allow for different types of changeover
control and operation of the Economizer and unit.
OUTDOOR DRY BULB CHANGEOVER— The standard
controller is shipped from the factory configured for outdoor dry bulb
changeover control. The outdoor air and supply air temperature
sensors are included as standard.
For this control mode, the outdoor temperature is compared to a
selectable set point on the sensor. See Fig. 39. If the outdoor--air
temperature is above the set point, the Economizer will adjust the
outdoor air dampers to minimum position. If the outdoor--air
temperature is below the set point, the position of the outdoor--air
dampers will be controlled to provide free cooling using outdoor
air. When in this mode, the LED next to the free cooling set point
potentiometer will be on. The changeover temperature set point is
set using the switches on the sensor. See Fig. 39 for the
corresponding temperature changeover values.
In this mode of operation, the outdoor--air temperature is compared
to the return--air temperature and the lower temperature airstream is
used for cooling. When using this mode of changeover control, turn
the free cooling/enthalpy set point potentiometer fully clockwise to
the D setting. See Fig. 38 and Fig. 43.
(8.9°C)
(11.7°C)
(12.8°C)
(14.4°C)
(17.2°C)
(20°C)
(22.8°C)
(25.6°C)
A10134
Fig. 39 -- Outdoor Air Temperature Changeover Set Points
EXHAUST FAN
SETPOINT
LED LIGHTS WHEN
EXHAUST CONTACT
IS MADE
MINIMUM DAMPER
POSITION SETTING
ECONOMIZER
MAXIMUM DAMPER DEMAND
CONTROL VENTILATION
SETPOINT
LED LIGHTS WHEN
DEMAND CONTROL
VENTILATION INPUT
IS ABOVE SETPOINT
DEMAND CONTROL
VENTILATION SETPOINT
RETURN AIR
SENSOR
LED LIGHTS WHEN
OUTDOOR AIR IS
SUITABLE FOR FREE
COOLING
RETURN DUCT
(FIELD-PROVIDED)
ENTHALPY
CHANGEOVER SETPOINT
A09710
A09708
Fig. 40 -- Enthalpy Sensor Mounting Location
Fig. 38 -- Economizer Controller Potentiometer and LED
Locations
40
90
95
(32) (25)
100
(38)
105
(41)
110
(43)
46
85
(29)
42
Y(
%)
38
IDIT
P
UM
Min
Pos
IVE
H
T1
RE
L AT
80
70
AQ+
60
10
0
90
22
20
2
50
5
40
DCV
Set
SO+
SO
20
C
SR+
D
SR
2V
3
4
EF
EF1
10V
Free
Cool
B
C
A
D
10
40
(4)
10V
DCV
AQ
30
18
16
14
1
Max
A
45
(7)
24 Vac
COM
Open
T
2V
55
(13) B
50
(10)
24
Vac
HOT
10V
DCV
60
(16)
12
2V
28
PY
AL
26
24
EN
65
(18)
TR1
35
(2)
A09712
35
(2)
40
(4)
45
(7)
50
(10)
55
(13)
60
(16)
65
70
(18) (21)
75
(24)
Fig. 43 -- Economizer Controller
A
B
D C
80
(27)
85
90
(29) (32)
95
(36)
100
(38)
105
(41)
110
(43)
APPROXIMATE DRY BULB TEMPERATURE — ˚F (˚C)
A09711
Fig. 41 -- Enthalpy Changeover Setpoints
6000
5000
4000
800 ppm
900 ppm
1000 ppm
1100 ppm
3000
2000
1000
0
2
3
4
5
6
7
8
A09713
Fig. 42 -- CO2 Sensor Maximum Range Setting
OUTDOOR ENTHALPY CHANGEOVER—For enthalpy
control, accessory enthalpy sensor (part number HH57AC078) is
required. Replace the standard outdoor dry bulb temperature sensor
with the accessory enthalpy sensor in the same mounting location.
When the outdoor air enthalpy rises above the outdoor enthalpy
changeover set point, the outdoor--air damper moves to its
minimum position. The outdoor enthalpy changeover set point is
set with the outdoor enthalpy set point potentiometer on the
Economizer controller. The set points are A, B, C, and D. See Fig.
41. The factory--installed 620--ohm jumper must be in place across
terminals SR and SR+ on the Economizer controller. See Fig. 43
and Fig. 44.
DIFFERENTIAL ENTHALPY CONTROL — For differential
enthalpy control, the Economizer controller uses two enthalpy
sensors (HH57AC078 and CRENTDIF004A00), one in the outside
air and one in the return airstream. The Economizer controller
compares the outdoor air enthalpy to the return air enthalpy to
determine Economizer use. The controller selects the lower enthalpy
air (return or outdoor) for cooling. For example, when the outdoor air
has a lower enthalpy than the return air and is below the set point, the
Economizer opens to bring in outdoor air for free cooling. Replace the
standard outside air dry bulb temperature sensor with the accessory
enthalpy sensor in the same mounting location. Mount the return air
enthalpy sensor in the return air duct. See Fig. 40. When using this
mode of changeover control, turn the enthalpy set point potentiometer fully clockwise to the D setting.
INDOOR AIR QUALITY (IAQ) SENSOR INPUT —The IAQ
input can be used for demand control ventilation control based on the
level of CO2 measured in the space or return air duct. Mount the
accessory IAQ sensor according to manufacturer specifications. The
IAQ sensor should be wired to the AQ and AQ1 terminals of the
controller. Adjust the DCV potentiometers to correspond to the DCV
voltage output of the indoor air quality sensor at the user determined
set point. See Fig. 42. If a separate field--supplied transformer is used
to power the IAQ sensor, the sensor must not be grounded or the
Economizer control board will be damaged.
EXHAUST SET POINT ADJUSTMENT—The exhaust set point
will determine when the exhaust fan runs based on damper position
(if power exhaust is installed). The set point is modified with the
Exhaust Fan Set Point (EXH SET) potentiometer. See Fig. 44 for
Wiring Diagram. The set point represents the damper position above
which the exhaust fans will be turned on. When there is a call for
exhaust, the Economizer controller provides a 45 ± 15 second delay
before exhaust fan activation to allow the dampers to open. This delay
allows the damper to reach the appropriate position to avoid
unnecessary fan overload.
MINIMUM POSITION CONTROL — There is a minimum
damper position potentiometer on the Economizer controller. See
Fig. 38 and 44. The minimum damper position maintains the
minimum airflow into the building during the occupied period. When
using demand ventilation, the minimum damper position represents
the minimum ventilation position for VOC (volatile organic
compound) ventilation requirements. The DCV Max potentiometer
must be fully closed (CCW) to allow the Minimum Position
potentiometer to function correctly.
41
604D -- -- A
R
DR
UN
PO
R
32
PE
U
30
70
(21)
–
BT
34
D
75
(24)
TR
Set
EXH
P1
Y
AI
67 (19)
63 (17)
TH
N
80
(27)
40
73 (23)
70 (21)
36
A
B
C
D
EXH
N1
44
CONTROL CONTROL POINT
CURVE
APPROX ˚F (˚C)
AT 50% RH
604D -- -- A
When demand ventilation control is not being used, the minimum
position potentiometer should be used to set the occupied ventilation
position. The maximum demand ventilation position should be
turned fully clockwise. Adjust the minimum position potentiometer
to allow the minimum amount of outdoor air, as required by local
codes, to enter the building. Make minimum position adjustments
with at least 10_F (12.2_C) temperature difference between the
outdoor and return--air temperatures. To determine the minimum
position setting, perform the following procedure:
1. Calculate the appropriate mixed air temperature using the
following formula:
(To x OA/100) + (TR x RA/100) = TM
TO = Outdoor--Air Temperature
OA = Percent of Outdoor Air
TR = Return--Air Temperature
RA = Percent of Return Air
TM = Mixed--Air Temperature
As an example, if local codes require 10% outdoor air
during occupied conditions, outdoor--air temperature is
60_F (15.6_C), and return--air temperature is 75_F
(23.9_C). (60 x .10) + (75 x .90) = 73.5_F (23.1_C)
2. Disconnect the supply air sensor from terminals T and T1.
3. Ensure that the factory--installed jumper is in place across
terminals P and P1. If remote damper positioning is being
used, make sure that the terminals are wired according to
Fig. 44 and that the minimum position potentiometer is
turned fully clockwise.
4. Connect 24 vac across terminals TR and TR1.
5. Carefully adjust the minimum position potentiometer until
the measured mixed--air temperature matches the calculated
value.
6. Reconnect the supply air sensor to terminals T and T1.
Remote control of the Economizer damper is desirable when
requiring additional temporary ventilation. If a field--supplied
remote potentiometer (Honeywell part number S963B1128) is
wired to the Economizer controller, the minimum position of the
damper can be controlled from a remote location. To control the
minimum damper position remotely, remove the factory installed
jumper on the P and P1 terminals on the Economizer controller.
Wire the field--supplied potentiometer to the P and P1 terminals on
the Economizer controller. See Fig. 43 and Fig. 44.
42
604D -- -- A
A10059
Fig. 44 -- Economizer Wiring Diagram
43
CONNECTION WIRING DIAGRAM
DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
NOTES:
1. IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED,
THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT.
2. SEE PRICE PAGES FOR THERMOSTATS.
3. USE 75 DEG. COPPER CONDUCTORS FOR FIELD INSTALLATION.
4. SEE INSTALLATION INSTRUCTIONS
FOR PROPER HEATING AND COOLING CONNECTIONS
FOR YOUR UNIT. INDOOR FAN MOTOR PLUGS
- ”DO NOT DISCONNECT UNDER LOAD”
5. THIS FUSE IS MANUFACTURED BY LITTELFUSE, P/N 257003.
6. REMOVE YELLOW SPLICE WHEN ECONOMIZER AND ECONOMIZER
RELAYS ARE USED AND CONNECT TO RELAY R1 AS SHOWN.
7. WHEN ECONOMIZER AND ECONOMIZER RELAYS ARE USED,
CONNECT THE YELLOW AND BLACK WIRES TO RELAY ”R” AS
SHOWN. RELAY KIT REQURED WITH ECONOMIZER AND HEAT
PUMP/DUAL FUEL UNITS.
8. WHEN ECONOMIZER AND ECONOMIZER RELAYS ARE USED, INSTALL
WIRES AS SHOWN ONTO THE COILS OF RELAY R AND RELAY R1.
9.DEHUM FEATURE CANNOT BE USED WHEN ECONOMIZER IS INSTALLED.
UNIT FACTORY-SHIPPED
IN STD MODE.
IF USED
SCHEMATIC
208/230-3-60
CCH
BLK
GRN
BLK
FIELD
SUPPLY
L1
OFM
DR
BLK
BLK OF1
BLK
OF2
BLK
BLK
YEL
YEL
BRN
BRN
COLOR CODE
C
L3
L2
BLK
11
21
YEL
13
23
BLK
YEL
1
CAP1
1
F
C
BLK T1
BLU
EQUIP_GND
YEL
T2
BLU
T3
COMPRESSOR PLUG
FIELD SPLICE
TERMINAL (MARKED)
TERMINAL (UNMARKED)
SPLICE (IF REQ’D)
SPLICE (MARKED)
FACTORY WIRING
FIELD CONTROL WIRING
FIELD POWER WIRING
ACCESSORY OR OPTIONAL
WIRING
AT
AUTO TRANSFORMER
460V - 230V
CONTACTOR
CAPACITOR, COMP
CRANK CASE HEATER
COMPRESSOR MOTOR
DEFROST BOARD
DEFROST TEMPERATURE
SWITCH
C
CAP 1
CCH
COMP
DB
DFT
DH
DEHUM
DR
ECON
EQUIP
FU
GND
HPS
HR
IFB
IFM
LPS
OFM
OFR
RVS
TRAN
T-STAT
R
R1
STD
BLK
FOR WIRING WITH
ELECTRIC HEATERS
SEE SCHEMATIC ON
HEATER ACCESSORY.
DEHUMIDIFICATION MODE
DEHUMIDIFICATION MODE
DEFROST RELAY
ECONOMIZER
EQUIPMENT
FUSE
GROUND
HIGH PRESSURE SWITCH
HEATER RELAY
INDOOR FAN BOARD
INDOOR FAN MOTOR
LOW PRESSURE SWITCH
OUTDOOR FAN MOTOR
OUTDOOR FAN RELAY
REVERSING VALVE
TRANSFORMER
THERMOSTAT
ECON RELAY
ECON RELAY
STANDARD MODE
COMP
BLACK
BLUE
BROWN
GRAY
GREEN
ORANGE
PINK
RED
VIOLET
WHITE
YELLOW
N
G
L
YEL
G/Y
BLK
YEL
IFM
C
COM
230
PRIMARY
208/230V
1 2435
TRAN
SECONDARY
24 V
C
BRN
24V
RED
BRN
G/Y
ECONOMIZER PLUG
SEE 50SD500625
ECONOMIZER LABEL DIAGRAM
ECON
7
7
6
6
11
11
10
10
8
8
2
2
3
3
4
4
1
1
5
5
9
9
12
12
P
BLU
P
BLU
BLU
SAT
Y2
GRY
YEL
C
BRN
RED
Y1
YEL
ACCESSORY ELECTRIC HEAT
BLK
HR1 (5 KW)
1
WHT
VIO
BRN
BRN
HR1
WHT
HR1-4 (20 KW)
1
G
GRN
DH
BLU
W
WHT
HR4
V
VIO
PNK
HR2
GRY
GRY
24VAC R
FUSE
COM
C
COM
COM
ORN
BRN
STD
P2
BRN
HR3
YEL
C
Y
W2
R
WHT
RED
HR1-3 (15 KW)
BRN
3A
P1
1
R
2
C
Y1/Y 3
G
4
Y2/DH5
W2
6
W3
7
LOW
BRN
HR1 & 2 (10 KW)
1
SEE
NOTE 4
SEE NOTE 5
O
1
PNK
BRN
RED
RED
BRN
VIO
RED
GRY
R
BRN
BLK
PNK ORN
T-STAT
1
2
3
4
HIGH
IFB
Y
BRN
BLK
DEHUM
1
C1
R
C2
C1
R1
C2
P4
WHT
PNK
C
W2
W2
W3
W3
BRN
VIO
GRY
1
2
3
4
5
BRN
SEE NOTE 6
YEL
SEE NOTE 8
R
SEE NOTE 9
R1
ORN
2
1
BLK
1
YEL
2
OUTDOOR FAN
SECTION
COMPRESSOR
SECTION
INDOOR FAN
SECTION
HPS
CAP
HC
COMP
23
SINGLE PT.
CONNECTION
FOR
ELEC. HEAT
LPS
0 45
T
T+45
W
W BR
BR
ENERGIZED DE-ENERGIZED
CONTROL BOX AREA
21
C
23
30
MINUTES
11
R
S
CCH
W2
P3
P1
F
DIP SWITCH
SETTINGS
90
MINUTES
1 2 3
24V SPLICE
BOX
BLK
PNK
OR
ON
1 2 3
1 2 3
QUIET
SHIFT
OR
OFF
(DEFAULT)
FIELD SELECTABLE OPTIONS FOR TIME PERIOD
BETWEEN DEFROST CYCLES (MINUTES)
24V POWER
ENTRY
R
T1
SPEED
UP
120
MINUTES
DEFAULT
DB
O
Y
IFB
DISCONNECT
PER NEC
C
60
Y
C
60
MINUTES
OR
120
30
11 22 33
TRAN
90
R
HEATING FAN LOGIC
OFM
C
C2
BRN
DFT
0
0
T T+90
G
G
ENERGIZED DE-ENERGIZED
C1
BLU
C
OF2
COOLING FAN LOGIC
UNIT COMPONENT ARRANGEMENT
T2
P2 C
WHT
YEL
3
BLK
DEFROST BOARD (DB)
CTD
DR
OF1
SPEED
UP
SEE NOTE 7
RED
3
BRN
604D -- -- A
LEGEND
BLK
BLU
BRN
GRY
GRN
ORN
PNK
RED
VIO
WHT
YEL
RVS
PNK
BLU
BLU
BRN
DFT
BLK
HPS
BLK
BLU
LPS
BLU
JUMPERED TEST PINS (USE METAL OBJECT)
FIELD SPEED-UP CYCLE
1) MOMENTARILY SHORT PINS AND RELEASE TO BYPASS
COMPRESSOR OFF DELAY.
2) SHORT FOR 5+ SEC. AND RELEASE FOR FORCED
DEFROST.
3) PERMANENT SHORT WILL BE IGNORED.
DEFROST WILL TERMINATE IN 30 SEC. IF DFT OPEN.
DEFROST WILL TERMINATE NORMALLY IF DFT IS
CLOSED.
THE COMPRESSOR WILL SHUT OFF FOR 30 SEC. ON
DEFROST INITIATION AND TERMINATION IN THE
”QUIET SHIFT” ON POSITION
A10200
Fig. 45 -- Connection Wiring Diagram 230--3
44
604D -- -- A
A10200
Fig. 45 Cont. -- Ladder Wiring Diagram 230--3
45
604D -- -- A
A10199
Fig. 46 -- Connection Wiring Diagram 460--3
46
604D -- -- A
A10199
Fig. 46 Cont. -- Ladder Wiring Diagram 460--3
47
604D -- -- A
DAMPER MOVEMENT — Damper movement from full open to
full closed (or vice versa) takes 2 1/2 minutes.
THERMOSTATS — The Economizer control works with conventional thermostats that have a Y1 (cool stage 1), Y2 (cool stage 2), W1
(heat stage 1), W2 (heat stage 2), and G (fan). The Economizer control
does not support space temperature sensors. Connections are made at
the thermostat terminal connection board located in the main control
box.
OCCUPANCY CONTROL — The factory default configuration
for the Economizer control is occupied mode. Occupied status is
provided by the black jumper from terminal TR to terminal N. When
unoccupied mode is desired, install a field supplied time clock
function in place of the jumper between TR and N. See Fig. 44. When
the time clock contacts are closed, the Economizer control will be in
occupied mode. When the time clock contacts are open (removing the
24--v signal from terminal N), the Economizer will be in unoccupied
mode.
DEMAND CONTROLLED VENTILATION (DCV)—When
using the Economizer for demand controlled ventilation, there are
some equipment selection criteria which should be considered. When
selecting the heat capacity and cool capacity of the equipment, the
maximum ventilation rate must be evaluated for design conditions.
The maximum damper position must be calculated to provide the
desired fresh air. Typically the maximum ventilation rate will be about
5 to 10% more than the typical CFM required per person, using
normal outside air design criteria. An exponential anticipatory
strategy should be taken with the following conditions: a zone with
a large area, varied occupancy, and equipment that cannot exceed the
required ventilation rate at design conditions. Exceeding the required
ventilation rate means the equipment can condition air at a maximum
ventilation rate that is greater than the required ventilation rate for
maximum occupancy. An exponential--anticipatory strategy will
cause the fresh air supplied to increase as the room CO2 level increases
even though the CO2set point has not been reached. By the time the
CO2 level reaches the set point, the damper will be at maximum
ventilation and should maintain the set point. In order to have the CO2
sensor control the economizer damper in this manner, first determine
the damper voltage output for minimum or base ventilation. Base
ventilation is the ventilation required to remove contaminants during
unoccupied periods. The following equation may be used to
determine the percent of outside--air entering the building for a given
damper position. For best results there should be at least a 10_F
(12.2_C) difference in outside and return--air temperatures.
(To x OA/100) + (TR x RA/100) = TM
TO = Outdoor--Air Temperature
OA = Percent of Outdoor Air
TR = Return--Air Temperature
RA = Percent of Return Air
TM = Mixed--Air Temperature
Once base ventilation has been determined, set the minimum damper
position potentiometer to the correct position. The same equation can
be used to determine the occupied or maximum ventilation rate to the
building. For example, an output of 3.6 volts to the actuator provides
a base ventilation rate of 5% and an output of 6.7 volts provides the
maximum ventilation rate of 20% (or base plus 15 CFM per person).
Use Fig. 42 to determine the maximum setting of the CO2 sensor. For
example, a 1100 ppm set point relates to a 15 CFM per person design.
Use the 1100 ppm curve on Fig. 42 to find the point when the CO2
sensor output will be 6.7 volts. Line up the point on the graph with
the left side of the chart to determine that the range configuration for
the CO2 sensor should be 1800 ppm. The Economizer controller will
output the 6.7 volts from the CO2 sensor to the actuator when the CO2
concentration in the space is at 1100 ppm.
The DCV set point may be left at 2 volts since the CO2 sensor
voltage will be ignored by the Economizer controller until it rises
above the 3.6 volt setting of the minimum position potentiometer.
Once the fully occupied damper position has been determined, set
the maximum damper demand control ventilation potentiometer to
this position. Do not set to the maximum position as this can result
in over ventilation to the space and potential high--humidity levels.
CO2 SENSOR CONFIGURATION — The CO2 sensor has preset
standard voltage settings that can be selected anytime after the sensor
is powered up. Use setting 1 or 2 for equipment. See Table 16.
1. Press Clear and Mode buttons. Hold at least 5 seconds until
the sensor enters the Edit mode.
2. Press Mode twice. The STDSET Menu will appear.
3. Use the Up/Down button to select the preset number. See
Table 16.
4. Press Enter to lock in the selection.
5. Press Mode to exit and resume normal operation.
The custom settings of the CO2 sensor can be changed anytime
after the sensor is energized. Follow the steps below to change the
nonstandard settings:
1. Press Clear and Mode buttons. Hold at least 5 seconds until
the sensor enters the Edit mode.
2. Press Mode twice. The STDSET Menu will appear.
3. Use the Up/Down button to toggle to the NONSTD menu
and press Enter.
4. Use the Up/Down button to toggle through each of the nine
variables, starting with Altitude, until the desired setting is
reached.
5. Press Mode to move through the variables.
6. Press Enter to lock in the selection, then press Mode to
continue to the next variable.
DEHUMIDIFICATION OF FRESH AIR WITH DCV
CONTROL—Information from ASHRAE indicates that the largest
humidity load on any zone is the fresh air introduced. For some
applications, an energy recovery unit can be added to reduce the
moisture content of the fresh air being brought into the building when
the enthalpy is high. In most cases, the normal heating and cooling
processes are more than adequate to remove the humidity loads for
most commercial applications.
If normal rooftop heating and cooling operation is not adequate for
the outdoor humidity level, an energy recovery unit and/or a
dehumidification option should be considered.
48
OUTPUT
VENTILATION
RATE
(CFM/
PERSON)
ANALOG
OUTPUT
CO2
CONTROL
RANGE
(PPM)
OPTIONAL
RELAY
SETPOINT
(PPM)
RELAY
HYSTERESIS
(PPM)
Proportional
Any
0--- 10V
4--- 20mA
0--- 2000
1000
50
Proportional
Any
2--- 10V
7--- 20mA
0--- 2000
1000
50
3
Exponential
Any
0--- 10V
4--- 20mA
0--- 2000
1100
50
4
Proportional
15
0--- 10V
4--- 20mA
0--- 1100
1100
50
Proportional
20
0--- 10V
4--- 20mA
0--- 900
900
50
6
Exponential
15
0--- 10V
4--- 20mA
1--- 1100
1100
50
7
Exponential
20
0--- 10V
4--- 20mA
0--- 900
900
50
SETTING
EQUIPMENT
1
Interface w/Standard Building
Control System
2
5
Economizer
8
Health & Safety
Proportional
---
0--- 10V
4--- 20mA
0--- 9999
5000
500
9
Parking/Air Intakes/Loading Docks
Proportional
---
0--- 10V
4--- 20mA
0--- 2000
700
50
Table 17 – CO2 Sensor Standard Settings Economizer Input/Output Logic
INPUTS
DEMAND
CONTROL
VENTILATION
(DCV)
OUTPUTS
ENTHALPY
COMPRESSOR
OUTDOOR
RETURN
High (Free Cooling
LED off)
Low
Low (Free Cooling
LED on)
High
Below set (DCV
LED Off)
High (Free Cooling
LED off)
Low
Above set (DCV
LED On)
Low (Free Cooling
LED on)
High
Y1
Y2
STAGE
1
STAGE
2
On
On
On
On
On
Off
On
Off
Off
Off
Off
Off
On
On
On
Off
On
Off
Off
Off
Off
On
On
On
N TERMINAL
OCCUPIED
UNOCCUPIED
DAMPER
Minimum position
Closed
Off
Modulating** (between min.
position and full ---open)
Modulating** (between closed
and full ---open)
Off
Off
Minimum position
Closed
On
On
Off
On
Off
Off
Off
Off
Off
Modulating{{ (between
min. position and DCV
maximum)
Modulating{{ (between closed
and DCV maximum)
On
On
On
Off
On
Off
Off
Off
Modulating***
Modulating{{{
Off
Off
Off
Off
* For single enthalpy control, the module compares outdoor enthalpy to the ABCD set point.
{Power at N terminal determines Occupied/Unoccupied setting: 24 vac (Occupied), now power (Unoccupied).
**Modulating is based on the supply--- air sensor signal.
{{Modulation is based on the DCV signal.
***Modulation is based on the greater of DCV and supply--- air sensor signals, between minimum position and either maximum position (DCV) or fully open (supply--- air signal).
{{{Modulating is based on the greater of DCV and supply--- air sensor signals, between closed and wither maximum position (DCV) or fully open (supply--- air signal).
OPERATION
Sequence of Operation—When free cooling is not available, the
compressor will be controlled by the thermostat. When free cooling
is available, the outdoor--air damper is modulated by the Economizer
control to provide a 50_ to 55_F (10_ to 12.8_C) supply--air
temperature into the zone. As the supply--air temperature fluctuates
above 55_ (12.8_C) or below 50_F (10_C), the dampers will be
modulated (open or close) to bring the supply--air temperature back
within the set points. For Economizer operation, there must be a
thermostat call for the fan (G). This will move the damper to its
minimum position during the occupied mode.
NOTE: The DCV Max potentiometer must be closed (CCW)
when not using CO2 sensor.
Above 50_F (10_C) supply--air temperature, the dampers will
modulate from 100% open to the minimum open position. From
50_F to 45_F (10_ to 7.2_C) supply--air temperature, the dampers
will maintain at the minimum open position. Below 45_F (7.2_C),
the dampers will be completely shut. As the supply--air temperature
rises, the dampers will come back open to the minimum open
position once the supply--air temperature rises to 48_F (8.9_C). If
power exhaust is installed, as the outdoor--air damper opens and
closes, the power exhaust fans will be energized and deenergized.
If field--installed accessory CO2 sensors are connected to the
Economizer control, a demand controlled ventilation strategy will
begin to operate. As the CO2 level in the zone increases above the
CO2 set point, the minimum position of the damper will be
increased proportionally. As the CO2 level decreases because of the
increase in fresh air, the outdoor--air damper will be proportionally
closed. Damper position will follow the higher demand condition
from DCV mode or free cooling mode. Damper movement from
full closed to full open (or vice versa) will take between 1 1/2 and
2 1/2 minutes. If free cooling can be used as determined from the
appropriate changeover command (dry bulb, enthalpy curve, or
differential enthalpy), a call for cooling (Y1 closes at the
thermostat) will cause the control to modulate the dampers open to
maintain the supply air temperature set point at 50_ to 55_F (10_
to 12.8_C). As the supply air temperature drops below the set point
range of 50_ to 55_F (10_ to 12.8_C), the control will modulate
the outdoor--air dampers closed to maintain the proper supply--air
temperature.
49
604D -- -- A
Table 16 – CO2 Sensor Standard Settings
604D -- -- A
TROUBLESHOOTING
See Table 17 for Economizer logic. An Economizer simulator
program is available to help with Economizer training and
troubleshooting.
Economizer Preparation —This procedure is used to prepare the
Economizer for troubleshooting. No troubleshooting or testing is
done by performing the following procedure.
NOTE: This procedure requires a 9--v battery, 1.2 kilo--ohm
resistor, and a 5.6 kilo--ohm resistor which are not supplied with
the Economizer.
1. Disconnect power at TR and TR1. All LEDs should be off.
Exhaust fan contacts should be open.
2. Disconnect device at P and P1.
3. Jumper P to P1.
4. Disconnect wires at T and T1. Place 5.6 kilo--ohm resistor
across T and T1.
5. Jumper TR to 1.
6. Jumper TR to N.
7. If connected, remove sensor from terminals So and +.
Connect 1.2 kilo--ohm 4074EJM checkout resistor across
terminals So and +.
8. Put 620--ohm resistor across terminals SR and +.
9. Set minimum position, DCV set point, and exhaust potentiometers fully CCW (counterclockwise).
10. Set DCV maximum position potentiometer fully CW
(clockwise).
11. Set enthalpy potentiometer to D.
12. Apply power (24 vac) to terminals TR and TR1.
Differential Enthalpy — To check differential enthalpy:
1. Make sure Economizer preparation procedure has been
performed.
2. Place 620--ohm resistor across So and +.
3. Place 1.2 kilo--ohm resistor across SR and +. The Free Cool
LED should be lit.
4. Remove 620--ohm resistor across So and +. The Free Cool
LED should turn off.
5. Return Economizer settings and wiring to normal after
completing troubleshooting.
Single Enthalpy—To check single enthalpy:
1. Make sure Economizer preparation procedure has been
performed.
2. Set the enthalpy potentiometer to A (fully CCW). The Free
Cool LED should be lit.
3. Set the enthalpy potentiometer to D (fully CW). The Free
Cool LED should turn off.
4. Return Economizer settings and wiring to normal after
completing troubleshooting.
DCV (Demand Controlled Ventilation) and Power
Exhaust—To check DCV and Power Exhaust:
1. Make sure Economizer IV preparation procedure has been
performed.
2. Ensure terminals AQ and AQ1 are open. The LED for both
DCV and Exhaust should be off. The actuator should be
fully closed.
3. Connect a 9--v battery to AQ (positive node) and AQ1
(negative node). The LED for both DCV and Exhaust
should turn on. The actuator should drive to between 90
and 95% open.
4. Turn the Exhaust potentiometer CW until the Exhaust LED
turns off. The LED should turn off when the potentiometer
is approximately 90%. The actuator should remain in
position.
5. Turn the DCV set point potentiometer CW until the DCV
LED turns off. The DCV LED should turn off when the
potentiometer is approximately 9--v. The actuator should
drive fully closed.
6. Turn the DCV and Exhaust potentiometers CCW until the
Exhaust LED turns on. The exhaust contacts will close 30
to 120 seconds after the Exhaust LED turns on.
7. Return Economizer settings and wiring to normal after
completing troubleshooting.
DCV Minimum and Maximum Position —To check the DCV
minimum and maximum position:
1. Make sure Economizer preparation procedure has been
performed.
2. Connect a 9--v battery to AQ (positive node) and AQ1
(negative node). The DCV LED should turn on. The actuator should drive to between 90 and 95% open.
3. Turn the DCV Maximum Position potentiometer to
midpoint. The actuator should drive to between 20 and 80%
open.
4. Turn the DCV Maximum Position potentiometer to fully
CCW. The actuator should drive fully closed.
5. Turn the Minimum Position potentiometer to midpoint. The
actuator should drive to between 20 and 80% open.
6. Turn the Minimum Position Potentiometer fully CW. The
actuator should drive fully open.
7. Remove the jumper from TR and N. The actuator should
drive fully closed.
8. Return Economizer settings and wiring to normal after
completing troubleshooting.
Supply--Air Input—To check supply--air input:
1. Make sure Economizer preparation procedure has
beenperformed.
2. Set the Enthalpy potentiometer to A. The Free Cool LED
turns on. The actuator should drive to between 20 and 80%
open.
3. Remove the 5.6 kilo--ohm resistor and jumper T to T1. The
actuator should drive fully open.
4. Remove the jumper across T and T1. The actuator should
drive fully closed.
5. Return Economizer settings and wiring to normal after
completing troubleshooting.
Economizer Troubleshooting Completion —This procedure is
used to return the Economizer to operation. No troubleshooting or
testing is done by performing the following procedure.
1. Disconnect power at TR and TR1.
2. Set enthalpy potentiometer to previous setting.
3. Set DCV maximum position potentiometer to previous
setting. Set DVC Max potentiometer to fully closed (CCW)
when not using a CO2 sensor.
4. Set minimum position, DCV set point, and exhaust potentiometers to previous settings.
5. Remove 620--ohm resistor from terminals SR and +.
6. Remove 1.2 kilo--ohm checkout resistor from terminals SO
and +. If used, reconnect sensor from terminals SO and +.
7. Remove jumper from TR to N.
8. Remove jumper from TR to 1.
9. Remove 5.6 kilo--ohm resistor from T and T1. Reconnect
wires at T and T1.
10. Remove jumper from P to P1. Reconnect device at P and
P1.
11. Apply power (24 vac) to terminals TR and TR1.
50
Fig. 47 -- 604D----A 30--36 3 Phase with Economizer
A10226
51
604D -- -- A
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
NEC. REQUIRED CLEARANCES
REQUIRED CLEARANCES TO COMBUSTIBLE MATL
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
NEC. REQUIRED CLEARANCES
REQUIRED CLEARANCES TO COMBUSTIBLE MATL
604D -- -- A
A10227
Fig. 48 -- 604D----A 42--60 3 Phase with Economizer
E2010 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231
Edition Date: 04/10
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
52
Catalog No. II604D---07
Replaces: II604D--- 06
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