Bryant 581B 036-072 rooftop gas heating/electric cooling unit Installation, start-up and service instructions
Below you will find brief information for rooftop gas heating/electric cooling unit 581B 036-072. This manual covers the installation, start-up and service requirements for the unit. The manual provides guidance on locating the unit, safety considerations, connecting the unit to gas, electrical and ductwork, as well as starting the unit and performing maintenance tasks.
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installation, start-up and service instructions
SINGLE PACKAGE ROOFTOP
GAS HEATING/ELECTRIC COOLING UNITS
Cancels: II 581B-36-1
581B
Sizes 036-072
3 to 6 Tons
II 581B-36-2
9/15/98
IMPORTANT — READ BEFORE INSTALLING
1. Read and become familiar with these installation instructions before installing this unit (Fig. 1).
2. Be sure the installation conforms to all applicable local and national codes.
3. These instructions contain important information for the proper maintenance and repair of this equipment. Retain these instructions for future use.
CONTENTS
Page
SAFETY CONSIDERATIONS
. . . . . . . . . . . . . . . . . . . . . . . 1,2
INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
I. Locate the Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II. Unit Duct Connections
. . . . . . . . . . . . . . . . . . . . . . 5
III. Rig and Place Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . 5
IV. Field Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRE-START-UP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
START-UP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-27
I. Compressor Rotation
. . . . . . . . . . . . . . . . . . . . . . . 17
II. Heating Section Start-Up and Adjustments
. . . . 18
III. Cooling Section Start-Up and Adjustments
. . . . 21
IV. Indoor Airflow and Airflow Adjustments
. . . . . . . 22
CARE AND MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . . 28
I. Air Filter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-32
I. Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
II. Lubrication
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
III. Condenser-Fan Adjustment
. . . . . . . . . . . . . . . . . 29
IV. Economizer Adjustment
. . . . . . . . . . . . . . . . . . . . 29
V. Refrigerant Charge
. . . . . . . . . . . . . . . . . . . . . . . . . 29
VI. Main Burners
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
VII. Flue Gas Passageways
. . . . . . . . . . . . . . . . . . . . . 30
VIII. Combustion-Air Blower
. . . . . . . . . . . . . . . . . . . . . 30
IX. Limit Switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
X. Burner Ignition
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
XI. Replacement Parts
. . . . . . . . . . . . . . . . . . . . . . . . . 32
TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . 33-36
START-UP CHECKLIST
. . . . . . . . . . . . . . . . . . . . . . . . . . CL-1
SAFETY CONSIDERATIONS
WARNING:
Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electric shock, or other occurrences which may injure you or damage your property. Consult a qualified installer, service agency, or the gas supplier for information or assistance. The qualified installer or agency must use only factoryauthorized kits or accessories when modifying this product.
Recognize safety information. This is the safety-alert symbol. ( ) When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.
Understand the signal words — DANGER, WARNING, and
CAUTION. These words are used with the safety-alert
Fig. 1 — Typical Unit
symbol. Danger identifies the most serious hazards which will result in severe personal injury or death. Warning indicates a condition that could result in personal injury. Caution is used to identify unsafe practices which would result in minor personal injury or product and property damage.
WARNING:
Disconnect gas piping from unit when leak testing at pressure greater than 0.5 psig. Pressures greater than 0.5 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subject to pressure greater than 0.5 psig, it must be replaced before use. When pressure testing field-supplied gas piping at pressures of 0.5 psig or less, a unit connected to such piping must be isolated by manually closing the gas valve.
WARNING:
Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.
1. The power supply (volts, hertz, and phase) must correspond to that specified on unit rating plate.
2. The electrical supply provided by the utility must be sufficient to handle load imposed by this unit.
3. Refer to the Locate the Unit section on page 3 and
Fig. 2 for locations of gas and electrical inlets, condensate drain, duct connections, and required clearances before setting unit in place.
4. Locate the unit where the vent cap will be a minimum of 4 ft from openable windows or doors.
5. This installation must conform with local building codes, the NFGC (National Fuel Gas Code), ANSI (American
National Standards Institute) Z223.1-1992, and NFPA
(National Fire Protection Association) 54 TIA-54-92-1.
In Canada, installation must conform with CAN/CGA
(Canadian Gas Association) B149.1,[2]-M86. Refer to Provincial and local plumbing or wastewater codes and other applicable local codes.
6. Approved for outdoor installation on wood flooring or on class A, B, or C roof-covering materials.
UNIT
581B
036
048
060
072
STANDARD
UNIT
WEIGHT
Lb
530
Kg
240
540
560
615
245
254
279
VARISLIDE™
ECONOMIZER
WEIGHT
Lb
34
34
34
34
Kg
15.4
15.4
15.4
15.4
CORNER
WEIGHT
‘‘A’’
CORNER
WEIGHT
‘‘B’’
CORNER
WEIGHT
‘‘C’’
CORNER
WEIGHT
‘‘D’’
Lb Kg Lb Kg Lb Kg Lb Kg
127 57.6
122 55.3
138 62.6
143 64.9
129 58.5
124 56.2
141 64.0
146 66.2
134 60.8
129 58.5
146 66.2
151 68.5
147 66.7
142 64.4
160 72.6
166 75.3
NOTES:
1. Dimensions in [ ] are in millimeters.
2.
Center of Gravity.
3.
Direction of airflow.
4. On vertical discharge units, ductwork to be attached to accessory roof curb only. For horizontal discharge units field-supplied flanges should be attached to horizontal discharge openings, and all ductwork should be attached to the flanges.
5. Minimum clearance (local codes or jurisdiction may prevail): a. Between unit, flue side and combustible surfaces, 48 inches.
b. Bottom of unit to combustible surfaces (when not using curb)
1 inch. Bottom of base rail to combustible surfaces (when not using curb) 0 inches.
c. Condenser coil, for proper airflow, 36 in. one side, 12 in. the other. The side getting the greater clearance is optional.
d. Overhead, 60 in. to assure proper condenser fan operation.
e. Between units, control box side, 42 in. per NEC (National
Electrical Code).
f. Between unit and ungrounded surfaces, control box side,
36 in. per NEC.
g. Between unit and block or concrete walls and other grounded surfaces, control box side, 42 in. per NEC.
h. Horizontal supply and return end, 0 inches.
6. With the exception of the clearance for the condenser coil and combustion side as stated in Note 5a, b, and c, a removable fence or barricade requires no clearance.
7. Units may be installed on combustible floors made from wood or
Class A, B, or C roof covering material if set on base rail.
8. The vertical center of gravity is 1
8
-6
9
[457] up from the bottom of the base rail.
CONNECTION SIZES
A 1 3 ⁄
8
9
Dia. [35] Field Power Supply Hole
B 2
9
Dia. [51] Power Supply Knock-Out
C 1 3 ⁄
4
9
Dia. [44] Charging Port Hole
D
7 ⁄
8
9
Dia. [22] Field Control Wiring Hole
E
3 ⁄
4
9
-14 NPT Condensate Drain
F
1 ⁄
2
9
-14 NPT Gas Connection
G 2 1 ⁄
2
9
Dia. [64] Power Supply Knock-Out
BOTTOM POWER CHART,
THESE HOLES REQUIRED FOR
USE WITH ACCESSORY PACKAGES —
CRBTMPWR001A00 ( 1 ⁄
2
9
, 3 ⁄
4
9
)
THREADED
CONDUIT
SIZE
1 ⁄
2
(
3 ⁄
4
(
WIRE
USE
24 V
Power
REQUIRED SIZES
(MAXIMUM)
1
7
1 ⁄
⁄
8
9
[22.2]
8
9
[28.4]
Fig. 2 — Base Unit Dimensions
—2—
INSTALLATION
Unit is shipped in the vertical airflow configuration. See
Fig. 1. To convert to horizontal discharge, remove horizontal duct opening covers. Using the same screws, install covers with insulation-side down (facing outside) on the unit on vertical duct openings. Seals around duct openings must be tight.
Model 581B meets the California maximum oxides of nitrogen (NO x
) emission regulations when equipped with accessory NO x
Reduction Kit (part no. 309424-101).
These units are equipped with an energy-saving, automatic, electric direct spark ignition system that does not have a continuously burning pilot. All units are manufactured with natural gas controls.
These units are designed for a minimum continuous return air temperature of 50 F (dry bulb) or an intermittent operation down to 45 F (dry bulb), such as when used with a night set-back thermostat.
All units can be connected into existing duct systems that are
properly sized and designed to handle an airflow of 300 to
500 cfm per each 12,000 Btuh of rated cooling capacity.
NOTE:
When installing any accessory or factory-installed option, see the manufacturer’s installation instructions packaged with the accessory or option. A qualified agency must use factory-authorized kits or accessories when modifying this unit.
I. LOCATE THE UNIT
A. Clearance
Maintain clearance around and above unit to provide minimum distance from combustible materials, proper airflow, and service access. See Fig. 2 and 3.
Minimum clearance to combustibles is 48 in. on flue side; bottom of unit (when not using curb) is 1 inch; bottom of base rail (when not using curb) is 0 inches.
Minimum clearance on all sides to block walls or any other grounded surface is 42 inches. Between unit and ungrounded surfaces, control box side is 36 inches; between units, control box side, is 42 inches.
Minimum clearance of condenser coil is 36 in. on one side,
12 in. the other. Side getting greater clearance is optional.
Minimum distance overhead is 60 inches.
Locate the unit where the vent cap will be a minimum of 4 ft from openable windows and doors.
Do not install unit in an indoor location. Do not locate unit air inlets near exhaust vents or other sources of contaminated air.
Be sure that unit is installed so that snow will not block the combustion intake or flue outlet.
Although unit is weatherproof, guard against water from higher level runoff and overhangs.
Slab-mounted units should be at least 4 in. above the highest expected water, flood, and runoff levels. Do not use the unit if it has been under water.
Locate mechanical draft system flue assembly at least 48 in.
from any opening through which combustion products could enter the building, and at least 24 in. from an adjacent building. When unit is located adjacent to public walkways, flue assembly must be at least 7 ft above grade.
Flue gas can deteriorate building materials. Orient unit such that flue gas will not affect building materials.
Adequate combustion-air space must be provided for proper operation of this equipment. Be sure that installation complies with all local codes.
Flue vent discharge must have a minimum horizontal clearance of 4 ft from electric and gas meters, gas regulators, and gas relief equipment.
B. Roof Curb Mount
Assemble and install accessory roof curb in accordance with instructions shipped with curb. See Fig. 4. Install insulation cant strips, roofing felt, and counter flashing as shown. Duct-
work must be attached to curb. If gas, electric power, or control power is to be routed through the curb, attach the utility connection plates to the roof curb in accordance with the accessory installation instructions. Accessory electric and gas utility connection plates must be installed before unit is in place on roof curb.
IMPORTANT:
The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket with the roof curb as shown in Fig. 4. Improperly applied gasket can also result in air leaks and poor unit performance.
Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are shown in Fig. 5.
C. Slab Mount (Horizontal Units Only)
Provide a level concrete slab that extends a minimum of 6 in.
beyond unit cabinet. Install a gravel apron in front of condensercoil air inlet to prevent grass and foliage from obstructing airflow.
NOTE:
Horizontal units may be installed on a roof curb if required.
Fig. 3 — Service and Operational Clearances
—3—
ROOF CURB
ACCESSORY
CRRFCURB001A00
CRRFCURB002A00
‘‘A’’
14
9
[356]
24
9
[610]
UNIT SIZE
581B036-072
NOTES:
1. Roof curb accessory is shipped disassembled.
2. Insulated panels.
3. Dimensions in [ ] are in millimeters.
4. Roof curb: galvanized steel.
5. Attach ductwork to curb (flanges of duct rest on curb).
6. Service clearance 4 ft on each side.
7.
Direction of airflow.
UNIT
581B
‘‘B’’
036-072
21 11 ⁄
16
9
[551]
‘‘C’’
SERVICE PLATE SIZES
‘‘D’’ Alt
Drain
Hole
‘‘E’’
Gas
‘‘F’’
Power
16
9
[406]
1 3 ⁄
4
9
[44.5]
‘‘G’’
Control
3 ⁄
4
9
NPT 3 ⁄
4
9
NPT 3 ⁄
4
9
NPT
3 ⁄
4
9
NPT 3 ⁄
4
9
NPT 1 ⁄
2
9
NPT
CONNECTOR
PACKAGE
ACCESSORY
314213-204
(Thru-the-Side)
CRBTMPWR001A00
(Thru-the-Bottom)
Fig. 4 — Roof Curb Dimensions
—4—
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
A-B
0.5
B-C
1.0
A-C
1.0
Fig. 5 — Unit Leveling Tolerances
II. UNIT DUCT CONNECTIONS
On vertical units, secure all ducts to roof curb and building structure. Do not connect ductwork to unit. On horizontal units, duct flanges should be attached to horizontal openings and all ductwork should be secured to flanges. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.
Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier.
If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.
A minimum clearance is not required around ductwork.
Cabinet return-air static shall not exceed −0.35 in. wg with
Varislide™ economizer, −0.35 in. wg with PARABLADE economizer, or −0.45 in. wg without economizer.
NOTE:
Connection must be made to roof curb before unit is set in place.
III. RIG AND PLACE UNIT
Inspect unit for transportation damage. File any claim with transportation agency. Keep unit upright and do not drop.
Spreader bars are not required if top crating is left on unit.
Rollers may be used to move unit across a roof. Level by using unit frame as a reference. See Table 1 and Fig. 6 for additional information. Operating weight is shown in Table 1 and Fig. 6.
Lifting holes are provided in base rails as shown in Fig. 6.
Refer to rigging instructions on unit.
IMPORTANT:
If unit has forklift protection skids, be sure to remove forklift protection skids from under unit before setting unit in place.
CAUTION:
All panels must be in place when rigging.
A properly positioned unit will have the following clearances between unit and roof curb:
1
⁄
4
-in. clearance between roof curb and base rails on each side and front of unit; 1 5 ⁄
32
-in. clearance between roof curb and rear of unit. See Fig. 4, Views
A-A and C-C.
After unit is in position, remove shipping materials and rigging skids.
NOTES:
1. Dimension in ( ) are in millimeters.
2. Hook rigging shackles through holes in base rail as shown in detail
‘‘A.’’ Holes in base rails are centered around the unit center of gravity. Use wooden top skid when rigging to prevent rigging straps from damaging unit.
3. Weights include base unit without economizer. See Table 1 for unit operating weights with an economizer.
CAUTION:
All panels must be in place when rigging.
UNIT
581B
MAX
WEIGHT
‘‘A’’
DIMENSIONS
‘‘B’’ ‘‘C’’
Lb Kg in.
mm in.
mm in.
mm
036
530 240 73.69
1872 35.50
902 33.31
847
048
540 245 73.69
1872 35.50
902 33.31
847
060
560 254 73.69
1872 35.50
902 33.31
847
072
615 279 73.69
1872 35.50
902 33.31
847
Fig. 6 — Rigging Details
—5—
Table 1 — Specifications
BASE UNIT 581B
NOMINAL CAPACITY (tons)
OPERATING WEIGHT (lb)
Unit
With Economizer
Roof Curb
COMPRESSOR
Quantity
Oil (oz)
REFRIGERANT TYPE
Operating Charge (lb-oz)
CONDENSER FAN
Quantity...Diameter (in.)
Nominal Cfm
Motor Hp...Rpm
Watts Input (Total)
CONDENSER COIL
Rows...Fins/in.
Total Face Area (sq ft)
EVAPORATOR FAN
Size (in.)
Type Drive
Nominal Cfm
Maximum Continuous Bhp
Motor Frame Size
Fan Rpm Range
Motor Bearing Type
Maximum Fan Rpm
Motor Pulley Pitch Diameter A/B (in.)
Nominal Motor Shaft Diameter (in.)
Fan Pulley Pitch Diameter (in.)
Belt — Type...Length (in.)
Pulley Center Line Distance (in.)
Speed Change Per Full Turn of
Movable Pulley Flange (rpm)
Movable Pulley Maximum Full Turns from Closed Position
Factory Setting — Full Turns Open
Factory Speed Setting (rpm)
Fan Shaft Diameter at Pulley (in.)
EVAPORATOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
FURNACE SECTION
1
036
3
530
564
115
1
42
5-8
1...22
3000
⁄
8
...825
180
1...17
14.58
10 x 10
Belt
1200
1.20
48
760-1090
Ball
2100
1.9/2.9
1 ⁄
2
4.5
A...33
10.0-12.4
65
048
4
540
574
115
70
Scroll
060
5
560
594
115
1
53
1
50
10 x 10
Belt
1600
1.20
48
840-1185
Ball
2100
1.9/2.9
1 ⁄
2
4.0
A...36
10.0-12.4
R-22
8-6 10.0
Propeller
1...22
3000
1 ⁄
8
...825
180
1
1...22
4000
⁄
4
...1100
300
Enhanced Copper Tubes, Aluminum Lanced Fins
2...17
16.53
2...17
16.53
Centrifugal
10 x 10
Belt
2000
1.80
56
1020-1460
Ball
2100
2.4/3.4
1 ⁄
2
4.0
A...40
14.7-15.5
75
1
072
6
615
649
115
1
60
9-10
1...22
4000
⁄
4
...1100
300
2...17
16.53
10 x 10
Belt
2400
2.40
56
1120-1585
Ball
2100
2.4/3.4
5 ⁄
8
3.7
A...38
14.7-15.5
93
5 5 5 5
3
890
5 ⁄
8
2...15
5.5
Medium
Heat
195
High
Heat
195
3
980
5 ⁄
8
3
1240
5 ⁄
8
3
1305
5 ⁄
8
Enhanced Copper Tubes, Aluminum Double Wavy Fins, Acutrol™ Feed Device
2...15
5.5
4...15
5.5
4...15
5.5
Low
Heat
195
Medium
Heat
195
High
Heat
195
Low
Heat
195
Medium
Heat
195
High
Heat
195
Low
Heat
195
Medium
Heat
195
Rollout Switch Cutout Temp (F)*
Burner Orifice Diameter (in. ...drill size)†
Natural Gas — Std
Liquid Propane — Alt**
Thermostat Heat Anticipator Setting (amps)
208/230/460 v
Stage 1
Stage 2
Gas Input (Btuh)
Stage 1
Stage 2
Efficiency (Steady State) (%)
Temperature Rise Range (F)
Manifold Pressure (in. wg)
Natural Gas (Std)
Liquid Propane (Alt)**
Maximum Static Pressure (in. wg)
Gas Valve Quantity
Field Gas Connection Size (in.)
HIGH-PRESSURE SWITCH (psig)
Standard Compressor Internal Relief
Cutout
Reset (Auto.)
LOSS-OF-CHARGE/LOW-PRESSURE SWITCH
(Liquid Line) (psig)
Cutout
Reset (Auto.)
FREEZE-PROTECTION THERMOSTAT
Opens (F)
Closes (F)
OUTDOOR-AIR INLET SCREENS
Quantity...Size (in.)
RETURN-AIR FILTERS
Quantity...Size (in.)
30 ± 5
45 ± 5
Cleanable
1...20 x 24 x 1
Throwaway
2...16 x 25 x 2
High
Heat
195
.113...33
.113...33
.113...33
.113...33 .129...30 .113...33
.113...33 .129...30 .113...33
.113...33 .129...30
.089...43 .089...43 .089...43 .089...43 .102...38 .089...43 .089...43 .102...38 .089...43 .089...43 .102...38
.14
.14
50,000
15-45
3.5
3.5
1.0
1
1
⁄
2
.14
.14
82,000
55-85
3.5
3.5
1.0
1
1
⁄
2
.14
.14
50,000
15-45
3.5
3.5
1.0
1
1
⁄
2
.14
.14
82,000
35-65
3.5
3.5
1.0
1
1
⁄
2
.14
.14
120,000
50-80
3.5
3.5
1.0
1
1
⁄
2
.14
.14
50,000
15-45
3.5
3.5
1.0
1
1
⁄
2
450
428
320
7 ± 3
22 ± 5
.14
.14
82,000
35-65
3.5
3.5
1.0
1
1
⁄
2
.14
.14
120,000
50-80
3.5
3.5
1.0
1
1
⁄
2
.14
.14
50,000
15-45
3.5
3.5
1.0
1
1
⁄
2
.14
.14
82,000
35-65
3.5
3.5
1.0
1
1
⁄
2
.14
.14
120,000
72,000 115,000 72,000 115,000 150,000 72,000 115,000 150,000 72,000 115,000 150,000
82 80 82 81 80 82 81 80 82 81 80
50-80
3.5
3.5
1.0
1
1
⁄
2
LEGEND
Bhp — Brake Horsepower
*Indicates automatic reset.
†581B036072-072072 units have 2 burners.
581B036115-072115 and 581B048150-072150 units have 3 burners.
**Indicates an accessory.
—6—
IV. FIELD CONNECTIONS
A. External Trap Condensate Drain
The unit’s 3 ⁄
4
-in. condensate drain connections are located at the bottom and side of the unit. Unit discharge connections do not determine the use of drain connections; either drain connection can be used with vertical or horizontal applications.
When using the standard side drain connection, make sure the plug in the alternate bottom connection is tight before installing the unit.
To use the bottom drain connection for a roof curb installation, relocate the factory-installed plug from the bottom connection to the side connection. See Fig. 7. The piping for the condensate drain and external trap can be completed after the unit is in place.
All units must have an external trap for condensate drainage. Install a trap at least 4-in. deep and protect against freezeup. See Fig. 8. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1 in. per
10 ft of run. Do not use a pipe size smaller than the unit connection.
B. Install Flue Hood
Flue hood is shipped screwed to the burner compartment access panel. Remove from shipping location and using screws provided, install flue hood in location shown in Fig. 2 and 9.
Fig. 9 — Flue Hood Details
For units being installed in California Air Quality Management Districts which require NO x emissions of 40 nanograms/ joule or less, kit CRLOWNOX001A00 must be installed.
C. Gas Piping (Fig. 10)
Unit is equipped for use with type of gas shown on nameplate.
The gas supply pipe enters the unit through the access hole provided. The gas connection to the unit is made to the 1 ⁄
2
-in.
female NPT gas inlet on the manual shutoff or gas valve.
Install a separate gas supply line that runs directly from the meter to the heating section. Refer to Table 2 and the NFGC for gas pipe sizing. Do not use cast iron pipe. Check the local utility for recommendations concerning existing lines. Choose a supply pipe that is large enough to keep the pressure loss as low as practical. Never use pipe smaller than the
1
⁄
2
-in. female NPT gas inlet on the unit gas valve.
For natural gas applications, the gas pressure at unit gas connection must not be less than 4 in. wg or greater than
13 in. wg while the unit is operating. On 581B048,060,072 high heat units, the gas pressure at unit gas connection must not be less than 5 in. wg or greater than 13 in. wg while the unit is operating. For propane applications, the gas pressure must not be less than 5 in. wg or greater than 13 in. wg at the unit connection.
NOTE: Drain plug is shown in factory-installed position.
Fig. 7 — Condensate Drain Pan
NOTE: Trap should be deep enough to offset maximum unit static difference. A 4-in. trap is recommended.
Fig. 8 — External Trap Condensate Drain
—7—
LEGEND
NFGC — National Fuel Gas Code
*Field Supplied.
NOTE: Follow all local codes.
STEEL PIPE NOMINAL
DIAMETER (in.)
1 ⁄
2
3 ⁄
4 or 1
1 1 ⁄
4 or Larger
SPACING OF SUPPORTS
X DIMENSION (ft)
6
8
10
Fig. 10 — Gas Piping Guide
(With Accessory Utility Connections Package)
Table 2 — Maximum Gas Flow Capacity of Pipe in Cubic Ft of Gas Per Hour for Gas Pressures of 0.5 Psig or Less and a Pressure Drop of 0.5 in. wg
(Based on a 0.60 Specific Gravity Gas)
NOMINAL
IRON PIPE
SIZE
(in.)
1 ⁄
2
3 ⁄
4
1
1 1 ⁄
4
1 1 ⁄
2
INTERNAL
DIAMETER
(in.)
.622
.824
1.049
1.380
1.610
10
175
360
680
1400
2100
20
120
250
465
950
1460
30
97
200
375
770
1180
40
82
170
320
600
990
50
73
151
285
580
900
LENGTH OF PIPE, FT*
60
66
138
260
530
810
70
61
125
240
490
750
80
57
118
220
460
690
Refer to Table 10-2, National Fire Protection Association (NFPA), latest edition.
*This length includes an ordinary number of fittings.
NOTE: Typical natural gas heating value is 1000 Btuh per cubic ft.
For example: A 115,000 Btuh input unit equals 115 cubic ft per hour or
115,000
1,000
= 115 cubic ft/hr.
90
53
110
205
430
650
100
50
103
195
400
620
125
44
93
175
360
550
150
40
84
160
325
500
175
—
77
145
300
460
200
—
72
135
280
430
When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFGC ANSI
Z223.1-1992 (in Canada, CAN/CGA B149.1, [2]-M86) or NFPA
54-1992, in the absence of local building codes. Adhere to the following pertinent recommendations:
1. Avoid low spots in long runs of pipe. Grade all pipe
1
⁄
4 inch in every 15 ft to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section and to meter.
2. Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a minimum of one hanger every 6 ft. See Fig. 10. For pipe sizes larger than 1 ⁄
2 in., follow recommendations of national codes.
3. Apply joint compound (pipe dope) sparingly and only to male threads of joint when making pipe connections. Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and/or national codes.
Never use Teflon-coated tape.
4. Install sediment trap in riser leading to heating section. This drip leg functions as a trap for dirt and condensate. Install trap where condensate can not freeze.
Install this sediment trap by connecting a piping tee to riser leading to heating section, so that straightthrough section of tee is vertical. See Fig. 11. Then, connect capped nipple into lower end of tee. Extend capped nipple below level of gas controls.
5. Install an accessible, external, manual main shut-off valve in gas supply pipe within 6 ft of heating section.
6. Install ground-joint union close to heating section between unit manual shutoff and external manual main shut-off valve.
7. Pressure-test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit.
NOTE:
When pressure testing the gas supply system after the gas supply piping has been connected to the unit gas valve, the supply piping must be disconnected from the gas valve during any pressure testing of the piping systems at test pressure in excess of 0.5 psig. When pressure testing the gas supply piping system at test pressures equal to or less than
0.5 psig, the unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the ground-joint union. After pressure test is completed, retighten ground-joint union.
CAUTION:
Fig. 11 — Sediment Trap
Unstable operation may occur when the gas valve and manifold assembly are forced out of position while connecting improperly routed rigid gas piping to the gas valve. Use a backup wrench when making connection to avoid strain on, or distortion of, the gas control piping.
CAUTION:
If a flexible conductor is required or allowed by the authority having jurisdiction, black iron pipe shall be installed at the gas valve and extend a minimum of 9 in. outside the unit casing.
WARNING:
Never use a match or other open flame when checking for gas leaks. Never purge gas line into combustion chamber. Failure to adhere to this warning could result in an explosion causing personal injury or death.
8. Check for gas leaks at all field- and factory-installed gas lines after all piping connections have been completed.
Use soap-and-water solution (or method specified by local codes and/or regulations).
—8—
Liquid Propane
Units are shipped for use with natural gas, but may be fieldconverted for use with liquid propane with accessory LP (liquid propane) kit.
All LP gas equipment must conform to NFPA safety standards.
LP gas pressure at the unit must not be less than 5 in. wg or greater than 13 in. wg under full load. Maintaining proper gas pressure depends on:
1. Vaporization rate. (Vaporization rate is determined by the temperature of the LP and the level of LP in the tank.)
2. Proper pressure regulation. (Two-stage regulation is more cost effective and efficient.)
3. Pressure drop in lines between regulators and between the second-stage regulator and the appliance. Pipe size is determined by the length of the pipe run and the total load of all appliances.
Contact your LP gas supplier or regulator manufacturer for further details regarding tank sizing, recommended regulator settings, and pipe sizing.
Special pipe compound must be used when assembling piping for liquid propane gas as white lead or commercial compounds will be easily dissolved. Use a shellac-based compound suitable for use with LP.
D. Field Duct Connections
NOTE:
The design and installation of the duct system must be in accordance with the standards of the NFPA for the installation of nonresidence-type air-conditioning and ventilating systems, NFPA No. 90A or residence-type, NFPA No. 90B; and/or local codes and ordinances.
Adhere to the following criteria when selecting, sizing, and installing the duct system:
1. Remove appropriate panels from unit to obtain either a horizontal or vertical application. If units are installed for horizontal applications, remove vertical duct covers, save screws, and install covers on vertical duct openings.
2. Select and size ductwork, supply-air registers, and returnair grilles according to ASHRAE (American Society of
Heating, Refrigeration and Air Conditioning Engineers) recommendations.
CAUTION:
When the duct system fastening holes are being drilled into the side of the unit for duct flanges, be careful not to puncture the coil or coil tubes. See
Fig. 12.
3. Use flexible transition between rigid ductwork and unit to prevent transmission of vibration. The transition may be screwed or bolted to duct flanges. Use suitable gaskets to ensure weather- and airtight seal.
4. When horizontal return is used, install external, fieldsupplied air filters in return-air ductwork where they are easily accessible for service. Recommended filter sizes are shown in Table 1.
5. For horizontal applications, be sure ductwork does not cover nameplate.
6. Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases.
7. Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through unconditioned space, and use vapor barrier in accordance with latest issue of SMACNA (Sheet Metal and Air Conditioning Contractors National Association) and ACCA (Air
Conditioning Contractors of America) minimum installation standards for heating and air-conditioning systems. Secure all ducts to building structure.
8. Flash, weatherproof, and vibration isolate all openings in building structure in accordance with local codes and good building practices.
E. Electrical Connections
WARNING:
The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to the unit ground lug in the control compartment or conduit approved for electrical ground when installed in accordance with the NEC (National Electrical Code); ANSI/NFPA, latest edition, (in Canada,
Canadian Electrical Code CSA [Canadian Standards Association] C22.1); and local electrical codes. Do not use
gas piping as an electrical ground. Failure to adhere to this warning could result in personal injury.
CAUTION:
Failure to follow these precautions could result in damage to the unit being installed:
Field Power Supply (Fig. 13-15)
1. Make all electrical connections in accordance with NEC
ANSI/NFPA, latest edition, and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1
Canadian Electrical Code Part 1 and applicable local codes.
Refer to unit wiring diagram.
2. Use only copper conductor for connections between fieldsupplied electrical disconnect switch and unit. DO NOT
USE ALUMINUM WIRE. Maximum wire size is no. 2
AWG (American Wire Gage).
Fig. 12 — Location of Coil Area Not To Be Drilled
—9—
3. Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate (also see Tables 3A and 3B). On 3-phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in Tables 3A and 3B, Note 2, to determine the percent voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable warranty.
4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are run in same conduit as high-voltage wires.
5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.
NOTE:
If accessory thru-the-bottom connections and roof curbs are used, refer the Thru-the-Bottom Installation Instructions for information on power wiring.
LEGEND
C
— Contactor
COMP — Compressor
EQUIP — Equipment
GND
— Ground
IFC
— Indoor (Evaporator) Fan
Contactor
NEC
— National Electrical Code
Fig. 13 — Power Wiring Connections
RACEWAY
LOW VOLTAGE
CONNECTIONS
(SCREW TERMINALS)
INTEGRATED GAS UNIT
CONTROLLER (IGC)
LEGEND
AHA — Adjustable Heat Anticipator
TC —
Thermostat-Cooling
CC
— Cooling Compensator
TH —
Thermostat-Heating
RC
— 24-v Cooling
RH
— 24-v Heating
Field Wiring
Factory Wiring
NOTE: Connect Y2 when unit is equipped with an integrated economizer.
Fig. 14 — Low-Voltage Connections With or
Without Economizer or Two-Position Damper
—10—
HOLE IN END PANEL (HIDDEN)
Fig. 15 — Field-Control Wiring Raceway
High-Voltage Connections (Fig. 13)
The unit must have a separate electrical service with a fieldsupplied, waterproof, fused disconnect switch mounted at, or within sight from the unit. Refer to the unit rating plate for maximum fuse/circuit breaker size and minimum circuit amps
(ampacity) for wire sizing.
The field-supplied disconnect switch box may be mounted on the unit over the high-voltage inlet hole in the control corner panel.
Proceed as follows to complete the high-voltage connections to the unit:
1. Connect ground lead to chassis ground connection when using separate ground wire.
2. Pigtails are provided for field power connection.
Use factory-supplied splices or UL (Underwriters’
Laboratories) approved copper connector. Install conduit connectors in side panel power supply knockout openings indicated in Fig. 2. Route power lines through connector to unit control box.
Special Procedures for 208-V Operation
DANGER:
Make sure that the power supply to the unit is switched OFF before making any wiring changes.
Electrical shock can cause personal injury or death.
For operation on 208 v, disconnect the black wire from the
230-v orange wire on the transformer and connect it to the
200-v red wire from the transformer. Insulate the end of the orange wire.
Table 3A — Electrical Data (Units Without Electrical Convenience Outlet)
UNIT
581B
036
(3 Tons)
048
(4 Tons)
060
(5 Tons)
072
(6 Tons)
NOMINAL
VOLTAGE
(V-Ph-Hz)
VOLTAGE
RANGE
Min Max
208/230-1-60 187
208/230-3-60 187
254
254
460-3-60
575-3-60
414
518
208/230-1-60 187
208/230-3-60 187
508
632
254
254
460-3-60
575-3-60
414
518
208/230-1-60 187
208/230-3-60 187
460-3-60
575-3-60
414
518
208/230-3-60 187
460-3-60
575-3-60
414
518
508
632
254
254
508
632
254
508
632
COMPRESSOR
LEGEND
FLA
— Full Load Amps
HACR — Heating, Air Conditioning and Refrigeration
IFM
— Indoor (Evaporator) Fan Motor
LRA
— Locked Rotor Amps
MCA
— Minimum Circuit Amps
MOCP — Maximum Overcurrent Protection
NEC
— National Electrical Code
OFM
— Outdoor (Condenser) Fan Motor
RLA
— Rated Load Amps
UL
— Underwriters’ Laboratories
*Used to determine minimum disconnect per NEC.
†Fuse or HACR circuit breaker.
7.4
5.8
28.8
17.3
9.0
7.1
20.5
9.6
7.7
RLA
16.0
10.3
5.1
4.2
23.7
13.5
49.5
40.0
169.0
123.0
62.0
50.0
156.0
70.0
56.0
LRA
88.0
77.0
39.0
31.0
129.0
99.0
NOTES:
1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker.
The CUL units may be fuse or circuit breaker.
2. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is greater than 2%.
Use the following formula to determine the percentage of voltage imbalance.
max voltage deviation from average voltage
% Voltage Imbalance = 100 x average voltage
OFM
0.8
0.8
1.4
0.6
0.6
0.4
0.4
1.5
1.5
FLA
0.7
0.7
0.4
0.4
0.7
0.7
IFM
2.6
2.6
5.8
2.6
2.6
2.2
2.2
8.8
5.8
FLA
4.9
4.9
2.2
2.2
4.9
4.9
COMBUSTION
FAN MOTOR
FLA
.57
.57
.30
.30
.57
.30
.30
.30
.30
.57
.57
.30
.30
.57
.57
POWER SUPPLY
MCA
25.6/25.6
18.5/18.5
9.0
7.3
35.2/35.2
22.5/22.5
9.7
9.3
46.3/46.3
29.0/29.0
14.7
11.6
32.8/32.8
15.2
12.2
MOCP†
35/35
25/25
15
15
45/45
30/30
15
15
60/60
35/35
20
15
40/40
20
15
MINIMUM UNIT
DISCONNECT
SIZE*
FLA LRA
25/25 101/101
18/18
9
7
90/ 90
46
37
34/34 142/142
22/22 112/112
12
9
57
46
45/45 216/216
28/28 168/168
14
11
84
59
32/32 200/200
15
12
92
74
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
452 + 464 + 455
Average Voltage =
3
1371
=
3
= 457
Determine maximum deviation from average voltage.
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
Maximum deviation is 7 v.
Determine percentage of voltage imbalance:
7
% Voltage Imbalance = 100 x
457
= 1.53%
This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.
IMPORTANT: If the supply voltage phase imbalance is more than
2%, contact your local electric utility company immediately.
3. 575-v units are UL, Canada approved only.
—11—
Table 3B — Electrical Data (Units with Electrical Convenience Outlet)
UNIT
581B
036
(3 Tons)
048
(4 Tons)
060
(5 Tons)
072
(6 Tons)
NOMINAL
VOLTAGE
(V-Ph-Hz)
VOLTAGE
RANGE
Min Max
208/230-1-60 187
208/230-3-60 187
254
254
460-3-60
575-3-60
414
518
208/230-1-60 187
208/230-3-60 187
460-3-60
575-3-60
414
518
208/230-1-60 187
508
632
254
254
508
632
254
208/230-3-60 187
460-3-60 414
575-3-60 518
208/230-3-60 187
460-3-60
575-3-60
414
518
254
508
632
254
508
632
COMPRESSOR
LEGEND
CUL
— Canadian Underwriters’ Laboratories
FLA
— Full Load Amps
HACR — Heating, Air Conditioning and Refrigeration
IFM
— Indoor (Evaporator) Fan Motor
LRA
— Locked Rotor Amps
MCA
— Minimum Circuit Amps
MOCP — Maximum Overcurrent Protection
NEC
— National Electrical Code
OFM
— Outdoor (Condenser) Fan Motor
RLA
— Rated Load Amps
*Used to determine minimum disconnect per NEC.
†Fuse or HACR circuit breaker.
17.3
9.0
7.1
20.5
9.6
7.7
RLA
16.0
10.3
5.1
4.2
23.7
13.5
7.4
5.8
28.8
LRA
88.0
77.0
39.0
31.0
129.0
99.0
49.5
40.0
169.0
123.0
62.0
50.0
156.0
70.0
56.0
NOTES:
1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker.
The CUL units may be fuse or circuit breaker.
2. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is greater than 2%.
Use the following formula to determine the percentage of voltage imbalance.
OFM IFM
1.5
0.8
0.8
1.4
0.6
0.6
FLA FLA
0.7
0.7
4.9
4.9
0.4
0.4
0.7
0.7
0.4
0.4
1.5
2.2
2.2
4.9
4.9
2.2
2.2
8.8
5.8
2.6
2.6
5.8
2.6
2.6
COMBUSTION
FAN MOTOR
FLA
.57
.57
.30
.30
.57
.57
.30
.30
.57
.57
.30
.30
.57
.30
.30
POWER SUPPLY
WITH OUTLET
MCA
31.6/31.66
24.5/24.5
14.6
11.5
41.2/41.2
28.5/28.5
14.6
11.5
52.3/52.3
34.9/34.9
17.4
13.8
38.8/38.8
17.9
14.4
MOCP†
40/40
30/30
20
15
50/50
35/35
20
15
60/60
40/40
20
20
45/45
20
20
MINIMUM UNIT
DISCONNECT
SIZE*
FLA LRA
30/30 106/106
24/24
14
11
14
11
13
95/ 95
59
47
39/39 147/147
28/28 117/117
59
47
51/51 221/221
34/34 173/173
17 87
61
35/35 205/205
17
14
95
75
% Voltage Imbalance = 100 x max voltage deviation from average voltage average voltage
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
Average Voltage =
452 + 464 + 455
3
=
1371
3
= 457
Determine maximum deviation from average voltage.
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
Maximum deviation is 7 v.
Determine percentage of voltage imbalance:
% Voltage Imbalance = 100 x
7
457
= 1.53%
This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.
IMPORTANT: If the supply voltage phase imbalance is more than
2%, contact your local electric utility company immediately.
3. 575-v units are CUL approved only.
Control Voltage Connections
Install a factory-approved room thermostat. See Table 4. Locate the thermostat on an inside wall in the space to be conditioned where it will not be subjected to either a cooling or heating source or direct exposure to sunlight. Mount the thermostat 4 to 5 ft above the floor.
Route thermostat cable or equivalent single leads of colored wire from subbase terminals through connector on unit to lowvoltage connections (shown in Fig. 14).
Connect thermostat wires to matching screw terminals of lowvoltage connection board. See Fig. 14.
NOTE:
For wire runs up to 50 ft, use no. 18 AWG insulated wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG insulated wire (35 C minimum). For 75 to 155 ft, use no. 14 AWG insulated wire (35 C minimum). All wire larger than no. 18
AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.
—12—
Pass control wires through the hole provided in the corner post; then feed wires through the raceway built into the corner post to the 24-v barrier located on the left side of the control box. See Fig. 15. The raceway provides the UL required clearance between high- and low-voltage wiring.
Connect thermostat wires to pigtails of low-voltage circuit in low-voltage section on control box using wirenuts.
Table 4 — Thermostat List*
TYPE
Manual Changeover (Standard)
2 Heat/2 Cool
Auto. Changeover (Standard)
2 Heat/2 Cool
Manual Changeover (Electronic Setback)
2 Heat/2 Cool
Auto. Changeover (Electronic Setback)
2 Heat/2 Cool
*See Trade Prices for part numbers.
Heat Anticipator Setting
The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance. Set the heat anticipator, using an ammeter to determine the exact required setting.
NOTE:
For thermostat selection purposes, use .14 amp for the approximate required setting. Set heat anticipator stage
1 and 2 at .14 amp.
Failure to make a proper heat anticipator adjustment may result in improper operation, discomfort to the occupants of the conditioned space, and inefficient energy utilization; however, the required setting may be changed slightly to provide a greater degree of comfort for a particular installation.
F. Accessory Installation
At this time any required accessories should be installed on the unit. Control wiring information is provided in the unit wiring book. Refer to accessory Installation Instructions provided with accessory.
G. Optional Varislide™ Economizer
The optional economizer hood assembly is packaged and shipped in the filter section. Damper blades and control boards are installed at the factory and the economizer is shipped in the vertical discharge position.
NOTE:
Horizontal discharge block-off plate is shipped with the air hood package. If unit is to be used for vertical discharge application, discard this plate.
Assembly
1. Determine if ventilation air is required in building. If so, determine the minimum amount to be supplied by each unit and record quantity of ventilation air needed for use in Step 7.
2. Remove filter access panel by raising panel and swinging panel outward. Panel is now disengaged from track and can be removed. No tools are required to remove filter access panel. Remove outdoor-air opening panel.
Save panels and screws. See Fig. 16. Remove optional outdoor-air damper hood package from filter section.
3. Assemble outdoor-air hood top and side plates as shown in Fig. 17. Install seal strips on hoop top and sides.
Put aside screen retainer and retainer screw for later assembly. Do not attach hood to unit at this time.
4. Slide economizer into unit and secure with screws. See
Fig. 18.
NOTE:
Be sure to engage rear economizer flange under tabs in vertical return-air opening.
5. To convert to horizontal discharge application: a. Rotate the economizer 90 degrees until the economizer motor faces the condenser section (see Fig. 19.).
b. Rotate the barometric relief damper cover 90 degrees.
c. Install horizontal discharge block-off plate over the opening on the access panel. (Block-off plate
MUST be installed before installing hood assembly.) See Fig. 20.
6. Insert economizer plug into economizer harness. Remove tape from barometric relief damper. See Fig. 21.
7. If ventilation air is not required, proceed to Step 9. If ventilation air is required, determine the minimum position setting for required airflow. See Fig. 22. Adjust minimum position setting by adjusting the screws on the position setting bracket. Slide bracket until the top screw is in the position determined by Fig. 22. Tighten screws.
—13—
Fig. 16 — Typical Access Panel Locations
Fig. 17 — Outdoor-Air Hood Details
ECONOMIZER
CONTROL BOARD
ECONOMIZER
PLUG
ECONOMIZER
MOTOR
BAROMETRIC
RELIEF DAMPER
TOP
SCREW
ECONOMIZER
MOUNTING SCREWS
POSITION SETTING
BRACKET
Fig. 18 — Varislide Economizer Installed in Unit
ECONOMIZER
CONTROL
BOARD
BAROMETRIC
RELIEF
DAMPER
ECONOMIZER
PLUG
ECONOMIZER
MOTOR
Fig. 19 — Horizontal Varislide™ Economizer Installation
(90 Degree Rotation)
EXAMPLE:
Given:
Negative Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 in. wg
Outdoor Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 cfm
Determine — Setting — 5 in.
Fig. 22 — Varislide Economizer Minimum Position Setting
BLOCK-OFF PLATE
Fig. 20 — Horizontal Discharge Block-Off Plate
WIRING
HARNESS
Fig. 21 — Typical Varislide Economizer and Wiring Harness
8. Remove tape from outdoor-air thermostat (OAT). Fasten OAT to inside of hood using screws and speed clips provided. See Fig. 23. Make sure OAT terminals are positioned up.
9. Replace outdoor-air opening panel using screws from
Step 2. Replace filter access panel. Ensure the filter access panel slides along the tracks and is securely engaged.
10. Fasten hood top and side plate assembly (Fig. 17) to outdoor-air opening panel with screws provided.
11. Place knob supplied with economizer on OAT. See
Fig. 23. Set for 3° F below indoor room thermostat setting. If accessory enthalpy control (EC) is used in place of OAT, see instructions shipped with EC for installation and adjustment. See Fig. 23.
12. Connect OAT per Fig. 24.
13. Slide outdoor-air inlet screen into screen track on hood side plate. While holding screen in place, fasten screen retainer to hood using screws provided.
NOTE:
Refer to Fig. 25 for economizer barometric relief damper characteristics.
H. Optional PARABLADE Economizer
The optional PARABLADE economizer hood assembly is packaged and shipped in the filter section. Damper blades and control boards are installed at the factory and the economizer is shipped in the vertical discharge position.
NOTE:
Horizontal discharge block-off plate is shipped with the air hood package. The PARABLADE economizer can only be used for vertical discharge applications. Discard this plate.
Assembly
1. Determine if ventilation air is required in building. If so, determine the minimum amount to be supplied by each unit and record quantity of ventilation air needed for use in Step 6.
2. Remove filter access panel by raising panel and swinging panel outward. Panel is now disengaged from track and can be removed. No tools are required to remove filter access panel. Remove outdoor-air opening panel.
—14—
LEGEND
OAT — Outdoor-Air Thermostat
NOTE: See unit wiring diagram for details.
Fig. 24 — Wiring Connections for Outdoor-Air
Thermostat
Fig. 25 — Varislide™ Economizer Barometric Relief
Damper Characteristics
OPEN
POSITION
MINIMUM
Y
10
30
D
60
M
70
U
H
90
%
CW–SETPOINTS–CCW
OR UNPOWERED ST
WN IN HIGH ENTHALPY
REV.
97-3672
Fig. 23 — Outdoor-Air Thermostat/Enthalpy
Control Installation
—15—
Save panels and screws. Remove optional economizer so the outdoor-air damper hood package can be removed from the filter section. See Fig. 16.
3. Assembly outdoor-air hood top and side plates as shown in Fig. 17. Install seal strips on hoop top and sides.
Put aside screen retainer and retainer screw for later assembly. Do not attach hood to unit at this time.
4. Slide economizer into unit and secure with screws. See
Fig. 26.
NOTE:
Be sure to engage rear economizer flange under tabs in vertical return-air opening.
5. Insert economizer plug into economizer harness. Remove tape from barometric relief damper. See Fig. 26.
6. If ventilation is not required, proceed to Step 7. If ventilation air is required, perform the following: a. Make sure the factory-installed jumper is in place across terminals P and P1 on the economizer logic module. T and T1 should be disconnected during adjustment.
b. The 2 potentiometers with slots for adjustment are located on the face of the economizer logic module.
Turn the lower potentiometer fully clockwise. The dampers should be fully closed. Turn the potentiometer gradually counterclockwise until the desired position is reached.
c. Connect T and T1 to the 24V power supply.
d. After installation is complete, calculate the minimum airflow across the economizer. To calculate the minimum airflow, the following data is needed: total cfm (cfm
3
), temperature of the total cfm (T
3
), temperature of the return air (T
2
), and temperature of the entering outside air (T
1
). Cfm
1 is the outside air cfm, which will be the minimum airflow.
Insert the data into the following equations:
T
1
(cfm
1
) + T
2
(cfm
2
)
= T
3 cfm
3 cfm
2
= (cfm
Therefore:
3
− cfm
1
)
T
1
(cfm
1
) + T
2
(cfm
3
− cfm
1
)
= T
3 cfm
3
Use this equation to determine cfm
1
, which is the minimum airflow across the economizer.
cfm
1
=
(T
3
−T
(T
1
2
) cfm
− T
2
)
3
If cfm
1 does not match the desired minimum airflow from Step 1, readjust the minimum position setting screw.
7. Determine the enthalpy changeover set point from
Fig. 27. The enthalpy changeover set point should be set to return the outdoor air damper to the minimum position when enthalpy rises above the set point. The settings are A, B, C, and D. Set the enthalpy changeover per the setting in Fig. 27.
8. Replace outdoor-air opening panel using screws from
Step 2. Replace filter access panel. Ensure the filter access panel slides along the tracks and is securely engaged. See Fig. 28.
9. Fasten hood top and side plate assembly (Fig. 29) to outdoor-air opening panel with screws provided.
10. Slide outdoor-air inlet screen into screen track on hood side plate. While holding screen in place, fasten screen retainer to hood using screws provided. See Fig. 30.
Fig. 26 — PARABLADE Economizer Installed in Unit
CONTROL
CURVE
A
B
C
D
CONTROL POINT
(APPOX. DEG.)
AT 50% RH
73 (23)
70 (21)
67 (19)
63 (17)
Fig. 28 — Panels Reinstalled On Unit
Fig. 27 — Enthalpy Settings for PARABLADE Economizer
—16—
Fig. 29 — Outdoor-Air Hood Installed On Unit
Fig. 30 — Filter Installed on Outdoor-Air Hood
PRE-START-UP
WARNING:
Failure to observe the following warnings could result in serious personal injury:
1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.
2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.
3. Do not remove compressor terminal cover until all electrical sources have been disconnected.
4. If refrigerant leak is suspected around compressor terminals, relieve all pressure from system before touching or disturbing anything inside terminal box.
5. Never attempt to repair soldered connection while refrigerant system is under pressure.
6. Do not use torch to remove any component. System contains oil and refrigerant under pressure.
To remove a component, wear protective goggles and proceed as follows: a. Shut off gas supply and then electrical power to unit.
b. Reclaim refrigerant to relieve all pressure 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.
refrigerant leak. Leak-test all refrigerant tubing connections using electronic leak detector, halide torch, or liquid-soap solution. If refrigerant leak is detected, see Refrigerant Leaks section on page 30.
c. Inspect all field- and factory-wiring connections. Be sure that connections are completed and tight.
d. Inspect coil fins. If damaged during shipping and handling, carefully straighten fins with a fin comb.
4. Verify the following conditions:
DANGER:
Do not purge gas supply into the combustion chamber. Do not use a match or other open flame to check for gas leaks. Failure to adhere to this warning could result in an explosion causing personal injury or death.
a. Make sure that gas supply has been purged, and that all gas piping has been checked for leaks.
b. Make sure that condenser-fan blade is correctly positioned in fan orifice. Blades should clear fan motor
and fan orifice ring.
c. Make sure that correct air filters are in place. (See
Table 1.) Do not operate unit without return-air filters.
d. Make sure that condensate drain pan and trap are filled with water to ensure proper drainage.
e. Make sure that all tools and miscellaneous loose parts have been removed.
f. Make sure outdoor-air inlet screen is in place.
5. Compressors are internally spring mounted. Do not loosen or remove compressor holddown bolts.
6. Each unit system has 4 Schrader-type gage ports: one on the suction line, one on the compressor discharge line, and two additional Schrader valves located under the high-pressure and low-pressure switches. Be sure that caps on the ports are tight.
Unit is now ready for initial start-up.
Proceed as follows to inspect and prepare the unit for initial startup:
1. Remove all access panels.
2. Read and follow instructions on all WARNING, CAU-
TION, 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
—17—
START-UP
I. COMPRESSOR ROTATION
On 3-phase units it is important to be certain the scroll compressor is rotating in the proper direction. To determine whether or not compressor is rotating in the proper direction:
1. Connect service gages to suction and discharge pressure fittings.
2. Energize the compressor.
3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start-up.
If the suction pressure does not drop and the discharge pressure does not rise to normal levels:
1. Note that the evaporator fan (006 and 007 only) is probably also rotating in the wrong direction.
2. Turn off power to the unit.
3. Reverse any 2 of the unit power leads.
4. Reapply power to the compressor.
The suction and discharge pressure levels should now move to their normal start-up levels.
NOTE:
When the compressor is rotating in the wrong direction, the unit will make an elevated level of noise and will not provide cooling.
II. HEATING SECTION START-UP AND ADJUSTMENTS
CAUTION:
Complete the required procedures given in the Pre-Start-Up section on this page before starting unit.
Do not jumper any safety devices when operating the unit.
Ensure that burner orifices are properly aligned. Unstable operation may occur when the burner orifices in the manifold are misaligned.
Follow the lighting instructions on the heating section operation label (located inside the burner access door) to start the heating section.
When lighting the unit for the first time, perform the following additional steps: If the gas supply pipe was not purged before connecting the unit, it will be full of air. It is recommended that the ground joint union be loosened and the supply line be allowed to purge until the odor of gas is detected. Never purge gas lines into a combustion chamber. Immediately upon detection of gas odor, retighten the union. Allow
5 minutes to elapse, then light unit in accordance with Checking Heating Control Operation section below.
A. Checking Heating Control Operation
Start and check the unit for proper heating control operation as follows: (Also see unit lighting instructions located inside the burner access panel.)
1. Turn on unit electrical supply and manual gas valve.
2. Set system switch selector at HEAT position and fan switch at AUTO. or ON position. Set heating temperature lever above room temperature.
3. The induced-draft motor will start immediately. The evaporator fan will have a 45-second delay before starting.
4. After a call for heating, the main burners should light within 5 seconds. If the burner does not light, then there is a 22-second delay before another 5-second try. If the burner still does not light, the time delay is repeated. If the burner does not light within 15 minutes, there is a lockout. To reset the control, break the 24-v power to
W1.
5. The evaporator-fan motor will turn on 45 seconds after burner ignition.
6. The evaporator-fan motor will turn off 45 seconds after thermostat temperature is satisfied.
7. Adjust airflow to obtain a temperature rise within the range specified on the unit nameplate.
NOTE:
The default value for the evaporator-fan motor ON/
OFF delay is 45 seconds. The Integrated Gas Unit Controller
(IGC) modifies this value when abnormal limit switch cycles occur. Based upon unit operating conditions, the ON delay can be reduced to 0 seconds and the OFF delay can be extended to 180 seconds. When one flash of the light-emitting diode (LED) is observed, the evaporator-fan ON/OFF delay has been modified.
If the limit switch trips at the start of the heating cycle during the evaporator ON delay, the time period of the ON delay for the next cycle will be 5 seconds less than the time at which the switch tripped.
EXAMPLE:
If the limit switch trips at 30 seconds, the evaporator-fan ON delay for the next cycle will occur at
25 seconds.
To prevent short-cycling, a 5-second reduction will only occur if a minimum of 10 minutes has elapsed since the last call for heating.
—18—
The evaporator-fan OFF delay can also be modified. Once the call for heating has ended, there is a 10 minute period during which the modification can occur. If the limit switch trips during this period, the evaporator-fan OFF delay will increase by 15 seconds. A maximum of 9 trips can occur, extending the evaporator-fan OFF delay to 180 seconds.
To restore the original default value, reset the power to the unit.
To shut off unit set system switch selector at OFF position.
Resetting heating selector lever below room temperature will temporarily shut unit off until space temperature falls below thermostat setting.
B. Safety Relief
A soft solder joint at the suction service Schrader port provides pressure relief under abnormal temperature and pressure conditions.
C. Ventilation (Continuous Fan)
Set fan and system switch selectors at ON and OFF positions, respectively. Evaporator fan operates continuously to provide constant air circulation. When the evaporator-fan selector switch is turned to the OFF position, there is a
30-second delay before the fan turns off.
D. Gas Input
Check gas input and manifold pressure after unit start-up.
(See Table 5.) If adjustment is required proceed as follows.
CAUTION:
These units are designed to consume the rated gas inputs using the fixed orifices at specified manifold pressures as shown in Table 5. DO
NOT REDRILL THE ORIFICES UNDER ANY
CIRCUMSTANCES.
The rated gas inputs shown in Table 5 are for altitudes from sea level up to 2000 ft above sea level. These inputs are based on natural gas with a heating value of 1050 Btu/ft
3 at
0.65 specific gravity, or LP gas with a heating value of
2500 Btu/ft
3 at 1.5 specific gravity. For elevations above
2000 ft, reduce input 4% for each 1000 ft above sea level. When the gas supply being used has a different heating value or specific gravity, refer to national and local codes, or contact your distributor or branch to determine the required orifice size. Refer to Table 6 for the correct orifice to use at high altitudes. Kits are available from your distributor.
E. Adjusting Gas Input
The gas input to the unit is determined by measuring the gas flow at the meter or by measuring the manifold pressure.
Measuring the gas flow at the meter is recommended for natural gas units. The manifold pressure must be measured to determine the input of propane gas units.
Measuring Gas Flow at Meter Method — Natural Gas Units
Minor adjustment can be made by changing the manifold pressure. The manifold pressure must be maintained between 3.2
and 3.8 in. wg on high-fire, two-stage units. If larger adjustments are required, change main burner orifices following the recommendations of national and local codes.
NOTE:
All other appliances that use the same meter must be turned off when gas flow is measured at the meter.
Proceed as follows:
1. Turn off gas supply to unit.
2. Remove pipe plug on outlet of gas valve or manifold, then connect manometer at this point. Turn on gas to unit.
Table 5 — Rated Gas Inputs at Indicated Manifold Pressures
UNIT
581B
036-072**
NUMBER
OF
ORIFICES
2
3
3
GAS SUPPLY PRESSURE
(in. wg)
Natural Propane
Min
4.0
4.0
5.0
Max
13.6
13.6
13.6
Min
5.0
5.0
5.0
Max
13.0
13.0
13.0
Natural Propane
3.5
MANIFOLD
PRESSURE
3.5††
3.5
\
(in. wg)
3.5
3.5††
3.5
\
Orifice
Drill Size
33
33
30
NATURAL GAS
Heating Input
(Btuh)†
72,000
115,000††
150,000
\
*When a 581B unit is converted to liquid propane (LP), the burners must be modified with accessory LP Kit.
†Based on altitudes from sea level up to 2000 ft above sea level. For altitudes above 2000 ft, reduce input rating 4% for each 1000 ft above sea level. In Canada, from 2000 ft above sea level to 4,500 ft above sea level, derate the unit 10%.
**581B036 with 150,000 Btuh input not available.
††581B036115 at high fire operation. At low fire, manifold pressure is 1.8 in. wg, and heating input is 82,000 Btuh.
\
581B048-072150 at high fire operation. At low fire, manifold pressure is 2.2 in. wg, and heating input is 120,000 Btuh.
PROPANE*
Orifice
Drill Size
43
43
38
Heating Input
(Btuh)†
72,000
115,000††
150,000
\
Table 6 — Altitude Compensation* — Units 581B036-072
ELEVATION
(ft)
0-2,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
11,000
12,000
13,000
14,000
72,000 AND 115,000
BTUH NOMINAL INPUT
Natural
Gas
Orifice
Size†
33
Liquid
Propane
Orifice
Size†
43
34
35
36
36
37
37
38
39
41
43
44
44
45
43
44
44
44
45
45
46
47
48
48
49
49
50
150,000 BTUH
NOMINAL INPUT
Natural
Gas
Orifice
Size†
30
30
31
32
33
34
35
36
37
38
39
40
41
42
Liquid
Propane
Orifice
Size†
38
39
40
41
42
45
45
46
47
47
43
43
44
44
*As the height above sea level increases, there is less oxygen per cubic foot of air. Therefore, heat input rate should be reduced at higher altitudes.
†Orifices are available through your local distributor or branch.
If the desired gas input is 115,000 Btuh, only a minor change in the manifold pressure is required.
Observe manifold pressure and proceed as follows to adjust gas input:
1. Remove cover screw over regulator adjustment screw on gas valve. See Fig. 31.
2. Turn regulator adjustment screw clockwise to increase gas input, or turn regulator adjustment screw counterclockwise to decrease input. Manifold pressure must be between 3.2 and 3.8 in. wg on high-fire, two-stage units.
WARNING:
Unsafe operation of the unit may result if manifold pressure is outside this range. Personal injury or unit damage may result.
3. Replace cover screw cap on gas valve.
4. Turn off gas supply to unit.
5. Remove manometer from pressure tap.
6. Replace pipe plug on gas valve or manifold.
7. Turn on gas to unit.
8. Check for leaks.
NOTE:
The gas manifold is equipped with a plug located approximately 5 in. down from the gas valve which may also be used to connect the manometer.
3. Record number of seconds for gas meter test dial to make one revolution.
4. Divide number of seconds in Step 3 into 3600 (number of seconds in 1 hour).
5. Multiply result of Step 4 by the number of cubic ft shown for one revolution of test dial to obtain cubic ft of gas flow per hour.
6. Multiply result of Step 5 by Btu heating value of gas to obtain total measured input in Btuh. Compare this value with heating input shown in Table 1. (Consult the local gas supplier if the heating value of gas is not known.)
EXAMPLE:
Assume that the size of test dial is 1 cubic ft, one revolution takes 33 seconds, and the heating value of the gas is 1050 Btu/ft
3
, then proceed as follows:
1. 33 seconds to complete one revolution.
2. 3600
4 33 = 109
3. 109 x 1 = 109 ft
3 of gas flow/hr
4. 109 x 1050 = 114,450 Btuh input
Fig. 31 — Burner Tray Details
—19—
Measuring Manifold Pressure — LP Gas Units
The main burner orifices on LP gas unit are sized for the unit rated input when the manifold pressure is 3.5 in. wg (highfire on two-stage units).
Proceed as follows to adjust gas input on an LP gas unit:
1. Turn off gas to unit.
2. Remove pipe plug on outlet of gas valve or manifold.
3. Connect manometer.
NOTE:
The gas manifold is equipped with a plug located approximately 5 in. down from the gas valve which may also be used to connect the manometer.
4. Turn on gas to unit.
5. Remove cover screw over regulator adjustment screw on gas valve. See Fig. 31.
6. Adjust regulator adjustment screw for a manifold pressure reading of 3.5 in. wg (high fire on two-stage units).
Turn adjusting screw clockwise to increase manifold pressure, or turn adjusting screw counterclockwise to decrease manifold pressure.
7. Replace cover screw.
8. Turn off gas to unit.
9. Remove manometer from pressure tap.
10. Replace pipe plug on gas valve or manifold.
11. Turn on gas to unit, and check for leaks.
F. Check Burner Flame and Ignition
Observe the unit heating operation. Watch the burner flames through the access door to see if they are light blue and soft in appearance and if the flames are approximately the same for each burner. See Fig. 32.
Fig. 32 — Monoport Burners
Main burners are factory set and should require no adjustment.
To check ignition of main burners and heating controls, move thermostat set point above room temperature and verify that the burners light and evaporator fan is energized. Check heating effect, then lower the thermostat setting below the room temperature and verify that the burners and evaporator fan turn off.
Refer to Table 6 for the correct orifice to use at high altitudes.
G. Airflow and Temperature Rise
The heating section of each side of unit is designed and approved for heating operation within the temperature rise range stamped on the unit rating plate. Temperature rise range is also found in Table 1.
The heating operation airflow must produce a temperature rise that falls within the approved range.
Refer to Care and Maintenance section on page 28 to adjust heating airflow when required.
H. Safety Check of Limit Control
Limit control is located on the deck next to the evaporator fan. The control shuts off the gas supply and energizes the evaporator-fan motor and inducer motor if the unit overheats.
The recommended method of checking this limit control is to gradually block off the return air after the unit has been operating for a period of at least 5 minutes. As soon as the limit control functions, the return-air opening should be unblocked to permit normal air circulation. By using this method to check the limit control, it can be established that the limit is functioning properly and the unit will ‘‘fail-safe’’ if there is a restricted circulating air supply or motor failure. If the limit control does not function during this test, the cause must be determined and corrected.
I. Heating Sequence of Operation
Heating, Units Without Economizer
When the thermostat calls for heating, terminal W1 is energized. In order to prevent thermostat short-cycling, the unit is locked into the Heating mode for at least 1 minute when
W1 is energized. The induced-draft motor is energized and burner ignition sequence begins. The indoor (evaporator) fan motor (IFM) is energized 45 seconds after a flame is ignited.
When additional heat is needed, W2 is energized and the highfire solenoid on the main gas valve (MGV) is energized. When the thermostat is satisfied and W1 is deenergized, the IFM stops after a 45-second time-off delay.
Heating, Units With Economizer
When the thermostat calls for heating, terminal W1 is energized. In order to prevent thermostat short-cycling, the unit is locked into the Heating mode for at least 1 minute when
W1 is energized. The induced-draft motor is energized and the burner ignition sequence begins. The indoor (evaporator) fan motor (IFM) is energized 45 seconds after a flame is ignited and the damper moves to the minimum position. If the two-position damper is used, the outdoor-air damper opens to the minimum position whenever the evaporator-fan runs.
When additional heat is needed, W2 is energized and the highfire solenoid on the main gas valve (MGV) is energized. When the thermostat is satisfied and W1 is energized, the IFM stops after a 45-second time-off delay. The economizer damper then moves to the fully-closed position. When using continuous fan, the damper will remain in the minimum position.
J. Limit Switches
Heating limit switch (LS) deenergizes the gas valve and the
Integrated Gas Unit Controller (IGC) if the leaving-air temperature exceeds the maximum allowable temperature.
Normally-closed limit switch completes a circuit to the gas valve. Should the leaving-air temperature rise above the maximum allowable temperature, the limit switch opens, instantly closing the gas valve and stopping gas flow to the burners. The inducer motor and the evaporator motor are energized to cool heat exchanger.
When the air temperature at the limit switch drops to the low-temperature setting of the limit switch, the switch closes and completes the gas valve circuit. The electric-spark ignition system cycles and the unit returns to normal heating operation.
K. Rollout Switch
Rollout switch (RS) is a temperature-actuated automatic reset switch connected in series with heating limit switch. The function of the switch is to close the main gas valve in the
—20—
event of flame rollout. The switch is located above the main burners on the internal wind baffle. When the temperature at the rollout switch exceeds the maximum allowable temperature, the W control circuit trips, deenergizing the gas valve and stopping gas flow to the burners. The inducer motor is energized when the rollout switch trips. Although the rollout switch has an automatic reset, the IGC locks out the unit when a trip occurs and must be reset at unit disconnect. If the switch cycles again, shut down the unit and call for service.
III. COOLING SECTION START-UP AND ADJUSTMENTS
CAUTION:
in the Pre-Start-Up section on page 17 before starting the unit.
unit.
Complete the required procedures given
Do not jumper any safety devices when operating the
Do not operate the compressor when the outdoor temperature is below 25 F (unless accessory low ambient kit is installed).
Do not rapid-cycle the compressor. Allow 5 minutes between ‘‘on’’ cycles to prevent compressor damage.
A. Checking Cooling Control Operation
Start and check the unit for proper cooling control operation as follows:
1. Place room thermostat SYSTEM switch in OFF position. Observe that blower motor starts when FAN switch is placed in ON position and shuts down when FAN switch is placed in AUTO. position.
2. Place SYSTEM switch in COOL position and FAN switch in AUTO. position. Set cooling control below room temperature. Observe that compressor, condenser-fan motor, and evaporator-fan motor start. Observe that cooling cycle shuts down when control setting is satisfied, or reset thermostat at a position above room temperature. Compressor will shut off. Evaporator fan will shut off after a 30-second delay.
3. Check unit charge. See Section B below.
4. To shut off unit, set system selector switch at OFF position. Resetting thermostat at a position above room temperature shuts unit off temporarily until space temperature exceeds thermostat setting. Units are equipped with Cycle-LOC™ protection device. Unit shuts down on any safety trip, and indicator light on thermostat comes on. Check reason for all safety trips.
5. When using an autochangeover room thermostat, place both SYSTEM and FAN switches in AUTO. positions.
Observe that unit operates in Heating mode when temperature control is set to call for heating (above room temperature) and operates in Cooling mode when temperature control is set to call for cooling (below room temperature).
6. Compressor restart is accomplished by manual reset at the thermostat by turning the selector switch to OFF and then to ON positions.
B. Checking and Adjusting Refrigerant Charge
The refrigerant system contains R-22 refrigerant, and is fully charged, tested, and factory-sealed.
NOTE:
Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R-22 charge. This unit uses charging charts to determine proper charge. See Refrigerant Charge section on page 29 for further details.
—21—
C. Unit Controls
All compressors have the following internal-protection controls:
1. High-Pressure Relief Valve — This valve (internal to the compressor) opens when the pressure differential between the low and high side becomes excessive and will automatically reset when pressure returns to normal.
2. Compressor Overload — This overload interrupts power to the compressor when either the current or internal temperature become excessive, and automatically resets when the internal temperature drops to a safe level.
This overload may require up to 60 minutes (or longer) to reset; therefore, if the internal overload is suspected of being open, disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester.
D. Cooling Sequence of Operation
Cooling, Units Without Economizer
When thermostat calls for cooling, terminals G and Y1 and the compressor contactor are energized. The indoor (evaporator) fan motor (IFM), compressor, and outdoor (condenser) fan motor (OFM) start. The OFM runs continuously while the unit is in cooling. When the thermostat is satisfied, C1 is deenergized and the compressor and OFM shut off. After a
30-second delay, the IFM shuts off. If the thermostat fan selector switch is in the ON position, the evaporator motor will run continuously.
Cooling, Units With Varislide™ Economizer
When the outdoor-air temperature is above the OAT setting and the room thermostat calls for cooling, compressor contactor is energized to start the compressor and outdoor (condenser) fan motor (OFM). The evaporator (indoor) fan motor
(IFM) is energized and the economizer damper moves to the minimum position. After the thermostat is satisfied, the damper moves to the fully closed position when IFM is deenergized.
When the outdoor-air temperature is below the OAT setting and the thermostat calls for Y1 and G (cooling), the economizer damper moves to the minimum position when the evaporator-fan starts. The first stage of cooling is provided by the economizer. If the supply-air temperature is above
57 F, a switch on the supply-air thermostat is closed between the T2 terminal and the 24 vac terminal. This causes the damper to continue to modulate open until the supply-air temperature falls below 55 F or the damper reaches the fully open position.
When the supply-air temperature is between 55 F and 52 F, the supply-air thermostat has open switches between the T2 and 24 vac terminals and between the T1 and 24 vac terminals. This causes the economizer damper to remain in an intermediate open position.
If the supply-air temperature falls below 52 F, a switch on the supply-air thermostat is closed between the T1 terminal and the 24 vac terminal. This causes the damper to modulate closed until the supply-air temperature rises above 55 F or the damper reaches the minimum position.
When the supply-air temperature is between 55 F and 57 F, the supply-air thermostat has open switches between the T2 and 24 vac terminals. This causes the economizer damper to remain in an intermediate open position.
If the outdoor air alone cannot satisfy the cooling requirements of the conditioned space, economizer cooling is integrated with mechanical cooling, providing second stage cooling. The compressor and condenser fan will be energized and the position of the economizer damper will be determined by the supply-air temperature.
When the second stage of cooling is satisfied, the compressor and OFM will be deenergized. The damper position will be determined by the supply-air temperature.
When the first stage of cooling is satisfied, there is a
30-second delay before evaporator shuts off (036-060). The damper will move to fully closed position.
Cooling, Units with PARABLADE Economizer
When the outdoor-air is above the enthalpy control setting, and the room thermostat calls for cooling, the compressor contactor is energized to start the compressor and the condenser (outdoor) fan motor. The evaporator (indoor) fan motor is energized and the economizer damper moves to the minimum position. After the room thermostat is satisfied the damper will spring return to the full closed position.
When the outdoor-air is below the enthalpy control setting and the thermostat calls for cooling, the economizer outdoor air damper is opened proportionally to maintain between
50 and 56 F at the mixed air sensor. If outside air alone cannot satisfy the cooling requirements, economizer cooling is integrated with mechanical cooling. When the room thermostat is satisfied, the damper will spring return to the fully closed position.
Time Guard t II Device
If the unit is equipped with accessory Time Guard II recycle timer, the unit will delay 5 minutes between compressor starts.
Low-Pressure Switch (LPS)
When the liquid line pressure drops below 7 psig, the LPS opens 24-v power to the compressor contactor and stops the compressor. When the pressure reaches 22 psig, the switch resets and the compressor is allowed to come back on.
High-Pressure Switch (HPS)
When the refrigerant high-side pressure reaches 428 psig, the
HPS opens 24-v power to the compressor contactor and stops the compressor. When the pressure drops to 320 psig, the switch resets and the compressor is allowed to restart.
Freeze Protection Thermostat (FPT)
When the evaporator coil leaving refrigerant temperature drops below 30 F, the FPT opens 24-v power to the compressor contactor and stops the compressor. When the leaving refrigerant temperature warms to 45 F, the switch resets and the compressor is allowed to restart.
IV. INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS
CAUTION:
For cooling operation, the recommended airflow is 300 to 500 cfm per each 12,000 Btuh of rated cooling capacity. For heating operation, the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate.
Adjust evaporator-fan speed to meet jobsite conditions and temperature rise in Table 1. Table 7 shows fan rpm at motor pulley settings. Table 8 shows evaporator-fan motor performance. Refer to Tables 9-16 to determine fan speed settings.
A. Belt Drive Motors
Fan motor pulleys are factory set for speed shown in Table 1.
Check pulley alignment and belt tension prior to start-up.
NOTE:
Before adjusting fan speed, make sure the new fan speed will provide an air temperature rise range as shown in
Table 1.
To change fan speed:
1. Shut off unit power supply.
2. Loosen belt by loosening fan motor mounting nuts. See
Fig. 33.
3. Loosen movable pulley flange setscrew (see Fig. 34).
4. Screw movable flange toward fixed flange to increase speed and away from fixed flange to decrease speed. Increasing fan speed increases load on motor. Do not exceed maximum speed specified in Table 1.
5. Set movable flange at nearest keyway of pulley hub and tighten setscrew. (See Table 1 for speed change for each full turn of pulley flange.)
To align fan and motor pulleys:
1. Loosen fan pulley setscrews.
2. Slide fan pulley along fan shaft.
3. Make angular alignment by loosening motor from mounting.
To adjust belt tension:
1. Loosen fan motor nuts.
2. Slide motor mounting plate away from fan scroll for proper belt tension (
1
⁄
2
-in. deflection with one finger) and tighten mounting nuts.
3. Adjust lock bolt and nut on mounting plate to secure motor in fixed position.
CAPACITOR
(581B036, 048
SINGLE-PHASE
UNITS ONLY)
MOTOR
MOUNTING
PLATE NUTS
Fig. 33 — Belt Drive Motor Mounting
Fig. 34 — Evaporator-Fan Pulley Adjustment
—22—
B. Ventilation Sequence
If unit is equipped with an economizer, the damper will open to the minimum position whenever the evaporator fan runs.
The damper motor will be energized with 24 vac power and damper will drive open until SW3 on the damper is deactivated. The damper motor will stop and damper will remain in the minimum ventilation position until the evaporator fan is shut off. When the evaporator fan is shut off, the damper motor is again energized and the damper runs closed until SW2 is activated and the damper motor turns off.
When unit is equipped with an economizer, additional outdoor air can be brought in through the damper to provide cooling. If the unit calls for cooling and the outdoor-air temperature is below the outdoor-air thermostat (OAT) setting or the outdoor-air enthalpy is below the enthalpy control (EC) setting, the damper motor starts. The damper drives open until it reaches full open and SW1 is activated. When SW1 is deactivated, the damper motor stops. When the cooling load is satisfied, or outdoor air is no longer below the OAT or EC setting, the damper returns to the minimum position.
If the supply-air thermostat (located on the evaporator-fan housing) senses a supply-air temperature less than 50 F, the damper closes until the supply-air temperature is above
50 F.
UNIT
581B
036
048
060
072
0
1090
1185
1460
1585
1 ⁄
2
1055
1150
1425
1540
*Approximate fan rpm shown.
1
1025
1115
1385
1490
1 1 ⁄
2
990
1080
1350
1445
Table 7 — Fan Rpm at Motor Pulley Settings*
2
960
1045
1315
1400
MOTOR PULLEY TURNS OPEN
2 1 ⁄
2
925
1015
1275
1350
3
890
980
1240
1305
3 1 ⁄
2
860
945
1205
1260
4
825
910
1165
1210
4 1 ⁄
2
795
875
1130
1165
5
760
840
1095
1120
5 1 ⁄
2
—
—
1055
—
6
—
—
1020
—
Table 8 — Evaporator Fan Motor Data
UNIT
581B
036
048
060
072
PHASE
Single
Three
Single
Three
Single
Three
Three
MAXIMUM
CONTINUOUS
BHP*
1.20
1.20
1.20
1.20
1.80
1.80
2.40
UNIT
VOLTAGE
208/230
208/230
460
575
208/230
208/230
460
575
208/230
208/230
460
575
208/230
460
575
MAXIMUM
AMP
DRAW
5.4
5.4
2.4
2.4
5.4
5.4
2.4
2.4
9.7
6.4
2.9
2.9
6.4
2.9
2.9
LEGEND
Bhp — Brake Horsepower
*Extensive motor and electrical testing on these units ensures that the full horsepower range of the motors can be utilized with confidence. Using your fan motors up to the ratings shown in this table will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
—23—
AIRFLOW
(Cfm)
900
1000
1100
1200
1300
1400
1500
Rpm
581
644
687
733
754
810
841
0.1
Bhp
0.12
0.19
0.22
0.26
0.29
0.35
0.42
Table 9 — 581B036 Air Delivery — Vertical Discharge Units
Rpm
673
709
746
785
826
868
911
0.2
Bhp
0.18
0.22
0.26
0.32
0.38
0.45
0.53
Rpm
736
782
806
843
891
937
985
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.3
0.4
Bhp
0.22
0.28
0.30
0.35
0.43
0.51
0.61
Rpm
805
835
867
903
942
984
1029
Bhp
0.25
0.30
0.35
0.41
0.48
0.57
0.66
Rpm
865
900
929
960
991
1032
1073
0.5
Bhp
0.29
0.35
0.40
0.47
0.53
0.62
0.72
Rpm
911
937
964
994
1047
1067
1109
0.6
Bhp
0.34
0.38
0.40
0.50
0.60
0.67
0.77
AIRFLOW
(Cfm)
1000
1100
1200
1300
1400
1500
Bhp — Brake Horsepower Input to Fan
NOTES:
900
Rpm
957
992
1013
1045
1075
1110
1150
LEGEND
0.7
Bhp
0.39
0.44
0.49
0.56
0.64
0.73
0.78
Rpm
988
1039
1068
1090
1122
1160
1190
0.8
Bhp
0.43
0.49
0.55
0.64
0.70
0.78
0.84
1. Boldface indicates a field-supplied drive is required. (See Note 2.)
Rpm
1039
1061
1091
1109
1152
1181
1225
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.9
1.0
2. Motor drive range is 760 to 1090 rpm. All other rpms require a field-supplied drive.
3. Values include losses for filters, unit casing, and wet coils.
4. Maximum continuous bhp is 1.2. Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with confidence.
Bhp
0.47
0.55
0.61
0.68
0.76
0.83
0.89
Rpm
1061
1088
1109
1156
1190
1237
1271
Bhp
0.51
0.60
0.66
0.73
0.82
0.88
0.95
Rpm
1083
1111
1127
1203
1228
1293
1317
1.1
Bhp
0.54
0.66
0.73
0.81
0.87
0.94
1.00
Rpm
1105
1136
1145
1250
1266
1349
1383
1.2
Bhp
0.58
0.72
0.80
0.86
0.94
0.99
1.05
Using your fan motors up to the ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
5. Use of a field-supplied motor may affect wire sizing. Contact your local representative to verify.
6. Interpolation is permissible. Do not extrapolate.
7. Minimum allowable cfm is 300 cfm/ton.
AIRFLOW
(Cfm)
1200
1300
1400
1500
1600
1700
1800
1900
2000
Rpm
596
633
672
711
751
791
831
872
913
0.1
Bhp
0.20
0.24
0.30
0.35
0.42
0.49
0.58
0.67
0.77
Table 10 — 581B048 Air Delivery — Vertical Discharge Units
Rpm
665
699
735
770
835
873
881
919
958
0.2
Bhp
0.25
0.30
0.36
0.42
0.49
0.57
0.66
0.75
0.86
Rpm
722
754
788
822
871
907
929
965
1002
0.3
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
Bhp
0.31
0.36
0.42
0.49
0.56
0.65
0.74
0.84
0.95
Rpm
779
809
840
873
907
941
976
1011
1046
Bhp
0.36
0.42
0.48
0.55
0.63
0.72
0.81
0.92
1.03
Rpm
872
902
933
963
993
1024
1057
1091
1125
0.6
Bhp
0.48
0.55
0.62
0.69
0.77
0.87
0.97
1.08
1.21
Rpm
915
943
972
1002
1033
1064
1095
1127
1160
0.7
Bhp
0.54
0.61
0.69
0.77
0.85
0.96
1.06
1.17
1.30
Rpm
957
984
1011
1041
1072
1103
1132
1162
1195
0.8
Bhp
0.60
0.67
0.75
0.84
0.93
1.04
1.14
1.25
1.38
AIRFLOW
(Cfm)
1200
1300
1400
1500
1600
1700
1800
1900
2000
Rpm
993
1021
1049
1077
1107
1137
1167
1197
1229
0.9
Bhp
0.65
0.74
0.82
0.92
1.00
1.12
1.23
1.35
1.48
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
2.
Rpm
1028
1058
1086
1113
1141
1171
1202
1232
1262
1.0
Bhp
0.69
0.80
0.89
0.99
1.09
1.20
1.32
1.45
1.58
indicates field-supplied motor and drive required.
Rpm
1056
1090
1120
1147
1174
1203
1233
1263
1294
1.1
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.2
Bhp
0.72
0.85
0.96
1.06
1.17
1.29
1.41
1.54
1.68
Rpm
1083
1121
1153
1180
1207
1235
1263
1294
1325
Bhp
0.74
0.89
1.00
1.13
1.25
1.37
1.49
1.63
1.78
Rpm
1134
1171
1210
1241
1269
1296
1323
1351
1362
1.4
Bhp
0.80
0.94
1.12
1.27
1.40
1.53
1.67
1.81
1.97
3.
indicates maximum usable bhp.
4. Motor drive range is 840 to 1185 rpm. All other rpms require a field-supplied drive.
5. Values include losses for filters, unit casing, and wet coils.
Rpm
1185
1219
1257
1295
1326
1354
1381
1408
1436
1.6
Bhp
0.88
1.00
1.17
1.37
1.54
1.70
1.85
2.00
2.16
Rpm
1331
1268
1307
1339
1376
1407
1436
1463
1489
1.8
Bhp
0.99
1.10
1.25
1.43
1.65
1.84
2.02
2.19
2.36
6. Maximum continuous bhp is 1.2. Extensive motor and electrical testing on these units ensure that the full range of the motor can be utilized with confidence.
Using your fan motors up to the ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
7. Use of a field-supplied motor may affect wire sizing. Contact your local representative to verify.
8. Interpolation is permissible. Do not extrapolate.
9. Minimum allowable cfm is 300 cfm/ton.
—24—
AIRFLOW
(Cfm)
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
AIRFLOW
(Cfm)
1500
1600
1600
1800
1900
2000
2100
2200
2300
2400
2500
AIRFLOW
(Cfm)
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
AIRFLOW
(Cfm)
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
Table 11 — 581B060 Air Delivery — Vertical Discharge Units
Rpm
1257
1286
1315
1395
1430
1459
1489
1528
1561
1584
1633
Rpm
771
816
902
942
982
1022
1063
1104
1130
1174
1201
0.1
1.2
Bhp
0.37
0.45
0.61
0.70
0.80
0.91
0.99
1.13
1.26
1.37
1.48
Rpm
828
869
940
978
1023
1068
1115
1159
1202
1237
1272
0.2
Bhp
0.44
0.51
0.62
0.66
0.78
0.90
1.00
1.15
1.29
1.41
1.53
Bhp
1.20
1.31
1.44
1.46
1.58
1.67
1.80
1.95
2.13
2.28
2.53
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.4
Rpm
1330
1353
1381
1475
1504
1532
1567
1603
1637
1671
1698
Bhp
1.38
1.49
1.52
1.56
1.69
1.82
1.99
2.17
2.35
2.55
2.72
Rpm
1411
1421
1443
1542
1556
1588
1626
1666
1710
1756
—
1.6
Rpm
935
968
1007
1063
1097
1132
1180
1214
1248
1292
1335
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
0.6
Bhp
0.58
0.66
0.75
0.82
0.91
1.01
1.17
1.28
1.38
1.55
1.71
Rpm
1027
1056
1094
1147
1175
1218
1261
1310
1358
1392
1427
Bhp
0.73
0.81
0.91
0.97
1.11
1.23
1.35
1.52
1.69
1.81
1.94
Bhp
1.59
1.68
1.69
1.71
1.82
1.97
2.16
2.37
2.54
2.70
—
Rpm
1107
1127
1175
1248
1266
1303
1340
1375
1410
1460
1518
0.8
Bhp
0.88
0.97
1.09
1.20
1.29
1.41
1.53
1.63
1.72
1.90
2.16
Rpm
1185
1215
1245
1322
1356
1397
1428
1459
1488
1532
1575
1.0
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
2.
indicates field-supplied motor and drive required.
3.
indicates maximum usable bhp.
4. Motor drive range is 1020 to 1460 rpm. All other rpms require a fieldsupplied drive.
5. Values include losses for filters, units casing, and wet coils.
6. Maximum continuous bhp is 1.8. Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with confidence. Using your fan motors up to the ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
7. Use of a field-supplied motor may affect wire sizing. Contact your local representative to verify.
8. Interpolation is permissible. Do not extrapolate.
9. Minimum allowable cfm is 300 cfm/ton.
Bhp
1.04
1.14
1.26
1.33
1.47
1.52
1.66
1.80
1.93
2.14
2.35
Table 12 — 581B072 Air Delivery — Vertical Discharge Units
Rpm
1395
1430
1459
1489
1528
1561
1584
1633
1675
—
—
—
—
Rpm
942
982
1022
1063
1104
1130
1174
1201
1246
1285
1304
1345
1378
0.1
1.2
Bhp
0.70
0.80
0.91
0.99
1.13
1.26
1.37
1.48
1.62
1.75
1.87
2.07
2.26
Rpm
978
1023
1068
1115
1159
1202
1237
1272
1320
1361
1402
1446
1489
0.2
Bhp
0.66
0.78
0.90
1.00
1.15
1.29
1.41
1.53
1.68
1.82
1.95
2.16
2.36
Bhp
1.46
1.58
1.67
1.80
1.95
2.13
2.28
2.53
2.77
—
—
—
—
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.4
Rpm
1475
1504
1532
1567
1603
1637
1671
1698
—
—
—
—
—
Bhp
1.56
1.69
1.82
1.99
2.17
2.35
2.55
2.72
—
—
—
—
—
Rpm
1542
1556
1588
1626
1666
1710
1756
—
—
—
—
—
—
1.6
Rpm
1063
1097
1132
1180
1214
1248
1292
1335
1368
1400
1439
1477
1529
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
0.6
Bhp
0.82
0.91
1.01
1.17
1.28
1.38
1.55
1.71
1.81
1.91
2.08
2.16
2.52
Rpm
1147
1175
1218
1261
1310
1358
1392
1427
1458
1490
1543
1585
1598
Bhp
0.97
1.11
1.23
1.35
1.52
1.69
1.81
1.94
2.06
2.19
2.43
2.65
2.73
Bhp
1.71
1.82
1.97
2.16
2.37
2.54
2.70
—
—
—
—
—
—
Rpm
1248
1266
1303
1340
1375
1410
1460
1518
1562
1602
1642
—
—
0.8
Bhp
1.20
1.29
1.41
1.53
1.63
1.72
1.90
2.16
2.42
2.64
2.86
—
—
Rpm
1322
1356
1397
1428
1459
1488
1532
1575
1620
1666
—
—
—
1.0
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
2.
indicates field-supplied motor and drive required.
3.
indicates maximum usable bhp.
4. Motor drive range is 1120 to 1585 rpm. All other rpms require a fieldsupplied drive.
5. Values include losses for filters, units casing, and wet coils.
6. Maximum continuous bhp is 2.40. Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with confidence. Using your fan motors up to the ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
7. Use of a field-supplied motor may affect wire sizing. Contact your local representative to verify.
8. Interpolation is permissible. Do not extrapolate.
9. Minimum allowable cfm is 300 cfm/ton.
Bhp
1.33
1.47
1.52
1.66
1.80
1.93
2.14
2.35
2.59
2.85
—
—
—
—25—
AIRFLOW
(Cfm)
900
1000
1100
1200
1300
1400
1500
Rpm
526
570
614
658
703
725
755
0.1
Bhp
0.06
0.09
0.13
0.16
0.20
0.29
0.33
Table 13 — 581B036 Air Delivery — Horizontal Discharge Units
Rpm
584
627
670
710
752
776
816
0.2
Bhp
0.08
0.13
0.16
0.23
0.27
0.31
0.38
Rpm
656
738
758
780
808
845
870
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.3
0.4
Bhp
0.12
0.19
0.23
0.28
0.32
0.38
0.43
Rpm
734
800
812
840
868
891
924
Bhp
0.22
0.26
0.29
0.32
0.37
0.42
0.48
Rpm
818
848
863
889
916
937
969
0.5
Bhp
0.25
0.29
0.32
0.36
0.41
0.47
0.53
Rpm
875
895
914
938
963
983
1014
0.6
Bhp
0.27
0.31
0.35
0.40
0.45
0.51
0.58
AIRFLOW
(Cfm)
900
1000
1100
1200
1300
1400
1500
Rpm
924
936
960
988
1012
1027
1056
0.7
Bhp
0.32
0.35
0.39
0.45
0.51
0.56
0.63
LEGEND
Bhp — Brake Horsepower Input to Fan
Rpm
953
977
1005
1038
1061
1071
1097
0.8
Bhp
0.35
0.39
0.43
0.50
0.56
0.60
0.68
NOTES:
1. Boldface indicates field-supplied drive required. (See Note 2.)
2. Motor drive range is 760 to 1090 rpm. All other rpms require field-supplied drive.
3. Values include losses for filters, unit casing, and wet coils.
Rpm
989
1020
1052
1076
1094
1108
1117
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.9
1.0
Bhp
0.38
0.44
0.49
0.53
0.61
0.67
0.70
Rpm
1028
1064
1100
1136
1172
1208
1245
Bhp
0.42
0.48
0.52
0.59
0.65
0.70
0.74
Rpm
1074
1124
1163
1201
1239
1278
1315
1.1
Bhp
0.45
0.52
0.56
0.61
0.69
0.75
0.80
Rpm
1120
1185
1225
1266
1306
1347
1385
1.2
Bhp
0.50
0.55
0.60
0.64
0.72
0.79
0.85
Using your fan motors up to the ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
5. Use of a field-supplied motor may affect wire sizing. Contact your local representative to verify.
6. Interpolation is permissible. Do not extrapolate.
7. Minimum allowable cfm is 300 cfm/ton.
4. Maximum continuous bhp is 1.2. Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with confidence.
AIRFLOW
(Cfm)
1200
1300
1400
1500
1600
1700
1800
1900
2000
Rpm
569
604
640
676
713
750
788
826
864
0.1
Bhp
0.18
0.22
0.27
0.32
0.38
0.45
0.52
0.60
0.70
Table 14 — 581B048 Air Delivery — Horizontal Discharge Units
Rpm
641
673
705
738
772
806
841
876
912
0.2
Bhp
0.23
0.28
0.33
0.38
0.44
0.51
0.59
0.68
0.77
Rpm
701
731
761
793
825
857
890
924
958
0.3
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
Bhp
0.29
0.34
0.39
0.45
0.51
0.59
0.67
0.76
0.86
Rpm
761
788
817
847
877
908
939
971
1004
Bhp
0.34
0.39
0.45
0.51
0.58
0.66
0.75
0.84
0.94
Rpm
859
887
914
940
967
997
1026
1056
1087
0.6
Bhp
0.46
0.52
0.59
0.65
0.73
0.81
0.91
1.01
1.12
Rpm
901
928
955
982
1009
1037
1065
1094
1125
0.7
Bhp
0.52
0.59
0.66
0.73
0.81
0.90
1.01
1.10
1.21
Rpm
943
968
996
1024
1051
1077
1104
1132
1162
0.8
Bhp
0.58
0.65
0.72
0.81
0.89
1.01
1.07
1.18
1.30
2.
AIRFLOW
(Cfm)
1200
1300
1400
1500
1600
1700
1800
1900
2000
Rpm
987
1006
1033
1060
1087
1114
1141
1168
1197
0.9
Bhp
0.64
0.71
0.79
0.88
1.01
1.07
1.17
1.28
1.39
Rpm
1030
1044
1069
1095
1123
1151
1178
1204
1231
1.0
Bhp
0.70
0.77
0.86
0.95
1.05
1.15
1.26
1.37
1.48
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive required. (See Note 4.) indicates field-supplied motor and drive required.
Rpm
1068
1086
1104
1129
1156
1183
1211
1238
1265
1.1
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.2
Bhp
0.79
0.84
0.93
1.02
1.13
1.23
1.35
1.47
1.59
3.
indicates maximum usable bhp.
4. Motor drive range: 840 to 1185 rpm. All other rpms require a field-supplied drive.
5. Values include losses for filters, unit casing, and wet coils.
Rpm
1106
1128
1139
1162
1185
1215
1243
1271
1298
Bhp
0.87
0.91
1.01
1.09
1.20
1.31
1.43
1.56
1.69
Rpm
1134
1183
1218
1228
1250
1276
1303
1330
1358
1.4
Bhp
0.98
1.10
1.14
1.24
1.35
1.48
1.61
1.74
1.89
Rpm
1189
1226
1286
1303
1319
1334
1359
1386
1413
1.6
Bhp
1.12
1.23
1.34
1.40
1.51
1.64
1.78
1.93
2.08
Rpm
1245
1297
1320
1343
1382
1398
1418
1439
1466
1.8
Bhp
1.21
1.35
1.48
1.60
1.68
1.80
1.95
2.11
2.27
6. Maximum continuous bhp is 1.2. Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with confidence.
Using your fan motors up to the ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
7. Use of a field-supplied motor may affect wire sizing. Contact your local representative to verify.
8. Interpolation is permissible. Do not extrapolate.
9. Minimum allowable cfm is 300 cfm/ton.
—26—
AIRFLOW
(Cfm)
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
AIRFLOW
(Cfm)
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
AIRFLOW
(Cfm)
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
AIRFLOW
(Cfm)
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
Table 15 — 581B060 Air Delivery — Horizontal Discharge Units
Rpm
1218
1251
1281
1341
1374
1396
1413
1434
1459
1502
1524
Rpm
741
783
825
885
928
971
1015
1060
1104
1138
1183
0.1
1.2
Bhp
0.38
0.45
0.53
0.63
0.73
0.84
0.97
1.10
1.25
1.30
1.43
Rpm
798
838
878
942
982
1022
1063
1104
1130
1174
1201
0.2
Bhp
0.43
0.51
0.60
0.73
0.83
0.94
1.10
1.20
1.27
1.37
1.50
Bhp
1.12
1.20
1.31
1.40
1.53
1.66
1.75
1.81
1.88
2.06
2.24
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.4
Rpm
1295
1310
1342
1413
1437
1460
1475
1487
1520
1552
1585
Bhp
1.36
1.40
1.48
1.55
1.62
1.68
1.73
1.85
2.07
2.24
2.42
Rpm
1360
1385
1398
1474
1490
1509
1529
1554
1576
1604
1638
1.6
Rpm
895
933
969
1047
1084
1121
1140
1159
1196
1245
1284
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
0.6
Bhp
0.54
0.63
0.72
0.90
1.02
1.12
1.18
1.23
1.37
1.57
1.65
Rpm
990
1016
1049
1139
1160
1188
1196
1229
1264
1305
1338
Bhp
0.67
0.75
0.84
1.05
1.11
1.22
1.27
1.41
1.56
1.63
1.75
Bhp
1.40
1.49
1.53
1.58
1.67
1.77
1.92
2.07
2.24
2.42
2.60
Rpm
1073
1102
1134
1193
1223
1254
1272
1306
1340
1373
1402
0.8
Bhp
0.80
0.90
1.00
1.14
1.24
1.36
1.45
1.53
1.66
1.84
1.99
Rpm
1154
1182
1206
1276
1301
1329
1354
1363
1397
1440
1469
1.0
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
2.
indicates field-supplied motor and drive required.
3.
indicates maximum usable bhp.
4. Motor drive range is 1020 to 1460 rpm. All other rpms require a fieldsupplied drive.
5. Values include losses for filters, units casing, and wet coils.
6. Maximum continuous bhp is 1.8. Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with confidence. Using your fan motors up to the ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
7. Use of a field-supplied motor may affect wire sizing. Contact your local representative to verify.
8. Interpolation is permissible. Do not extrapolate.
9. Minimum allowable cfm is 300 cfm/ton.
Bhp
0.95
1.04
1.14
1.30
1.38
1.44
1.58
1.70
1.86
1.95
2.04
Table 16 — 581B072 Air Delivery — Horizontal Discharge Units
Rpm
1341
1374
1396
1413
1434
1459
1502
1524
1552
1584
1624
1671
—
Rpm
885
928
971
1015
1060
1104
1138
1183
1210
1254
1274
1318
1362
0.1
1.2
Bhp
0.63
0.73
0.84
0.97
1.10
1.25
1.30
1.43
1.58
1.76
1.82
1.95
2.20
Rpm
942
982
1022
1063
1104
1130
1174
1201
1246
1285
1304
1345
1378
0.2
Bhp
0.73
0.83
0.94
1.10
1.20
1.27
1.37
1.50
1.67
1.80
1.85
2.05
2.30
Bhp
1.40
1.53
1.66
1.75
1.81
1.88
2.06
2.24
2.40
2.61
2.85
3.03
—
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.4
Rpm
1413
1437
1460
1475
1487
1520
1552
1585
1616
1646
1677
—
—
Bhp
1.55
1.62
1.68
1.73
1.85
2.07
2.24
2.42
2.63
2.83
2.99
—
—
Rpm
1474
1490
1509
1529
1554
1576
1604
1638
1671
1706
—
—
—
1.6
Rpm
1047
1084
1121
1140
1159
1196
1245
1284
1312
1354
1374
1412
1451
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
0.6
Bhp
0.90
1.02
1.12
1.18
1.23
1.37
1.57
1.65
1.76
1.95
2.12
2.32
2.40
Rpm
1139
1160
1188
1196
1229
1264
1305
1338
1366
1403
1459
1496
1534
Bhp
1.05
1.11
1.22
1.27
1.41
1.56
1.63
1.75
1.96
2.14
2.25
2.54
2.66
Bhp
1.58
1.67
1.77
1.92
2.07
2.24
2.42
2.60
2.80
2.97
—
—
—
Rpm
1193
1223
1254
1272
1306
1340
1373
1402
1435
1474
1514
1529
1560
0.8
Bhp
1.14
1.24
1.36
1.45
1.53
1.66
1.84
1.99
2.10
2.21
2.42
2.61
2.81
Rpm
1276
1301
1329
1354
1363
1397
1440
1469
1494
1536
1570
1603
1611
1.0
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
2.
indicates field-supplied motor and drive required.
3.
indicates maximum usable bhp.
4. Motor drive range is 1120 to 1585 rpm. All other rpms require a fieldsupplied drive.
5. Values include losses for filters, units casing, and wet coils.
6. Maximum continuous bhp is 2.4. Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with confidence. Using your fan motors up to the ratings shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.
7. Use of a field-supplied motor may affect wire sizing. Contact your local representative to verify.
8. Interpolation is permissible. Do not extrapolate.
9. Minimum allowable cfm is 300 cfm/ton.
Bhp
1.30
1.38
1.44
1.58
1.70
1.86
1.95
2.04
2.19
2.46
2.66
2.87
3.01
—27—
CARE AND MAINTENANMCE
To ensure continuing high performance and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This combination heating/cooling unit should be inspected at least once each year by a qualified service person.
NOTE TO EQUIPMENT OWNER:
Consult your local dealer about the availability of a maintenance contract.
WARNING:
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 User’s Manual. FAILURE TO HEED
THIS WARNING COULD RESULT IN SERIOUS PER-
SONAL INJURY AND POSSIBLE DAMAGE TO THIS
EQUIPMENT.
The minimum maintenance requirements for this equipment are as follows:
1. Inspect air filter(s) each month. Clean or replace when necessary.
2. Inspect cooling coil, drain pan, and condensate drain each cooling season for cleanliness. Clean when necessary.
3. Inspect fan motor and wheel for cleanliness and check lubrication each heating and cooling season. Clean and lubricate (if required) when necessary.
4. Check electrical connections for tightness and controls for proper operation each heating and cooling season.
Service when necessary.
5. Check and inspect heating section before each heating season. Clean and adjust when necessary.
6. Check and clean vent screen if needed.
WARNING:
Failure to follow these warnings could result in serious personal injury:
1. Turn off gas supply, then turn off electrical power to the unit before performing any maintenance or service on the unit.
2. Use extreme caution when removing panels and parts. As with any mechanical equipment, personal injury can result from sharp edges, etc.
3. Never place anything combustible either on, or in contact with, the unit.
4. Should overheating occur, or the gas supply fail to shut off, shut off the external main manual gas valve to the unit, then shut off the electrical supply.
I. AIR FILTER
CAUTION:
Never operate the unit without a suitble 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 heating and cooling season and whenever the filter(s) becomes clogged with dust and lint.
When necessary, replace filters with the same dimensional size and type as originally provided.
SERVICE
CAUTION:
When servicing unit, shut off all electrical power to unit to avoid shock hazard or injury from rotating parts.
I. CLEANING
Inspect unit interior at the beginning of each heating and cooling season and as operating conditions require.
A. Evaporator Coil
1. Turn unit power off. Remove evaporator coil access panel.
2. If economizer is installed, remove economizer by disconnecting economizer plug and removing mounting screws. See Fig. 18 and 19. Refer to Accessory Economizer Installation Instructions or Optional Economizer sections on pages 13 and 14 for further details.
3. Slide filters out of unit.
4. Clean coil using a commercial coil cleaner or dishwasher detergent in a pressurized spray canister. Wash both sides of coil and flush with clean water. For best results, backflush toward return-air section to remove foreign material.
5. Flush condensate pan.
6. Reinstall economizer and filters.
7. Reconnect wiring.
8. Replace access panels.
B. Condenser Coil
Inspect coil monthly. Clean condenser coil annually, and as required by location and outdoor-air conditions.
One-Row Coil (size 036)
Wash coil with commercial coil cleaner. It is not necessary to remove top panel.
2-Row Coils (sizes 048-072)
NOTE:
Save all screws removed in this section. The screws must be used when reinstalling the equipment.
1. Turn off unit power.
2. Remove top panel screws on condenser end of unit.
3. Remove condenser coil corner post. See Fig. 35. To hold top panel open, place coil corner post between top panel and center post. See Fig. 36.
4. Remove screws securing coil to center post.
5. Remove fastener holding coil sections together at return end of condenser coil. Carefully separate the outer coil section 3 to 4 in. from the inner coil section. See
Fig. 37.
6. Use a water hose or other suitable equipment to flush down between the 2 coil sections to remove dirt and debris. Clean the outer surfaces with a stiff brush in the normal manner.
7. Secure inner and outer coil rows together with a fieldsupplied fastener.
8. Reposition the outer coil section and remove the coil corner post from between the top panel and center post.
9. Reinstall the coil corner post and replace all screws.
C. Condensate Drain
Check and clean each year at start of cooling season. In winter, keep drain dry or protect against freeze-up.
—28—
Fig. 35 — Cleaning Condenser Coil
E. Outdoor-Air Inlet Screens
Clean screens with steam or hot water and a mild detergent.
Do not use disposable filters in place of screens.
II. LUBRICATION
A. Compressors
Each compressor is charged with the correct amount of oil at the factory.
B. Fan Motor Bearings
Fan motor bearings are of the permanently lubricated type.
No further lubrication is required. No lubrication of condenseror evaporator-fan motors is required.
III. CONDENSER-FAN ADJUSTMENT (Fig. 38)
1. Shut off unit power supply.
2. Remove condenser-fan assembly (grille, motor, motor cover, and fan).
3. Loosen fan hub setscrews.
4. Adjust fan height as shown in Fig. 38.
5. Tighten setscrews.
6. Replace condenser-fan assembly.
Fig. 36 — Propping Up Top Panel
Fig. 37 — Separating Coil Sections
D. Filters
Clean or replace at start of each heating and cooling season, or more often if operating conditions require it. Replacement filters must be same dimensions as original filters.
UNIT 581B
036-060 and,
072
(208/230 V)
072
(460 and 575 V)
FAN HEIGHT
(in.)
2.75
3.50
Fig. 38 — Condenser Fan Adjustment
IV. ECONOMIZER ADJUSTMENT
Refer to Optional Economizer sections on pages 13 and 14.
V. REFRIGERANT CHARGE
Amount of refrigerant charge is listed on unit nameplate (also refer to Table 1). Refer to GTAC2-5 Charging, Recovery, Recycling, and Reclamation training manual and the following procedures. Unit panels must be in place when unit is operating during charging procedure.
This unit uses a fixed orifice refrigerant metering device located in the coil header. There is one orifice in each coil circuit. The size of the orifice is stamped on the outside of the tube where the orifice is located. Orifices are factory selected for optimum performance and are not designed to be changed in the field. To determine if an orifice has become plugged, disconnect power to the evaporator-fan motor and start the unit in cooling. Observe the coil for an uneven frost pattern, indicating a plugged orifice.
A. No Charge
Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant. (Refer to
Table 1.)
—29—
B. Low Charge Cooling
Using Cooling Charging Charts, Fig. 39-42, vary refrigerant until the conditions of the appropriate chart are met. Note the charging charts are different from type normally used.
Charts are based on charging the units to the correct superheat for the various operating conditions. Accurate pressure gage and temperature-sensing device are required. Connect the pressure gage to the service port on the suction line. Mount the temperature-sensing device on the suction line and insulate it so that outdoor ambient temperature does not affect the reading. Indoor-air cfm must be within the normal operating range of the unit.
C. To Use Cooling Charging Charts
Take the outdoor ambient temperature and read the suction pressure gage. Refer to appropriate chart to determine what suction temperature should be. If suction temperature is high, add refrigerant. If suction temperature is low, carefully reclaim some of the charge. Recheck the suction pressure as charge is adjusted.
EXAMPLE:
(Fig. 41)
Outdoor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 F
Suction Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 psig
Suction Temperature should be . . . . . . . . . . . . . . . . . . . 48 F
(Suction Temperature may vary ± 5 F.)
D. Refrigerant Leaks
Proceed as follows to repair a refrigerant leak and to charge the unit:
1. Locate leak and ensure that refrigerant system pressure has been relieved.
2. Repair leak following accepted practices.
NOTE:
Replace filter drier in the liquid line whenever the system has been opened for repair.
3. Add a small charge of R-22 refrigerant vapor to system and leak-test unit.
4. Evacuate refrigerant system if additional leaks are not found.
5. Charge unit with R-22 refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit rating
plate for required charge. Be sure to add extra refrigerant to compensate for internal volume of filter drier.
VI. MAIN BURNERS
At the beginning of each heating season, inspect for deterioration or blockage due to corrosion or other causes. Observe the main burner flames and adjust if necessary.
VII. FLUE GAS PASSAGEWAYS
To inspect the flue collector box and upper areas of the heat exchanger:
1. Remove the combustion blower wheel and motor assembly according to directions in Combustion-Air Blower section below.
2. Remove the 3 screws holding the blower housing to the flue cover.
3. Remove the flue cover to inspect the heat exchanger.
4. Clean all surfaces as required using a wire brush.
VIII. COMBUSTION-AIR BLOWER
Clean periodically to ensure proper airflow and heating efficiency. Inspect blower wheel every fall and periodically during heating season. For the first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency.
Fig. 39 — Cooling Charging Chart, 581B036
Fig. 40 — Cooling Charging Chart, 581B048
To inspect blower wheel, remove draft hood and screen. Shine a flashlight into opening to inspect wheel. If cleaning is required, remove motor and wheel as follows:
1. Slide burner access panel out.
2. Remove the 2 screws which hold the heat shield in place, and remove heat shield.
3. Remove the 7 screws that attach induced-draft motor mounting plate to blower housing (Fig. 43).
—30—
INDUCED-
DRAFT
MOTOR
MOUNTING
PLATE
ROLLOUT
SWITCH
BURNER
SECTION
FLUE
EXHAUST
INDUCED-
DRAFT
MOTOR
MANIFOLD
PRESSURE
TAP
Fig. 43 — Burner Section Details
BLOWER
HOUSING
GAS
VALVE
Fig. 41 — Cooling Charging Chart, 581B060
IX. LIMIT SWITCH
Remove blower access panel (Fig. 2). Limit switch is located on the fan deck.
X. BURNER IGNITION
Unit is equipped with a direct spark ignition 100% lockout system. Integrated Gas Unit Controller (IGC) is located in the control box (Fig. 15). The IGC contains a self-diagnostic
LED (light-emitting diode). A single LED on the IGC provides a visual display of operational or sequential problems when the power supply is uninterrupted. When a break in power occurs, the IGC will be reset (resulting in a loss of fault history). The indoor (evaporator) fan ON/OFF times will also be reset. The LED error code can be observed through the viewport. During servicing refer to the label on the control box cover or Table 17 for an explanation of LED error code descriptions.
If lockout occurs, unit may be reset by interrupting the power supply to unit for at least 5 seconds.
CAUTION:
When servicing gas train, do not hit or plug orifice spuds.
Table 17 — LED Error Code Description*
Fig. 42 — Cooling Charging Chart, 581B072
4. Slide the motor and blower wheel assembly out of the blower housing. The blower wheel can be cleaned at this point. If additional cleaning is required, continue with steps 5 and 6.
5. To remove blower from the motor shaft, remove
2 setscrews.
6. To remove motor, remove 4 screws that hold the motor to mounting plate. Remove the motor cooling fan by removing one setscrew. Then remove nuts that hold motor to mounting plate.
7. To reinstall, reverse the procedure outlined above.
—31—
LED INDICATION
ON
OFF
1 Flash†
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
ERROR CODE DESCRIPTION
Normal Operation
Hardware Failure
Evaporator Fan On/Off Delay Modified
Limit Switch Fault
Flame Sense Fault
4 Consecutive Limit Switch Faults
Ignition Lockout Fault
Induced-Draft Motor Fault
Rollout Switch Fault
Internal Control Fault
LEGEND
LED — Light-Emitting Diode
*A 3-second pause exists between LED error code flashes. If more than one error code exists, all applicable codes will be displayed in numerical sequence.
†Indicates a code that is not an error. The unit will continue to operate when this code is displayed.
IMPORTANT: Refer to Troubleshooting Tables 18-22 for additional information.
A. Removal and Replacement of Gas Train (See Fig. 31 and 43.)
1. Shut off manual gas valve.
2. Shut off power to unit.
3. Remove compressor access panel.
4. Slide out burner compartment side panel.
5. Remove heat shield.
6. Disconnect gas piping at unit gas valve.
7. Remove wires connected to gas valve. Mark each wire.
8. Remove induced-draft motor, ignitor, and sensor wires at the Integrated Gas Unit Controller (IGC).
9. Remove the 2 screws that attach the burner rack to the vestibule plate.
10. Remove the gas valve bracket.
11. Slide the burner tray out of the unit (Fig. 31).
12. To reinstall, reverse the procedure outlined above.
B. Cleaning and Adjustment
1. Remove burner rack from unit as described in Removal and Replacement of Gas Train section above.
2. Inspect burners; if dirty, remove burners from rack.
3. Using a soft brush, clean burners and crossover port as required.
4. Adjust spark gap. See Fig. 44.
5. Reinstall burners on rack.
6. Reinstall burner rack as described in Removal and Replacement of Gas Train section above.
XI. REPLACEMENT PARTS
A complete list of replacement parts may be obtained from your distributor upon request.
Fig. 44 — Spark Adjustment
—32—
TROUBLESHOOTING
Table 18 — LED Error Code Service Analysis
PROBLEM
Hardware failure.
(LED Off)
Limit switch fault.
(LED 2 Flashes)
Flame sense fault.
(LED 3 Flashes)
4 consecutive limit switch trips.
(LED 4 Flashes)
Ignition lockout.
(LED 5 Flashes)
Induced-draft motor fault.
(LED 6 Flashes)
Rollout switch fault.
(LED 7 Flashes)
is open.
CAUSE
Loss of power to IGC.
High-temperature limit switch
The IGC sensed flame that should not be present.
Inadequate airflow to unit.
Unit unsuccessfully attempted ignition for 15 minutes.
IGC does not sense that induced-draft motor is operating.
Rollout switch has opened.
Internal control fault.
(LED 8 Flashes)
Microprocessor has sensed an error in the software or hardware.
LEGEND
IGC
— Integrated Gas Unit Controller
LED — Light-Emitting Diode
REMEDY
Check 5-amp fuse on IGC, power to unit, 24-v circuit breaker, and transformer. Units without a 24-v circuit breaker have an internal overload in the 24-v transformer. If the overload trips, allow 10 minutes for automatic reset.
Check the operation of the indoor (evaporator) fan motor. Ensure that the supply-air temperature rise is in accordance with the range on the unit nameplate.
Reset unit. If problem persists, replace control board.
Check operation of indoor (evaporator) fan motor and that supply-air temperature rise agrees with range on unit nameplate information.
Check ignitor and flame sense electrode spacing, gas, etc. Ensure that flame sense and ignition wires are properly terminated. Verify that unit is obtaining proper amount of gas.
Check for proper voltage. If motor is operating, check the speed sensor plug/IGC Terminal J2 connection. Proper connection: PIN 1-White,
PIN 2-Red, PIN 3-Black.
Rollout switch will automatically reset, but IGC will continue to lock out unit. Check gas valve operation. Ensure that induced-draft blower wheel is properly secured to motor shaft. Reset unit at unit disconnect.
If error code is not cleared by resetting unit power, replace the IGC.
IMPORTANT:
Refer to Table 19 — Heating Service Analysis for additional troubleshooting analysis.
WARNING:
If the IGC must be replaced, be sure to ground yourself to dissipate any electrical charge that may be present before handling new control board. The IGC is sensitive to static electricity and may be damaged if the necessary precautions are not taken.
Table 19 — Heating Service Analysis
PROBLEM
Burners will not ignite.
CAUSE
Misaligned spark electrodes.
No gas at main burners.
Water in gas line.
No power to furnace.
No 24 v power supply to control circuit.
Miswired or loose connections.
Burned-out heat anticipator in thermostat.
Broken thermostat wires.
Inadequate heating.
Dirty air filter.
Gas input to unit too low.
Poor flame characteristics.
Burners will not turn off.
REMEDY
Check flame ignition and sensor electrode positioning. Adjust as needed.
Check gas line for air, purge as necessary. After purging gas line of air, allow gas to dissipate for at least 5 minutes before attempting to relight unit.
Check gas valve.
Drain water and install drip leg to trap water.
Check power supply, fuses, wiring, and circuit breaker.
Check transformer. Transformers with internal overcurrent protection require a cool down period before resetting. Check 24-v circuit breaker, reset as necessary.
Check all wiring and wirenut connections.
Replace thermostat.
Unit undersized for application.
Restricted airflow.
Blower speed too low.
Limit switch cycles main burners.
Too much outdoor air.
Incomplete combustion (lack of combustion air) results in:
Aldehyde odors, carbon monoxide, sooting flame, or floating flame.
Unit is locked into Heating mode for a one minute minimum.
Run continuity check. Replace wires, if necessary.
Clean or replace filter as necessary.
Check gas pressure at manifold. Clock gas meter for input. If too low, increase manifold pressure, or replace with correct orifices.
Replace with proper unit or add additional unit.
Clean filter, replace filter, or remove any restrictions.
Install field-supplied motor and drive or adjust pulley to increase fan speed.
Check rotation of blower, thermostat heat anticipator settings, and temperature rise of unit. Adjust as needed.
Adjust minimum position.
Check economizer operation.
Check all screws around flue outlets and burner compartment. Tighten as necessary.
Cracked heat exchanger.
Overfired unit — reduce input, change orifices, or adjust gas line or manifold pressure.
Check vent for restriction. Clean as necessary.
Check orifice to burner alignment.
Wait until mandatory one minute time period has elapsed or reset power to unit.
—33—
Table 20 — Cooling Service Analysis
PROBLEM
Compressor and condenser fan will not start.
Compressor will not start but condenser fan runs.
Compressor cycles
(other than normally satisfying thermostat).
Compressor operates continuously.
Air in system.
Condenser coil dirty or restricted.
Compressor makes excessive noise.
Compressor rotating in wrong direction.
Excessive head pressure.
Dirty air filter.
Head pressure too low.
Excessive suction pressure.
Suction pressure too low.
CAUSE
Power failure.
Fuse blown or circuit breaker tripped.
Defective thermostat, contactor, transformer, control relay or capacitor.
Insufficient line voltage.
Incorrect or faulty wiring.
Call power company.
REMEDY
Replace fuse or reset circuit breaker.
Replace component.
Thermostat setting too high.
Faulty wiring or loose connections in compressor circuit.
Compressor motor burned out, seized, or internal overload open.
Defective run/start capacitor, overload, start relay.
One leg of of 3-phase power dead.
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.
Refrigerant overcharge or undercharge.
Reclaim refrigerant, evacuate system, and recharge to nameplate.
Replace and determine cause.
Defective compressor.
Insufficient line voltage.
Blocked condenser.
Determine cause and correct.
Determine cause and correct.
Defective run/start capacitor, overload, or start relay.
Determine cause and replace.
Defective thermostat.
Replace 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.
Leaking valves in compressor.
Dirty condenser coil.
Refrigerant overcharged.
Air in system.
Condenser air restricted or air short-cycling.
Low refrigerant charge.
Compressor valves leaking.
Restriction in liquid tube.
Compressor rotating in wrong direction
High heat load.
Compressor valves leaking.
Refrigerant overcharged.
Compressor rotating in wrong direction.
Dirty air filter.
Low refrigerant charge.
Metering device or low side restricted.
Insufficient evaporator airflow.
Replace.
Locate restriction and remove.
Replace filter.
Decrease load or increase unit size.
Reset thermostat.
Locate leak; repair and recharge.
Replace compressor.
Reclaim refrigerant, evacuate system, and recharge.
Clean coil or remove restriction.
Reverse the 3-phase motor power leads as described in
Start-Up on page 17.
Replace filter.
Clean coil.
Reclaim excess refrigerant.
Reclaim refrigerant, evacuate system, and recharge.
Determine cause and correct.
Check for leaks; repair and recharge.
Replace compressor.
Remove restriction.
Reverse the 3-phase motor power leads as described in
Start-Up on page 17.
Check for source and eliminate.
Replace compressor.
Reclaim excess refrigerant.
Reverse the 3-phase motor power leads as described in
Start-Up on page 17.
Replace filter.
Check for leaks; repair and recharge.
Remove source of restriction.
Evaporator fan will not shut off.
Temperature too low in conditioned area.
Outdoor ambient below 25 F.
Time off delay not finished.
Increase air quantity. Check filter and replace if necessary.
Reset thermostat.
Install low-ambient kit.
Wait for 30-second off delay.
—34—
Table 21 — Varislide™ Economizer Troubleshooting
close.
PROBLEM
Damper does not open.
Economizer operation limited to minimum position.
Damper does not
Economizer damper does not close on power loss.
Indoor (evaporator) fan is off.
CAUSE
No power to economizer motor.
Economizer motor failure.
OAT or EC set too high.
Economizer control board incorrectly wired or not functioning.
Incorrect SAT wiring or inoperative SAT.
Incorrect economizer wiring.
Incorrect damper actuator wiring or inoperative economizer circuit board.
Incorrect SAT wiring or inoperative SAT.
Economizer motor failure.
Insufficient battery power, inoperative economizer control board.
REMEDY
1. Check to ensure that 24 vac is present at terminal C1 on the IFC or that
24 vac is present at the IFO terminal. Check whether 24 vac is present at
PL6-1 (red wire) and/or PL6-3 (black wire). If 24 vac is not present, check wiring (see unit label diagram).
2. Check proper thermostat connection to G on the connection board.
1. Check that SW3 is properly making contact with the damper blade. Check that SW1 is in the NC (normally closed) position.
2. Check diode D18. If diode is not functioning properly, replace economizer control board.
3. Confirm that the economizer control board is grounded properly at PL6-4
(brown wire) and at brown terminal of the economizer control board (brown wire). The economizer motor must also be grounded properly at the negative motor terminal (brown wire).
4. Verify SW1 and SW3 are working and wired properly (see unit label diagram).
5. Check for 24 vac input at both PL6-1 (red wire) and PL6-3 (black wire). If
24 vac not present, check unit wiring (see unit label diagram). If 24 vac is found in both places, check for 24 vac at the yellow terminal of the economizer control board (yellow wire). If 24 vac power is not present, replace the economizer control board.
If the indoor (evaporator) fan and economizer motor are energized, verify that there is a minimum of 18 vdc at the positive motor terminal. If the motor is not operating, replace the motor.
1. Set at correct temperature (3 F below indoor space temperature).
2. Check OAT or EC by setting above outdoor temperature or humidity level.
If the OAT or EC switches do not close, replace OAT or EC.
1. Perform the following tests when OAT or EC is closed, Y1 is called for, and damper is at minimum position. Confirm 24 vac on gray terminal of the economizer control board (gray wire). If 24 vac is not present, check wiring
(see unit label diagram).
2. Verify that SW1 and SW3 are wired correctly and working properly (see unit label diagram).
3. Check to ensure that 24 vac exists at PL6-2 (blue wire). If 24 vac is not present, check wiring (see unit wiring label diagram).
4. Check 24 vac output at PL6-10 (white wire). If 24 vac is not present, replace economizer control board.
1. After verifying that the OAT and EC settings and the economizer control board wiring are correct, check to ensure that the 24 vac terminal of the SAT has 24 vac (white wire). If OAT, EC, and control board are functioning and wired properly and no 24 vac exists, check wiring (see unit label diagram).
2. If supply-air temperature is greater than 57 F, 24 vac should be found at terminal T2 on the SAT (pink wire). If 24 vac is not present, replace SAT.
1. Verify that SW2 and SW4 are wired and working properly (see unit label diagram).
2. Check diode D19. If diode is not functioning properly, replace economizer control board.
1. After verifying that the wiring is correct, modulate the damper to the minimum position. Remove the calls for G.
2. If the damper does not move, check for 24 vac at PL6-1 (red wire). If 24 vac is not present, check wiring (see unit label diagram).
3. If damper still does not move, check for 24 vac at blue terminal of economizer control board (blue wire). If 24 vac is not present, replace the economizer control board.
1. After verifying that the wiring is correct and the economizer control board is functioning properly, place the OAT or EC switch in the closed position.
Place a call for Y1 and open the damper to the fully open position. Confirm that the 24 vac terminal of the SAT has 24 vac (white wire). If 24 vac is not present, check wiring (see unit label diagram).
2. If supply-air temperature is less than 52 F, 24 vac should be found at terminal T1 on the SAT (violet wire). If 24 vac not found, replace SAT.
If economizer control board and SAT are functioning properly, verify that there is a minimum of 18 vdc at the positive motor terminal. If a minimum of 18 vdc is present and the motor is still not operating, replace the motor.
1. Check voltage potential across batteries. If lower than 14 vdc, replace closeon-power-loss power supply (9-v alkaline batteries). Check this emergency power supply on a regular basis or whenever the filters are changed.
2. If the close-on-power-loss and economizer control board are functioning properly, check for 14 vdc or higher at the blue terminal of the economizer control board (blue wire) when power is disconnected from unit. If 14 vdc is not present, replace the control board.
LEGEND
CI
— Common
EC
— Enthalpy Control
OAT — Outdoor-Air Thermostat
PL
— Plug
IFC — Indoor (Evaporator) Fan Contactor SAT — Supply-Air Thermostat
IFO — Indoor (Evaporator) Fan On
SW
— Economizer Position Switch
—35—
PROBLEM
Damper does not open.
Economizer operation limited to minimum position.
Damper does not close.
Damper does not open or close according to enthalpy readings.
Table 22 — PARABLADE Economizer Troubleshooting
CAUSE
Evaporator fan not on.
No power to economizer motor.
Economizer motor failure.
Economizer control module failure.
No power to economizer.
Return spring failure.
Economizer motor failure.
Sensor incorrectly wired or bad.
REMEDY
Check wiring between G on connection board and indoor fan contactor.
1. Disconnect power at TR and TR1. Disconnect jumper across P and P1.
2. Connect jumper across TR and 1.
3. Connect jumper across T1 and T.
4. If connected, remove enthalpy sensor from terminals S
0 and +. Factoryinstalled 620 ohm resistor should be connected to terminals S
R and +.
5. Apply power (24 vac) to terminals TR and TR1. The LED should be off and the damper should be in the closed position.
6. Disconnect the factory-installed 620 ohm resistor from terminals S
R and
+. The LED should light up and the motor should drive towards open. If this does not happen, replace the economizer control module.
If the indoor fan and economizer motor are energized, verify that there is a minimum of 24 vac at terminals TR and TR1. If the motor is not operating, replace the motor.
1. To simulate high or low enthalpy, reconnect the factory-installed 620 ohm resistor across terminals S
R and +.
2. Connect 1.2 Kohm checkout resistor across terminals S
O and +. Turn the enthalpy set point to ‘‘A.’’ The LED should turn on, indicating low enthalpy. The motor should drive towards open. If LED does not light, replace module. If motor does not drive open, check motor operation.
3. Turn the enthalpy set point to ‘‘D.’’ The LED should turn off, indicating high enthalpy. The motor should drive towards closed. If these actions do not occur, replace module.
4. Disconnection 1.2 Kohm checkout resistor before resuming operation.
1. Disconnect power at TR and TR1. Disconnect jumper across P and P1.
2. Connect jumper across TR and 1.
3. Connect jumper across T1 and T.
4. If connected, remove enthalpy sensor from terminals S
O and +. Factoryinstalled 620 ohm resistor should be connected to terminals S
R and +.
5. Apply power (24 Vac) to terminals TR and TR1. The LED should be off and the damper should be in the closed position.
6. Disconnect the factory-installed 620 ohm resistor from terminals S
R and
+. The LED should light up and the motor should drive towards open. If this does not happen, replace the economizer control module.
If power to unit is off and damper does not close, check for a bound linkage.
If linkage is not bound, then internal spring may be broken. Replace actuator.
If the economizer control module is functioning properly, verify that there is a minimum of 24 Vac at terminals TR and TR1. If the motor is not operating, replace the motor.
To verify sensor operation, reconnect the + lead of the outdoor enthalpy sensor to the + terminal of the economizer control module. Connect a DC milliammeter between terminals S
O of the economizer control module and terminals S of the enthalpy sensor. The milliammeter should indicate between 3 and 25 mA if the sensor is operating properly. If the milliammeter indicates 0, the sensor may be wired backwards. If any other readings are shown, replace the sensor.
—36—
Fig. 45 — Typical Wiring Schematic and Component Arrangement
LEGEND AND NOTES FOR FIG. 45 — TYPICAL CONTROL WIRING SCHEMATIC
AND COMPONENT ARRANGEMENT
AHA
— Adjustable Heat Anticipator
C
— Contactor, Compressor
CAP
CC
— Capacitor
— Cooling Compensator
CLO
— Compressor Lockout
COMP — Compressor Motor
D
EC
— Diode
— Enthalpy Control
ECON
— Economizer
EPS
— Emergency Power Supply (9-V Battery)
EQUIP — Equipment
ER
— Economizer Relay
FPT
FU
— Freeze-Protection Thermostat
— Fuse
GND
— Ground
HPS
— High-Pressure Switch
I
HS
IDM
IFC
IFM
IGC
LPS
LS
— Hall Effect Sensor
— Ignitor
— Induced Draft Motor
— Indoor-Fan Contactor
— Indoor-Fan Motor
— Integrated Gas Unit Controller
— Low-Pressure Switch
— Limit Switch
MGV
— Main Gas Valve
MTR
— Motor
OAT
— Outdoor-Air Thermostat
OFM
— Outdoor-Fan Motor
P
PL
QT
R
RS
— Plug
— Plug Assembly
— Quadruple Terminal
— Relay
— Rollout Switch
SAT
— Supply-Air Thermostat
SEN
— Sensor
SW1
— Switch Fully Open
SW2
— Switch Fully Closed
SW3
— Switch Minimum Vent Position
SW4
— Switch Maximum Vent Position
TC
TH
— Thermostat-Cooling
— Thermostat-Heating
TRAN — Transformer
Field Splice
Marked Wire
Terminal (Marked)
Terminal (Unmarked)
Terminal Block
Splice
Factory Wiring
Field Control Wiring
Field Power Wiring
Accessory or Optional Wiring
To indicate common potential only, not to represent wiring.
NOTES:
1. Replace original wire with type 90 C wire or its equivalent.
2. Three-phase motors are protected under primary single-phasing conditions.
3. Use thermostats: HH07AT170,172
Subbases: HH93AZ176, 177, 178, and 179
4. Set heat anticipator at .14 amp for first stage and .14 amp for second stage.
5. Use copper conductors only.
6. TRAN is wired for 230 V unit. If unit is to be run with 208 V power supply, disconnect
BLK wire from 230 V tap and connect to 208 V tap (RED). Insulate end of 230 V tap.
Copyright 1998 Bryant Heating & Cooling Systems CATALOG NO. 5358-100
I. PRELIMINARY INFORMATION
MODEL NO.:
DATE:
START-UP CHECKLIST
(Remove and Store in Job File)
SERIAL NO.:
TECHNICIAN:
II. PRE-START-UP (insert checkmark in box as each item is completed)
M VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
M REMOVE ALL SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS
M VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS
M CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS
M CHECK GAS PIPING FOR LEAKS
M CHECK THAT INDOOR-AIR FILTER IS CLEAN AND IN PLACE
M VERIFY THAT UNIT INSTALLATION IS LEVEL
M CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW
TIGHTNESS
III. START-UP
ELECTRICAL
SUPPLY VOLTAGE L1-L2
COMPRESSOR AMPS L1
INDOOR-FAN AMPS L1
TEMPERATURES
OUTDOOR-AIR TEMPERATURE
RETURN-AIR TEMPERATURE
COOLING SUPPLY AIR
GAS HEAT SUPPLY AIR
L2-L3
L2
L2
DB
DB WB
L3-L1
L3
L3
PRESSURES
GAS INLET PRESSURE
GAS MANIFOLD PRESSURE
REFRIGERANT SUCTION
REFRIGERANT DISCHARGE
IN. WG
IN. WG (HI FIRE)
PSIG
PSIG
M VERIFY REFRIGERANT CHARGE USING CHARGING TABLES
M VERIFY THAT 3-PHASE SCROLL COMPRESSOR ROTATING IN CORRECT DIRECTION
Copyright 1998 Bryant Heating & Cooling Systems CL-1 CATALOG NO. 5358-100

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Key features
- Variable-speed compressor for improved efficiency and comfort
- Economizer for increased energy savings
- High-efficiency blower motor for reduced operating costs
- Easy to install and maintain