Specifications | Bryant 581B Air Conditioner User Manual

installation, start-up
and service instructions
SINGLE PACKAGE ROOFTOP
GAS HEATING/ELECTRIC COOLING UNITS
581B
Sizes 036-072
3 to 6 Tons
Cancels: II 581B-36-1
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
Kg
530
240
540
245
560
254
615
279
VARISLIDE™
ECONOMIZER
WEIGHT
Lb
Kg
34
15.4
34
15.4
34
15.4
34
15.4
CORNER
WEIGHT
‘‘A’’
Lb
Kg
127 57.6
129 58.5
134 60.8
147 66.7
CORNER
WEIGHT
‘‘B’’
Lb
Kg
122 55.3
124 56.2
129 58.5
142 64.4
CORNER
WEIGHT
‘‘C’’
Lb
Kg
138 62.6
141 64.0
146 66.2
160 72.6
CORNER
WEIGHT
‘‘D’’
Lb
Kg
143 64.9
146 66.2
151 68.5
166 75.3
NOTES:
1. Dimensions in [ ] are in millimeters.
2.
Center of Gravity.
3.
A
B
C
D
E
F
G
CONNECTION SIZES
13⁄89 Dia. [35] Field Power Supply Hole
29 Dia. [51] Power Supply Knock-Out
13⁄49 Dia. [44] Charging Port Hole
7⁄89 Dia. [22] Field Control Wiring Hole
3⁄49-14 NPT Condensate Drain
1⁄29-14 NPT Gas Connection
21⁄29 Dia. [64] Power Supply Knock-Out
BOTTOM POWER CHART,
THESE HOLES REQUIRED FOR
USE WITH ACCESSORY PACKAGES —
CRBTMPWR001A00 (1⁄29, 3⁄49)
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 18-69 [457] up from the bottom of
the base rail.
THREADED
CONDUIT
SIZE
1⁄2(
3⁄4(
Fig. 2 — Base Unit Dimensions
—2—
WIRE
USE
REQUIRED SIZES
(MAXIMUM)
24 V
Power
7⁄89 [22.2]
11⁄89 [28.4]
Minimum clearance of condenser coil is 36 in. on one side,
12 in. the other. Side getting greater clearance is optional.
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.
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.
Model 581B meets the California maximum oxides of nitrogen (NOx) emission regulations when equipped with accessory NOx Reduction Kit (part no. 309424-101).
Be sure that unit is installed so that snow will not block the
combustion intake or flue outlet.
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.
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.
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.
B. Roof Curb Mount
Assemble and install accessory roof curb in accordance with
instructions shipped with curb. See Fig. 4. Install insulation
cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb. If gas, electric power, or control power is to be routed through the curb, attach the utility
connection plates to the roof curb in accordance with the accessory installation instructions. Accessory electric and gas
utility connection plates must be installed before unit is in
place on roof curb.
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
‘‘A’’
UNIT SIZE
149
CRRFCURB001A00 [356]
581B036-072
249
CRRFCURB002A00 [610]
UNIT
581B
‘‘B’’
SERVICE PLATE SIZES
‘‘D’’ Alt
‘‘E’’
‘‘F’’
‘‘C’’ Drain
Gas
Power
Hole
11
036-072 21 ⁄169 169
[551] [406]
13⁄49
[44.5]
Fig. 4 — Roof Curb Dimensions
—4—
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.
‘‘G’’
Control
CONNECTOR
PACKAGE
ACCESSORY
314213-204
(Thru-the-Side)
3⁄49 NPT 3⁄49 NPT 1⁄29 NPT CRBTMPWR001A00
(Thru-the-Bottom)
⁄ 9 NPT
34
⁄ 9 NPT
34
⁄ 9 NPT
34
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.
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
A-B
0.5
B-C
1.0
A-C
1.0
Fig. 5 — Unit Leveling Tolerances
Lifting holes are provided in base rails as shown in Fig. 6.
Refer to rigging instructions on unit.
II. UNIT DUCT CONNECTIONS
IMPORTANT: If unit has forklift protection skids, be sure to
remove forklift protection skids from under unit before setting unit in place.
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.
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; 15⁄32-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.
UNIT
581B
036
048
060
072
CAUTION: All panels must be in place when rigging.
MAX
WEIGHT
Lb
530
540
560
615
Fig. 6 — Rigging Details
—5—
Kg
240
245
254
279
‘‘A’’
in.
73.69
73.69
73.69
73.69
mm
1872
1872
1872
1872
DIMENSIONS
‘‘B’’
in.
mm
35.50 902
35.50 902
35.50 902
35.50 902
‘‘C’’
in.
mm
33.31 847
33.31 847
33.31 847
33.31 847
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
036
3
048
4
060
5
072
6
530
564
115
540
574
115
560
594
115
615
649
115
1
42
1
53
1
50
1
60
5-8
8-6
10.0
9-10
Scroll
R-22
Propeller
1...22
3000
⁄ ...825
180
1...22
1...22
3000
4000
1
⁄ ...825
⁄4...1100
180
300
Enhanced Copper Tubes, Aluminum Lanced Fins
2...17
2...17
16.53
16.53
Centrifugal
10 x 10
10 x 10
Belt
Belt
1600
2000
1.20
1.80
48
56
840-1185
1020-1460
Ball
Ball
2100
2100
1.9/2.9
2.4/3.4
1⁄2
1⁄2
4.0
4.0
A...36
A...40
10.0-12.4
14.7-15.5
70
75
18
18
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
5
3
890
5⁄8
Enhanced
2...15
5.5
Medium
High
Heat
Heat
195
195
Low
Heat
195
5
3
980
5⁄8
Copper Tubes, Aluminum
2...15
5.5
Medium
High
Heat
Heat
195
195
1...22
4000
⁄ ...1100
300
14
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
3
3
1240
1305
5⁄8
5⁄8
Double Wavy Fins, Acutrol™ Feed Device
4...15
4...15
5.5
5.5
Low
Medium
High
Low
Medium
Heat
Heat
Heat
Heat
Heat
195
195
195
195
195
High
Heat
195
Rollout Switch Cutout Temp (F)*
Burner Orifice Diameter (in. ...drill size)†
Natural Gas — Std
.113...33 .113...33 .113...33 .113...33 .129...30 .113...33 .113...33 .129...30 .113...33 .113...33 .129...30
Liquid Propane — Alt**
.089...43 .089...43 .089...43 .089...43 .102...38 .089...43 .089...43 .102...38 .089...43 .089...43 .102...38
Thermostat Heat Anticipator Setting (amps)
208/230/460 v
Stage 1
.14
.14
.14
.14
.14
.14
.14
.14
.14
.14
.14
Stage 2
.14
.14
.14
.14
.14
.14
.14
.14
.14
.14
.14
Gas Input (Btuh)
Stage 1
50,000
82,000 50,000
82,000 120,000 50,000
82,000 120,000 50,000
82,000 120,000
Stage 2
72,000 115,000 72,000 115,000 150,000 72,000 115,000 150,000 72,000 115,000 150,000
Efficiency (Steady State) (%)
82
80
82
81
80
82
81
80
82
81
80
Temperature Rise Range (F)
15-45
55-85
15-45
35-65
50-80
15-45
35-65
50-80
15-45
35-65
50-80
Manifold Pressure (in. wg)
Natural Gas (Std)
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
Liquid Propane (Alt)**
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
Maximum Static Pressure (in. wg)
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
Gas Valve Quantity
1
1
1
1
1
1
1
1
1
1
1
1⁄2
1⁄2
1⁄2
1⁄2
1⁄2
1⁄2
1⁄2
1⁄2
1⁄2
1⁄2
1⁄2
Field Gas Connection Size (in.)
HIGH-PRESSURE SWITCH (psig)
Standard Compressor Internal Relief
450
Cutout
428
Reset (Auto.)
320
LOSS-OF-CHARGE/LOW-PRESSURE SWITCH
(Liquid Line) (psig)
Cutout
7±3
Reset (Auto.)
22 ± 5
FREEZE-PROTECTION THERMOSTAT
Opens (F)
30 ± 5
Closes (F)
45 ± 5
OUTDOOR-AIR INLET SCREENS
Cleanable
Quantity...Size (in.)
1...20 x 24 x 1
RETURN-AIR FILTERS
Throwaway
Quantity...Size (in.)
2...16 x 25 x 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.
Fig. 9 — Flue Hood Details
For units being installed in California Air Quality Management Districts which require NOx 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.
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.
NOTE: Drain plug is shown in factory-installed position.
Fig. 7 — Condensate Drain Pan
LEGEND
NFGC — National Fuel Gas Code
*Field Supplied.
NOTE: Follow all local codes.
STEEL PIPE NOMINAL
DIAMETER (in.)
1⁄2
3⁄4 or 1
11⁄4 or Larger
NOTE: Trap should be deep enough to offset maximum unit static difference. A 4-in. trap is recommended.
SPACING OF SUPPORTS
X DIMENSION (ft)
6
8
10
Fig. 10 — Gas Piping Guide
(With Accessory Utility Connections Package)
Fig. 8 — External Trap Condensate Drain
—7—
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
11⁄4
11⁄2
LENGTH OF PIPE, FT*
INTERNAL
DIAMETER
(in.)
10
20
30
40
50
60
70
80
90
100
125
150
175
200
.622
.824
1.049
1.380
1.610
175
360
680
1400
2100
120
250
465
950
1460
97
200
375
770
1180
82
170
320
600
990
73
151
285
580
900
66
138
260
530
810
61
125
240
490
750
57
118
220
460
690
53
110
205
430
650
50
103
195
400
620
44
93
175
360
550
40
84
160
325
500
—
77
145
300
460
—
72
135
280
430
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.
115,000
For example: A 115,000 Btuh input unit equals 115 cubic ft per hour or
= 115 cubic ft/hr.
1,000
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.
Fig. 11 — Sediment Trap
CAUTION: Unstable operation may occur when the
gas valve and manifold assembly are forced out of position while connecting improperly routed rigid gas piping to the gas valve. Use a backup wrench when making connection to avoid strain on, or distortion of, the
gas control piping.
CAUTION: If a flexible conductor is required or allowed by the authority having jurisdiction, black iron
pipe shall be installed at the gas valve and extend a
minimum of 9 in. outside the unit casing.
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
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.
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:
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.
1. Vaporization rate. (Vaporization rate is determined by
the temperature of the LP and the level of LP in the
tank.)
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.
2. Proper pressure regulation. (Two-stage regulation is more
cost effective and efficient.)
5. For horizontal applications, be sure ductwork does not
cover nameplate.
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.
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.
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.
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.
C
COMP
EQUIP
GND
IFC
NEC
LEGEND
Contactor
Compressor
Equipment
Ground
Indoor (Evaporator) Fan
Contactor
— National Electrical Code
—
—
—
—
—
Fig. 13 — Power Wiring Connections
RACEWAY
AHA
CC
RC
RH
—
—
—
—
LOW VOLTAGE
CONNECTIONS
(SCREW TERMINALS)
INTEGRATED GAS UNIT
CONTROLLER (IGC)
LEGEND
Adjustable Heat Anticipator TC — Thermostat-Cooling
Cooling Compensator
TH — Thermostat-Heating
24-v Cooling
Field Wiring
24-v Heating
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)
208/230-1-60
208/230-3-60
460-3-60
575-3-60
208/230-1-60
208/230-3-60
460-3-60
575-3-60
208/230-1-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
VOLTAGE
RANGE
Min
187
187
414
518
187
187
414
518
187
187
414
518
187
414
518
Max
254
254
508
632
254
254
508
632
254
254
508
632
254
508
632
COMPRESSOR
OFM
IFM
COMBUSTION
FAN MOTOR
RLA
16.0
10.3
5.1
4.2
23.7
13.5
7.4
5.8
28.8
17.3
9.0
7.1
20.5
9.6
7.7
FLA
0.7
0.7
0.4
0.4
0.7
0.7
0.4
0.4
1.5
1.5
0.8
0.8
1.4
0.6
0.6
FLA
4.9
4.9
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
FLA
.57
.57
.30
.30
.57
.57
.30
.30
.57
.57
.30
.30
.57
.30
.30
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
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.
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
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
90/ 90
9
46
7
37
34/34
142/142
22/22
112/112
12
57
9
46
45/45
216/216
28/28
168/168
14
84
11
59
32/32
200/200
15
92
12
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)
CUL
FLA
HACR
IFM
LRA
MCA
MOCP
NEC
OFM
RLA
—
—
—
—
—
—
—
—
—
—
NOMINAL
VOLTAGE
(V-Ph-Hz)
208/230-1-60
208/230-3-60
460-3-60
575-3-60
208/230-1-60
208/230-3-60
460-3-60
575-3-60
208/230-1-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
VOLTAGE
RANGE
Min
187
187
414
518
187
187
414
518
187
187
414
518
187
414
518
Max
254
254
508
632
254
254
508
632
254
254
508
632
254
508
632
COMPRESSOR
OFM
IFM
COMBUSTION
FAN MOTOR
RLA
16.0
10.3
5.1
4.2
23.7
13.5
7.4
5.8
28.8
17.3
9.0
7.1
20.5
9.6
7.7
FLA
0.7
0.7
0.4
0.4
0.7
0.7
0.4
0.4
1.5
1.5
0.8
0.8
1.4
0.6
0.6
FLA
4.9
4.9
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
FLA
.57
.57
.30
.30
.57
.57
.30
.30
.57
.57
.30
.30
.57
.30
.30
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
LEGEND
Canadian Underwriters’ Laboratories
Full Load Amps
Heating, Air Conditioning and Refrigeration
Indoor (Evaporator) Fan Motor
Locked Rotor Amps
Minimum Circuit Amps
Maximum Overcurrent Protection
National Electrical Code
Outdoor (Condenser) Fan Motor
Rated Load Amps
*Used to determine minimum disconnect per NEC.
†Fuse or HACR circuit breaker.
NOTES:
1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker.
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.
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.
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
95/ 95
14
59
11
47
39/39
147/147
28/28
117/117
14
59
11
47
51/51
221/221
34/34
173/173
17
87
13
61
35/35
205/205
17
95
14
75
max voltage deviation
from average voltage
% Voltage Imbalance = 100 x
average voltage
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 CUL approved only.
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.
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—
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.
Fig. 16 — Typical Access Panel Locations
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. 17 — Outdoor-Air Hood Details
ECONOMIZER
CONTROL BOARD
ECONOMIZER
PLUG
ECONOMIZER
MOTOR
TOP
SCREW
BAROMETRIC
RELIEF DAMPER
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
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.
BLOCK-OFF PLATE
Fig. 20 — Horizontal Discharge Block-Off Plate
WIRING
HARNESS
Fig. 21 — Typical Varislide Economizer and Wiring Harness
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
B
C
SO
D
TR
REV. B 1 9 8 8 1 8 A
S
1
P
T
MINIMUM 3
POSITION
OPEN
5
4
2
P1
T1
TR
24VAC
2
TR1
1
3 mA MIN. AT 11 VDC
B A
ENTHALPY CONTROL
3
C
CONTACTS SHOWN IN HIGH ENTHALPY
OR UNPOWERED STATE
D
CW–SETPOINTS–CCW
RUSH AT 24VAC
°F
CONTACT RATINGS: 1.5A RUN, 3.5A IN
OUTDOOR TEMP.
% 90
H
DAMPER
U 70
CLOSED
M
I 60
DAMPER
D
OPEN
I 30
T
Y 10
50 55 60 65 70 75 80 85
REV.
97-3672
Fig. 23 — Outdoor-Air Thermostat/Enthalpy
Control Installation
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.
—15—
d. After installation is complete, calculate the minimum airflow across the economizer. To calculate the
minimum airflow, the following data is needed:
total cfm (cfm3), temperature of the total cfm (T3),
temperature of the return air (T2), and temperature of the entering outside air (T1). Cfm1 is the
outside air cfm, which will be the minimum airflow.
Insert the data into the following equations:
T1 (cfm1) + T2 (cfm2)
= T3
cfm3
cfm2 = (cfm3 − cfm1)
Therefore:
T1 (cfm1) + T2 (cfm3 − cfm1)
cfm3
= T3
Use this equation to determine cfm1, which is the
minimum airflow across the economizer.
(T3 −T2) cfm3
cfm1 =
(T1 − T2)
If cfm1 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
POINT
CONTROL CONTROL
(APPOX. DEG.)
CURVE
AT 50% RH
A
73 (23)
B
70 (21)
C
67 (19)
D
63 (17)
Fig. 28 — Panels Reinstalled On Unit
Fig. 29 — Outdoor-Air Hood Installed On Unit
Fig. 27 — Enthalpy Settings for PARABLADE Economizer
—16—
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.
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.
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, CAUTION, and INFORMATION labels attached to, or shipped
with, unit.
3. Make the following inspections:
a. Inspect for shipping and handling damages, such as
broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections
and on unit base. Detecting oil generally indicates a
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.
—17—
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.
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/ft3 at
0.65 specific gravity, or LP gas with a heating value of
2500 Btu/ft3 at 1.5 specific gravity. For elevations above
2000 ft, reduce input 4% for each 1000 ft above sea level. When
the gas supply being used has a different heating value or
specific gravity, refer to national and local codes, or contact
your distributor or branch to determine the required orifice
size. Refer to Table 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.
—18—
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
Max
Min
Max
4.0
13.6
5.0
13.0
4.0
13.6
5.0
13.0
5.0
13.6
5.0
13.0
MANIFOLD
PRESSURE
(in. wg)
Natural
3.5
3.5††
3.5\
NATURAL GAS
Propane
3.5
3.5††
3.5\
PROPANE*
Orifice
Drill Size
Heating Input
(Btuh)†
Orifice
Drill Size
Heating Input
(Btuh)†
33
33
30
72,000
115,000††
150,000\
43
43
38
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.
If the desired gas input is 115,000 Btuh, only a minor change
in the manifold pressure is required.
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
Liquid
Gas
Propane
Orifice
Orifice
Size†
Size†
33
43
34
43
35
44
36
44
36
44
37
45
37
45
38
46
39
47
41
48
43
48
44
49
44
49
45
50
150,000 BTUH
NOMINAL INPUT
Natural
Liquid
Gas
Propane
Orifice
Orifice
Size†
Size†
30
38
30
39
31
40
32
41
33
42
34
43
35
43
36
44
37
44
38
45
39
45
40
46
41
47
42
47
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.
4.
5.
6.
7.
8.
*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.
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/ft3, then proceed as follows:
1. 33 seconds to complete one revolution.
2. 3600 4 33 = 109
3. 109 x 1 = 109 ft3 of gas flow/hr
4. 109 x 1050 = 114,450 Btuh input
Replace cover screw cap on gas valve.
Turn off gas supply to unit.
Remove manometer from pressure tap.
Replace pipe plug on gas valve or manifold.
Turn on gas to unit.
Check for leaks.
Fig. 31 — Burner Tray Details
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.
—19—
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.
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.
10. Replace pipe plug on gas valve or manifold.
I. Heating Sequence of Operation
11. Turn on gas to unit, and check for leaks.
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.
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.
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.
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.
III. COOLING SECTION START-UP AND ADJUSTMENTS
CAUTION: Complete the required procedures given
in the Pre-Start-Up section on page 17 before starting
the unit.
Do not jumper any safety devices when operating the
unit.
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.
D. Cooling Sequence of Operation
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.
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.
—21—
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 Guardt 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.
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
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.
—22—
Fig. 34 — Evaporator-Fan Pulley Adjustment
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.
Table 7 — Fan Rpm at Motor Pulley Settings*
UNIT
581B
036
048
060
072
0
1090
1185
1460
1585
⁄
1055
1150
1425
1540
1
1025
1115
1385
1490
12
11⁄2
990
1080
1350
1445
2
960
1045
1315
1400
MOTOR PULLEY TURNS OPEN
21⁄2
3
31⁄2
4
925
890
860
825
1015
980
945
910
1275
1240
1205
1165
1350
1305
1260
1210
41⁄2
795
875
1130
1165
5
760
840
1095
1120
*Approximate fan rpm shown.
Table 8 — Evaporator Fan Motor Data
UNIT
581B
036
048
060
072
Single
MAXIMUM
CONTINUOUS
BHP*
1.20
Three
1.20
Single
1.20
Three
1.20
Single
1.80
Three
1.80
Three
2.40
PHASE
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—
51⁄2
—
—
1055
—
6
—
—
1020
—
Table 9 — 581B036 Air Delivery — Vertical Discharge Units
AIRFLOW
(Cfm)
900
1000
1100
1200
1300
1400
1500
0.1
Rpm
581
644
687
733
754
810
841
AIRFLOW
(Cfm)
900
1000
1100
1200
1300
1400
1500
Rpm
865
900
929
960
991
1032
1073
Bhp
0.43
0.49
0.55
0.64
0.70
0.78
0.84
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.9
1.0
Rpm
Bhp
Rpm
Bhp
1039
0.47
1061
0.51
1061
0.55
1088
0.60
1091
0.61
1109
0.66
1109
0.68
1156
0.73
1152
0.76
1190
0.82
1181
0.83
1237
0.88
1225
0.89
1271
0.95
Rpm
1083
1111
1127
1203
1228
1293
1317
0.2
Bhp
0.12
0.19
0.22
0.26
0.29
0.35
0.42
Rpm
673
709
746
785
826
868
911
0.7
Rpm
957
992
1013
1045
1075
1110
1150
Bhp
0.18
0.22
0.26
0.32
0.38
0.45
0.53
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.3
0.4
Rpm
Bhp
Rpm
Bhp
736
0.22
805
0.25
782
0.28
835
0.30
806
0.30
867
0.35
843
0.35
903
0.41
891
0.43
942
0.48
937
0.51
984
0.57
985
0.61
1029
0.66
0.8
Bhp
0.39
0.44
0.49
0.56
0.64
0.73
0.78
Rpm
988
1039
1068
1090
1122
1160
1190
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates a field-supplied drive is required. (See Note 2.)
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.
0.5
0.6
Bhp
0.29
0.35
0.40
0.47
0.53
0.62
0.72
Rpm
911
937
964
994
1047
1067
1109
Bhp
0.54
0.66
0.73
0.81
0.87
0.94
1.00
Rpm
1105
1136
1145
1250
1266
1349
1383
1.1
Bhp
0.34
0.38
0.40
0.50
0.60
0.67
0.77
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.
Table 10 — 581B048 Air Delivery — Vertical Discharge Units
AIRFLOW
(Cfm)
1200
1300
1400
1500
1600
1700
1800
1900
2000
0.1
Rpm
596
633
672
711
751
791
831
872
913
AIRFLOW
(Cfm)
1200
1300
1400
1500
1600
1700
1800
1900
2000
Bhp
0.69
0.80
0.89
0.99
1.09
1.20
1.32
1.45
1.58
BELT DRIVE MOTOR
External Static Pressure (in.
1.1
1.2
Rpm
Bhp
Rpm
Bhp
1056
0.72
1083
0.74
1090
0.85
1121
0.89
1120
0.96
1153
1.00
1147
1.06
1180
1.13
1174
1.17
1207
1.25
1203
1.29
1235
1.37
1233
1.41
1263
1.49
1263
1.54
1294
1.63
1294
1.68
1325
1.78
0.2
Bhp
0.20
0.24
0.30
0.35
0.42
0.49
0.58
0.67
0.77
Rpm
665
699
735
770
835
873
881
919
958
0.9
Rpm
993
1021
1049
1077
1107
1137
1167
1197
1229
Bhp
0.25
0.30
0.36
0.42
0.49
0.57
0.66
0.75
0.86
BELT DRIVE MOTOR
External Static Pressure (in.
0.3
0.4
Rpm
Bhp
Rpm
Bhp
722
0.31
779
0.36
754
0.36
809
0.42
788
0.42
840
0.48
822
0.49
873
0.55
871
0.56
907
0.63
907
0.65
941
0.72
929
0.74
976
0.81
965
0.84
1011
0.92
1002
0.95
1046
1.03
1.0
Bhp
0.65
0.74
0.82
0.92
1.00
1.12
1.23
1.35
1.48
Rpm
1028
1058
1086
1113
1141
1171
1202
1232
1262
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.
indicates maximum usable bhp.
3.
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.
wg)
0.6
Rpm
872
902
933
963
993
1024
1057
1091
1125
0.7
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
Bhp
0.80
0.94
1.12
1.27
1.40
1.53
1.67
1.81
1.97
Rpm
1185
1219
1257
1295
1326
1354
1381
1408
1436
0.8
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
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
Bhp
0.60
0.67
0.75
0.84
0.93
1.04
1.14
1.25
1.38
wg)
1.4
Rpm
1134
1171
1210
1241
1269
1296
1323
1351
1362
1.6
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—
Table 11 — 581B060 Air Delivery — Vertical Discharge Units
AIRFLOW
(Cfm)
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
0.1
Rpm
771
816
902
942
982
1022
1063
1104
1130
1174
1201
Bhp
0.37
0.45
0.61
0.70
0.80
0.91
0.99
1.13
1.26
1.37
1.48
Rpm
1257
1286
1315
1395
1430
1459
1489
1528
1561
1584
1633
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.4
1.6
Bhp
Rpm
Bhp
Rpm
1.20
1330
1.38
1411
1.31
1353
1.49
1421
1.44
1381
1.52
1443
1.46
1475
1.56
1542
1.58
1504
1.69
1556
1.67
1532
1.82
1588
1.80
1567
1.99
1626
1.95
1603
2.17
1666
2.13
1637
2.35
1710
2.28
1671
2.55
1756
2.53
1698
2.72
—
AIRFLOW
(Cfm)
1500
1600
1600
1800
1900
2000
2100
2200
2300
2400
2500
0.2
1.2
Rpm
828
869
940
978
1023
1068
1115
1159
1202
1237
1272
Bhp
0.44
0.51
0.62
0.66
0.78
0.90
1.00
1.15
1.29
1.41
1.53
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
0.6
Rpm
Bhp
Rpm
Bhp
935
0.58
1027
0.73
968
0.66
1056
0.81
1007
0.75
1094
0.91
1063
0.82
1147
0.97
1097
0.91
1175
1.11
1132
1.01
1218
1.23
1180
1.17
1261
1.35
1214
1.28
1310
1.52
1248
1.38
1358
1.69
1292
1.55
1392
1.81
1335
1.71
1427
1.94
0.8
Rpm
1107
1127
1175
1248
1266
1303
1340
1375
1410
1460
1518
1.0
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
Bhp
1.04
1.14
1.26
1.33
1.47
1.52
1.66
1.80
1.93
2.14
2.35
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
Bhp
1.59
1.68
1.69
1.71
1.82
1.97
2.16
2.37
2.54
2.70
—
2.
indicates field-supplied motor and drive required.
indicates maximum usable bhp.
3.
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.
Table 12 — 581B072 Air Delivery — Vertical Discharge Units
AIRFLOW
(Cfm)
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
0.1
Rpm
942
982
1022
1063
1104
1130
1174
1201
1246
1285
1304
1345
1378
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
1395
1430
1459
1489
1528
1561
1584
1633
1675
—
—
—
—
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.4
1.6
Bhp
Rpm
Bhp
Rpm
1.46
1475
1.56
1542
1.58
1504
1.69
1556
1.67
1532
1.82
1588
1.80
1567
1.99
1626
1.95
1603
2.17
1666
2.13
1637
2.35
1710
2.28
1671
2.55
1756
2.53
1698
2.72
—
2.77
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
AIRFLOW
(Cfm)
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
0.2
1.2
Rpm
978
1023
1068
1115
1159
1202
1237
1272
1320
1361
1402
1446
1489
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
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
0.6
Rpm
Bhp
Rpm
Bhp
1063
0.82
1147
0.97
1097
0.91
1175
1.11
1132
1.01
1218
1.23
1180
1.17
1261
1.35
1214
1.28
1310
1.52
1248
1.38
1358
1.69
1292
1.55
1392
1.81
1335
1.71
1427
1.94
1368
1.81
1458
2.06
1400
1.91
1490
2.19
1439
2.08
1543
2.43
1477
2.16
1585
2.65
1529
2.52
1598
2.73
0.8
Rpm
1248
1266
1303
1340
1375
1410
1460
1518
1562
1602
1642
—
—
1.0
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
—
—
—
Bhp
1.33
1.47
1.52
1.66
1.80
1.93
2.14
2.35
2.59
2.85
—
—
—
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
Bhp
1.71
1.82
1.97
2.16
2.37
2.54
2.70
—
—
—
—
—
—
—25—
2.
indicates field-supplied motor and drive required.
indicates maximum usable bhp.
3.
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.
Table 13 — 581B036 Air Delivery — Horizontal Discharge Units
AIRFLOW
(Cfm)
900
1000
1100
1200
1300
1400
1500
0.1
Rpm
526
570
614
658
703
725
755
AIRFLOW
(Cfm)
900
1000
1100
1200
1300
1400
1500
Rpm
818
848
863
889
916
937
969
Bhp
0.35
0.39
0.43
0.50
0.56
0.60
0.68
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.9
1.0
Rpm
Bhp
Rpm
Bhp
989
0.38
1028
0.42
1020
0.44
1064
0.48
1052
0.49
1100
0.52
1076
0.53
1136
0.59
1094
0.61
1172
0.65
1108
0.67
1208
0.70
1117
0.70
1245
0.74
Rpm
1074
1124
1163
1201
1239
1278
1315
0.2
Bhp
0.06
0.09
0.13
0.16
0.20
0.29
0.33
Rpm
584
627
670
710
752
776
816
0.7
Rpm
924
936
960
988
1012
1027
1056
Bhp
0.08
0.13
0.16
0.23
0.27
0.31
0.38
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.3
0.4
Rpm
Bhp
Rpm
Bhp
656
0.12
734
0.22
738
0.19
800
0.26
758
0.23
812
0.29
780
0.28
840
0.32
808
0.32
868
0.37
845
0.38
891
0.42
870
0.43
924
0.48
0.8
Bhp
0.32
0.35
0.39
0.45
0.51
0.56
0.63
Rpm
953
977
1005
1038
1061
1071
1097
LEGEND
Bhp — Brake Horsepower Input to Fan
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.
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.
0.5
0.6
Bhp
0.25
0.29
0.32
0.36
0.41
0.47
0.53
Rpm
875
895
914
938
963
983
1014
Bhp
0.45
0.52
0.56
0.61
0.69
0.75
0.80
Rpm
1120
1185
1225
1266
1306
1347
1385
1.1
Bhp
0.27
0.31
0.35
0.40
0.45
0.51
0.58
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.
Table 14 — 581B048 Air Delivery — Horizontal Discharge Units
AIRFLOW
(Cfm)
1200
1300
1400
1500
1600
1700
1800
1900
2000
0.1
Rpm
569
604
640
676
713
750
788
826
864
AIRFLOW
(Cfm)
1200
1300
1400
1500
1600
1700
1800
1900
2000
Bhp
0.70
0.77
0.86
0.95
1.05
1.15
1.26
1.37
1.48
BELT DRIVE MOTOR
External Static Pressure (in.
1.1
1.2
Rpm
Bhp
Rpm
Bhp
1068
0.79
1106
0.87
1086
0.84
1128
0.91
1104
0.93
1139
1.01
1129
1.02
1162
1.09
1156
1.13
1185
1.20
1183
1.23
1215
1.31
1211
1.35
1243
1.43
1238
1.47
1271
1.56
1265
1.59
1298
1.69
0.2
Bhp
0.18
0.22
0.27
0.32
0.38
0.45
0.52
0.60
0.70
Rpm
641
673
705
738
772
806
841
876
912
0.9
Rpm
987
1006
1033
1060
1087
1114
1141
1168
1197
Bhp
0.23
0.28
0.33
0.38
0.44
0.51
0.59
0.68
0.77
BELT DRIVE MOTOR
External Static Pressure (in.
0.3
0.4
Rpm
Bhp
Rpm
Bhp
701
0.29
761
0.34
731
0.34
788
0.39
761
0.39
817
0.45
793
0.45
847
0.51
825
0.51
877
0.58
857
0.59
908
0.66
890
0.67
939
0.75
924
0.76
971
0.84
958
0.86
1004
0.94
1.0
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
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive required. (See Note 4.)
2.
indicates field-supplied motor and drive required.
indicates maximum usable bhp.
3.
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.
wg)
0.6
Rpm
859
887
914
940
967
997
1026
1056
1087
0.7
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
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
0.8
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
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
Bhp
0.58
0.65
0.72
0.81
0.89
1.01
1.07
1.18
1.30
wg)
1.4
Rpm
1134
1183
1218
1228
1250
1276
1303
1330
1358
1.6
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—
Table 15 — 581B060 Air Delivery — Horizontal Discharge Units
AIRFLOW
(Cfm)
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
0.1
Rpm
741
783
825
885
928
971
1015
1060
1104
1138
1183
Bhp
0.38
0.45
0.53
0.63
0.73
0.84
0.97
1.10
1.25
1.30
1.43
Rpm
1218
1251
1281
1341
1374
1396
1413
1434
1459
1502
1524
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.4
1.6
Bhp
Rpm
Bhp
Rpm
1.12
1295
1.36
1360
1.20
1310
1.40
1385
1.31
1342
1.48
1398
1.40
1413
1.55
1474
1.53
1437
1.62
1490
1.66
1460
1.68
1509
1.75
1475
1.73
1529
1.81
1487
1.85
1554
1.88
1520
2.07
1576
2.06
1552
2.24
1604
2.24
1585
2.42
1638
AIRFLOW
(Cfm)
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
0.2
1.2
Rpm
798
838
878
942
982
1022
1063
1104
1130
1174
1201
Bhp
0.43
0.51
0.60
0.73
0.83
0.94
1.10
1.20
1.27
1.37
1.50
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
0.6
Rpm
Bhp
Rpm
Bhp
895
0.54
990
0.67
933
0.63
1016
0.75
969
0.72
1049
0.84
1047
0.90
1139
1.05
1084
1.02
1160
1.11
1121
1.12
1188
1.22
1140
1.18
1196
1.27
1159
1.23
1229
1.41
1196
1.37
1264
1.56
1245
1.57
1305
1.63
1284
1.65
1338
1.75
0.8
Rpm
1073
1102
1134
1193
1223
1254
1272
1306
1340
1373
1402
1.0
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
Bhp
0.95
1.04
1.14
1.30
1.38
1.44
1.58
1.70
1.86
1.95
2.04
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
Bhp
1.40
1.49
1.53
1.58
1.67
1.77
1.92
2.07
2.24
2.42
2.60
2.
indicates field-supplied motor and drive required.
indicates maximum usable bhp.
3.
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.
Table 16 — 581B072 Air Delivery — Horizontal Discharge Units
AIRFLOW
(Cfm)
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
0.1
Rpm
885
928
971
1015
1060
1104
1138
1183
1210
1254
1274
1318
1362
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
1341
1374
1396
1413
1434
1459
1502
1524
1552
1584
1624
1671
—
BELT DRIVE MOTOR
External Static Pressure (in. wg)
1.4
1.6
Bhp
Rpm
Bhp
Rpm
1.40
1413
1.55
1474
1.53
1437
1.62
1490
1.66
1460
1.68
1509
1.75
1475
1.73
1529
1.81
1487
1.85
1554
1.88
1520
2.07
1576
2.06
1552
2.24
1604
2.24
1585
2.42
1638
2.40
1616
2.63
1671
2.61
1646
2.83
1706
2.85
1677
2.99
—
3.03
—
—
—
—
—
—
—
AIRFLOW
(Cfm)
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
0.2
1.2
Rpm
942
982
1022
1063
1104
1130
1174
1201
1246
1285
1304
1345
1378
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
BELT DRIVE MOTOR
External Static Pressure (in. wg)
0.4
0.6
Rpm
Bhp
Rpm
Bhp
1047
0.90
1139
1.05
1084
1.02
1160
1.11
1121
1.12
1188
1.22
1140
1.18
1196
1.27
1159
1.23
1229
1.41
1196
1.37
1264
1.56
1245
1.57
1305
1.63
1284
1.65
1338
1.75
1312
1.76
1366
1.96
1354
1.95
1403
2.14
1374
2.12
1459
2.25
1412
2.32
1496
2.54
1451
2.40
1534
2.66
0.8
Rpm
1193
1223
1254
1272
1306
1340
1373
1402
1435
1474
1514
1529
1560
1.0
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
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
LEGEND
Bhp — Brake Horsepower Input to Fan
NOTES:
1. Boldface indicates field-supplied drive is required. (See Note 4.)
Bhp
1.58
1.67
1.77
1.92
2.07
2.24
2.42
2.60
2.80
2.97
—
—
—
—27—
2.
indicates field-supplied motor and drive required.
indicates maximum usable bhp.
3.
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.
CARE AND MAINTENANMCE
SERVICE
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.
CAUTION: When servicing unit, shut off all electrical power to unit to avoid shock hazard or injury from
rotating parts.
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 PERSONAL INJURY AND POSSIBLE DAMAGE TO THIS
EQUIPMENT.
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.
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.
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—
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).
Fig. 35 — Cleaning Condenser Coil
3.
4.
5.
6.
Loosen fan hub setscrews.
Adjust fan height as shown in Fig. 38.
Tighten setscrews.
Replace condenser-fan assembly.
UNIT 581B
Fig. 36 — Propping Up Top Panel
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.
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.
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.)
Fig. 39 — Cooling Charging Chart, 581B036
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. 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—
ROLLOUT
SWITCH
INDUCEDDRAFT
MOTOR
MOUNTING
PLATE
BURNER
SECTION
FLUE
EXHAUST
INDUCEDDRAFT
MOTOR
BLOWER
HOUSING
MANIFOLD
PRESSURE
TAP
GAS
VALVE
Fig. 43 — Burner Section Details
IX. LIMIT SWITCH
Remove blower access panel (Fig. 2). Limit switch is located
on the fan deck.
Fig. 41 — Cooling Charging Chart, 581B060
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*
LED INDICATION
ON
OFF
1 Flash†
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
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.
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.
7. To reinstall, reverse the procedure outlined above.
—31—
A. Removal and Replacement of Gas Train (See Fig. 31
and 43.)
1.
2.
3.
4.
5.
6.
7.
8.
Shut off manual gas valve.
Shut off power to unit.
Remove compressor access panel.
Slide out burner compartment side panel.
Remove heat shield.
Disconnect gas piping at unit gas valve.
Remove wires connected to gas valve. Mark each wire.
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)
CAUSE
Loss of power to IGC.
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.
Limit switch fault.
(LED 2 Flashes)
High-temperature limit switch
is open.
Flame sense fault.
(LED 3 Flashes)
4 consecutive limit switch trips.
(LED 4 Flashes)
Ignition lockout.
(LED 5 Flashes)
The IGC sensed flame that
should not be present.
Inadequate airflow to unit.
Unit unsuccessfully attempted
ignition for 15 minutes.
Induced-draft motor fault.
(LED 6 Flashes)
IGC does not sense that
induced-draft motor is operating.
Rollout switch fault.
(LED 7 Flashes)
Rollout switch has opened.
Internal control fault.
(LED 8 Flashes)
Microprocessor has sensed an
error in the software or hardware.
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.
LEGEND
IGC — Integrated Gas Unit Controller
LED — Light-Emitting Diode
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.
Inadequate heating.
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.
Dirty air filter.
Gas input to unit too low.
Unit undersized for application.
Restricted airflow.
Blower speed too low.
Limit switch cycles main burners.
Too much outdoor air.
Poor flame
characteristics.
Incomplete combustion (lack of
combustion air) results in:
Aldehyde odors, carbon monoxide,
sooting flame, or floating flame.
Burners will not
turn off.
Unit is locked into Heating mode
for a one minute minimum.
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.
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.
Compressor makes
excessive noise.
Excessive head pressure.
Head 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.
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.
Refrigerant overcharge or undercharge.
Defective compressor.
Insufficient line voltage.
Blocked condenser.
Defective run/start capacitor, overload, or start relay.
Defective thermostat.
Faulty condenser-fan motor or capacitor.
Restriction in refrigerant system.
Dirty air filter.
Unit undersized for load.
Thermostat set too low.
Low refrigerant charge.
Leaking valves in compressor.
Air in system.
Condenser coil dirty or restricted.
Compressor rotating in wrong direction.
Dirty air filter.
Dirty condenser coil.
Refrigerant overcharged.
Air in system.
Condenser air restricted or air short-cycling.
Low refrigerant charge.
Compressor valves leaking.
Restriction in liquid tube.
Compressor rotating in wrong direction
Excessive suction
pressure.
High heat load.
Compressor valves leaking.
Refrigerant overcharged.
Compressor rotating in wrong direction.
Suction pressure too low.
Dirty air filter.
Low refrigerant charge.
Metering device or low side restricted.
Insufficient evaporator airflow.
Evaporator fan
will not shut off.
Temperature too low in conditioned area.
Outdoor ambient below 25 F.
Time off delay not finished.
—34—
REMEDY
Call power company.
Replace fuse or reset circuit breaker.
Replace component.
Determine cause and correct.
Check wiring diagram and rewire correctly.
Lower thermostat setting below room temperature.
Check wiring and repair or replace.
Determine cause. Replace compressor.
Determine cause and replace.
Replace fuse or reset circuit breaker.
Determine cause.
Reclaim refrigerant, evacuate system, and recharge
to nameplate.
Replace and determine cause.
Determine cause and correct.
Determine cause and correct.
Determine cause and replace.
Replace thermostat.
Replace.
Locate restriction and remove.
Replace filter.
Decrease load or increase unit size.
Reset thermostat.
Locate leak; repair and recharge.
Replace compressor.
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.
Increase air quantity. Check filter and replace
if necessary.
Reset thermostat.
Install low-ambient kit.
Wait for 30-second off delay.
Table 21 — Varislide™ Economizer Troubleshooting
PROBLEM
Damper does not
open.
CAUSE
Indoor (evaporator) fan
is off.
No power to economizer
motor.
Economizer motor failure.
Economizer operation
limited to minimum
position.
OAT or EC set too high.
Economizer control board
incorrectly wired or not
functioning.
Incorrect SAT wiring or inoperative SAT.
Damper does not
close.
Incorrect economizer
wiring.
Incorrect damper actuator
wiring or inoperative economizer circuit board.
Incorrect SAT wiring or inoperative SAT.
Economizer motor failure.
Economizer damper
does not close on
power loss.
CI
EC
IFC
IFO
—
—
—
—
Insufficient battery power, inoperative economizer control
board.
LEGEND
Common
Enthalpy Control
Indoor (Evaporator) Fan Contactor
Indoor (Evaporator) Fan On
OAT
PL
SAT
SW
—
—
—
—
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.
Outdoor-Air Thermostat
Plug
Supply-Air Thermostat
Economizer Position Switch
—35—
Table 22 — PARABLADE Economizer Troubleshooting
PROBLEM
Damper does not open.
CAUSE
Evaporator fan not on.
No power to economizer motor.
Economizer motor failure.
Economizer operation
limited to minimum
position.
Economizer control module
failure.
Damper does not close.
No power to economizer.
Return spring failure.
Economizer motor failure.
Damper does not open
or close according to
enthalpy readings.
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 S0 and +. Factoryinstalled 620 ohm resistor should be connected to terminals SR 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 SR 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 SR and +.
2. Connect 1.2 Kohm checkout resistor across terminals SO 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 SO and +. Factoryinstalled 620 ohm resistor should be connected to terminals SR 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 SR 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 SO 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—
—37—
Fig. 45 — Typical Wiring Schematic and Component Arrangement
LEGEND AND NOTES FOR FIG. 45 — TYPICAL CONTROL WIRING SCHEMATIC
AND COMPONENT ARRANGEMENT
AHA
C
CAP
CC
CLO
COMP
D
EC
ECON
EPS
EQUIP
ER
FPT
FU
GND
HPS
HS
I
IDM
IFC
IFM
IGC
LPS
LS
MGV
MTR
OAT
OFM
P
PL
QT
R
RS
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Adjustable Heat Anticipator
Contactor, Compressor
Capacitor
Cooling Compensator
Compressor Lockout
Compressor Motor
Diode
Enthalpy Control
Economizer
Emergency Power Supply (9-V Battery)
Equipment
Economizer Relay
Freeze-Protection Thermostat
Fuse
Ground
High-Pressure Switch
Hall Effect Sensor
Ignitor
Induced Draft Motor
Indoor-Fan Contactor
Indoor-Fan Motor
Integrated Gas Unit Controller
Low-Pressure Switch
Limit Switch
Main Gas Valve
Motor
Outdoor-Air Thermostat
Outdoor-Fan Motor
Plug
Plug Assembly
Quadruple Terminal
Relay
Rollout Switch
SAT
SEN
SW1
SW2
SW3
SW4
TC
TH
TRAN
—
—
—
—
—
—
—
—
—
Supply-Air Thermostat
Sensor
Switch Fully Open
Switch Fully Closed
Switch Minimum Vent Position
Switch Maximum Vent Position
Thermostat-Cooling
Thermostat-Heating
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.:
SERIAL NO.:
DATE:
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
L2-L3
L3-L1
COMPRESSOR AMPS
L1
L2
L3
INDOOR-FAN AMPS
L1
L2
L3
TEMPERATURES
OUTDOOR-AIR TEMPERATURE
DB
RETURN-AIR TEMPERATURE
DB
WB
CUT ALONG DOTTED LINE
COOLING SUPPLY AIR
GAS HEAT SUPPLY AIR
PRESSURES
GAS INLET PRESSURE
IN. WG
GAS MANIFOLD PRESSURE
IN. WG (HI FIRE)
REFRIGERANT SUCTION
PSIG
REFRIGERANT DISCHARGE
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
CUT ALONG DOTTED LINE
(Remove and Store in Job File)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
START-UP CHECKLIST
CATALOG NO. 5358-100
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