Bryant 583B 030-060 gas heating/air conditioners Installation, start-up, and operating instructions

installation, start-up, and operating instructions

3-PHASE SINGLE PACKAGE

GAS HEATING/AIR CONDITIONERS

WITH PURON® (R-410A) REFRIGERANT

Cancels: New

583B

Sizes

030-060

II 583B-30-1

2-06

Low NOx Models Available

NOTE: Read the entire instruction manual before starting the installation.

Index Page

SAFETY CONSIDERATIONS .....................................................1

RULES FOR SAFE INSTALLATION AND OPERATION....1-2

RECEIVING AND INSTALLATION ..........................................2

CHECK EQUIPMENT ..................................................................2

PROVIDE UNIT SUPPORT .........................................................2

Roof Curb..................................................................................2

Slab Mount................................................................................2

Ground Mount...........................................................................2

FIELD FABRICATE DUCTWORK..........................................2-3

PROVIDE CLEARANCES ........................................................4-7

RIG AND PLACE UNIT ...........................................................7-8

CONNECT CONDENSATE DRAIN ...........................................8

INSTALL FLUE HOOD ...............................................................8

INSTALL GAS PIPING............................................................... 9

INSTALL DUCT CONNECTIONS ..................................... 10-11

INSTALL ELECTRICAL CONNECTIONS.........................12-14

High-Voltage Connections......................................................12

Special Procedures for 208-V Operation ...............................12

Control Voltage Connections .................................................13

Standard Connection...............................................................13

Heat Anticipator Setting....................................................13-14

Transformer Protection ...........................................................14

PRE-START-UP ......................................................................... 14

START-UP ............................................................................ 14-23

MAINTENANCE....................................................................23-27

REFRIGERANT SYSTEM..........................................................27

QUICK REFERENCE GUIDE....................................................28

TROUBLESHOOTING......................................................... 29-31

START-UP CHECKLIST............................................................32

NOTE TO INSTALLER — Before the installation, READ

THESE INSTRUCTIONS CAREFULLY AND COMPLETELY.

Also, make sure the User’s Manual and Replacement Guide are left with the unit after installation. the furnace is NOT to be used for temporary heating of buildings or structures under construction.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified personnel should install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.

—1—

C99087

Fig. 1—Unit 583B

RULES FOR SAFE INSTALLATION AND OPERATION

WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, fire, or an explosion which can result in serious injury or unit damage. Consult a qualified installer, service agency, or gas supplier for information or assistance. The qualified installer or agency must use only factory-authorized kits or accessories when modifying this product.

Understand the signal words —DANGER, WARNING, and

CAUTION. DANGER identifies the most serious hazards which will result in severe serious injury or death. WARNING indicates a condition that could result in serious injury or death. CAUTION is used to identify unsafe practices which would result in minor or moderate injury or product and property damage.

The power supply (volts, phase, and hertz) must correspond to that specified on unit rating plate.

The electrical supply provided by the utility must be sufficient to handle load imposed by this unit.

This installation must conform with local building codes and with

NEC (National Electrical Code) and NFPA 70, NFPA 54/ANSI

Z223.1 latest revision, and NFGC (National Fuel Gas Code). Refer to provincial and local plumbing or waste water codes and other applicable local codes.

Approved for outdoor installation on wood flooring or on class A,

B or C roof covering materials.

WARNING: Before performing service or maintenance operations on unit, turn off gas supply then unit main power switch. Electrical shock or explosion could cause serious injury or death.

CAUTION: Puron (R-410A) systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on Puron (R-410A) equipment. Ensure service equipment is rated for Puron

(R-410A).

A.

General

The 583B units (see Fig. 1) are fully self-contained, combination

Category I gas heating/electric cooling units designed for outdoor installation. See Fig. 6 and 7 for unit dimensions. All unit sizes have discharge openings for both horizontal and downflow configurations, and are factory shipped with all downflow duct openings covered . Units may be installed either on a rooftop, cement slab, or directly on the ground (if permitted by local codes). See Figs. 4 and 5 for roof curb dimensions.

Models with an N in the thirteenth position of the model number are dedicated Low NO x units designed for California installation.

These models meet the California maximum oxides of nitrogen

(NO x

) emissions requirements of 40 nanograms/joule or less as shipped from the factory and must be installed in California Air

Quality Management Districts where a Low NO x rule exists.

RECEIVING AND INSTALLATION

I.

CHECK EQUIPMENT

IDENTIFY UNIT — The unit model number and serial number are stamped on unit identification plate. Check this information against shipping papers and job data.

INSPECT SHIPMENT — Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit.

Check all items against shipping list. Immediately notify the nearest Bryant Air Conditioning office if any item is missing.

To prevent loss or damage, leave all parts in original packages until installation.

II.

PROVIDE UNIT SUPPORT

ROOF CURB — Install accessory roof curb in accordance with instructions shipped with curb. See Figs. 4 and 5 and Table 1 for roof curb dimensions. Install insulation, cant strips, roofing, and flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasketing material supplied with the roof curb. Improperly applied gasketing can also result in air leaks and poor unit performance.

Curb should be level to within 1 /4 inch. This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required (see Fig. 2).

A

B

C

MAXIMUM ALLOWABLE

DIFFERENCE (in.)

A-B

1/4

B-C

1/4

A-C

1/4

Fig. 2—Unit Leveling Tolerances

C99065

OPTIONAL

RETURN

AIR

OPENING

OPTIONAL

SUPPLY

AIR

OPENING

2"

(50.8mm)

EVAP.

COIL

COND.

COIL

Fig. 3—Slab Mounting Details

C99014

SLAB MOUNT — Place the unit on a solid, level concrete pad that is a minimum of 4 in. thick with 2 in. above grade. The slab should be flush on the compressor end of the unit (to allow condensate drain installation) and should extend 2 in. on the three remaining sides of the unit. See Fig. 3. Do not secure the unit to the slab except when required by local codes.

GROUND MOUNT — The unit may be installed either on a slab or placed directly on the ground if local codes permit. Place the unit on level ground prepared with gravel for condensate discharge.

III.

FIELD FABRICATE DUCTWORK

Secure all ducts to roof curb and building structure on vertical discharge units. Do not connect ductwork to unit. For horizontal applications, unit is provided with flanges on the horizontal openings. All ductwork should be secured to the 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 -.25 in. wg.

—2—

6

46 3/16

44 5/16

B

17 3/8

TYP.

D

C

B

END

(2)

1 TYP.

7/8

SUPPORT B

SIDE

(2)

SUPPORT A (2)

A

3

2

END VIEW

13/16

DECK PAN (INSULATED)

Fig. 4—Roof Curb Dimensions

Top View

SIDE PANEL

0.75"

3.0"

BASE PAN

BOTTOM SUPPLY

4.0"

SUPPORT RIB(S)

SEAL STRIP

(FACTORY SUPPLIED)

COUNTER FLASHING

(FIELD SUPPLIED)

ROOFING FELT

(FIELD SUPPLIED)

CANT STRIP

(FIELD SUPPLIED)

NAILER

ROOFING MATERIAL

(FIELD SUPPLIED)

Fig. 5—Roof Curb Dimensions

Side View

INSULATION

(FIELD SUPPLIED)

A99320

A99340

—3—

TABLE 1—ROOF CURB DIMENSIONS

UNIT SIZE ODS ORDER NUMBER

ROOF

CURB

583B030-036

583B042-060

CPRFCURB006A00

CPRFCURB007A00

CPRFCURB008A00

CPRFCURB009A00

Notes:

1. Roof curb must be set up for unit being installed.

2. Seal strip must be applied as required to unit being installed.

3. Dimensions in ( ) are in millimeters.

4. Roof curb is made of 16 gauge steel.

5. Table lists only the dimensions per part number that have changed.

6. Attach ductwork to curb (flanges of duct rest on curb).

7. Insulated panels: 1-in. thick fiberglass 1 lb. density.

8. Dimensions are in inches.

A

IN. (MM)

8 (203)

14 (356)

8 (203)

14 (356)

B

IN. (MM)

11 27/32 (301)

11 27/32 (301)

15 27/32 (402)

15 27/32 (402)

C

IN. (MM)

30 5/8 (778)

30 5/8 (778)

42 1/8 (1070)

42 1/8 (1070)

D

IN. (MM)

28 3/4 (730)

28 3/4 (730)

40 1/4 (1022)

40 1/4 (1022)

IV.

PROVIDE CLEARANCES

The required minimum operating and service clearances are shown in Fig. 6 and 7. Adequate combustion, ventilation, and condenser air must be provided, in accordance with section 5.3, Air for

Combustion and Ventilation, of the National Fuel Gas Code ANSI

(American National Standards Institute) Z223.1 (in Canada, sections 7.2, 7.3 or 7.4 or Can/CGA (Canadian Gas Association)

B149 Installation Codes), or applicable provisions of local building code.

CAUTION: Do not restrict condenser airflow. An air restriction at either the outdoor-air inlet or the fan discharge can be detrimental to compressor life.

WARNING:

Never exceed 200 lbs. per bracket lifting force.

Accessory lifting kit is only to be used with Small

Packaged units which have a composite base pan with molded hand holds.

Never stand beneath rigged units or lift over people.

Lifting point should be directly over the center of gravity for the unit.

A dropped unit could cause serious injury or death.

The condenser pulls air through the condenser coil and discharges it through the top cover. Be sure that the fan discharge does not recirculate to the condenser coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is

48-in. above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 inches.

Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting, tile, or other combustible materials. The unit may be installed on wood flooring or on Class A, B, or C roof covering materials.

V.

RIG AND PLACE UNIT

Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.).

Only trained, qualified crane operators and ground support staff should handle and install this equipment.

When working with this equipment, observe precautions in the literature, on tags, stickers and labels attached to the equipment, and any other safety precautions that might apply.

Training for operations of the lifting equipment should include, but

NOT be limited to the following:

1. Application of the lifter to the load and adjustment of the lifts, if any, that adapts it to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load itself, required for operation of the lifting kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work gloves.

—4—

INSPECTION — Prior to initial use, and at monthly intervals, all rigging brackets and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks.

Particular attention should be paid to excessive wear at hoist hooking points and load support areas. Brackets or straps showing any kind of wear in these areas must not be used and should be discarded.

INSTALLATION:

1. Position the lifting bracket assembly around the base of the unit. Leave the top shipping skid on the unit to act as a spreader bar. Be sure the strap does not twist.

2. Place each of the four (4) metal lifting brackets into the handholds in the composite pan.

3. Tighten the ratchet strap until tight. Lifting brackets should be secure in the handholds.

4. Attach the clevis or hook of sufficient strength to hole in the lifting bracket as shown in Fig. 8.

5. Attach safety straps directly to the field supplied rigging straps or clevis clip. Do not attach the safety straps to the lifting brackets.

6. Use the top of the unit as a spreader bar to prevent the rigging straps from damaging the unit. If the wood top is not available, use a spreader bar of sufficient length to not damage the unit.

VI.

CONNECT CONDENSATE DRAIN

NOTE: When installing condensate drain connection be sure to comply with local codes and restrictions.

The 583B units dispose of condensate water through a 3/4 in. NPT fitting which exits through the compressor access panel. See Fig.

6 and 7 for location.

Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in groundlevel installations. Install a field-supplied condensate trap at end of condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain pan condensate connection to prevent the pan from overflowing. See

Fig. 9. Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit.

REQ’D CLEARANCES FOR OPERATION AND SERVICING. in. (mm)

Evaporator coil access side . . . . . . . . . . . . . . . . . . 36 (914)

Power entry side (except for NEC requirements) . . . . . . . . . 36 (914)

Unit top . . . . . . . . . . . . . . . . . . . . . . . . . . 48 (1219)

Side opposite ducts . . . . . . . . . . . . . . . . . . . . . 36 (914)

Duct panel . . . . . . . . . . . . . . . . . . . . . . . . 12 (304.8)*

Flue Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 (914.4)

*Minimum distances: If unit is placed less than 12 in. (304.8 mm) from wall system, then the system performance may be compromised.

LEGEND

CG - Center of Gravity

COND - Condenser

EVAP - Evaporator

NEC - National Electrical Code

REQ'D - Required

Note: Dimensions are in in. (mm)

REQ’D CLEARANCES TO COMBUSTIBLE MAT’L. in. (mm)

Top of unit . . . . . . . . . . . . . . . . . . . . . . . . . 14 (355.6)

Duct side of unit . . . . . . . . . . . . . . . . . . . . . . . 2 (50.8)

Side opposite ducts . . . . . . . . . . . . . . . . . . . . . 14 (355.6)

Bottom of unit . . . . . . . . . . . . . . . . . . . . . . . 0.50 (12.7)

NEC REQ’D CLEARANCES. in. (mm)

Between units, power entry side . . . . . . . . . . . . . . 42 (1066.8)

Unit and ungrounded surfaces, power entry side . . . . . . . . . 36 (914)

Unit and block or concrete walls and other grounded surfaces, control box side . . . . . . . . . . . . . . . . . 42 (1066.8)

UNIT

583B030040/060

583B036060/090

ELECTRICAL

CHARACTERISTICS

208/230-3-60

208/230-3-60,

460-3-60

UNIT WEIGHT lb.

313.0

321.0

kg.

142.0

145.6

UNIT HEIGHT

IN. (MM)

"A"

39.02 (991.1)

35.02 (889.5)

Fig. 6—583B030, 036 Unit Dimensions

—5—

C99017

X

22.0 (558.8)

CENTER OF GRAVITY

IN. (MM)

Y

15.3 (387.4)

Z

17.6 (447.0)

22.0 (558.8) 15.3 (387.4) 16.5 (419.1)

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

in. [mm]

EVAP. COIL ACCESS SIDE..............................................................36.00 [914.0]

POWER ENTRY SIDE......................................................................36.00 [914.0]

(EXCEPT FOR NEC REQUIREMENTS)

UNIT TOP .........................................................................................36.00 [914.0]

SIDE OPPOSITE DUCTS ................................................................36.00 [914.0]

DUCT PANEL ...................................................................................12.00 [304.8] *

FLUE HEAT PANEL

.................................................................36.00 [914.4]

*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 12.00 [304.8] FROM

WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.

REQUIRED CLEARANCE TO COMBUSTIBLE MATL.

in. [mm]

TOP OF UNIT...................................................................................14.00 [355.6]

DUCT SIDE OF UNIT.........................................................................2.00 [50.8]

SIDE OPPOSITE DUCTS ................................................................14.00 [355.6]

BOTTOM OF UNIT .............................................................................0.50 [12.7]

NEC. REQUIRED CLEARANCES.

in. [mm.]

BETWEEN UNITS, POWER ENTRY SIDE ....................................42.00 [1066.8]

UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE ...36.00 [914.0]

UNIT AND BLOCK OR CONCRETE WALLS AND OTHER

GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]

FLUE HOOD

UNIT

583B042060/090

583B048090/115/130

583B060090/115/130

ELECTRICAL

CHARACTERISTICS

208/230-3-60

460-3-60

208/230-3-60

460-3-60

208/230-3-60,

460-3-60

UNIT WEIGHT lb.

kg.

382 173.3

421

468

191.0

212.3

UNIT HEIGHT

IN. (MM)

"A"

38.98 (990.2)

38.98 (990.2)

42.98 (1091.7)

Fig. 7—583B042-060 Unit Dimensions

—6—

C99074

X

23.0 (584.2)

CENTER OF GRAVITY

IN. (MM)

Y

16.3 (412.8)

Z

16.6 (421.6)

21.5 (546.1)

23.5 (596.9)

16.6 (422.1)

16.3 (412.8)

18.0 (457.2)

17.6 (447.0)

DETAIL A

UNIT 583B

SIZE

030

036

042

048

060 lb

MAXIMUM WEIGHT kg

335

343

152

156

404

443

490

183

201

222

in.

22.0

22.0

23.0

21.5

23.5

Fig. 8—Suggested Rigging

A mm

558.5

558.5

584.2

546.1

596.9

in.

15.3

15.3

16.3

16.3

16.3

B mm

388.6

388.6

414.0

414.0

414.3

A05179

If the installation requires draining the condensate water away from the unit, install a 2-in. trap at the condensate connection to ensure proper drainage. See Fig. 9. Make sure that the outlet of the trap is at least 1 in. lower than the drain pan condensate connection to prevent the pan from overflowing. Prime the trap with water.

Connect a drain tube using a minimum of 3/4 -in. PVC or 3/4 -in.

copper pipe (all field-supplied) at the outlet end of the 2-in. trap.

Do not undersize the tube. Pitch the drain tube downward at a slope of at least one in. for every 10 ft of horizontal run. Be sure to check the drain tube for leaks.

1” (25mm) MIN.

TRAP

OUTLET

2” (50mm) MIN.

C99013

Fig. 9—Condensate Trap

VII.

INSTALL FLUE HOOD

The flue hood assembly is shipped screwed to the coil panel in the indoor blower compartment. Remove the service access panel to locate the assembly.

CAUTION: The venting system is designed to ensure proper venting. The flue hood assembly must be installed as indicated in this section of the unit installation instructions.

NOTE: Dedicated low NO x exists.

models MUST be installed in California Air Quality Management Districts where a Low NO x rule

—7—

IN

TEE

OUT

3˝ MIN

NIPPLE

CAP

C99020

Fig. 10—Sediment Trap

These models meet the California maximum oxides of nitrogen

(NO x

) emissions requirements of 40 nanograms/joule or less as shipped from the factory.

NOTE: Low NO x lations.

requirements apply only to natural gas instal-

Install the flue hood as follows:

1. This installation must conform with local building codes and with the National Fuel Gas Code (NFGC), ANSI

Z223.1 (in Canada, CAN/CGA B149.1, and B149.2) or

NFPA (National Fire Protection Association) latest revision. Refer to Provincial and local plumbing or waste water codes and other applicable local codes.

2. Remove flue hood from shipping location (inside the blower compartment). Place vent cap assembly over flue panel. Orient screw holes in vent cap with holes in the flue panel.

3. Secure flue hood to flue panel by inserting a single screw on the right side and the left side of the hood.

VIII.

INSTALL GAS PIPING

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. FPT gas inlet on the manual shutoff or gas valve.

Install a gas supply line that runs to the heating section. Refer to

Table 4 and the NFGC for gas pipe sizing. Do not use cast-iron

pipe. It is recommended that a black iron pipe is used. check the local utility for recommendations concerning existing lines. Size gas supply piping for 0.5 in. wg maximum pressure drop. Never

use pipe smaller than the 1/2-in. FPT gas inlet on the unit gas

valve.

For natural gas applications, the gas pressure at unit gas connection must not be less than 4.0 in. wg or greater than 13 in. wg while the unit is operating. For propane applications, the gas pressure must not be less than 7.0 in. wg or greater than 13 in. wg at the unit connection.

A 1/8-in. NPT plugged tapping accessible for test gauge connection must be installed immediately upstream of the gas supply connection to the gas valve.

When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFGC ANSI Z223.1, NFPA

54 latest edition (in Canada, CAN/CGA B149.1, B149.2 latest edition). 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 in.

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. 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 tape.

4. Install sediment trap in riser leading to heating section per

Fig. 10. This drip leg functions as a trap for dirt and condensate.

5. Install an accessible, external, manual main shutoff valve in gas supply pipe within 6 ft. of heating section.

6. Install ground-joint union close to heating section between unit manual shutoff and external manual main shutoff valve.

7. Pressure-test all gas piping in accordance with local and national plumbing and gas codes before connection of piping to unit.

NOTE: The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig (13.8 WC). If the test pressure is 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.

—8—

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 shall extend a minimum of 2 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 follow this warning could result in an explosion causing serious injury or death

8. Check for gas leaks at the field-installed and factoryinstalled gas lines after all piping connections have been completed. Use soap and water solution (or method specified by local codes and/or regulations).

IX.

INSTALL DUCT CONNECTIONS

The unit has duct flanges on the supply- and return-air openings on the side and bottom of the unit. For downshot applications the ductwork can be connected to the roof curb. See Fig. 6 and 7 for connection sizes and locations.

CONFIGURING UNITS FOR DOWNFLOW (VERTICAL) DIS-

CHARGE

WARNING: Before performing service or maintenance operations on the system, turn off main power to unit.

Electrical shock could cause serious injury or death.

1. Open all electrical disconnects before starting any service work.

2. Remove return duct cover located on duct panel by breaking connecting tabs with screwdriver and a hammer (Fig. 11).

3. To remove supply duct cover, break front and right side connecting tabs with a screwdriver and a hammer. Push louver down to break rear and left side tabs (Fig. 12).

4. If unit ductwork is to be attached to vertical opening flanges on the unit basepan (jackstand applications only), do so at this time. Collect ALL screws that were removed. Do not leave screws on rooftop as permanent damage to the roof may occur.

5. It is recommended that the basepan insulation around the perimeter of the vertical return-air opening be secured to the basepan with aluminum tape. Applicable local codes may require aluminum tape to prevent exposed fiberglass.

6. Cover both horizontal duct openings with the duct covers from the accessory duct cover kit. Ensure opening is air-and watertight.

7. After completing unit conversion, perform all safety checks and power up unit.

NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of nonresidence-type air conditioning and ventilating systems, NFPA

90A or residence-type, NFPA 90B; and/or local codes and residence-type, NFPA 90B; and/or local codes and ordinances.

TABLE 2—PHYSICAL DATA — UNIT 583B — 030040-042090

UNIT SIZE 583B

NOMINAL CAPACITY (ton)

OPERATING WEIGHT (lb)

COMPRESSORS

Quantity

REFRIGERANT (R-410A) Qty (lb)

REFRIGERANT METERING DEVICE

Orifice ID (in.)Check-Flo-Rater® Piston

CONDENSER COIL

Rows...Fins/in.

Face Area (sq ft)

CONDENSER FAN

Nominal CFM

Diameter (in.)

Motor Hp (RPM)

EVAPORATOR COIL

Rows...Fins/in.

Face Area (sq ft)

EVAPORATOR BLOWER

Nominal Airflow (CFM)

Size (in.)

Motor Hp

FURNACE SECTION*

Burner Orifice No.

(Qty...Drill Size) Natural

Burner Orifice No.

(Qty...Drill Size) Propane

HIGH-PRESSURE SWITCH (psig)

Cutout

Reset (Auto.)

LOSS-OF-CHARGE/LOW-PRESSURE

SWITCH (Liquid Line) (psig)

Cutout

Reset (Auto.)

RETURN-AIR FILTERS (in.)Throwaway

030040

2 1/2

313

5.5

.057

1/17

12.7

2350

22

1/8 (825)

3/15

3.7

800

10 x 10

1/4

2...44

2...50

20 x 24x1

030060

2 1/2

313

5.5

.057

1/17

12.7

2350

22

1/8 (825)

3/15

3.7

1000

10 x 10

1/4

2...38

2...46

20 x 24x1

036060

3

321

6.9

.065

2/17

9.1

2350

22

1/8 (825)

3/15

3.7

1200

10 x 10

1/2

2...38

2...46

Scroll

1

610

± 15

420

± 25

20 x 24x1

20

± 5

45

± 10

036090

3

321

6.9

.065

2/17

9.1

2350

22

1/8 (825)

3/15

3.7

1200

10 x 10

1/2

3...38

3...46

20 x 24x1

A.

Adhere to the following criteria when selecting, sizing, and installing the duct system:

1. Units are shipped for side shot installation.

2. Select and size ductwork, supply-air registers, and return-air grilles according to American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) recommendations.

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 tight and airtight seal.

4. All units must have field-supplied filters or accessory filter rack installed in the return-air side of the unit. Recommended sizes for filters are shown in Tables 2 and 3.

5. Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases or performance may be affected.

6. Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through unconditioned space, and use vapor barrier in accordance with latest issue

X.

042060

3 1/2

382

9.0

.070

2/17

12.3

2350

22

1/8 (825)

3/15

4.7

1400

11 x 10

3/4

2...38

2...46

24 x 30x1 of Sheet Metal and Air Conditioning Contractors National

Association (SMACNA) and Air Conditioning Contractors of America (ACCA) minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure.

7. Flash, weatherproof, and vibration-isolate all openings in building structure in accordance with local codes and good building practices.

INSTALL ELECTRICAL CONNECTIONS

042090

3 1/2

382

9.0

.070

2/17

12.3

2350

22

1/8 (825)

3/15

4.7

1400

11 x 10

3/4

3...38

3...46

24 x 30x1

WARNING: The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of serious injury if an electrical fault should occur.

This ground may consist of an electrical wire connected to the unit ground lug in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code) ANSI/

NFPA 70 (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 serious injury or death.

—9—

TABLE 3—PHYSICAL DATA — UNIT 583B — 048090-060130

UNIT SIZE 583B

NOMINAL CAPACITY (ton)

OPERATING WEIGHT (lb)

COMPRESSORS

Quantity

REFRIGERANT (R-410A) Qty (lb)

REFRIGERANT METERING DEVICE

Orifice ID (in.)Check-Flo-Rater® Piston

CONDENSER COIL

Rows...Fins/in.

Face Area (sq ft)

CONDENSER FAN

Nominal Cfm

Diameter (in.)

Motor Hp (Rpm)

EVAPORATOR COIL

Rows...Fins/in.

Face Area (sq ft)

EVAPORATOR BLOWER

Nominal Airflow (Cfm)

Size (in.)

Motor Hp

FURNACE SECTION*

Burner Orifice No.

(Qty...Drill Size) Natural

Burner Orifice No.

(Qty...Drill Size) Propane

HIGH-PRESSURE SWITCH (psig)

Cutout

Reset (Auto.)

LOSS-OF-CHARGE/LOW-PRESSURE

SWITCH (Liquid Line) (psig)

Cutout

Reset (Auto.)

RETURN-AIR FILTERS (in.)Throwaway

048090

4

421

9.5

.073

2/17

12.3

3300

22

1/4 (1100)

4/15

4.7

1600

11 x 10

3/4

3...38

3...46

24 x 30

048115

4

421

9.5

.073

2/17

12.3

3300

22

1/4 (1100)

4/15

4.7

1600

11 x 10

3/4

3...33

3...42

24 x 30

048130

4

421

9.5

.073

2/17

12.3

3300

22

1/4 (1100)

4/15

4.7

1600

11 x 10

3/4

3...31

3...41

24 x 30

Scroll

1

610

± 15

420

± 25

20

± 5

45

± 10

060090

5

468

10.0

.086

2/17

16.4

3300

22

1/4 (1100)

4/15

4.7

1750

11 x 10

1.0

3...38

3...46

24 x 30

060115

5

468

10.0

.086

2/17

16.4

3300

22

1/4 (1100)

4/15

4.7

1750

11 x 10

1.0

3...33

3...42

24 x 30

060130

5

468

10.0

.086

2/17

16.4

3300

22

1/4 (1100)

4/15

4.7

1750

11 x 10

1.0

3...31

3...41

24 x 30

TABLE 4—MAXIMUM GAS FLOW CAPACITY*

NOMINAL IRON PIPE SIZE (IN.) INTERNAL DIAMETER (IN.)

1/2

3/4

1

1-1/4

1-1/2

.622

.824

1.049

1.380

1.610

10 20 30 40

LENGTH OF PIPE, FT†

50 60 70 80 90 100 125 150 175 200

175 120 97 82 73 66 61 57 53 50 44 40 — —

360

680

1400

250

465

950

200

375

770

170 151 138 125 118 110 103 93 84 77 72

320 285 260 240 220 205 195 175 160 145 135

600 580 530 490 460 430 400 360 325 300 280

2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430

*Capacity of pipe in cu. ft. of gas per hr. for gas pressure of 0.5 psig or less. Pressure drop of 0.5-in. wg (based on a 0.60 specific gravity gas). Refer to Table C-4, National

Fire Protection Association NFPA 54

†This length includes an ordinary number of fittings.

—10—

SUPPLY

DUCT

OPENING

RETURN

DUCT

OPENING

Fig. 11—Supply and Return Duct Opening

C99089

The field-supplied disconnect switch box may be mounted on the unit over the high-voltage inlet hole when the standard power and low-voltage entry points are used. See Fig. 6 and 7 for acceptable location.

See unit wiring label and Fig. 14 for reference when making high voltage connections. Proceed as follows to complete the highvoltage connections to the unit.

1. Run the high-voltage (L1, L2, L3) and ground leads into the control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the lines side of the contactor.

4. Connect field L1 to black wire on connection 11 of the compressor contactor.

5. Connect field wire L2 to yellow wire on connection 13 of the compressor contactor.

6. Connect field wire L3 to Blue wire from compressor.

B.

Special Procedures For 208-V Operation

WARNING: Make sure that the gas supply then the power supply to the unit is switched OFF before making any wiring changes. Electrical shock or explosion could cause serious injury or death.

DUCT COVERS REMOVED

C99012

Fig. 12—Vertical Duct Cover Removed

CAUTION: Failure to follow these precautions could result in damage to the unit being installed:

1. Make all electrical connections in accordance with

NEC ANSI/NFPA 70 (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO

NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within operating voltage range indicated on unit rating plate.

4. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.

5. On 3-phase units, ensure phases are balanced within

2%. Consult local power company for correction of improper voltage and/or phase imbalance (refer to

Table 5).

A.

HIGH-VOLTAGE CONNECTIONS

The unit must have a separate electrical service with a fieldsupplied, water-proof, 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. See Table 5 for electrical data.

—11—

With disconnect switch open, move yellow wire from transformer

(3/16 in.) terminal marked 230 to terminal marked 200. This retaps transformer to primary voltage of 208 vac.

C.

CONTROL VOLTAGE CONNECTIONS

NOTE: Do not use any type of power-stealing thermostat. Unit control problems may result.

Use no. 18 American Wire Gage (AWG) color-coded, insulated

(35° C minimum) wires to make the control voltage connections between the thermostat and the unit. If the thermostat is located more than 100 ft from the unit (as measured along the control voltage wires), use no. 16 AWG color-coded, insulated (35° C minimum) wires.

STANDARD CONNECTION — Remove knockout hole located in the flue panel adjacent to the control access panel. See Fig. 6 and 7. Remove the rubber grommet from the installer’s packet

(included with unit) and install grommet in the knockout opening.

Provide a drip loop before running wire through panel.

Run the low-voltage leads from the thermostat, through the inlet hole, and into unit low-voltage splice box.

Locate five 18-gauge wires leaving control box. These low-voltage connection leads can be identified by the colors red, green, yellow, brown, and white. (See Fig. 14.) Ensure the leads are long enough to be routed into the low-voltage splice box (located below right side of control box). Stripped yellow wire is located in connection box. Route leads through hole in bottom of control box and make low-voltage connections as shown in Fig. 14. Secure all cut wires, so that they do not interfere with operation of unit.

HEAT ANTICIPATOR SETTING — The room thermostat heat anticipator must be properly adjusted to ensure proper heating performance. Set the heat anticipator, using an ammeter between the W and R terminals to determine the exact required setting.

NOTE: For thermostat selection purposes, use 0.18 amp for the approximate required setting.

Failure to make a proper heat anticipator adjustment will 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.

UNIT

SIZE 583B

030

036

042

048

060

V-PH-HZ

VOLTAGE

RANGE

Min Max

208/230-3-60 187 253

208/230-3-60 187

460-3-60 414

208/230-3-60 187

460-3-60 414

253

506

253

506

208/230-3-60 187

460-3-60 414

208/230-3-60 187

460-3-60 414

253

506

253

506

TABLE 5—ELECTRICAL DATA — 583B

COMPRESSOR

RLA

9.6

12.2

5.1

13.5

6.3

14.7

6.5

18.1

9.0

LRA

63.0

77.0

35.0

77.0

39.0

91.0

46.0

137.0

62.0

OUTDOOR FAN MOTOR INDOOR FAN MOTOR

FLA

0.8

0.8

0.8

1.6

0.9

1.6

0.9

1.6

0.9

FLA

2.1

3.6

1.9

4.1

2.0

4.1

2.0

6.2

3.2

POWER SUPPLY

MCA

14.9

19.7

9.1

22.6

10.8

24.1

11.0

30.4

15.4

MOCP*

20

30

15

35

15

35

15

45

20

LEGEND

FLA

LRA

— Full Load Amps

— Locked Rotor Amps

MCA — Minimum Circuit Amps

MOCP — Maximum Overcurrent Protection

RLA — Rated Load Amps

CKT BKR — Circuit Breaker

®

NOTES:

1. In compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NEC

Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse . Canadian units may be fuse or circuit breaker.

2. Minimum wire size is based on 60 C copper wire. If other than

60 C wire is used, or if length exceeds wire length in table, determine size from NEC.

3. 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.

% Voltage imbalance

= 100 x max voltage deviation from average voltage average voltage

EXAMPLE: Supply voltage is 460-3-60.

AB = 452 v

BC = 464 v

AC = 455 v

Average Voltage =

452 + 464 + 455

3

=

1371

3

= 457

Determine maximum deviation from average voltage.

(AB) 457

(BC) 464

452 = 5 v

457 = 7 v

(AC) 457 455 = 2 v

Maximum deviation is 7 v.

Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x

7

457

= 1.53%

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

C99024

Fig. 13—Electrical Data Legend

HIGH VOLTAGE

POWER LEADS

(SEE UNIT WIRING

LABEL)

POWER

SUPPLY

FIELD-SUPPLIED

FUSED DISCONNECT

GND

CONTROL BOX

LOW-VOLTAGE

POWER LEADS

(SEE UNIT

WIRING LABEL)

WHT(W1)

YEL(Y)

GRN(G)

RED(R)

BRN(C)

THERMOSTAT

(TYPICAL)

SPLICE BOX

Fig. 14—High- and Control-Voltage Connections

—12—

G

R

W

Y

C

C99018

TRANSFORMER PROTECTION — The transformer is of the energy-limiting type. It is set to withstand a 30-second overload or shorted secondary condition.

PRE-START-UP

WARNING: Failure to observe the following warnings could result in serious injury or death:

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 are disconnected.

4. Relieve and recover all refrigerant from both high- and low-pressure sides of system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals.

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. Relieve and reclaim all refrigerant from system using both high- and low-pressure ports.

c. Cut component connecting tubing with tubing cutter and remove component from unit.

d. Carefully unsweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame.

Proceed as follows to inspect and prepare the unit for initial startup:

1. Remove access panel.

2. Read and follow instructions on all DANGER, WARNING,

CAUTION, and INFORMATION labels attached to, or shipped with, unit.

3. Make the following inspections: a. Inspect for shipping and handling damages such as broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and on unit base. Detecting oil generally indicates a refrigerant leak. Leak test all refrigerant tubing connections using electronic leak detector, halide torch, or liquidsoap solution. If a refrigerant leak is detected, see Check for Refrigerant Leaks section of this manual.

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:

WARNING: 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 follow this warning could result in an explosion causing serious injury or death.

a. Before lighting the unit for the first time, perform the following with the gas valve in the "OFF" position: If the gas supply pipe was not purged before connecting the unit, it will be full of air. It is recommended that the

—13— 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, re-tighten the union. Allow 5 minutes to elapse, then light unit.

b. Make sure that condenser-fan blade is correctly positioned in fan orifice. Leading edge of condenser-fan blade should be 1/2 in. maximum from fan orifice (see

Fig. 15).

c. Ensure fan hub is 1/8 in. max from motor housing.

d. Make sure that air filter(s) is in place.

e. Make sure that condensate drain trap is filled with water to ensure proper drainage.

f. Make sure that all tools and miscellaneous loose parts have been removed.

MOTOR

FAN GRILLE

1/8" MAX BETWEEN

MOTOR AND FAN HUB

MOTOR SHAFT

1/2˝

C99009

Fig. 15—Fan Blade Clearance

START-UP

Use the Start-Up Checklist supplied at the end of this book, and proceed as follows:

A.

CHECK FOR REFRIGERANT LEAKS

Proceed as follows to locate and repair refrigerant leaks and charge the unit:

1. Locate leak and make sure that refrigerant system pressure has been relieved and refrigerant recovered from both highand low-pressure ports.

2. Repair leak following accepted practices.

NOTE: Replace filter drier whenever the system has been opened for repair.

3. Check system for leaks using an approved method.

4. Evacuate refrigerant system and reclaim refrigerant if no additional leaks are found.

5. Charge unit with R-410a refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit rating

plate for required charge.

B.

Start Up Heating Section and Make Adjustments

IMPORTANT: Complete the required procedures given in the

Pre-Start-Up section above before starting the unit.

Do not jumper any safety devices when operating the unit.

Make sure that burner orifices are properly aligned. Unstable operation may occur when the burner orifices in the manifold are misaligned.

NOTE: Make sure that gas supply has been purged, and that all gas piping has been checked for leaks.

CHECK HEATING CONTROL — Start and check the unit for proper heating control operation as follows. (see furnace lighting instructions located inside burner or blower access panel.):

1. Place room thermostat SYSTEM switch in the HEAT position and the FAN switch in the AUTO position.

2. Set the heating temperature control of the thermostat above room temperature.

TABLE 6—HEATING INPUTS

HEATING

INPUT

(BTUH)*

40,000

60,000

90,000

115,000

130,000

NUMBER

OF

ORIFICES

3

3

3

2

2

Min

4.0

4.0

4.0

4.0

4.0

GAS SUPPLY PRESSURE

(IN. WG)

Natural

Propane†

Max

13.0

Min

7.0

Max

13.0

13.0

13.0

13.0

13.0

7.0

7.0

7.0

7.0

13.0

13.0

13.0

13.0

MANIFOLD PRESSURE

(IN. WG)

Natural

3.5

3.5

3.5

3.5

3.5

Propane†

3.5

3.5

3.5

3.5

3.5

*When a unit is converted to propane, different size orifices must be used. See separate natural-to-propane conversion kit instructions.

†Based on altitudes from sea level to 2000 ft. above sea level. For altitudes above 2000 ft., reduce input rating 4% for each 1000 ft. above sea level. In Canada, from 2000 ft. above sea level to 4500 ft. above sea level, derate the unit 10%.

3. The induced-draft motor will start.

4. After a call for heating, the main burner should light within

5 seconds. If the burners do not light, there is a 22-second delay before another 5-second try. If the burners still do not light, this sequence is repeated. If the burners do not light within 15 minutes from the initial call for heat, there is a lockout. To reset the control, break the 24-v power to W.

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 6. (Consult the local gas supplier if the heating value of gas is not known.)

EXAMPLE: Assume that the size of test dial is 1 cu. ft., one revolution takes 32 seconds, and the heating value of the gas is

1050 Btu/ft

3

.

Proceed as follows:

5. The evaporator fan will turn on 45 seconds after the flame has been established. The evaporator fan will turn off 45 seconds after the thermostat has been satisfied.

CHECK GAS INPUT—Check gas input and manifold pressure after unit start-up (see Table 6.) If adjustment is required, proceed as follows:

1. 32 seconds to complete one revolution.

2. 3600

÷ 32 = 112.5

3. 112.5 x 1 = 112.5 ft

3 of gas flow/hr.

4. 112.5 x 1050 = 118,125 Btuh input.

If the desired gas input is 115,000 Btuh, only a minor change in the manifold pressure is required.

The rated gas inputs shown in Table 6 are for altitudes from sea level to 2000 ft. above sea level. These inputs are based on natural gas with a heating value of 1050 Btu/ft

3 at 0.65 specific gravity, or propane gas with a heating value of 2500 Btu/ft

3 at 1.5 specific gravity. For elevations above 2000 ft., reduce input 4% for each

1000 ft. above sea level. When the gas supply being used has a different heating value, or specific gravity, refer to national and local codes, or contact your distributor to determine the required orifice size.

CAUTION: These units are designed to consume the rated gas inputs using the fixed orifices at specified manifold pressures as shown in Table 6. DO NOT

REDRILL THE ORIFICES UNDER ANY CIRCUM-

STANCES.

ADJUST 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.

MEASURE GAS FLOW (Natural Gas Units)—Minor adjustment to the gas flow can be made by changing the manifold pressure.

The manifold pressure must be maintained between 3.4 and 3.6 in.

wg. If larger adjustments are required, change main burner orifices following the recommendations of national 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 manifold (see Fig. 16) then connect manometer at this point. turn on gas to unit.

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 on one hour).

5. Multiply result of Step 4 by the number of cu. ft. shown for one revolution of test dial to obtain cu. ft. of gas flow per hour.

—14—

MANIFOLD PIPE PLUG

C99019

Fig. 16—Burner Assembly

Observe manifold pressure and proceed as follows to adjust gas input:

1. Remove cover screw over regulator adjustment screw on gas valve.

2. Turn regulator adjustment screw clockwise to increase gas input, or turn regulator adjustment screw counterclockwise to decrease input. Manifold pressure must be between 3.4

and 3.6 in. wg.

WARNING: Unsafe operation of the unit may result if manifold pressure is outside this range. Serious injury or unit damage may result.

3. Replace cover screw cap on gas valve.

4. Turn off gas supply to unit. Remove manometer from pressure tap and replace pipe plug on gas valve. Turn on gas to unit and check for leaks.

TABLE 7—AIR DELIVERY (CFM) AT INDICATED TEMPERATURE RISE AND RATED HEATING INPUT

HEATING

INPUT

(BTUH)

INPUT

40,000

60,000

90,000

115,000

130,000

20

1500

2250

—

—

—

25

1200

1800

2700

—

—

30

1000

1500

2250

—

—

35

857

1286

1929

2464

—

TEMPERATURE RISE °F

40

750

1125

1688

2156

2438

NOTE: Dashed areas do not fall within the approved temperature rise range of the unit.

45

667

1000

1500

1917

2167

50

600

900

1350

1725

1950

55

—

818

1227

1568

1773

60

—

750

1125

1438

1625

65

—

692

1038

1327

1500

MEASURE MANIFOLD PRESSURE (Propane Units)—The main burner orifices on a propane unit are sized for the unit rated input when the manifold pressure reading matches the level specified in Table 6.

WARNING: If converting to propane gas, remove the burner assembly and inspect the heat exchanger tubes. If there are V-shaped NOx baffles installed in the firing tubes, THEY MUST BE REMOVED.

Discard the baffles after removal.

Refer to Maintenance section for information on burner removal.

Proceed as follows to adjust gas input on a propane gas unit:

1. Turn off gas to unit.

2. Remove pipe plug on manifold (see Fig. 16) then connect manometer at this point.

3. Turn on gas to unit.

4. Remove cover screw over regulator adjustment screw on gas valve.

5. Adjust regulator adjustment screw to the correct manifold pressure, as specified in Table 6. Turn adjusting screw clockwise to increase manifold pressure, or turn adjusting screw counterclockwise to decrease manifold pressure.

6. Replace cover screw.

7. Turn off gas to unit. Remove manometer from pressure tap.

Replace pipe plug on gas valve, then turn on gas to unit.

check for leaks.

CHECK BURNER FLAME—With burner access panel removed, observe the unit heating operation. Watch the burner flames to see if they are light blue and soft in appearance, and that the flames are approximately the same for each burner. Propane will have blue flame with yellow tips. (See Fig. 17). Refer to Maintenance section for information on burner removal.

BURNER FLAME

BURNER

Fig. 17—Monoport Burners

MANIFOLD

C99021

AIRFLOW AND TEMPERATURE RISE—The heating section for each size unit is designed and approved for heating operation within the temperature rise range stamped on the unit rating plate.

Table 7 shows the approved temperature rise range for each heating input, and the air delivery cfm at various temperature rises.

The heating operation airflow must produce a temperature rise that falls within the approved range.

Refer to Indoor Airflow and Airflow Adjustments section on the following pages to adjust heating airflow when required.

HEATING SEQUENCE OF OPERATION—See Fig. 18-19 and unit wiring label.

On a call for heating, terminal "W" of the thermostat is energized, starting the induced-draft motor. When the hall-effect sensor on the induced-draft motor senses that it has reached the required speed, the burner sequence begins. This function is performed by the integrated gas control (IGC). The evaporator fan motor is energized 45 seconds after flame is established. When the thermostat is satisfied and "W" is de-energized, the burners stop firing and the evaporator fan motor shuts off after a 45-second time-off delay.

An LED (light-emitting diode) indicator is provided on the control board to monitor operation. The control board is located by removing the burner access panel. During normal operation, the

LED is continuously on. See Table 8 for error codes.

TABLE 8—LED INDICATIONS

70

—

—

964

—

1393

ERROR CODE

Normal Operation

Hardware Failure

Fan On/Off Delay Modified

Limit Switch Fault

Flame Sense Fault

Four Consecutive Limit Switch Faults

Ignition Lockout Fault

Induced-Draft Motor Fault

Rollout Switch Fault

Internal Control Fault

Internal Software Fault

LED INDICATION

On

Off

1 Flash

2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

7 Flashes

8 Flashes

9 Flashes

NOTES:

1.There is a 3-second pause between error code displays.

2. If more than one error code exists, all applicable error codes will be displayed in numerical sequence.

3. This chart is on the wiring diagram located inside the burner access panel.

LIMIT SWITCHES—Normally closed limit switch (LS) completes the control circuit through the thermostat R circuit. Should the leaving-air temperature rise above the maximum allowable temperature, the limit switch opens and the R control circuit

"breaks". Any interruption in the R control circuit instantly closes the gas valve and stops gas flow to the burners and pilot. The blower motor continues to run until LS resets.

When the air temperature at the limit switch drops to the low-temperature setting of the limit switch, the switch closes and completes the R control circuit. The electric spark ignition system cycles and the unit returns to normal heating operation. When this fault occurs, the IGC LED will display FAULT CODE 2.

—15—

AUXILIARY LIMIT SWITCH (ROLLOUT)—The function of the switch is to close the main gas valve in the event of flame rollout. The switch is located above the main burners. When the temperature at the auxiliary switch reaches the maximum allowable temperature, the R control circuit trips, closing the gas valve and stopping gas flow to the burners. The indoor (evaporator) fan motor (IFM) and induced draft motor continue to run until switch is reset. The IGC LED will display FAULT CODE 7.

C.

Start-Up Cooling Section and Make Adjustments

CAUTION: Complete the required procedures given in the Pre-Start-Up section on previous pages 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 40° F (unless accessory low-ambient kit is installed).

Do not rapid-cycle the compressor. Allow 5 minutes between "on" cycles to prevent compressor damage.

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, and evaporator blower motors start. Observe that cooling cycle shuts down when control setting is satisfied. The evaporator fan will continue to run for 30 seconds.

3. When using an auto-changeover 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).

IMPORTANT: Three-phase,

scroll

compressor units are direction-oriented. These units must be checked to ensure proper compressor 3-phase power lead orientation. If not corrected within

5 minutes, the internal protector will shut off the compressor. The

3-phase power leads to the unit must be reversed to correct rotation. When turning backwards, scroll compressors emit elevated noise levels, and the difference between compressor suction and discharge pressures may be dramatically lower than normal.

CHECKING AND ADJUSTING REFRIGERANT

CHARGE—The refrigerant system is fully charged with R-410A

(Puron) refrigerant, and is tested and factory sealed.

NOTE: Adjustment of the refrigerant charge is not required

unless the unit is suspected of not having the proper R-410A charge. The charging label and the tables shown refer to system temperatures and pressures.

A refrigerant charging chart label is attached to the outside of the compressor access door. The chart includes the required suction line temperature at given suction line pressures and outdoor ambients..

An accurate superheat, thermocouple- or thermistor-type thermometer, and a gauge manifold are required when using the superheat charging method for evaluating the unit charge. Do not

use mercury or small dial-type thermometers because they are not adequate for this type of measurement.

—16—

IMPORTANT: When evaluating the refrigerant charge, an indicated adjustment to the specified factory charge must always be very minimal. If a substantial adjustment is indicated, an abnormal condition exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils.

REFRIGERANT CHARGE—The amount of refrigerant charge is listed on the unit nameplate. Refer to Bryant Refrigeration Service

Techniques Manual, Refrigerants section.

Unit panels must be in place when unit is operating during charging procedures.

NO CHARGE: Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant (refer to system data plate).

LOW CHARGE COOLING: Measure outdoor ambient using

Cooling Charging Charts (Figs. 20-24). Vary refrigerant until the conditions of the chart are met. Note that charging charts are different from type normally used. Charts are based on charging the units to correct superheat for the various operating conditions.

Accurate pressure gauge and temperature sensing devices are required. Connect the pressure gauge to the service port on the suction line. Mount the temperature sensing device on the suction line and insulate it so that the outdoor ambient does not effect the reading. Indoor air CFM must be within the normal operating range of the unit.

TO USE COOLING CHARGING CHARTS: Take the outdoor ambient temperature and read the suction pressure gauge. Refer to the chart to determine what the suction temperature should be.

NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to Check for Refrigerant Leaks section in this document.

D.

Indoor Airflow and Airflow Adjustments

CAUTION: For cooling operation, the recommended airflow is 350 to 450 cfm for each 12,000 Btuh of rated cooling capacity. For heating operation, the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate.

Table 7 shows the temperature rise at various air-flow rates. Table

9 shows both heating and cooling airflows at various external static pressures. Refer to these tables to determine the airflow for the system being installed.

NOTE: Be sure that all supply- and return-air grilles are open, free from obstructions, and adjusted properly.

WARNING: Shut off gas supply then disconnect electrical power to the unit before changing blower speed.

Electrical shock or explosion could cause serious injury or death.

Airflow can be changed by changing the lead connections of the blower motor.

All 583B units are factory wired for low speed and may need to be wired for medium or high speed in the field.

For 208/230-v — The motor leads are color-coded as follows:

3-SPEED

black = high speed blue = medium speed

2-SPEED

black = high speed

--red = low speed red = low speed

To change the speed of the blower motor (BM), remove the fan motor speed leg lead from the blower relay (BR). This wire is attached to terminal BM for single-phase and 3-phase units. To change the speed, remove and replace with lead for desired blower motor speed. Insulate the removed lead to avoid contact with

chassis parts.

—17—

—18—

For 460-v GE Motors — The motor leads are color coded as follows:

3-SPEED

black = high speed violet = jumper orange = medium speed red = low speed

2-SPEED

black = high speed blue = jumper

--red = low speed

To change the speed of the blower motor (BM), remove fan motor speed lead from the blower relay (BR) and replace with the lead for the desired blower motor speed. The motor speed lead is attached to terminal BM. For low and medium speeds black must be connected to the jumper wire. Insulate removed lead end to

avoid contact with chassis parts. To select high speed on 460-v GE motors, separate the black female quick connect (QC) from the jumper lead male quick connect (QC) and connect the black lead to the BR. Insulate the jumper to avoid contact with any chassis

parts.

COOLING SEQUENCE OF OPERATION — With the room thermostat SYSTEM switch in the COOL position and the FAN switch in the AUTO. position, the cooling sequence of operation is as follows:

When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat, the thermostat completes the circuit between thermostat terminal R to terminals Y and G. These completed circuits through the thermostat connect contactor coil (C) (through unit wire Y) and blower relay coil (BR)

(through unit wire G) across the 24-v secondary of transformer

(TRAN).

The normally open contacts of energized contactor (C) close and complete the circuit through compressor motor (COMP) to condenser (outdoor) fan motor (OFM). Both motors start instantly.

The set of normally open contacts of energized relay BR close and complete the circuit through evaporator blower (indoor) fan motor

(IFM).

NOTE: Once the compressor has started and then has stopped, it should not be started again until 5 minutes have elapsed.

The cooling cycle remains ‘‘on’’ until the room temperature drops to a point that is slightly below the cooling control setting of the room thermostat. At this point, the thermostat ‘‘breaks’’ the circuit between thermostat terminal R to terminals Y and G. These open circuits de-energize contactor coil C and relay coil BR. The condenser and compressor motors stop. After a 30-second delay, the blower motor stops. The unit is in a ‘‘standby’’ condition, waiting for the next ‘‘call for cooling’’ from the room thermostat.

MAINTENANCE

To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This combination heating/cooling unit should be inspected at least once each year by a qualified service person. To troubleshoot heating or cooling of units, refer to tables at the back of the book.

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 IN-

JURY AND POSSIBLE DAMAGE TO THIS EQUIP-

MENT.

WARNING: Failure to follow these warnings could result in serious injury or death:

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, serious 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.

—19—

CAUTION: Errors made when reconnecting wires may cause improper and dangerous operation. Label all wires prior to disconnection when servicing.

The minimum maintenance requirements for this equipment are as follows:

1. Inspect air filter(s) each month. Clean or replace when necessary.

2. Inspect indoor coil, drain pan, and condensate drain each cooling season for cleanliness. Clean when necessary.

3. Inspect blower motor and wheel for cleanliness and check lubrication each heating and cooling season. Clean when necessary. For first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency.

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 flue hood and remove any obstructions if necessary.

A.

Air Filter

IMPORTANT: Never operate the unit without a suitable air filter in the return-air duct system. Always replace the filter with the same dimensional size and type as originally installed. See Tables

2 and 3 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 or whenever the filter(s) becomes clogged with dust and lint.

B.

Evaporator Blower and Motor

NOTE: All motors are pre-lubricated. Do not attempt to lubricate these motors.

For longer life, operating economy, and continuing efficiency, clean accumulated dirt and grease from the blower wheel and motor annually.

WARNING: Turn off the gas supply, then disconnect and tag electrical power to the unit before cleaning the blower motor and wheel. Failure to adhere to this warning could cause serious injury or death.

To clean the blower motor and wheel:

1. Remove and disassemble blower assembly as follows: a. Remove unit access panel.

b. Disconnect motor lead from blower relay (BR). Disconnect yellow lead from terminal L2 of the contactor.

1241

1172

180

170

1103 160

1034 150

965

896

140

130

827

758

120

110

690 100

20.0

-7

1241

1172

180

170

1103 160

1034 150

965

896

140

130

827

758

120

110

690 100

20.0

-7

(030) 60 Hz CHARGING CHART

FOR USE WITH UNITS USING R410A REFRIGERANT

30.0

-1

40.0

50.0

60.0

SUCTION LINE TEMPERATURE (DEG. F)

4 10 16

SUCTION LINE TEMPERATURE (DEG. C)

70.0

21

80.0

27

OUTDOOR

TEMP

F C

125 52

115 46

105 41

95 35

85 29

75 24

65 18

55 13

45 7

Fig. 20—Cooling Charging Chart, 583B030 Units

C99080

(036) 60 Hz CHARGING CHART

FOR USE WITH UNITS USING R410A REFRIGERANT

30.0

-1

40.0

50.0

60.0

SUCTION LINE TEMPERATURE (DEG. F)

4 10 16

SUCTION LINE TEMPERATURE (DEG. C)

70.0

21

80.0

27

OUTDOOR

TEMP

F C

125 52

115 46

105 41

95 35

85 29

75 24

65 18

55 13

45 7

Fig. 21—Cooling Charging Chart, 583B036 Units

C99081

1241

1172

1103

180

170

160

1034 150

965

896

140

130

827

758

120

110

690 100

20.0

-7

(042) 60 Hz CHARGING CHART

FOR USE WITH UNITS USING R410A REFRIGERANT

OUTDOOR

TEMP

F C

125 52

115 46

105 41

95 35

85 29

75 24

65 18

55 13

45 7

30.0

-1

40.0

50.0

60.0

SUCTION LINE TEMPERATURE (DEG. F)

4 10 16

SUCTION LINE TEMPERATURE (DEG. C)

70.0

21

80.0

27

Fig. 22—Cooling Charging Chart, 583B042 Units

C99082

1241

1172

180

170

1103 160

1034 150

965 140

896

827

130

120

758 110

690 100

20.0

-7

(048) 60 Hz CHARGING CHART

FOR USE WITH UNITS USING R410A REFRIGERANT

OUTDOOR

TEMP

F C

125 52

115 46

105 41

95 35

85 29

75 24

65 18

55 13

45 7

30.0

-1

40.0

50.0

60.0

SUCTION LINE TEMPERATURE (DEG. F)

4 10 16

SUCTION LINE TEMPERATURE (DEG. C)

70.0

21

80.0

27

Fig. 23—Cooling Charging Chart, 583B048 Units

C99083

1241

1172

1103

180

170

160

1034 150

965

896

140

130

827

758

120

110

690 100

20.0

-7

(060) 60 Hz CHARGING CHART

FOR USE WITH UNITS USING R410A REFRIGERANT

30.0

-1

40.0

50.0

60.0

SUCTION LINE TEMPERATURE (DEG. F)

4 10 16

SUCTION LINE TEMPERATURE (DEG. C)

70.0

21

80.0

27

OUTDOOR

TEMP

F C

125 52

115 46

105 41

95 35

85 29

75 24

65 18

55 13

45 7

Fig. 24—Cooling Charging Chart, 583B060 Units

A99084

—20—

TABLE 9—WET COIL AIR DELIVERY* — HORIZONTAL AND DOWNFLOW DISCHARGE

UNIT 583B030-060

(DEDUCT 10% FOR 208 VOLTS)

Unit

583B

030

036

042

048

060

Low

Motor

Speed

Medium

High

Low

Medium

High

Low

Medium

High

Low

Medium

High

Low

Medium

High

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

Watts

Cfm

0.0

243

885

353

1195

–

–

490

1431

–

–

–

–

634

1669

–

–

–

–

591

1554

755

1834

–

–

589

1946

750

2189

–

–

0.1

244

842

339

1134

–

–

463

1398

513

1491

–

–

618

1599

–

–

–

–

578

1523

737

1802

–

–

576

1891

733

2097

879

2337

1496

719

1758

–

–

569

1545

–

–

–

–

573

0.2

242

786

333

1070

–

230 AND 460 VOLT

0.3

–

–

330

997

443

External Static Pressure (in. wg)

0.4

0.5

0.6

–

–

326

911

436

–

–

320

818

426

–

–

–

–

416

–

446

1347

501

1230

432

1281

488

1145

418

1205

474

1061

403

1118

459

977

389

1024

443

–

406

888

378

0.7

–

–

–

1426

645

1484

608

1351

636

1410

598

1267

627

1330

583

1175

616

1243

562

1077

605

1147

534

921

428

976

593

1044

502

1836

715

2021

850

2159

1498

733

1746

–

–

568

1467

699

1706

890

1943

566

1779

695

1952

821

2050

1448

704

1688

–

–

559

1432

678

1648

858

1870

559

1718

673

1883

795

1974

1391

672

1630

–

–

544

1387

653

1585

828

1793

541

1651

648

1809

772

1905

1326

638

1566

797

1727

524

1332

627

1520

801

1711

499

1577

623

1727

750

1824

–

598

1635

728

1722

1269

602

1455

777

1624

–

1257

604

1492

773

1632

500

*Air delivery values are without air filter.

Note: Deduct field-supplied air filter pressure drop to obtain external static pressure available for ducting.

1189

574

1399

751

1537

–

–

–

–

583

936

473

–

397

786

–

0.8

–

–

–

–

579

1392

756

1531

–

–

577

1530

701

1597

1132

550

1279

727

1423

–

–

–

–

–

–

454

–

–

–

–

0.9

–

–

–

–

–

–

–

–

–

562

1332

734

1433

–

1101

536

1120

696

1308

–

–

–

–

–

–

457

–

–

–

–

1.0

–

–

–

–

–

–

–

–

–

556

1276

709

1329

– c. On all units, remove blower assembly from unit. Remove screws securing blower to blower partition and slide assembly out. Be careful not to tear insulation in blower compartment.

d. Ensure proper reassembly by marking blower wheel and motor in relation to blower housing before disassembly.

e. Loosen setscrew(s) that secures wheel to motor shaft, remove screws that secure motor mount brackets to housing, and slide motor and motor mount out of housing.

2. Remove and clean blower wheel as follows: a. Ensure proper reassembly by marking wheel orientation.

b. Lift wheel from housing. When handling and/or cleaning blower wheel, be sure not to disturb balance weights

(clips) on blower wheel vanes.

c. Remove caked-on dirt from wheel and housing with a brush. Remove lint and/or dirt accumulations from wheel and housing with vacuum cleaner, using soft brush attachment. Remove grease and oil with mild solvent.

d. Reassemble wheel into housing.

e. Reassemble motor into housing. Be sure setscrew(s) are tightened on motor shaft flats and not on round part of shaft.

f. Reinstall unit access panel.

—21—

3. Restore electrical power, then gas supply to unit. Start unit and check for proper blower rotation and motor speeds during heating and cooling cycles.

INDUCED DRAFT MOTOR MOUNT

FLUE

COLLECTOR

BOX

BLOWER

HOUSING

BURNER

RACK

MOUNTING

SCREW

ROLLOUT

SWITCH

C99022

Fig. 25—Blower Housing and Flue Collector Box

C.

Flue Gas Passageways

To inspect the flue collector box and upper areas of the heat exchanger:

BLOWER

HOUSING

2 SETSCREWS

(HIDDEN)

Fig. 26—Removal of Motor and Blower Wheel

C99085

5. To remove motor and cooling fan assembly, remove 4 screws that hold blower housing to mounting plate.

6. To reinstall, reverse the procedure outlined above.

E.

Limit Switch

Remove unit access panel. Limit switch is located on the blower partition.

F.

Burner Ignition

Unit is equipped with a direct spark ignition 100% lockout system.

Ignition module is located in the control box. Module contains a self-diagnostic LED. During servicing, refer to label diagram for

LED interpretations.

If lockout occurs, unit may be reset by either momentarily interrupting power supply to unit, or turning selector switch to

OFF position at the thermostat.

G.

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.

CAUTION: When servicing gas train, do not hit or plug orifice spuds.

C99090

Fig. 27—Unit Access Panel

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 collector box cover (see Fig. 25).

3. Remove the 12 screws holding the flue collector box cover

(Fig. 25) to the heat exchanger assembly. Inspect the heat exchangers.

4. Clean all surfaces as required, using the wire brush.

D.

Combustion-Air Blower

Clean periodically to assure proper airflow and heating efficiency.

Inspect blower wheel every fall and periodically during heating season. For the first heating season, inspect blower wheel bimonthly to determine proper cleaning frequency.

To inspect blower wheel, remove draft hood assembly. Shine a flashlight into opening to inspect wheel. If cleaning is required, remove motor and wheel as follows:

1. Remove unit access panel (See Fig. 24).

2. Remove the 7 screws that attach induced-draft motor mounting plate to blower housing (See Fig. 25).

3. Slide the motor and blower wheel assembly out of the blower housing (See Fig. 26). Clean the blower wheel. If additional cleaning is required, continue with Steps 4 and 5.

4. To remove blower, remove 2 setscrews (See Fig. 26).

—22—

REMOVAL OF GAS TRAIN

1. Shut off manual gas valve.

2. Shut off power to unit.

3. Remove unit access panel (See Fig. 27).

4. Disconnect gas piping at unit gas valve.

5. Remove wires connected to gas valve. Mark each wire.

6. Remove ignitor and sensor wires at the ignitor module.

7. Remove the mounting screw that attaches the burner rack to the basepan (See Fig. 25).

8. Slide the burner rack out of the unit (See Figs. 25 and 28).

9. To reinstall, reverse the procedure outlined above.

H.

Condenser Coil, Evaporator Coil, and Condensate

Drain Pan

Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year.

The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season. Remove all obstructions, including weeds and shrubs, that interfere with the airflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint, clean the coils with a vacuum cleaner, using the soft brush attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a mild detergent-and-water solution.

Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors, insulation, wiring, or air filter(s). For best results, spray condenser coil fins from inside to outside the unit.

On units with an outer and inner condenser coil, be sure to clean between the coils. Be sure to flush all dirt and debris from the unit base.

Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain tube with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain tube is restricted, clear it with a

‘‘plumbers snake’’ or similar probe device. Ensure that the auxiliary drain port above the drain tube is also clear.

C99086

Fig. 28—Burner Rack Removed

I.

Condenser Fan

CAUTION: Keep the condenser fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the unit. Damage to unit may result.

1. Remove 6 screws holding condenser grille and motor to top cover.

2. Turn motor/grille assembly upside down on top cover to expose the fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen the setscrew and slide the fan off the motor shaft.

5. When replacing fan blade, position blade so that the hub is

1/8 in. away from the motor end (1/8 in. of motor shaft will be visible).

6. Ensure that setscrew engages the flat area on the motor shaft when tightening.

7. Replace grille.

J.

Electrical Controls and Wiring

Inspect and check the electrical controls and wiring annually. Be

sure to turn off the gas supply, and then the electrical power to the unit.

Remove access panel to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smokey or burned connections are noticed, disassemble the connection, clean all the parts, restrip the wire end and reassemble the connection properly and securely.

After inspecting the electrical controls and wiring, replace the access panel. Start the unit, and observe at least one complete heating cycle and one complete cooling cycle to ensure proper operation. If discrepancies are observed in either or both operating cycles, or if a suspected malfunction has occurred, check each electrical component with the proper electrical instrumentation.

Refer to the unit wiring label when making these checkouts.

NOTE: Refer to the heating and/or cooling sequence of operation in this publication as an aid in determining proper control operation.

—23—

K.

Refrigerant Circuit

Inspect all refrigerant tubing connections and the unit base for oil accumulations annually. Detecting oil generally indicates a refrigerant leak.

If oil is detected or if low cooling performance is suspected, leak-test all refrigerant tubing using an electronic leak-detector, halide torch, or liquid-soap solution. If a refrigerant leak is detected, refer to Check for Refrigerant Leaks section on page 13.

If no refrigerant leaks are found and low cooling performance is suspected, refer to Checking and Adjusting Refrigerant Charge section in this document.

L.

Evaporator Airflow

The heating and/or cooling air-flow does not require checking unless improper performance is suspected. If a problem exists, be

sure that all supply- and return-air grilles are open and free from

obstructions, and that the air filter is clean. When necessary, refer to Indoor Airflow and Airflow Adjustments section in this document to check the system airflow.

M.

Metering Device–Check-Flo-Rater® Piston

This metering device is a fixed orifice and is contained in the brass hex-body in the liquid line.

N.

Pressure Switches

Pressure switches are protective devices wired into control circuit

(low voltage). They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit. These pressure switches are specifically designed to operate with Puron (R-410A) systems. R-22 pressure switches must not be used as replacements for the Puron (R-410A) air conditioner.

LOSS OF CHARGE/LOW-PRESSURE SWITCH (air conditioner only)

This switch is located on the liquid line and protects against low suction pressures caused by such events as loss of charge, low airflow across indoor coil, dirty filters, etc. It opens on a pressure drop at about 20 psig. If system pressure is above this, switch should be closed.

To check switch:

1. Turn off gas and then all power to unit.

2. Disconnect leads on switch.

3. Apply ohmmeter leads across switch. You should have continuity on a good switch.

NOTE: Because these switches are attached to refrigeration system under pressure, it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists. If switch must be removed, remove and recover all system charge so that pressure gauges read 0 psi. Never open system without breaking vacuum with dry nitrogen.

HIGH-PRESSURE SWITCH—The high-pressure switch is located in the discharge line and protects against excessive condenser coil pressure. It opens at 610 psig.

High pressure may be caused by a dirty condenser coil, failed fan motor, or condenser air recirculation.

To check switch:

1. Turn off gas and then all power to unit.

2. Disconnect leads on switch.

3. Apply ohmmeter leads across switch. You should have continuity on a good switch.

O.

Copeland Scroll Compressor (Puron Refrigerant

The compressor used in this product is specifically designed to operate with Puron (R-410A) refrigerant and cannot be interchanged.

The compressor is an electrical (as well as mechanical) device.

Exercise extreme caution when working near compressors. Power should be shut off, if possible, for most troubleshooting techniques. Refrigerants present additional safety hazards.

WARNING: Wear safety glasses and gloves when handling refrigerants. Failure to follow this warning can cause a fire, serious injury, or death.

The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll. The scroll compressor has no dynamic suction or discharge valves, and it is more tolerant of stresses caused by debris, liquid slugging, and flooded starts. The compressor is equipped with an anti-rotational device and an internal pressure relief port. The anti-rotational device prevents the scroll from turning backwards and replaces the need for a cycle protector. The pressure relief port is a safety device, designed to protect against extreme high pressure. the relief port has an operating range between 550 and 625 psi differential pressure.

The Copeland scroll compressor uses Mobil 3MA POE oil.

This is the only oil allowed for oil recharge.

P.

REFRIGERANT SYSTEM

CAUTION: This system uses Puron (R-410A) refrigerant which has higher operating pressures than R-22 and other refrigerants. No other refrigerant may be used in this system. Gage set, hoses, and recovery system must be designed to handle Puron. If you are unsure consult the equipment manufacturer.

Failure to use Puron compatible servicing equipment or replacement components may result in property damage or injury.

Q.

Compressor Oil

The compressor in this system uses a polyolester (POE) oil, Mobil

3MA POE. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere.

R.

Servicing Systems on Roofs with

Synthetic Materials

POE (polyolester) compressor lubricants are known to cause long term damage to some synthetic roofing materials. Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. When performing any service that may risk exposure of compressor oil to the roof, take appropriate precautions to protect roofing. Procedures which risk oil leakage include, but are not limited to, compressor replacement, repairing refrigerant leaks, replacing refrigerant components such as filter drier, pressure switch, metering device, coil, accumulator, or reversing valve.

SYNTHETIC ROOF PRECAUTIONARY PROCEDURE:

1. Cover extended roof working area with an impermeable polyethylene (plastic) drip cloth or tarp. Cover an approximate 10 x 10 ft. area.

2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs, and protect drop cloth from tears caused by tools or components.

3. Place terry cloth shop towel inside unit immediately under component(s) to be serviced and prevent lubricant run-offs through the louvered openings in the base pan.

4. Perform required service.

5. Remove and dispose of any oil contaminated material per local codes.

S.

Liquid Line Filter Drier

The filter drier is specifically designed to operate with Puron. Use only factory-authorized components. Filter drier must be replaced whenever the refrigerant system is opened. When removing a filter drier, use a tubing cutter to cut the drier from the system. Do not

unsweat a filter drier from the system. Heat from unsweating will release moisture and contaminants from drier into system.

T.

Puron (R-410A) Refrigerant Charging

Refer to unit information plate and charging chart. Some R-410A

refrigerant cylinders contain a dip tube to allow liquid refrig-

erant to flow from cylinder in upright position. For cylinders equipped with a dip tube, charge Puron units with cylinder in upright position and a commercial metering device in manifold hose. Charge refrigerant into suction-line.

—24—

AIR CONDITIONER WITH PURON® (R-410A)—QUICK REFERENCE GUIDE

Puron® refrigerant operates at 50%-70% higher pressures than R-22. Be sure that servicing equipment and replacement components are designed to operate with Puron.

• Puron refrigerant cylinders are rose colored.

• Puron refrigerant cylinders manufactured prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright position.

Cylinders manufactured March 1, 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid to flow.

• Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.

• Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose.

• Manifold sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard.

• Use hoses with 750 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• Puron, as with other HFCs, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Only use factory specified liquid-line filter driers with rated working pressures no less than 600 psig.

• Do not install a suction-line filter drier in liquid-line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

• POE oils may cause damage to certain plastics and roofing materials.

• Wrap all filter driers and service valves with wet cloth when brazing.

• A Puron liquid-line filter drier is required on every unit.

• Do not use an R-22 TXV.

• Never open system to atmosphere while it is under a vacuum.

• When system must be opened for service, break vacuum with dry nitrogen and replace filter driers.

• Always replace filter drier after opening system for service.

• Do not vent Puron into the atmosphere.

• Observe all warnings, cautions, and bold text.

• Do not leave Puron suction line driers in place for more than 72 hours.

—25—

TABLE 10—TROUBLESHOOTING — COOLING

SYMPTOM

Compressor and condenser fan will not start.

Compressor will not start but condenser fan runs.

Three-phase scroll compressor makes excessive noise, and there may be a low pressure differential.

Compressor cycles (other than normally satisfying thermostat).

Compressor operates continuously.

Excessive head pressure.

Head pressure too low.

Excessive suction pressure.

Suction pressure too low.

CAUSE

Power failure

Fuse blown or circuit breaker tripped

Defective thermostat, contactor, transformer, control relay, high pressure, or loss of charge switch

Insufficient line voltage

Incorrect or faulty wiring

REMEDY

Call power company.

Replace fuse or reset circuit breaker.

Replace component.

Thermostat setting too high

Determine cause and correct.

Check wiring diagram and rewire correctly.

Lower thermostat setting below room temperature.

Faulty wiring or loose connections in compressor circuit

Compressor motor burned out, seized, or internal overload open

Defective run/start capacitor, overload, start relay

Check wiring and repair or replace.

Determine cause. Replace compressor.

Determine cause and replace.

One leg of 3-phase power dead

Scroll compressor is rotating in the wrong direction

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

Dirty air filter

Dirty condenser coil

Refrigerant overcharged

Air in system

Condenser air restricted or air short-cycling

Low refrigerant charge

Compressor valves leaking

Restriction in liquid tube

High heat load

Compressor valves leaking

Refrigerant overcharged

Dirty air filter

Low refrigerant charge

Metering device or low side restricted

Insufficient evaporator airflow

Temperature too low in conditioned area

Outdoor ambient below 40 F

Field-installed filter-drier restricted

Replace fuse or reset circuit breaker. Determine cause.

Correct the direction of rotation by reversing the

3-phase power leads to the unit. Shut down unit to allow pressures to equalize.

Recover refrigerant, evacuate system, and recharge to capacities shown on 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.

Recover refrigerant, evacuate system, and recharge.

Clean coil or remove restriction.

Replace filter.

Clean coil.

Recover excess refrigerant.

Recover refrigerant, evacuate system, and recharge.

Determine cause and correct.

Check for leaks, repair and recharge.

Replace compressor.

Remove restriction.

Check for source and eliminate.

Replace compressor.

Recover excess refrigerant.

Replace filter.

Check for leaks, repair and recharge.

Remove source of restriction.

Increase air quantity. Check filter — replace if necessary.

Reset thermostat.

Install low-ambient kit.

Replace.

—26—

SYMPTOM

Burners will not ignite.

Inadequate heating.

Poor flame. characteristics

TABLE 11—TROUBLESHOOTING — HEATING

CAUSE

Water in gas line

No power to furnace

Miswired or loose connections

Burned-out heat anticipator in thermostat

Broken thermostat wire

Misaligned spark electrodes

No gas at main burners

Dirty air filter

Gas input to furnace too low

Unit undersized for application

Restricted airflow

Blower speed too low

Limit switch cycles main burners

Incomplete combustion results in: Aldehyde odors, carbon monoxide, sooting flame, floating flame

REMEDY

Drain. Install drip leg.

Check power supply fuses, wiring, or circuit breaker.

Check all wiring and wirenut connections.

Replace thermostat.

Run continuity check. Replace wire if necessary.

Check flame ignition and sense electrode positioning.

Adjust as necessary

1. Check gas line for air. Purge as necessary. NOTE:

After purging gas line of air, wait at least 5 minutes for any gas to dissipate before attempting to light unit.

2. Check gas valve.

Clean or replace filter as necessary.

check gas pressure at manifold. Match with that on unit nameplate.

Replace with proper unit or add additional unit.

Clean or replace filter. Remove any restriction.

Use faster speed tap if available, or install alternate motor.

Check rotation of blower, thermostat heat anticipator settings, and temperature rise of unit. Adjust as necessary.

1. Tighten all screws around burner compartments.

2. Cracked heat exchanger. Replace

3. Unit overfired. Reduce input (change orifices or adjust gas line or manifold pressure).

4. Check burner alignment.

—27—

TABLE 12—LED TROUBLESHOOTING–ERROR CODE

SYMPTOM

Hardware failure.

(LED OFF)

Fan ON/OFF delay modified. (LED/FLASH)

Limit switch fault. (LED 2 flashes)

Flame sense fault. (LED 3 flashes)

4 consecutive limit switch faults. (LED 4 flashes)

Ignition lockout. (LED 5 flashes)

Induce-draft motor fault. (LED 6 flashes)

Rollout switch fault. (LED 7 flashes)

Internal control fault. (LED 8 flashes)

Internal software fault. (LED 9 flashes)

CAUSE

Loss of power to control module (IGC)

High limit switch opens during heat exchanger warm-up period before fan-on delay expires

Limit switch opens within three minutes after blower-off delay timing in Heating mode

High temperature limit switch is open

The IGC sensed flame that should not be present

Inadequate airflow to unit

Unit unsuccessfully attempted ignition for 15 minutes

IGC does not sense that induced-draft motor is operating

Rollout switch has opened

Microprocessor has sensed an error in the software or hardware

Microprocessor has sensed an error in it’s redundant software comparison

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

20 minutes for automatic reset.

Ensure unit is fired on rate and temperature rise is correct.

Ensure unit’s external static pressure is within application guidelines.

Check operation of indoor (evaporator) fan motor.

Ensure that the supply-air temperature rise is in accordance with the range on the unit nameplate.

Reset unit. If problem persists, replace control board.

Check operation of indoor (evaporator) fan motor and that supply-air temperature rise agrees with range on unit nameplate information.

Check ignitor and flame sensor electrode spacing, gaps, etc. Ensure that flame sensor 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 lockout 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.

If error code is not cleared by resetting unit power, replace the IGC.

CAUTION: 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.

IMPORTANT: Refer to Heating Troubleshooting Chart for additional troubleshooting analysis.

LEGEND

IGC – Integrated Gas Unit Controller

LED – Light-Emitting Diode

—28—

START-UP CHECKLIST

(REMOVE AND STORE IN JOB FILE)

I. PRELIMINARY INFORMATION

MODEL NO.: _____________________________ SERIAL NO.: ________________________________________

DATE: __________________________________ TECHNICIAN: ________________________________________

II. PRE-START-UP (Insert checkmark in box as each item is completed)

( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

( ) VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS

( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS

( ) CHECK GAS PIPING FOR LEAKS

( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE

( ) VERIFY THAT UNIT INSTALLATION IS LEVEL

( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS

III. START-UP

ELECTRICAL

SUPPLY VOLTAGE L1-L2__________ L2-L3__________ L3-L1__________

COMPRESSOR AMPS L1 __________ L2 __________ L3 __________

INDOOR (EVAPORATOR) FAN AMPS __________

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE __________ DB

RETURN-AIR TEMPERATURE __________ DB __________ WB

COOLING SUPPLY AIR __________ DB __________ WB

GAS HEAT SUPPLY AIR __________

PRESSURES

GAS INLET PRESSURE __________ IN. WG

GAS MANIFOLD PRESSURE __________ IN. WG

REFRIGERANT SUCTION __________ PSIG SUCTION LINE TEMP* __________

REFRIGERANT DISCHARGE __________ PSIG DISCHARGE TEMP† __________

( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS

( ) VERIFY THAT THREE-PHASE SCROLL COMPRESSOR IS ROTATING IN CORRECT DIRECTION.

* Measured at suction inlet to compressor.

† Measured at liquid line leaving condenser.

—29—

© 2006 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231 —30—

Printed in U.S.A.

Catalog No. II 583B-30-1