Bryant 583B Air Conditioner User Manual

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
Fig. 1—Unit 583B
C99087
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.
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.
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.
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.
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.
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.
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.
Follow all safety codes. Wear safety glasses and work gloves. Use
quenching cloth for unbrazing operations. Have fire extinguisher
available for all brazing operations.
Approved for outdoor installation on wood flooring or on class A,
B or C roof covering materials.
—1—
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.
A
C
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
B
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.
A-B
B-C
A-C
1/4
1/4
1/4
Fig. 2—Unit Leveling Tolerances
General
OPTIONAL
RETURN
AIR
OPENING
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 NOx units designed for California installation.
These models meet the California maximum oxides of nitrogen
(NOx) 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 NOx rule exists.
C99065
OPTIONAL
SUPPLY
AIR
OPENING
2"
(50.8mm)
EVAP.
COIL
COND.
COIL
C99014
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).
Fig. 3—Slab Mounting Details
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
C
46 3/16
B
17 3/8
TYP.
D
44 5/16
1 TYP.
7/8
3
13/16
SUPPORT B
A
B
SUPPORT A (2)
SIDE
(2)
2
END VIEW
END
(2)
DECK PAN (INSULATED)
A99320
Fig. 4—Roof Curb Dimensions
Top View
SIDE PANEL
0.75"
3.0"
SUPPORT RIB(S)
BASE PAN
BOTTOM SUPPLY
4.0"
SEAL STRIP
(FACTORY SUPPLIED)
COUNTER FLASHING
(FIELD SUPPLIED)
NAILER
ROOFING FELT
(FIELD SUPPLIED)
INSULATION
(FIELD SUPPLIED)
CANT STRIP
(FIELD SUPPLIED)
ROOFING MATERIAL
(FIELD SUPPLIED)
Fig. 5—Roof Curb Dimensions
Side View
—3—
A99340
TABLE 1—ROOF CURB DIMENSIONS
UNIT SIZE
ROOF
CURB
583B030-036
583B042-060
ODS ORDER NUMBER
CPRFCURB006A00
CPRFCURB007A00
CPRFCURB008A00
CPRFCURB009A00
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)
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.
IV.
PROVIDE CLEARANCES
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 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.
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:
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.
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.
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.
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.
V. RIG AND PLACE UNIT
5. Attach safety straps directly to the field supplied rigging
straps or clevis clip. Do not attach the safety straps to the
lifting brackets.
Rigging and handling of this equipment can be hazardous for many
reasons due to the installation location (roofs, elevated structures,
etc.).
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.
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.
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.
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—
REQ’D CLEARANCES FOR OPERATION AND SERVICING. in. (mm)
REQ’D CLEARANCES TO COMBUSTIBLE MAT’L. 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)
Top of unit . . . . .
Duct side of unit . .
Side opposite ducts .
Bottom of unit . . .
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. 14 (355.6)
. . 2 (50.8)
. 14 (355.6)
. 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)
C99017
UNIT
583B030040/060
583B036060/090
ELECTRICAL
CHARACTERISTICS
208/230-3-60
208/230-3-60,
460-3-60
UNIT WEIGHT
lb.
313.0
kg.
142.0
321.0
145.6
39.02 (991.1)
CENTER OF GRAVITY
IN. (MM)
X
Y
Z
22.0 (558.8)
15.3 (387.4)
17.6 (447.0)
35.02 (889.5)
22.0 (558.8)
UNIT HEIGHT
IN. (MM)
"A"
Fig. 6—583B030, 036 Unit Dimensions
—5—
15.3 (387.4)
16.5 (419.1)
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
REQUIRED CLEARANCE TO COMBUSTIBLE MATL.
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.
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
C99074
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
CENTER OF GRAVITY
IN. (MM)
Y
lb.
kg.
UNIT HEIGHT
IN. (MM)
"A"
382
173.3
38.98 (990.2)
23.0 (584.2)
16.3 (412.8)
16.6 (421.6)
421
191.0
38.98 (990.2)
21.5 (546.1)
16.6 (422.1)
18.0 (457.2)
468
212.3
42.98 (1091.7)
23.5 (596.9)
16.3 (412.8)
17.6 (447.0)
UNIT WEIGHT
Fig. 7—583B042-060 Unit Dimensions
—6—
X
Z
DETAIL A
A05179
MAXIMUM WEIGHT
UNIT 583B
SIZE
lb
335
343
404
443
490
030
036
042
048
060
A
kg
152
156
183
201
222
in.
22.0
22.0
23.0
21.5
23.5
B
mm
558.5
558.5
584.2
546.1
596.9
in.
15.3
15.3
16.3
16.3
16.3
mm
388.6
388.6
414.0
414.0
414.3
Fig. 8—Suggested Rigging
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.
IN
TEE
OUT
NIPPLE
1” (25mm) MIN.
3˝ MIN
TRAP
OUTLET
C99020
2” (50mm) MIN.
Fig. 10—Sediment Trap
These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/joule or less as
shipped from the factory.
NOTE: Low NOx requirements apply only to natural gas installations.
C99013
Fig. 9—Condensate Trap
VII.
CAP
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.
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.
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.
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.
NOTE: Dedicated low NOx models MUST be installed in California Air Quality Management Districts where a Low NOx rule
exists.
—7—
3. Secure flue hood to flue panel by inserting a single screw on
the right side and the left side of the hood.
VIII.
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.
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.
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
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.
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).
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:
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) DISCHARGE
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.
WARNING: Before performing service or maintenance
operations on the system, turn off main power to unit.
Electrical shock could cause serious injury or death.
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.
1. Open all electrical disconnects before starting any service
work.
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.
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. Install sediment trap in riser leading to heating section per
Fig. 10. This drip leg functions as a trap for dirt and
condensate.
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.
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—
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
030060
2 1/2
313
036060
3
321
036090
3
321
042060
3 1/2
382
042090
3 1/2
382
Scroll
1
5.5
5.5
6.9
6.9
9.0
9.0
.057
.057
.065
.065
.070
.070
1/17
12.7
1/17
12.7
2/17
9.1
2/17
9.1
2/17
12.3
2/17
12.3
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
2350
22
1/8 (825)
3/15
3.7
3/15
3.7
3/15
3.7
3/15
3.7
3/15
4.7
3/15
4.7
800
10 x 10
1/4
1000
10 x 10
1/4
1200
10 x 10
1/2
1200
10 x 10
1/2
1400
11 x 10
3/4
1400
11 x 10
3/4
2...44
2...50
2...38
2...46
2...38
2...46
3...38
3...46
2...38
2...46
3...38
3...46
20 x 24x1
24 x 30x1
24 x 30x1
610 ± 15
420 ± 25
20 ± 5
45 ± 10
20 x 24x1
20 x 24x1
20 x 24x1
A. Adhere to the following criteria when selecting,
sizing, and installing the duct system:
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.
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.
7. Flash, weatherproof, and vibration-isolate all openings in
building structure in accordance with local codes and good
building practices.
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.
X.
INSTALL ELECTRICAL CONNECTIONS
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.
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
—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
048115
4
421
048130
4
421
060090
5
468
060115
5
468
060130
5
468
Scroll
1
9.5
9.5
9.5
10.0
10.0
10.0
.073
.073
.073
.086
.086
.086
2/17
12.3
2/17
12.3
2/17
12.3
2/17
16.4
2/17
16.4
2/17
16.4
3300
22
1/4 (1100)
3300
22
1/4 (1100)
3300
22
1/4 (1100)
3300
22
1/4 (1100)
3300
22
1/4 (1100)
3300
22
1/4 (1100)
4/15
4.7
4/15
4.7
4/15
4.7
4/15
4.7
4/15
4.7
4/15
4.7
1600
11 x 10
3/4
1600
11 x 10
3/4
1600
11 x 10
3/4
1750
11 x 10
1.0
1750
11 x 10
1.0
1750
11 x 10
1.0
3...38
3...46
3...33
3...42
3...31
3...41
3...38
3...46
3...33
3...42
3...31
3...41
24 x 30
24 x 30
24 x 30
610 ± 15
420 ± 25
20 ± 5
45 ± 10
24 x 30
24 x 30
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
175 120
97
360 250 200
680 465 375
1400 950 770
2100 1460 1180
40
82
170
320
600
990
LENGTH OF
50 60 70
73 66 61
151 138 125
285 260 240
580 530 490
900 810 750
PIPE,
80
57
118
220
460
690
FT†
90
53
110
205
430
650
100
50
103
195
400
620
125
44
93
175
360
550
150
40
84
160
325
500
175
—
77
145
300
460
200
—
72
135
280
430
*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—
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.
SUPPLY
DUCT
OPENING
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
RETURN
DUCT
OPENING
5. Connect field wire L2 to yellow wire on connection 13 of
the compressor contactor.
C99089
Fig. 11—Supply and Return Duct Opening
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.
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.
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—
TABLE 5—ELECTRICAL DATA — 583B
UNIT
SIZE 583B
030
036
042
048
060
V-PH-HZ
208/230-3-60
208/230-3-60
460-3-60
208/230-3-60
460-3-60
208/230-3-60
460-3-60
208/230-3-60
460-3-60
VOLTAGE
RANGE
Min
Max
187
253
187
253
414
506
187
253
414
506
187
253
414
506
187
253
414
506
COMPRESSOR
RLA
9.6
12.2
5.1
13.5
6.3
14.7
6.5
18.1
9.0
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
LRA
63.0
77.0
35.0
77.0
39.0
91.0
46.0
137.0
62.0
MOCP*
20
30
15
35
15
35
15
45
20
452 + 464 + 455
3
1371
=
3
= 457
®
Average Voltage =
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.
Determine maximum deviation from average voltage.
(AB) 457 452 = 5 v
(BC) 464 457 = 7 v
(AC) 457 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
7
% Voltage Imbalance = 100 x
457
= 1.53%
This amount of phase imbalance is satisfactory as it is below the
maximum allowable 2%.
% Voltage imbalance
= 100 x
MCA
14.9
19.7
9.1
22.6
10.8
24.1
11.0
30.4
15.4
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
LEGEND
FLA
— Full Load Amps
LRA
— Locked Rotor Amps
MCA
— Minimum Circuit Amps
MOCP — Maximum Overcurrent Protection
RLA
— Rated Load Amps
CKT BKR — Circuit Breaker
POWER SUPPLY
max voltage deviation from average voltage
average voltage
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
WHT(W1)
YEL(Y)
GRN(G)
LOW-VOLTAGE
POWER LEADS
(SEE UNIT
WIRING LABEL)
RED(R)
BRN(C)
W
Y
G
THERMOSTAT
(TYPICAL)
R
C
SPLICE BOX
C99018
Fig. 14—High- and Control-Voltage Connections
—12—
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.
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
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).
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.
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.
FAN GRILLE
MOTOR
1/2˝
1/8" MAX BETWEEN
MOTOR AND FAN HUB
MOTOR SHAFT
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:
Proceed as follows to inspect and prepare the unit for initial
startup:
1. Locate leak and make sure that refrigerant system pressure
has been relieved and refrigerant recovered from both highand low-pressure ports.
1. Remove access panel.
2. Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION labels attached to, or
shipped with, unit.
2. Repair leak following accepted practices.
NOTE: Replace filter drier whenever the system has been opened
for repair.
3. Make the following inspections:
a. Inspect for shipping and handling damages such as
broken lines, loose parts, disconnected wires, etc.
3. Check system for leaks using an approved method.
4. Evacuate refrigerant system and reclaim refrigerant if no
additional leaks are found.
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.
5. Charge unit with R-410a refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit rating
plate for required charge.
B.
c. Inspect all field- and factory-wiring connections. Be sure
that connections are completed and tight.
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.):
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.
1. Place room thermostat SYSTEM switch in the HEAT
position and the FAN switch in the AUTO position.
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
2. Set the heating temperature control of the thermostat above
room temperature.
—13—
TABLE 6—HEATING INPUTS
HEATING
INPUT
(BTUH)*
NUMBER
OF
ORIFICES
40,000
60,000
90,000
115,000
130,000
2
2
3
3
3
GAS SUPPLY PRESSURE
(IN. WG)
Natural
Propane†
Min
Max
Min
Max
4.0
13.0
7.0
13.0
4.0
13.0
7.0
13.0
4.0
13.0
7.0
13.0
4.0
13.0
7.0
13.0
4.0
13.0
7.0
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.
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:
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/ft3 at 0.65 specific gravity, or
propane gas with a heating value of 2500 Btu/ft3 at 1.5 specific
gravity. For elevations above 2000 ft., reduce input 4% for each
1000 ft. above sea level. When the gas supply being used has a
different heating value, or specific gravity, refer to national and
local codes, or contact your distributor to determine the required
orifice size.
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/ft3.
Proceed as follows:
1. 32 seconds to complete one revolution.
2. 3600 ÷ 32 = 112.5
3. 112.5 x 1 = 112.5 ft3 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.
CAUTION: These units are designed to consume the
rated gas inputs using the fixed orifices at specified
manifold pressures as shown in Table 6. DO NOT
REDRILL THE ORIFICES UNDER ANY CIRCUMSTANCES.
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.
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.
—14—
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
TEMPERATURE RISE °F
20
25
30
35
40
45
50
55
60
65
70
1500
2250
—
—
—
1200
1800
2700
—
—
1000
1500
2250
—
—
857
1286
1929
2464
—
750
1125
1688
2156
2438
667
1000
1500
1917
2167
600
900
1350
1725
1950
—
818
1227
1568
1773
—
750
1125
1438
1625
—
692
1038
1327
1500
—
—
964
—
1393
NOTE: Dashed areas do not fall within the approved temperature rise range of the unit.
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.
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.
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.
TABLE 8—LED INDICATIONS
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
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
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.
BURNER
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.
MANIFOLD
C99021
Fig. 17—Monoport Burners
—15—
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
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.
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.
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).
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.
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.
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.
CHECKING
AND
ADJUSTING
REFRIGERANT
CHARGE—The refrigerant system is fully charged with R-410A
(Puron) refrigerant, and is tested and factory sealed.
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:
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.
3-SPEED
black = high speed
blue = medium speed
red = low speed
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..
2-SPEED
black = high 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.
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—
—17—
Fig. 18—208/230-3-60 Wiring Diagram
C99077
—18—
Fig. 19—460-3-60 Wiring Diagram
C99078
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
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.
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:
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:
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.
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.
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.
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.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
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.
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 INJURY AND POSSIBLE DAMAGE TO THIS EQUIPMENT.
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.
—19—
180
1172
170
1103
160
1034
965
896
827
SUCTION LINE PRESSURE (PSIG)
SUCTION LINE PRESSURE (KILOPASCALS)
(030) 60 Hz CHARGING CHART
FOR USE WITH UNITS USING R410A REFRIGERANT
1241
OUTDOOR
TEMP
F
C
150
125
115
105
52
46
41
95
35
85
29
75
24
140
65
18
55
45
13
7
130
120
758
110
690
100
20.0
-7
30.0
40.0
50.0
60.0
SUCTION LINE TEMPERATURE (DEG. F)
70.0
80.0
-1
4
10
16
SUCTION LINE TEMPERATURE (DEG. C)
21
27
C99080
Fig. 20—Cooling Charging Chart, 583B030 Units
170
1103
1034
965
896
827
160
150
140
125
115
52
46
105
95
85
41
35
29
75
24
65
18
130
55
13
45
7
120
758
110
690
100
20.0
-7
1241
180
1172
170
1103
1034
965
896
827
OUTDOOR
TEMP
F
C
125
52
115
46
105
41
95
85
35
29
75
24
160
SUCTION LINE PRESSURE (PSIG)
1172
(042) 60 Hz CHARGING CHART
FOR USE WITH UNITS USING R410A REFRIGERANT
OUTDOOR
TEMP
F
C
SUCTION LINE PRESSURE (KILOPASCALS)
180
SUCTION LINE PRESSURE (PSIG)
SUCTION LINE PRESSURE (KILOPASCALS)
(036) 60 Hz CHARGING CHART
FOR USE WITH UNITS USING R410A REFRIGERANT
1241
150
140
65
18
55
13
45
7
130
120
30.0
40.0
50.0
60.0
SUCTION LINE TEMPERATURE (DEG. F)
70.0
80.0
758
110
-1
4
10
16
SUCTION LINE TEMPERATURE (DEG. C)
21
27
690
100
20.0
30.0
40.0
50.0
60.0
SUCTION LINE TEMPERATURE (DEG. F)
70.0
80.0
-1
4
10
16
SUCTION LINE TEMPERATURE (DEG. C)
21
27
-7
C99081
Fig. 21—Cooling Charging Chart, 583B036 Units
170
1103
1034
965
896
827
OUTDOOR
TEMP
F
C
160
125
52
115
46
105
95
41
35
85
29
75
24
(060) 60 Hz CHARGING CHART
FOR USE WITH UNITS USING R410A REFRIGERANT
150
140
130
65
18
55
13
45
7
120
1241
180
1172
170
1103
160
1034
965
896
827
SUCTION LINE PRESSURE (PSIG)
1172
Fig. 22—Cooling Charging Chart, 583B042 Units
SUCTION LINE PRESSURE (KILOPASCALS)
180
SUCTION LINE PRESSURE (PSIG)
SUCTION LINE PRESSURE (KILOPASCALS)
(048) 60 Hz CHARGING CHART
FOR USE WITH UNITS USING R410A REFRIGERANT
1241
C99082
140
758
110
100
20.0
690
100
20.0
-7
80.0
-1
4
10
16
SUCTION LINE TEMPERATURE (DEG. C)
21
27
-7
C99083
Fig. 23—Cooling Charging Chart, 583B048 Units
95
35
85
29
75
24
65
18
55
13
45
7
120
690
70.0
52
46
41
130
110
40.0
50.0
60.0
SUCTION LINE TEMPERATURE (DEG. F)
125
115
105
150
758
30.0
OUTDOOR
TEMP
F
C
30.0
40.0
50.0
60.0
SUCTION LINE TEMPERATURE (DEG. F)
70.0
80.0
-1
4
10
16
SUCTION LINE TEMPERATURE (DEG. C)
21
27
A99084
Fig. 24—Cooling Charging Chart, 583B060 Units
—20—
TABLE 9—WET COIL AIR DELIVERY* — HORIZONTAL AND DOWNFLOW DISCHARGE
UNIT 583B030-060 (DEDUCT 10% FOR 208 VOLTS)
Unit
583B
Motor
Speed
Low
030
Medium
High
Low
036
Medium
High
Low
042
Medium
High
Low
048
Medium
High
Low
060
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
230 AND 460 VOLT
External Static Pressure (in. wg)
0.2
0.3
0.4
0.5
0.6
0.7
242
–
–
–
–
–
786
–
–
–
–
–
333
330
326
320
–
–
1070
997
911
818
–
–
–
443
436
426
416
406
–
1230
1145
1061
977
888
446
432
418
403
389
378
1347
1281
1205
1118
1024
921
501
488
474
459
443
428
1426
1351
1267
1175
1077
976
645
636
627
616
605
593
1484
1410
1330
1243
1147
1044
608
598
583
562
534
502
1545
1498
1448
1391
1326
1257
–
733
704
672
638
604
–
1746
1688
1630
1566
1492
–
–
–
–
797
773
–
–
–
–
1727
1632
573
568
559
544
524
500
1496
1467
1432
1387
1332
1269
719
699
678
653
627
602
1758
1706
1648
1585
1520
1455
–
890
858
828
801
777
–
1943
1870
1793
1711
1624
569
566
559
541
499
–
1836
1779
1718
1651
1577
–
715
695
673
648
623
598
2021
1952
1883
1809
1727
1635
850
821
795
772
750
728
2159
2050
1974
1905
1824
1722
0.8
–
–
–
–
397
786
–
–
–
–
583
936
473
1189
574
1399
751
1537
–
–
579
1392
756
1531
–
–
577
1530
701
1597
0.9
–
–
–
–
–
–
–
–
–
–
–
–
454
1132
550
1279
727
1423
–
–
562
1332
734
1433
–
–
–
–
–
–
1.0
–
–
–
–
–
–
–
–
–
–
–
–
457
1101
536
1120
696
1308
–
–
556
1276
709
1329
–
–
–
–
–
–
*Air delivery values are without air filter.
Note: Deduct field-supplied air filter pressure drop to obtain external static pressure available for ducting.
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.
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
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.
FLUE
COLLECTOR BLOWER
HOUSING
BOX
ROLLOUT
SWITCH
BURNER MOUNTING
RACK
SCREW
C99022
d. Reassemble wheel into housing.
Fig. 25—Blower Housing and Flue Collector Box
e. Reassemble motor into housing. Be sure setscrew(s) are
tightened on motor shaft flats and not on round part of
shaft.
C.
Flue Gas Passageways
To inspect the flue collector box and upper areas of the heat
exchanger:
f. Reinstall unit access panel.
—21—
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.
BLOWER
HOUSING
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.
2 SETSCREWS
(HIDDEN)
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.
C99085
Fig. 26—Removal of Motor and Blower Wheel
CAUTION: When servicing gas train, do not hit or plug
orifice spuds.
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).
C99090
Fig. 27—Unit Access Panel
8. Slide the burner rack out of the unit (See Figs. 25 and 28).
1. Remove the combustion blower wheel and motor assembly
according to directions in Combustion-Air Blower section
below.
9. To reinstall, reverse the procedure outlined above.
H. Condenser Coil, Evaporator Coil, and Condensate
Drain Pan
2. Remove the 3 screws holding the blower housing to the flue
collector box cover (see Fig. 25).
Inspect the condenser coil, evaporator coil, and condensate drain
pan at least once each year.
3. Remove the 12 screws holding the flue collector box cover
(Fig. 25) to the heat exchanger assembly. Inspect the heat
exchangers.
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.
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—
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.
This metering device is a fixed orifice and is contained in the brass
hex-body in the liquid line.
C99086
Fig. 28—Burner Rack Removed
I.
N.
Condenser Fan
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:
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).
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:
6. Ensure that setscrew engages the flat area on the motor shaft
when tightening.
7. Replace grille.
J.
Metering Device–Check-Flo-Rater® Piston
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.
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.
—23—
R. Servicing Systems on Roofs with
Synthetic Materials
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.
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.
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.
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 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.
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.
Q.
Puron (R-410A) Refrigerant Charging
Refer to unit information plate and charging chart. Some R-410A
refrigerant cylinders contain a dip tube to allow liquid refrigerant to flow from cylinder in upright position. For cylinders
equipped with a dip tube, charge Puron units with cylinder in
upright position and a commercial metering device in manifold
hose. Charge refrigerant into suction-line.
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.
—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.
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
Thermostat setting too high
Compressor will not start but condenser fan
runs.
Faulty wiring or loose connections in compressor circuit
Compressor motor burned out, seized, or internal overload open
Defective run/start capacitor, overload, start relay
REMEDY
Call power company.
Replace fuse or reset circuit breaker.
Replace component.
Determine cause and correct.
Check wiring diagram and rewire correctly.
Lower thermostat setting below room temperature.
Check wiring and repair or replace.
Determine cause. Replace compressor.
Determine cause and replace.
Replace fuse or reset circuit breaker. Determine
cause.
Three-phase scroll compressor makes exCorrect the direction of rotation by reversing the
Scroll compressor is rotating in the wrong direccessive noise, and there may be a low pres3-phase power leads to the unit. Shut down unit
tion
sure differential.
to allow pressures to equalize.
Recover refrigerant, evacuate system, and reRefrigerant overcharge or undercharge
charge to capacities shown on nameplate.
Defective compressor
Replace and determine cause.
Insufficient line voltage
Determine cause and correct.
Blocked condenser
Determine cause and correct.
Compressor cycles (other than normally satisfying thermostat).
Defective run/start capacitor, overload or start
Determine cause and replace.
relay
Defective thermostat
Replace thermostat.
Faulty condenser-fan motor or capacitor
Replace.
Restriction in refrigerant system
Locate restriction and remove.
Dirty air filter
Replace filter.
Unit undersized for load
Decrease load or increase unit size.
Thermostat set too low
Reset thermostat.
Low refrigerant charge
Locate leak, repair, and recharge.
Compressor operates continuously.
Leaking valves in compressor
Replace compressor.
Recover refrigerant, evacuate system, and reAir in system
charge.
Condenser coil dirty or restricted
Clean coil or remove restriction.
Dirty air filter
Replace filter.
Dirty condenser coil
Clean coil.
Refrigerant overcharged
Recover excess refrigerant.
Excessive head pressure.
Recover refrigerant, evacuate system, and reAir in system
charge.
Condenser air restricted or air short-cycling
Determine cause and correct.
Low refrigerant charge
Check for leaks, repair and recharge.
Head pressure too low.
Compressor valves leaking
Replace compressor.
Restriction in liquid tube
Remove restriction.
High heat load
Check for source and eliminate.
Excessive suction pressure.
Compressor valves leaking
Replace compressor.
Refrigerant overcharged
Recover excess refrigerant.
Dirty air filter
Replace filter.
Low refrigerant charge
Check for leaks, repair and recharge.
Metering device or low side restricted
Remove source of restriction.
Increase air quantity. Check filter — replace if
Suction pressure too low.
Insufficient evaporator airflow
necessary.
Temperature too low in conditioned area
Reset thermostat.
Outdoor ambient below 40 F
Install low-ambient kit.
Field-installed filter-drier restricted
Replace.
One leg of 3-phase power dead
—26—
TABLE 11—TROUBLESHOOTING — HEATING
SYMPTOM
Burners will not ignite.
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
Inadequate heating.
Unit undersized for application
Restricted airflow
Blower speed too low
Limit switch cycles main burners
Poor flame. characteristics
Incomplete combustion results in: Aldehyde odors, carbon monoxide, sooting flame, floating flame
—27—
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.
TABLE 12—LED TROUBLESHOOTING–ERROR CODE
SYMPTOM
CAUSE
REMEDY
Check 5 amp fuse on IGC, power to unit, 24-v
circuit breaker, and transformer. Units without a
Hardware failure.
Loss of power to control module (IGC)
24-v circuit breaker have an internal overload in
(LED OFF)
the 24-v transformer. If the overload trips, allow
20 minutes for automatic reset.
High limit switch opens during heat exchanger
Ensure unit is fired on rate and temperature rise
warm-up period before fan-on delay expires
is correct.
Fan ON/OFF delay modified. (LED/FLASH)
Limit switch opens within three minutes after
Ensure unit’s external static pressure is within
blower-off delay timing in Heating mode
application guidelines.
Check operation of indoor (evaporator) fan motor.
Limit switch fault. (LED 2 flashes)
High temperature limit switch is open
Ensure that the supply-air temperature rise is in
accordance with the range on the unit nameplate.
Reset unit. If problem persists, replace control
Flame sense fault. (LED 3 flashes)
The IGC sensed flame that should not be present
board.
Check operation of indoor (evaporator) fan motor
4 consecutive limit switch faults. (LED 4
Inadequate airflow to unit
and that supply-air temperature rise agrees with
flashes)
range on unit nameplate information.
Check ignitor and flame sensor electrode spacing,
Unit unsuccessfully attempted ignition for 15 min- gaps, etc. Ensure that flame sensor and ignition
Ignition lockout. (LED 5 flashes)
utes
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
IGC does not sense that induced-draft motor is
connection. Proper connection:
Induce-draft motor fault. (LED 6 flashes)
operating
PIN 1 – White,
PIN 2 – Red,
PIN 3 – Black.
Rollout switch will automatically reset, but IGC will
continue to lockout unit. check gas valve operaRollout switch fault. (LED 7 flashes)
Rollout switch has opened
tion. ensure that induced-draft blower wheel is
properly secured to motor shaft. Reset unit at unit
disconnect.
Microprocessor has sensed an error in the softIf error code is not cleared by resetting unit
Internal control fault. (LED 8 flashes)
ware or hardware
power, replace the IGC.
Microprocessor has sensed an error in it’s redunIf error code is not cleared by resetting unit
Internal software fault. (LED 9 flashes)
dant software comparison
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