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Bryant 580G Air Conditioner User Manual

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1. A66 4200 BRN 162 SEFORDART id L 460 BRI 1 D 05 A95 BRN ul 4155 165 4143 BLU a A219 ALE L 142 2 F PA 418 WHT 33 BRI PL2 8 185 W130 BLE BLK 3 2 AMPS 5 148 BLU BRN SEE PORER LABEL 4220 RED oar HUA eM PL2 7 SE et Ps YEL 1 1 ii RSI R82 BASE MODULE x LIEN E 9104 GRE E PLI 3 PL2 3 12 BLU 108 6R 131 GRA gt RED 2 MI GRA 151 15 RED mO ELU ao 138 BRN 1 8 z d 8 GROUNDED THAU STANDOFF ies lose 2 3134 135 TE 2 PL3 4 PLA 4 OMP 2 UKLOADER oct L Con MIIE BRN OHP 1 UHLOADER CYCLIC COND FAN 3 PL2 4 PLI 4 com m 1 LK 66 BRI FAN A105 RED n 8073 PL2 6 su ns eue CERO 8 POWER EXHAUST 1 94 Y10 3 DISCRETE PLI 6 OUTPUTS PONER EXHAUST 2 381 10 vio VIO tome BLK 1 5 PL2 5 206 REETZ wes RED 5 0Ri gt a 68 fr m DE tm 4 BLU 24 VOLT OD ENTHALPT PLE I PL2 1 INPUTS 2 SAfETIES W106 RED N82 RED 84 RED COMP WI SAFETIES 483 RED 27 BLK 160 BLK
2. w FPS HHIBHBO31 gt ES 4 PASSE 1 cT 4 PASS I rl 4 PASS ER cie Circuit 1 4 lt 2 2 55 tI PASS APRES rures RENI EPR a PASS PASS 4 ss A PASS HPS LPS amp Tee ue uq ane u mountet on conpressor ES T L4 PASS Filter Drier Muffler 4 PASS Fusible Cp ERE n 4 4 PASS Z CPS Fusible xm fie 1 HPS HKO2ZA428 PEERS 2 4 55 p yon 0 rass 3 HPS Snubber 5060400532 Lpass t s HH T4 PASS L n 4 Passc ne cut pes FES i H A PASS utout Circuit 2 s CU E A PASS PASS iF A amp Fusible T 2 mounted bj Conpressor EI P amp ll Pass MufFl err ED j 4 PASS LP re Liquid Line AT PASS S TPR Filter Drier 4 55 pres H 4 PASS PRS ES L Br PASS Ba m Plug 4 PASS Li T4 PASSLLL drop 1 4 PASSL I A PASS ass E Ta PASSL Fusible jon A Plug PASSE iw apu uM 2 LEGEND FPS Freeze Protection Switch HPS High Pressure Switch LPS Low Pressure Switch Fig 44 Typical Refrigerant Circuiting I DIAGNOSTIC LEDs Light Emitti
3. 58 BLK PONER EXHAUST m FIELO ACCESSORT MODULA FLAME SEN 0 0 Oo GROUNDED THRU STANDOFF 98 BRN 195 BRN 200 BRI 4165 BRN NOTE Red wire and violet wire are spliced together at the factory The brown wire has a wire nut added at the factory Fig 49 24 V Control Schematic 580G H240 360 60 BRU 728 ta IL ILI CI gt 10 24VAC EXPANSION BOARD CACCESSORY ONLY BASE MODULE MODULATING POWER EXHAUST ONLY 515V ONLY NC NO COM LOCATED ON LEFT HAND INDOOR BLOWER ASY GAS SECTION 1662 ELEC MAT Ba 2 ELECTRIC HEAT SECTION TMG an D NYC 0 TY KD F COMPR 2 NE OFMI 2 B 8 1 ME I i H 1 Y 2 LE I H I ot I 1 7 TES H TU c83 CBA MI 111 1 prbo 1 1 1 1 FIELD POWER WIRING DISCONNECT PER NEC mm ee Fig 50 Component Arrangement 580G H240 360 41 PACKAGE
4. DETAN C SCALE 1 4 1 8 IN SCALE 1 4 PIPE PLUG MANIFOLD z ORIFICE SEE DETAIL Fig 38 Main Burner Removal Vil POWER EXHAUST OPERATION The power exhaust packages are factory or field installed with vertical units and optionally installed in the return air duct work for horizontal applications The standard and the modu lating power exhaust are the two packages offered The modulating power exhaust package is equipped with a field adjustable static pressure controller to stage up to 4 power exhausts stages which will maintain a building static pres sure The blue sequencer located in the control box below the control board can be adjusted by removing the covers and adjusting the set point dial to the desired building pressure The standard power exhaust package controls up to 2 stages of power exhaust to maintain building pressure These power exhaust stages are staged according to a percentage of the economizer dampers position Vill HEAD PRESSURE CONTROL Each unit has a fan cycling outdoor thermostat to shut off the outdoor fan motor at 55 F The head pressure control per mits unit to operate with correct condensing temperatures down to 35 F outdoor air temperature IX LOW AMBIENT KIT Low Ambient Kit is a fan speed control device actuated by a temperature sensor The field installed accessory is specifi cally designed for use on this equipment and controls the condenser fan motor speed
5. D E D 0 96 122 8 120 6 150 150 1 0 96 146 4 144 2 175 175 0 96 129 4 126 6 150 150 1 6 0 96 153 0 150 2 175 175 I 0 96 144 8 140 6 175 175 1 6 0 96 168 4 164 0 200 200 0 50 61 2 80 3 6 0 50 73 8 90 0 50 64 2 80 3 3 0 50 76 8 90 0 50 71 2 90 3 6 0 50 83 8 100 EN DNOINN a S s AL DO ON EN E D AR E D D A E eee ds mam zu cae alolalalolatltlalolalalolalalofla 35 gus 0 50 49 8 60 12 6 23 6 0 50 62 4 70 0 50 51 8 60 oso e 0 50 57 8 70 170 12 6 23 6 0 50 70 4 80 EXAMPLE Supply voltage is 460 3 60 AB 452 v BC 464 v AC 455 v Average Voltage 452 464 455 gt m pare 51 k Determine maximum deviation from average voltage 457 452 5v BC 464 457 7 v 457 455 2v Maximum deviation is 7 v Determine percent voltage imbalance 7 Voltage Imbalance 100 x nee 457 1 53 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately Table 3 Electrical Data 580G H240 360 cont
6. See Fig 2 3 and 9 for drain location Condensate drain is open to the atmosphere and must be trapped Install a trapped drain at the drain location One 1 in NPT coupling is pro vided inside unit evaporator section for condensate drain con nection A trap at least 4 in deep must be used Trap must be installed to prevent freeze up Fig 9 Condensate Drain Connections Typical Roof Curb or Slab Mount Shown Condensate pans are sloped so that water will completely drain from the condensate pan to comply with indoor air quality guidelines VII GAS PIPING Unit is equipped for use with natural gas Installation must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 Install manual gas shutoff valve with a Ye in NPT pressure tap for test gage connection at unit Field gas piping must include sediment trap and union See Fig 10 WARNING Do not pressure test gas supply while connected to unit Always disconnect union before servicing Natural gas pressure at unit gas connection must not be less than 5 in wg or greater than 13 5 in wg Size gas supply piping for 0 5 in wg maximum pressure drop Do not use supply pipe smaller than unit gas connection MANUAL SHUTOFF GAS lt SUPPLY PRESSURE TAP 1 8 NPT PLUG TO UNIT SEDIMENT TRAP Fig 10 Field Gas Piping Vill ELECT
7. 114 62 162 44 2 Fig 1 Roof Curb Sizes 240 360 10 112 8 11 32 5 1 2 INSIDE BASE RAIL 24 RETURN 15 4 88 1 4 TOP orat 24 SUPPLY 15 13 16 ECONOMI ZER AIR EXHAUST AIR 17 15132 2 9 16 108 1 8 RETURN 50 I LE ue Li l lt SA fil 5 1 l sel Il 1 ACCESS HINGE NOTES 1 Weights include economizer STD SSOR POR 2 Center of gravity 3 Do not locate adjacent units with flue discharge facing economizer inlet Min clearances to be Adjacent Units 15 0 Top of Units No Overhang 3 Condenser Coil 4 0 Economizer Side 6 0 Heat Side 4 0 UN Filter Access Side 10 0 For Removal of Evapo rator Coil A For smaller service and operational clearances con tact Carrier Application Engineering department 5 Bottom ducts designed to be attached to acces sory roof curb If unit is mounted on dunnage it is T 4 18 CONTROL BOX recommended the ducts be supported by braces as done on accessory roof curb g 15 32 1977 8 41 251 32 GAS SECTION ACCESS PANEL 60 1716 SUPPLY INDOOR BLOWER ACCESS PANEL 3 1 2 NPT FIEL 3 4 NPT LOW VOLTAGE 4 D POWER ONTROL BOX ACCESS 0008 HINGED ere eue 49 1132 FILTER ACCESS
8. A Roof Curb Assemble and install accessory roof curb in accordance with instructions shipped with the curb Accessory roof curb and information required to field fabricate a roof curb or horizon tal adapter are shown in Fig 1 Install insulation cant strips roofing and counter flashing as shown Ductwork can be secured to roof curb before unit is set in place IMPORTANT The gasketing of the unit to the roof curb is critical for a leak proof seal Install gasket supplied with the roof curb as shown in Fig 1 Improperly applied gasket can result in air leaks and poor unit performance Curb should be level This is necessary to permit unit drain to function properly Unit leveling tolerance is shown in Fig 1 Refer toAccessory Roof Curb Installation Instructions for additional information as required When accessory roof curb is used unit may be installed on class A B or C roof covering material NOTES 1 Unless otherwise specified all dimensions are to outside of part 2 Roof curb accessory is shipped disassembled 3 All roof curb parts are to be 16 ga galvanized steel 4 Dimensions are in inches CONDENSER CONDENSER ND AN COMPRESSOR END M COMPRESSOR END NOTE To prevent standing water in the drain pan of the indoor section and the heat exchangers UNIT CAN ONLY BE PITCHED AS SHOWN UNIT LEVELING TOLERANCES DIMENSIONS Degrees and Inches A B Deg in Deg in 1 75 From
9. CM ON COMPRESSOR AND OUTDOOR FAN STOP IF IDM IS TURNING AT CORRECT SPEED AT LEAST 2400 RPM HALL IMMEDIATELY EFFECT SENSOR SENDS CORRECT SIGNAL TO TERMINAL ON IGC 30 SECOND OFF DELAY FOR INDDOR FAN IGC HIGH VOLTAGE TRANSFORMER CREATES A 10 000 VOLT SPARK FOR 5 AFTER 45 SECONDS OR LESS IF THE TIMING HAS BEEN REDUCED DUE TO LIMIT SWATCH TRIPS WILL ENERGIZE BLOWER RELAY IDM STOPS SAFETY LOGIC SHUTS OFF GAS VALVE LEGEND IDM Induced Draft Motor IGC Integrated Gas Controller DELAY EXTENDED BY SECONDS FOR GACH LIMIT SWITCH TRIP NOTE Thermostat Fan Switch in the AUTO position MAXIMUM DELAY S MINUTES Fig 45 IGC Control Heating and Cooling 36 LEGEND FOR FIG 46 50 AHA Adjustable Heat Anticipator 1 Ignitor RS Rollout Switch BP Building Pressure IDM Induced Draft Motor SAT Supply Air Thermistor BR Burner Relay IFC Indoor Fan Contactor SW Switch C Contactor Compressor IFCB Indoor Fan Circuit Breaker TB Terminal Block CAP Capacitor Indoor Fan Motor TC Thermostat Cooling CB Circuit Breaker IFR Indoor Fan Relay TH Thermostat Heating cc Cooling Compensator IGC Integrated Gas Unit Controller TRAN Transformer CCB Compressor Circuit Breaker IP Internal Protector CCH Crankcase Heater L Light 6 lt gt Terminal Marked
10. COM Common LPS Low Pressure Switch COMP Compressor Motor LS Limit Switch Q Terminal Unmarked CR Control Relay MGV Main Gas Valve Constant Volume NC Normally Closed Terminal Block DM Damper Motor National Electrical Code EC Enthalpy Control Normally Open Splice EQUIP Equipment AT Outdoor Air Thermostat FLA Full Load Amps OD Outside Diameter Factory Wiring FPT Freeze Protection Thermostat OFC Outdoor Fan Contactor Field Wiring FU Fuse OFM Outdoor Fan Motor To Indi ial Onl GND GRD Ground PEC Power Exhaust Contactor ONN ee end ti Potential Only GVR Gas Valve Relay PEM Power Exhaust Motor Not To Represent Wiring HPS High Pressure Switch PES Power Exhaust Sequencer HR Heat Relay PESC Power Exhaust Sequencer HS Hall Effect Sensor Controller HV Heat Valve PL Plug Assembly TRANI SECONDARY 120V Tu TA W198 BLK 4133 WHT IFR 153 BLK 155 PNK 137 MT 5 2 AMPS li W136 WHT W129 428 ORN ANA W26 WHT 5 W26 WHT BASE MODULE ege sse m n aX s wi INDOOR FAN COMPRESSOR 1 240 360 ONLY 1 54 BLK w 1 65 WHT LPSI WRT CCH No I W29 ORN 2 52 COMPRESSOR 2 24 VOLT INPUTS cw H
11. NOTE Partitions shown indicate both side supply 580H and vertical supply 580G units PARTITION PARTITION 580G ONLY X POWER EXHAUST BAROMETRIC RELIEF DAMPER HOOD All electrical connections have been made and adjusted at the factory The power exhaust blowers and barometric relief damp ers are shipped assembled and tilted back into the unit for shipping Brackets and extra screws are shipped in shrink wrap around the dampers If ordered each unit will have 4 power exhaust blowers and motors or 4 barometric relief dampers 1 Remove 9 screws holding each damper assembly in place See Fig 30 Each damper assembly is secured with 3 screws on each side and 3 screws along the bottom Save screws 2 Pivot each damper assembly outward until edges of damper assembly rest against inside wall of unit CAUTION Be careful when tilting blower assembly Hoods and blowers are heavy and can cause injury if dropped 3 Secure each damper assembly to unit with 6 screws across top 3 screws provided and bottom 3 screws from Step 1 of damper 4 With screws saved from Step 1 install brackets on each side of damper assembly 5 Remove tape from damper blades DAMPER LINKAGE CONDENSATE RETURN DRAIN AIR 5800 Fig 29 Economizer Details 18 10 19 12 00 12 00 10 19 NOTES 1 Unless otherwise specified all dimension
12. VOLTAGE COMPRESSOR POWER COMBUSTION NOMINAL OFM IFM POWER SUPPLY VOLTAGE RANGE 1 No 2 EXHAUST FAN MOTOR 580G H 3 Ph 60 Hz un Kas ap 10 30 8 0 96 151 9 149 1 200 200 28 0 23 6 41 6 0 96 175 5 172 7 225 225 2 1 15 46 2 0 96 167 3 163 1 200 200 42 0 23 6 41 6 0 96 190 9 186 7 225 225 20 59 4 0 96 180 5 175 1 225 225 54 0 23 6 41 6 0 96 204 1 198 7 250 250 0 50 71 3 90 0 50 78 3 100 ema 0 50 84 3 100 0 50 57 4 70 0 50 63 4 80 0 50 68 4 80 10 30 8 0 96 169 9 167 1 225 200 28 0 23 6 41 6 0 96 193 5 190 7 250 225 2 15 46 2 0 96 185 3 181 1 225 225 i 42 0 23 6 41 6 0 96 208 9 204 7 250 250 20 59 4 0 96 198 5 193 1 250 250 54 0 23 6 41 6 0 96 222 1 216 7 275 250 0 50 77 0 100 0 50 84 0 100 0 50 90 0 110 0 50 61 9 80 0 50 67 9 80 0 50 72 9 90 460 575 460 B LEGEND EXAMPLE Supply voltage is 460 3 60 FLA Full Load Amps 452 v HACR Heating Air Conditioning and Refrigeration A B C BC 464 v IFM Indoor Evaporator Fan Motor AC 455 v LRA Locked Amps Minimum Circuit Amps 452 464 455 MOCP Maximum Overcurrent Protection Average Voltage 3 NEC National Electrical Code OFM Outdoor Condenser Fan Motor _ 1371 RLA Rated L
13. in 8 6 11 1 8 1 Nominal Fan Shaft Diameter 11836 11836 Belt Quantity Type a 2 51 2 5VX530 2 5VX530 Belt Length in 50 53 Pulley Center Line Distance in Factory Speed Setting rpm FURNACE SECTION Rollout Switch Cutout Temp F tt Burner Orifice Diameter in drill size Natural Gas Std Liquid Propane Alt Thermostat Heat Anticipator Setting amps Stage 1 1 8 7 Stage 2 Gas Input Btuh Stage 1 Low High Stage 2 Low High Efficiency Steady State 82 82 82 82 Temperature Rise Range 15 45 35 65 15 45 35 65 15 45 35 65 15 45 35 65 Manifold Pressure in wg Natural Gas d 3 5 3 5 3 5 3 5 Liquid Propane 3 5 3 5 3 5 3 5 Gas Valve Quantity 2 2 2 2 Field Gas Connection Size 1 5 1 5 1 5 1 5 HIGH PRESSURE SWITCH psig Cutout 426 426 426 Reset Auto 320 320 320 320 LOW PRESSURE SWITCH psig Cutout T 7 7 7 Reset Auto 22 22 22 22 RETURN AIR FILTERS Quantity Size in 10 20x24x2 10 20x24x2 10 20x24x2 10 20x24x2 OUTDOOR AIR FILTERS 8 16 25 Quantity Size in 4 20 25 POWER EXHAUST Direct Drive 3 Speed Single Phase Motor Factory Wired for High Speed Forward Curved Fan 4 1 Motor Quantity Hp Fan Diameter Width in 11 10 LEGEND Motor and drive shown will deliver approximately 2 5 in net external static For more fan motor data see Table 2 Al Aluminum tRollout switch is manual reset Cu C
14. start up Otherwise damage to compressor may result 11 The optional non modulating power exhaust is a two stage design where the operation of the exhaust fans is linked to economizer position When the supply fan is running and the economizer is 25 open the base module closes contacts activating 2 exhaust fans When the economizer position reaches 75 open the base mod ule activates the other 2 exhaust fans The fans will turn off when the economizer closes below the same points START UP COOLING SECTION START UP AND ADJUSTMENTS N CAUTION Complete the required procedures given in the Pre Start U p section on page 20 before starting the unit Do not jumper any safety devices when operating the unit Do not operate the compressor when the outdoor tem perature 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 A Checking Cooling Control Operation Start and check the unit for proper cooling control operation as follows Place SYSTEM switch in COOL position and FAN switch in AUTO position Set cooling control below room temperature Observe that compressor condenser fan motor and evapora tor blower motors start Observe that cooling cycle shuts down when control setting is satisfied B Cooling Sequence of Operation On power up the control module will activate the initializa tion software T
15. 1B5V110 5VX590 59 2B5V86 2 5VX530 53 2 2B5V94 2 BX52 55 2 5VX500 50 2 5VX530 53 2 2B5V80 2B5V86 BX51 54 5VX530 53 2B5V90 2B5V90 5VX530 53 2B5V86 B 580H Units Remove shipping covers from supply and return air open ings Attach field supplied ductwork to unit Usea single duct over both return openings and a single duct over both sup ply openings See Fig 3 for duct opening dimensions Secure all ducts to the building structure See Fig 6 Use flexible duct connectors between unit and ducts as required Install accessory barometric relief or power exhaust in the field fabricated return ductwork Refer to Power Exhaust Barometric Relief Damper Hood section for more information SUPPLY Al AIR Fig 5 Air Distribution Thru the Bottom ECONOMIZER AIR RETURN AIR SUPPLY AIR CONDENSATE DRAIN Fig 6 Air Distribution Thru the Side V FLUE HOOD Flue hood is shipped inside gas section of unit To install se cure flue hood to access panel See Fig 7 NOTE When properly installed flue hood will line up with combustion fan housing See Fig 8 GAS SECTION ACCESS PANEL 2 PER UNIT Fig 7 Flue Hood Location Fig 8 Combustion Fan Housing Location VI TRAP CONDENSATE DRAIN
16. Damper Hood 18 Accessories 19 WARNING Before performing service mainte PRE STARTSUP rhone e doe 20 21 nance operations on unit turn off main power switch START UP 21 28 to unit Electrical shock could cause personal injury Cooling Section Start Up and Adjustments DP AP Rr Pp UL RN Dan RE EN 21 A WARNING Heating Section Start Up and 1 Improper installation adjustment alteration serv Adjustments EEE 22 ice or maintenance can cause property damage per III Field Test Operation ST dune at 24 sonal injury or loss of life Refer to the User s IV and Airflow 7 Information Manual provided with this unit for more Caca details V Gas Valve Adjustment 25 VI Main Burners 28 2 Do not store or use gasoline or other flammable Vil Power Exhaust Operation 28 vapors and liquids in the vicinity of this or any other Vill Head Pressure Control 28 appliance IX Low Ambient Kit 28 What to do if you smell gas CARE AND MAINTENANCE 28 1 DO NOT try to light any appliance SERVICE 29 32 2 DO NOT touch any electrical switch or use any phone in Cleaning ERA OPE A ORE TR EUR ete 29 your building I See Fan Service and ME EE 29 3 IMMEDIATELY call your gas supplier from a neighbor s
17. economizer inlet Min clearances to be i ul ACCESS DOOR Adjacent Units 15 0 HINGED Top of Units No Overhang Condenser Coil 4 0 2 Economizer Side 6 0 H Heat Side 4 0 Filter Access Side 10 0 For Removal of Evapora tor Coil 4 For smaller service and operational clearances con tact Application Engineering department 5 Dimensions are in inches 88 1 4 i TOP COVER MUN 6 For side supply return applications a single return and supply ductwork connection is recommended for cov ering both return and both supply openings ONTROL BOX 9 Ppy opening i i i i 1 8 1 ET 73184 4 3 1 2 NPT FIELD POWER 3 4 NPT LOW VOLTAGE ONTROL BOX INDOOR BLOWER ACCESS DOOR ACCESS ACCESS PANEL HINGED 3 1 2 1891 pM 12 15 16 1 8 DIA LOW VOLTAGE RETURN L RETURN Jt 1 15178 SUPPLY SUPPLY 13 3 16 x L 6 31 32 22 11 32 49 1132 87 11716 11 11 32 a Pr l 12 578 165 3 32 L 39 7732 DIA Le 5 518 nt FIELD HIRING 2 FILTER ACCESS DOOR HINGED CONDENSER COIL ACCESS book MT ECONOMI ZER HOODS 42 518 I NPT HINGED GAS INLET HOL HOODS FIELD INSTALLED DRAIN CONN INCLUDED WITH UNIT PRE WIND FIELD INSTALLED 13 1 8 ECONOMIZER AIR TQ SUPPLY 23 Nig nie P 119 1716 1529132 z 49 11 32 HE 82 1132 INSIDE BASE RAILS gg FRAME EN 3 23 32 LIFTING POSI
18. first call basis The heating and the cooling functions cannot operate simultaneously C Cooling Capacity Control The cooling capacity staging is shown in Table 6 Table 6 Cooling Capacity Staging Table Units with 2 Compressors 1 smes o 2 2 compressori of of On On NOTE On units which require additional unloading add suction pres sure unloaders to compressor no 1 only HEATING SECTION START UP AND ADJUSTMENTS CAUTION Complete the required procedures given in the Pre Start Up section on page 20 before starting unit Do not jumper any safety devices when operating the unit Verify gas pressures before turning on heat as follows a Turn off manual gas stop b Connect pressure gage to supply gas tap See Fig 10 on page 8 c Connect pressure gage to manifold pressure tap on gas valve d Supply gas pressure must not exceed 13 5 in wg Check pressure e Turn on manual gas stop and set thermostat to HEAT position After the unit has run for several minutes verify that incoming pressure is 5 0 in wg or greater and that the manifold pressure is 3 5 wg If mani fold pressure must be adjusted refer to Gas Valve Adjustment section on page 25 A Checking Heating Control Operation Start and check the unit for proper heating control operation as follows 1 Turn on manual gas stop 2 Set thermostat setting to HEAT position 3 The evaporator fan and first sta
19. in response to the saturated condensing temperature For outdoor temperatures down to 20 F it maintains condensing temperature at 100 F CARE AND MAINTENANCE To ensure continuing high performance and to minimize the possibility of premature equipment failure periodic mainte nance must be performed on this equipment This combina tion heating cooling unit should be inspected at least once each year by a qualified service person NOTE TO EQUIPMENT OWNER Consult your local dealer about the availability of a maintenance contract WARNING The ability to properly perform mainte nance on this equipment requires certain expertise mechanical skills tools and equipment If you do not possess these do not attempt to perform any mainte nance on this equipment other than those procedures recommended in the User s Manual FAILURE TO HEED THIS WARNING COULD RESULT IN SERIOUS PER SONAL INJ URY AND POSSIBLE DAMAGE TO THIS EQUIPMENT The minimum maintenance requirements for this equi pment are as follows 1 Inspect air filters each month Clean or replace when necessary 2 Inspec cooling coil drain pan and condensate drain each cooling season for deanliness Clean when necessary 3 Inspect blower motor and wheel each heating and cooling season Clean and lubricate if required when necessary 4 Lubricate bearings every 6 months if fan runs continu ously or annually if fan runs intermittently 5 Check electrical connect
20. test Open DIP switch no 4 and then no 6 The outdoor air damper will close The control allows 90 seconds for the damper to close in case it is in the full open position Next the indoor fan contactor will energize The outdoor air damper will remain at 0 for 30 seconds It will then move to the 10 position for another 30 seconds This will be repeated at every 10 increment for 30 seconds until the damper reaches 100 open Close DIP switch no 4 during the 30 seconds immediately after the desired outdoor air minimum damper position The 30 second time period is to allow time where DIP switch no 4 can be closed The de fault value of the minimum outdoor air damper position is 20 If the desired minimum position is 30 allow the damper position to go to 10 for 30 seconds then 20 for 30 seconds and when it reaches 30 close DIP switch no 4 during the 30 second period following the 30 position The minimum outdoor air damper position is now set Close DIP switch no 6 IV INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS CAUTION For cooling operation the recommended airflow is 300 to 450 cfm per each 12 000 Btuh of rated cooling capacity For heating operation the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate A Evaporator Fan Performance Adjustment Be sure evaporator fans rotate in the proper direction See Tables 8 and 9 for Fan Performance data See Table 10 for Motor
21. the supply voltage to the control to 460 v Transform ers can be mounted anywhere outside the control box 19 G RO ik 1 SENSOR LOCATION E 10 TUBES FROM BOTTOM HAHAHA HEADER END Fig 32 Low Ambient Kit Sensor Location PRE START UP WARNING Failure to observe the following warn ings could result in serious personal injury 1 Follow recognized safety practices and wear pro tective goggles when checking or servicing refrig erant system 2 Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured 3 Donot remove compressor terminal cover until all electrical sources have been disconnected 4 Remove and redaim refrigerant from system be fore touching or disturbing anything inside termi nal 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 Sys tem contains oil and refrigerant under pressure To remove a component wear protective goggles and proceed as follows a Shut off electrical power to unit b Remove and redaim refrigerant from system 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 torc
22. unit control box Field supplied strain relief must be used going into the box After wiring is in con trol box make connections to proper terminals on terminal blocks see Field Control Wiring section on page 11 Install conduit connector in unit basepan or side panel open ings provided Route power and ground lines through con nector to connections in unit control box as shown on unit wiring diagram and Fig 13 Routing Through Side of Unit Route power wiring in field supplied watertight conduit into unit through 2 2 in hole Strain relief field supplied must be used in hole Use field supplied strain relief going into control box through 2 diameter hole provided After wires are in unit con trol box connect to power terminal block see Power Wiring section on this page Bring low voltage control wiring through factory drilled diameter hole in condenser side post Use strain relief going into 7s in diameter hole in bottom of unit control box After wiringis in control box make connection to proper ter minals on terminal blocks see Field Control Wiring section on page 11 WARNING The unit must be electrically grounded in accordance with local codes and NEC ANSI NF PA 70 National Fire Protection Association 19 1107 HOIH 35Nv c EX OW SADW EN ganw 2708 664 C gt gt 864 C gt gt eo Z o 5
23. 125 in TO 140 in SPARK GAP 142 in TO 220 in Fig 40 Spark Gap Adjustment PROPELLER FAN BLOWER MOTOR SIDE VIEW IGC MODULE SCALE 3 32 1 Torque setscrews on blower wheel to 70 in Ibs 2 in Ibs 2 Torque setscrew on propeller fan to 15 in Ibs 2 in Ibs 3 Dimensions are in inches Fig 41 Typical Gas Heating Section FLUE COLLECTOR MOTOR ASSEMBLY FLUE BOX LUE COVER COLLECTOR FLUE GAS BOX PASSAGEWAYS Fig 42 Gas Heat Section Details 30 B Fan Shaft Bearings Lubricate the bearings at least twice annually with suitable bearing grease Do not over grease Typical lubricants are shown below MANUFACTURER LUBRICANT Texaco Regal AFB 2 Mobil Mobilplex EP No 1 Sunoco Texaco Prestige 42 Multifak 2 Preferred lubricant because it contains rust and oxidation inhibitors C Condenser and Evaporator Fan Motor Bearings The condenser and evaporator fan motors have permanently sealed bearings so no field lubrication is necessary EVAPORATOR FAN SERVICE AND REPLACEMENT 1 Turn off unit power Remove supply air section panels Remove belt and blower pulley Loosen setscrews in blower wheels Remove locking collars from bearings Remove shaft Remove venturi on opposite side of bearing Lift out wheel Reverse above procedure to reinstall fan Check and adjust belt tension as necessary AB IV EVAP
24. A 24 V Circuit This control circuit is protected against overcurrent by a 3 2 amp circuit breaker CB4 Breaker can bereset If it trips determine cause of trouble before resetting B 115 V Circuit This control circuit is protected against overcurrent by a 5 0 amp circuit breaker CB3 Breaker can bereset If it trips determine cause of trouble before resetting XII COMPRESSOR LOCKOUT LOGIC If any of the safeties trip the circuit will automatically reset providing the safety has reset and restart the compressor in 15 minutes If any of the safeties trip 3 times within a 90 minute period then the circuit will belocked out and will require manual resetting by turning off either the unit dis connect or the control circuit breaker XIII REPLACEMENT PARTS A complete list of replacement parts may be obtained from any distributor upon request 32 TROUBLESHOOTING Typical refrigerant circuiting diagram is shown in Fig 44
25. APACITY OPERATING WEIGHT Ib nit Lo Heat Hi Heat 4176 4256 4262 4342 4262 4342 4262 4342 Al Cu Lo Heat Hi Heat 4396 4476 4482 4562 4482 4562 4482 4562 Roof Curb 14 in curb 365 365 COMPRESSOR Type Ckt 1 06D328 06D328 06D537 06D537 Ckt 2 06D818 06D328 06D328 06D537 Number of Refrigerant Circuits 2 2 2 2 Oil oz Ckt 1 Ckt 2 115 88 115 ea 115 ea 115 ea REFRIGERANT TYPE Operating Charge Ib oz Circuit 1T Circuit 2 CONDENSER COIL Quantity Rows Fins in 4 15 Total Face Area sq ft 33 3 CONDENSER FAN Propeller Type Nominal Cfm 13 420 13 420 Quantity Diameter in 30 2 30 2 30 Motor Hp 1075 Rpm EVAPORATOR COIL Rows Fins in M Total Face Area sq ft 31 7 31 7 EVAPORATOR FAN Centrifugal Type Quantity Size in 2 20 15 2 20 15 2 20x15 2 20x15 Cross Hatched 3 Copper Tubes Aluminum Lanced Aluminum Pre Coated or Copper Plate Fins 1 1 Cross Hatched 3 Copper Tubes Aluminum Plate Fins Intertwined Circuits 4 15 4 15 Type Drive Nominal Cfm Belt 8 000 Belt 10 000 Belt 11 000 Belt 12 000 Motor Hp 5 10 10 15 20 15 Motor Frame Size Standard S184T S215T 5215 D254T S256T D254T High Efficiency S184T S215T 215 S254T S256T S254T Motor Bearing Type Ball Ball Ball Maximum Allowable Rpm 1200 1200 1200 Motor Pulley Pitch Diameter 4 4 6 1 4 9 5 9 Nominal Motor Shaft Diameter in 1 1 1 Fan Pulley Pitch Diameter
26. BLK 910 YEL Hed 397 YEL OF M2 130 BLU i w98 BLU CONNECT TO APPROPRIATE ok UNIT VOLTAGE 2S SEE NOTE 41 I PLI 8 PL2 8 yy su SEE 24V LABEL PLI T PL2 7 OR WIRE GAS UNITS ONLY ty CONTINUATION NON MODULATING OR POWER EXHAUST PLS TRANI SECONDARY 120v LS 1 52 334 BS caue BLK PL5 2 PEMI 13 Kis VEL gt was YEL onn CONDAM PEC2 KH H2D 925436 MONIO DERE NT BLK PEW2 5 4 PL6 4 Q3 155 EL ret 5 gt 2 annas tt Ti SEE WOTE Ao I PEC3 6 11 L 1 1 TH BL BL eux TRAK 1 1 YEL PEN3 A YEL SE 4154 YEL 5 149 YEL z PEC4 PLS 1 3 PL6 1 3 5 42 gt 4d PLS 1 4 PEM4 L r _ gt wisi t E PEE NOTES 1 Connect TRAN1 to H4 for 460 v units Connect for 230 v If 208 230 v units are run with a 208 v power supply connect to H2 2 Connect TRAN2 to black lead for 460 v units Connect to orange lead for 230 v units If 208 230 v units are run with a 208 v power supply connect to red lead 3 Circuit breaker must trip amps are equal to or less than 156 FLA for CB1 and 2 All others are 140 4 If any of the original wire furnished must be replaced it must be replaced with type 90 C wire or its equivalent 5 Compr
27. D SERVICE TRAINING Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual Product programs cover Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs is available All programs include a video cassette and or slides and a companion booklet Use these for self teaching or to conduct full training sessions ae Service Training Material Catalog STM call 1 800 962 9212 Ordering instructions are included Copyright 1997 Carrier Corporation CATALOG NO 5358 000 START UP CHECKLIST MODEL NO SERIAL NO SOFTWARE VERSION SEE FIG 11 20 TECHNICIAN DATE PRE START UP VERIFY THAT DIP SWITCH SETTINGS ARE CORRECT VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT REMOVE ALL SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS VERIFY INSTALLATION OF ECONOMIZER HOOD VERIFY INSTALLATION OF ALL OPTIONS AND ACCESSORIES VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT CHECK GAS PIPING FOR LEAKS CHECK THAT INDOOR AIR FILTERS ARE CLEAN AND IN PLACE VERIFY THAT UNIT IS LEVEL WITHIN TOLERANCES CHECK FAN WHEELS AND PROPELLERS FOR LOCATION IN HOUSING ORIFICE AND VERIFY SETSCREW IS TIGHT VERIFY THAT SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED VERIFY THAT SUCTION
28. DE Fig 19 Add Seal Strip to Hood Top Mounting Flange GRAY FOAM STRIP CROSS MEMBER Fig 20 Adding Foam Strip to Cross Member 15 HOOD SIDE SLOTTED Fig 21 Adding Foam Strip to Hood Side BLOCKOFF BAFFLE GRAY FOAM STRIP Fig 22 Adding Foam Strip To Blockoff Baffle 4 Remove screws along bottom of damper assembly Lo cate and mount blockoff baffle using these screws 5 Assemble 2 filter tracks side by side with the as sembled ends together 6 a Attach mounting angle without tabs to the as sembled end of the filter track See Fig 23 b Attach 6 green clips provided to mounting angles Engagement section of clip faces inside of rack c Attach remaining mounting angle with tabs to other end of the filter track with no 10 screws provided See Fig 24 7 a Place filter track assembly in bottom of hood by plac ing tabbed end into slotted side with tab on bottom and attaching opposite end to hood with speed clips and gasketed screws provided Tabs can be hand bent after inserted into the side NOTE The filter track assembly end with screws should face away from the other hood when mounted on the unit NOTE Tabs from both filter tracks will be in the same space After one filter track has been inserted into board bend the tabs so they will not interfere with installation of the second hood b Attach black seal strip to filter cover Seal strip should be applied to fl
29. DISCHARGE AND LIQUID SERVICE VALVES ON EACH CIRCUIT ARE OPEN START UP ELECTRICAL SUPPLY VOLTAGE L112 L2 L3 _ L3 L1 COMPRESSOR AMPS COMPRESSOR NO 1 L1 L2 L3 COMPRESSOR NO 2 11 L2 L3 SUPPLY FAN AMPS EXHAUST FAN AMPS TEMPERATURES OUTDOOR AIR TEMPERATURE F DB Dry Bulb RETURN AIR TEMPERATURE DB F WB Wet Bulb COOLING SUPPLY AIR GAS HEAT SUPPLY AIR aF PRESSURES GAS INLET PRESSURE WG GAS MANIFOLD PRESSURE STAGE NO 1 WG STAGE NO 2 WG REFRIGERANT SUCTION CIRCUIT NO 1 PSIG CIRCUIT 0 2 PSIG REFRIGERANT DISCHARGE CIRCUIT NO 1 _______ PSIG CIRCUIT NO 2 PSIG VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGE 31 CL 1 GENERAL SET ECONOMIZER MINIMUM VENT POSITION TO J OB REQUIREMENTS HIGH PRESSURE SWITCH SETTING PSIG LOW PRESSURE SWITCH SETTING PSIG MOTOR PULLEY PART NUMBER FAN PULLEY PART NUMBER BELT PART NUMBER BELT SIZE in FILTER QUANTITY FILTER SIZES in ADDITIONAL NOTES ENSURE DRIVES OPERATE WITHIN LIMITS OF FAN PERFORMANCE TABLES Copyright 1997 Carrier Corporation CATALOG NO 5358 000 CUT ALONG DOTTED CUT ALONG DOTTED LINE
30. DOOR HINGED I NPT DRAIN CONN 165 3 32 INDOOR MOTOR ACCESS DOOR HINGED 49 11 32 88 FRAME LIFTING POSITION 91 112 OVERALL LIFTING 94 SHIPPING DIM NPT 12 GAS INLET HOLE 3 8 DIA HOLE IN LIFTING LUG 22 17 32 17 17 32 30 7 32 5 5 8 ONDENSER COIL ECONOMIZER HOODS HOODS FIELD INSTALLED INCLUDED WITH UNIT 42 5 8 WIND CAP FIELD INSTALLED 13 118 11 29 32 3 82 1 32 3 23132 POWER EXHAUST OR BAROMETRIC RELIEF HOODS INSIDE BASE d NR E UNIT SIZE OPERATING K e us CEN 240 350 0 6 240 525 4256 6 1 6 3 61 6 917 973 1218 1148 EP ee 4262 5 958 3 8 899 899 1232 1232 4342 5 10 3 8716 929 916 1240 1257 360350 462 5 9 3 8 899 899 1232 1232 360525 4342 sion sens 929 ie 1240 1257 Fig 2 Base Unit Dimensions 580G240 360 ELS xi 1 Weights include economizer STD 10 172 2 Center of gravity SNR 3 Do not locate adjacent units with flue discharge facing
31. L SECONDART nik oqa eC CONTINUATION NON MODULATING OR MODULATING POWER EXHAUST 15 1 PL6 10H KED Bik BLK 35 I PLS 2 PL6 2 car EEMI IH H3 92 4s ES s t 24107 fti 3 I I PEC2 PLS 3 PL6 3 KID 8u 355 24138 BLK _ PLS 4 PL6 4 lear _ BH Kass vt gt 56 t 35 5948 vet 25 orn i er PEC3 15 1 1 PL6 1 I ces NTH ZT iss Bu 40 gt w eus WISI ORN PL5 1 2 Pi6 1 2 me PENS T af 1 L PRIMARY 2 2 z oc PECA PLS_1 3 61 3 3 KID anh pr 4 I amp 120v wt PENS PL5 1 4 PL6 1 4 Yt gt ani 51 v 5 5 50 rti 4 NOTES 1 Connect TRAN1 to H4 for 575V units 2 Connect TRAN to black lead for 575V units 3 Circuit breaker must trip amps are equal to or less than 15696 FLA for CB1 and CB2 All others are 14076 4 If any of the original wire furnished must be replaced it must be replaced with Type 90 C wire or its equivalent 5 Compressors and or fan motors are thermally protected 6 Three phase motors are protected against primary single phasing conditions Fig 48 Power Schematic 580G H240 360 575 3 60 39 27 BLK 25 BLK A96 w58 BLK 4150 BLK 25 BLE
32. Limitation data See Table 11 for air quantity limits IMPORTANT Check to ensure that the unit drive matches the duct static pressure using Table 8 Fan motor pulleys are factory set for speed shown in Table 1 To change fan speeds change pulleys To align fan and motor pulleys Fig 34 Shut off unit power supply Loosen fan shaft pulley bushing Slide fan pulley along fan shaft Make angular alignment by loosening motor from mount ing plate 5 Retighten pulley AN STRAIGHTEDGE MUST BE PARALLEL WITH BELT PULLEY MOTOR AND FAN SHAFTS MUST BE PARALLEL PULLEY Fig 34 Evaporator Fan Pulley Alignment and Adjustment B Belt Tension Adjustment To adjust belt tension 1 Remove power to unit 2 Remove motor mount nuts and bolts 3 Loosen fan motor nuts See Fig 35 24 MOUNTING NUTS AND BOLTS MOTOR JACKING J BOLIS FAN MOTOR NUTS Fig 35 Belt Tension Adjustment 4 Turn motor jacking bolts to move motor mounting plate left or right for proper belt tension Refer to Table 2 for proper belt tension 5 Tighten nuts 6 Adjust bolts and nut on mounting plate to secure motor in fixed position Recheck belt tension after 24 hours of operation Adjust as necessary C Condenser Fan Adjustment Shut off unit power supply Remove fan guard Loosen fan hub setscrews Adjust fan height on shaft using a straightedge placed across venturi and me
33. ORATOR FAN MOTOR REPLACEMENT 1 Shut off unit power supply 2 Remove upper outside panel and open hinged door to gain access to motor 3 Fully retract motor plate adjusting bolts 4 Loosen the 2 rear nearest the evaporator coil motor plate nuts 5 Removethe 2 front motor plate nuts and carriage bolts 6 Slide motor plate to the rear toward the coil and remove fan belt s 7 Slide motor plate to the front and hand tighten one of the rear motor plate nuts tight enough to prevent the motor plate from sliding back but loose enough to al low the plate to pivot upward 8 Pivot the front of the motor plate upward enough to allow access to the motor mounting hex bolts and secure in place by inserting a prop 9 Remove the nuts from the motor mounting hex bolts and remove motor 10 Reverse above steps to install new motor V POWER FAILURE Dampers have spring return event of power failure damp ers will return to fully closed position until power is restored VI REFRIGERANT CHARGE Amount of refrigerant charge is listed on unit nameplate and in Table 1 Refer to 11 Module 5 Charging Recovery Recycling and Reclamation section for charging methods and procedures Unit panels must be in place when unit is operating during charging procedure A No Charge Use standard evacuating techniques After evacuating sys tem weigh in the specified amount of refrigerant refer to Table 1 B Low C
34. RGE IF ABOVE CURVE 1904 TT T3344 80 REDUCE CHARGE IF BELOW CURVE LIQUID TEMPERATURE AT LIQUID VALVE DEG F 50 100 150 200 250 300 350 400 LIQUID PRESSURE AT LIQUID VALVE PSIG Fig 43 Cooling Charging Chart 580G H240 360 31 Vil FILTER DRIER Replace whenever refrigerant system is exposed to atmosphere Vill THERMOSTATIC EXPANSION VALVE TXV Each circuit has one It is nonadjustable and is factory set to maintain 10 to 13 F superheat leaving the evaporator coil Controls flow of liquid refrigerant to the evaporator coils IX PROTECTIVE DEVICES A Compressor Protection Overcurrent Each compressor has one manual reset calibrated trip mag netic circuit breaker Do not bypass connections or increase the size of the circuit breaker to correct trouble Determine the cause and correct it before resetting the breaker Overtemperature Each 06D type compressor has an internal protector to pro tect it against excessively high discharge gas temperatures Crankcase Heater Each compressor has a crankcase heater to prevent absorp tion of liquid refrigerant by oil in the crankcase when the com pressor is idle Since power for the crankcase heaters is drawn from the unit incoming power main unit power must be on for the heaters t
35. RICAL CONNECTIONS A Controls Options The standard constant volume CV units as shipped are operable as stand alone units using a standard mechanical or electronic 2 stage heat 2 stage cool thermostat With a standard thermostat programmable is optional heat ing and cooling operation is set by space temperature The standard DDC direct digital controls are installed in the con trol box The DDC control board diagram is shown in Fig 11 Features with Thermostat Control of Unit two stage heating two stage cooling control of unit using Y1 Y2 W1 W2 and G thermostat inputs control of the indoor fan outdoor air temperature supply air temperature monitoring control of modulating economizer damper to provide free cooling when outdoor conditions are suitable using supply air temperature as a control point control of the economizer damper and indoor fan to obtain unoccupied free cooling provide power exhaust output to an external power exhaust controller support a field test for field checkout control of 2 stages of CV power exhaust compressor time delay for power up and minimum off and on times An electronic expansion board may be field installed to pro vide the following features control of modulating economizer damper to maintain indoor air quality IAQ when outdoor conditions are suitable NOTE The IAQ sensor must be set for current output 4 to 20 mA This requires removing the sensor cover an
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37. SURE in wg AIRFLOW 02 o4 06 os 10 12 14 16 TQ 0102 D amp IG O cO LONDON ES ET ER ND ND 02N BSD ouw P O 0 amp ON NO 0101 UN E NB NN 6 ID O D GQ CO O O1 01 OO CO TO CNORROND VINS NN 0 1 1 2 3 3 4 5 6 8 AIRFLOW Cfm AVAILABLE EXTERNAL STATIC PRESSURE LEGEND AIRFLOW in wg Bhp Brake Horsepower Cm 34 36 38 d x Bhp Rpm Bhp Rpm Bhp A Ra i i i 1 Fan performance is based on wet coils economizer roof curb cabinet losses and clean 2 in filters 2 Conversion Bhp to watts Bhp x 746 Watts Motor efficiency 26 Table 9 Fan Performance Power Exhaust 580G H240 360 230 460 575v 230 460 575v 208v 230 460 575 ESP Bhp Watts ESP Bhp wats ESP np Wans ESP Bhp wats ESP np wans ESP Bhp wans 0 60 3 69 0 73 3 98 0 56 3 74 0 69 4 02 0 51 3 78 0 65 4 07 0 41 3 83 0 56 4 12 0 31 3 93 0 47 4 23 0 20 4 07 0 37 4 37 0 11 4 17 0 30 4 47 0 04 4 25 0 23 4 56 0 17 4 66 0 12 4 75 0 07 4 80 0 04 4 83 LEGEND Bhp Brake Horsepower ESP External Static Pressure in wg Watts Input Watts to M
38. TION 3 8 DIA 31 172 HOLE IN LIFTING LUG ga OVERALL LIFTING SHIPPING DIM OPERATING CORNER WEIGHT UNIT SIZE RE VE p sr ox T22 240525 4256 6 19 36 917 973 1218 1148 300350 4262 5 5 38 899 899 1232 1232 300525 434 510 38 929 916 1240 1257 324525 426 s o 38 1991 899 1232 1232 324525 432 510 38 929 916 1240 1257 360350 4262 s o 8 899 1232 1232 360525 4342 510 se Fig 3 Base Unit Dimensions 580H240 360 CAUTION NOTICE TO RIGGERS ALL PANELS MUST BE IN PLACE WHEN RIGGING NOTE Rig with four cables and spread with two 92 in 2337 mm spreader bars Maintain a distance of 74 in 1880 mm from top of unit to eyehook NOTE Add 32 16 14 5 kg for domestic crating Add 312 Ib 142 kg for export crating Add 220 Ib 100 kg for copper condenser coil Add 250 Ib 113 kg for power exhaust weent B C 580GH ib kg in mm in mm in mm 240 350 4176 1894 72 4 1839 42 4 1072 240 525 4256 1930 73 3 1862 42 7 1085 87 68 2227 300 350 324 350 4262 1933 1768 44 0 1118 360 350 300 525 324 525 4342 1969 70 1 1781 44 3 1125 360 525 Fig 4 Rigging Label Table 1 Specifications SGH 90 3e o 3 I 39 NOMINAL C
39. adjacent to the outdoor air thermistor 4 Locate the red violet and brown wires near the out door air thermistor Remove the splice from the red and violet wires Remove the cap from the brown wire 5 Install 4 in push on terminal field supplied on the violet and brown wires 6 Connect 4 in push on terminal field provided to one end of a 18 gage 6 in jumper wire field provided Con nect the other end to the red wire and attach a Vin push on connector field provided 7 Connect the red wire with the jumper to terminal TR1 Connect the jumper to terminal 2 Connect the brown wire to terminal TR Connect the violet wire to termi nal 3 All connections are on the enthalpy control 8 Replace the economizer filters 9 Return power to unit Accessory Differential Enthalpy Control Fig 26 The control HH57AC077 in conjunction with the accessory enthalpy sensor 57 078 controls economizer opera tion according to the differential enthalpy The control is mounted in the economizer hood The sensor is mounted in the return duct 580G or the return air plenum 580H Differential Enthalpy Sensor Installation To install the control perform the following procedure 1 Turn off all power Ensure disconnect is locked out 2 Remove the economizer inlet filters from the bottom of the right hand economizer hood 3 Remove the factory installed 620 ohm jumper be tween terminals SR and the enthal
40. amper will close The control allows 90 seconds for the damper to close in case it was in the full open position Next the indoor fan con tactor will be energized and the outsideair damper will begin to open to its default value of 20 and stay at that po sition for a short period of time The outdoor air damper will then open to its full open position and stay at that position for a short period of time The outdoor air damper will then close If the unit is equipped with power exhaust stage 1 will be energized for 5 seconds If the unit is configured for stage 2 of power exhaust stage 2 will be energized for 5 seconds after the first stage is deenergized The first stage of heat will be energized for 30 seconds after which the second stage heat will be energized for an addi tional 30 seconds Heat is then deenergized The last step is the Cooling mode Outdoor fan contactor no 1 is energized This is followed by each stage of cooling energized with a 10 second delay between stages After this is complete outdoor fan contactor no 2 is energized for 10 seconds compressors will now deenergize followed by the outdoor fan contactors and indoor fan contactors If the unit is equipped with the Integrated Gas Control IGC board the indoor fan will operate for an additional 30 seconds after deenergizing the circuit Setting of the outdoor air damper position is performed in con junction with a shortened version of the field
41. ange covering holes and center of large flange See Fig 25 8 Slide two 20 x 25 in filters into cross members of hood assembly Attach filter cover over filters with screws and speed clips provided Minimum Damper Position Setting Setting of the outdoor air damper position is performed in conjunction with a shortened version of the field run test This is performed by first opening DIP switch no 4 then no 6 The outdoor air damper closes The control allows 90 seconds for the damper to close in case it is in the full open position Next the indoor fan contactor will energize The outdoor air damper will remain at 0 for 30 seconds It will then move to the 10 position for another 30 seconds This will be repeated at every 10 increment for 30 seconds until the damper reaches 100 open Close DIP switch no 4 during the 30 seconds immediately after the desired outdoor air mini mum damper position The 30 second time period is to allow time where DIP switch no 4 can be closed The default value of the minimum outdoor air damper position is 20 If the desired minimum position is 30 allow the damper posi tion to go to 10 for 30 seconds then 20 for 30 seconds and when it reaches 30 close DIP switch no 4 during the 30 second period following the 30 position The minimum outdoor air damper position is now set Close DIP switch no 6 B Economizer Settings Accessory Enthalpy Control Fig 26 The control HH57AC077 is mo
42. asure per Fig 36 Tighten setscrews and replace fan guard 6 Turn on unit power Q N V GAS VALVE ADJUSTMENT A Natural Gas The gas valve opens and closes in response to the thermostat or limit control When power is supplied to valve terminals 3 and 4 the pilot valve opens to the preset position When power is supplied to terminals 1 and 2 the main valve opens to its preset position The regular factory setting is stamped on the valve body 3 5 in wg To adjust regulator 1 Turn field supplied main gas valve to OFF position Set thermostat at setting for no call for heat Remove Ye in pipe plug from manifold Install a water manometer pressure measuring device Set main gas valve to ON position Set thermostat at setting to call for heat Remove screw cap covering regulator adjustment screw See Fig 37 Turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure Once desired pressure is established set thermostat set ting for no call for heat turn off main gas valve remove pressure measuring device and replace s in pipe plug and screw cap 25 REGULATOR ADJUSTMENT SCREW REMOVE COVER PILOT ADJUSTMENT SCREW REMOVE COVER Fig 37 Gas Valve Table 8 Fan Performance 580G240 360 Vertical Discharge Units For 580H units reduce net available external static pressure by 0 3 in wg AVAILABLE EXTERNAL STATIC PRES
43. cally reset HF 05 SAT Thermistor Failure The supply air temperature SAT sensor has failed First check for wiring errors then replace sensor HF 06 OAT Thermistor Failure The outside air temperature OAT sensor has failed First check for wiring errors then replace sensor 7 HF 03 DIP Switch 2 is Open Close DIP switch 2 HF 12 DIP Switch 1 is Open Close DIP switch 1 a SE 05 Loss of Communications Communications between the expansion board and the control with Expansion Board board have been interrupted Ensure that an expansion board is installed and wired using the wire harness supplied with the expansion module If an expansion board is not used ensure that DIP switch position 3 is in the closed position and reset power HF 16 Control Board Failure Generated when hardware has failed on control board Replace the control board HF 17 Expansion Board Failure Generated when hardware has failed on the expansion board Replace the expansion board LEGEND DIP Dual In Line Package LED Light Emitting Diode ERROR CODE SUMMARY INPUT AND OUTPUT CHANNEL DESIGNATIONS A summary of the error codes is listed in Table 13 If more Table 14 shows the input and output channel designations than one error code exists they will be displayed on theLED The Integrated Gas Controls for heating and cooling are shown of the IGC board in sequence Fault history is deleted when in Fig 45 power is turned off Table 13 IGC Boar
44. d Sensor Install the sensor for thermistor input control in the location shown in Fig 32 Connect sensor leads to the violet and grey control signal leads on the Motormaster 111 control Signal Sdection Switch Remove the cover of the Motor master 111 control Set the switch to accept the thermistor sensor input signal Set the frequency to match the unit power supply 60 Hz gt 1 BOTH SIDES lt 77 7 0 312 DIA HOLES 61 17 167 BETWEEN HOLES TYPICAL CROSS BREAK 78 7 0 5 4 62 lt NOTE All dimensions in inches Material 20 gage galvanized steel or other non corrosive material Fig 31 Motormaster Ill Baffle Details Motormaster 111 Control The recommended mounting location is in the indoor fan section mounted on the panel that separates the indoor and outdoor sections Electrical Connections WARNING To avoid possibility of electrical shock and personal injury turn off all power to unit before mak ing electrical connections When replacing the OFM reconnect the black yellow and blue wires from the outdoor fan contactor to the black yel low and blue wires of the Motormaster control Run new wires from the red orange and brown wires to the leads of the new OFM Connect the green wire from the control to ground NOTE On all 575 v units 2 transformers part no 1 851 must be used for each Motormaster 111 control to lower
45. d Error Code Summary INDICATION 1 FLASH 2 FLASHES 3 FLASHES 4 FLASHES 5 FLASHES 6 FLASHES 7 FLASHES 8 FLASHES 34 Table 14 1 0 Channel Designations Base Module ASSIGNMENT RE OAT 5 Thermistor C C Hil ES T15 16 Y2 DI 24 vac 1 DI 24 vac W2 DI 24 vac G DI 24 vac Compressor 1 Safety DI 24 vac Compressor 2 Safety DI 24 vac Outside Air Enthalpy DI 24 vac Economizer Pos AO 4 20 mA Heat 1 Relay DO 24 vac T30 29 Heat 2 Relay DO 24 vac CV Power Exhaust 1 Modulating Pwr Exht DO 115 vac OFC2 DO 115 vac ur LEGEND AO Analog Output Constant Volume DI Direct Input DO Direct Output High Voltage Kilo Ohms OAT Outdoor Air Thermistor OFC Outdoor Condenser Fan Contactor SAT Supply Air Thermistor T Terminal NOTE For 4 to 20 mA signals all even numbered terminals are negative polarity all odd numbered terminals are positive polarity 3 FLASHES FLAME SENSOR INDICATES FLAME WITH CLOSED GAS VALVE E OUTDOOR FAN MOTOR START IMMEDIATELY WY FROM THERMOSTAT ENERGIZES W ON IGC 1 MINUTE LOCK ON 1 SECOND ON DELAY FOR ndi COMBUSTION RELAY IS ENERGIZED COOLING DEMAND COMBUSTION RELAY ENERGIZES INDUCED DRAFT MOTOR IDM THROUGH TERMINAL
46. d remov ing a jumper on the sensor See Fig 12 provide discrete inputs for fan status filter status field applied status and demand limit provide an output for the external alarm light indicator provide power exhaust fire outputs for direct control of power exhaust stages during fire or smoke control modes control of smoke control modes including evacuation smoke purge pressurization and fire shutdown non modulating or modulating power exhaust required B Power Wiring Units arefactory wired for the voltage shown on the unit name plate The main terminal block is suitable for use with alu minum or copper wires When installing units provide a disconnect per NEC National Electrical Code of adequate size MOCP maxi mum overcurrent protection of unit is on the informative plate All field wiring must comply with NEC and all local codes Size wire based on MCA minimum circuit amps on the unit informative plate See Fig 13 for power wiring connections to the unit power terminal block and equipment ground The main power terminal block is suitable for use with alu minum or copper wire See Fig 13 Units have circuit break ers for compressors fan motors and control circuit If required by local codes provide an additional disconnect per NEC and local codes requirements of adequate size Table 3 When ever external electrical sources are used unit must be elec trically grounded in accordance with local codes
47. des which can be used to control smoke within the con ditioned area The modes of operation are fire shutdown pres surization evacuation and smoke purge See Table 7 E Smoke Detector A smoke detector can be used to initiate fire shutdown This can be accomplished by a set of normally closed pilot relay contacts which will interrupt power from the 24 v trans former secondary B terminal to the control circuit breaker CB4 See Fig 33 The wire that connects these two points is white and labeled W78 NOTE On standard gas models the indoor fan will continue torun 45 seconds after the call for heat has been terminated If fire shutdown is initiated the fan will stop immediately No 45 second delay will occur The smoke detector may be mounted in the return air duct or the supply duct F Indoor Air Quality Control The accessory expansion board and accessory AQ sensor are required for control The IAQ sensors operate with a 4 to 20 mA signal The 4 to 20 mA signal is connected to T11 T12 on the expansion board for the IAQ sen sor and T13 and T14 on the expansion board for the OAQ Outdoor Air Quality sensor The sensor is field mounted and wired to the expansion board installed in the unit main control box The I AQ sensor must be powered by a field supplied 24 v power supply ungrounded Do not use the unit 24 v power supply to power the sensor Once installed the sensor must b
48. e enabled The sensor is con figured with default values which may be changed through network access software To work properly the IAQ sensor high and low reference points for the sensor that is used must match the configured values The expansion board reacts to a 4 to 20 mA signal from the IAQ sensor The low reference 4 mA output must be configured to the minimum sensor reading The high reference 20 mA output must be configured to the maximum IAQ sensor reading IAQ sensor be configured to either low or high pri ority The priority value can be changed by the user The default is low Low Priority When the priority is set to low the initial control is to the set point but the outside air damper position will change toits minimum position when the space temperature is greater than the occupied cooling set point plus 2 F or when the space temperature is less than the occupied heating set point minus 2 F The damper will also change to minimum posi tion when the outdoor air quality is greater than the outdoor air quality set point ppm High Priority When the priority is set to high the IAQ set point controls the outside air damper exclusively with no regard to comfort conditioning G Time Guard Circuit The Time Guard function built into the rooftop control board maintains a minimum off time of 5 minutes a minimum on time of 10 seconds and a 10 second delay between compres sor start
49. e maxi mum delay is 3 minutes Once modified the fan off delay will not change back to 45 seconds unless power is reset to the control C Power Exhaust Operation The optional power exhaust packages are factory or field installed with vertical units and optionally installed in the return air ductwork for horizontal applications The stand ard and the modulating power exhaust used with non modulatng to modulating conversion package are the two packages offered The modulating power exhaust package is equipped with a field adjustable static pressure controller to stage up to 4 power exhaust stages which will maintain a building static pressure The blue controller located in the control box below the control board can be adjusted by removing the covers and adjusting the set point dial to the desired building pressure The blue controller monitors the 4 individual sequencers which activate the 4 individual power exhaust motors The standard power exhaust package 22 controls up to 2 stages of power exhaust to maintain building pressure The power exhaust package can be configured to deliver positive or negative building pressure These power exhaust stages are staged according to a percentage of the economizer dampers position Default values are 25 for Stage 1 and 75 for Stage 2 D Smoke Control Modes The 580G H units with an optional expansion board perform fire and smoke control modes The expansion board provides 4 mo
50. e service port on the liquid line valve and one on the compressor discharge valve Crankcase heaters are energized as long as there is power to the unit except when the compressors are operating IMPORTANT Unit power must be on for 24 hours prior to start up Otherwise damage to compressor may result Proceed as follows to inspect and prepare the unit for initial start up 2 Read and follow instructions on all WARNING CAU TION and INFORMATION labels attached to or shipped with unit 20 8 Ensurethat the suction discharge and liquid line serv ice valves are open Damage to the compressor could result if they are left closed Check Direct Digital Controls DIP dual in line pack age switch configuration The Direct Digital Control DDC board must be configured for each applica tion The DDC board is configured through the DIP switches located on the board There are8 DIP switches which configure 8 different applications of the DDC See Table 4 DIP switch 1 is on the left of the block DIP switch 8 is on the right of the block To open a DIP switch push the switch up with suitable tool small blade screwdriver To close a DI P switch push the switch down Factory settings are shown in Table 5 The DIP switch configurations for the unit control soft ware are as follows DIP switch 1 should be set to dosed CV operation DIP switch 2 should be set to closed thermostat DIP switch 3 is
51. edge of unit to horizontal 5 28 14 00 3 00 GASKET SUPPLIED WITH CURB BASE RAIL CROSS SECTION 2 SIDES NAIL COUNTER FLASHING FIELD SUPPLIED ROOFING FELT FIELD SUPPLIED CANT STRIP FIELD SUPPLIED RIGIO INSULATION FIELD SUPPLIED NOTE On retrofit jobs ductwork may be attached toold unit instead of roof curb Be careful not to damage ductwork when removing old unit B Alternate Unit Support When the preferred curb or adapter cannot be used support unit with sleepers using unit curb or adapter support area If sleepers cannot be used support long sides of unit refer to Fig 2 and 3 with 3 equally spaced 4 in x 4 in pads on each side Unit may sag if supported by corners only RIG AND PLACE UNIT Inspect unit for transportation damage File any claim with transportation agency Keep unit upright and do not drop Use spreader bars over unit to prevent sling or cable dam age Rollers may be used to move unit across a roof Level by using unit frame as a reference leveling tolerance is shown in Fig 1 See Fig 4 for additional information Unit weight is shown in Table 1 Four lifting lugs are provided on the unit base rails as shown in Fig 4 Refer to rigging instructions on unit Copy continued on page 7 81 25 ROOF CURB CROSS SECTI TYP 4 SIDES 14 GAGE 16 GAGE 43 07 24 00 1 15 38 15 60 00
52. ee of com fort for a particular installation EXPANSION BOARD ACCESSORY ONLY BASE MODULE DIP SWITCHES FAR SIDE TRANG PEC PESI 52 PES3 PES4 2 PEC3 PECA DETAIL msk THERMOSTAT CONNECTION Del 00000000 LOCATION b SEE DETAIL A LEGEND C Compressor Contactor CB Circuit Breaker DIP Dual In Line Package FU Fuse HR Heater Relay IF Indoor Fan OF Outdoor Fan PEC Power Exhaust Controller TB Terminal Block TRAN Transformer Fig 14 Control Box Diagram 11 Table 3 Electrical Data 580G H240 360 COMPRESSOR NOMINAL Berna VOLTAGE 580G H 3 Ph 60 Hz 1 RLA 160 64 228 114 91 25 6 11 5 460 575 LEGEND k E B _ FLA Full Load Amps HACR Heating Air Conditioning and Refrigeration IFM Indoor Evaporator Fan Motor LRA Locked Rotor Amps MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protection NEC National Elec
53. entaaupy 124 COMP 2 SAFETIES coup 41 SAFETIES HE 2 UNLOADER OHP 1 UNLOADER CYCLIC CORD FAN COM CONT COND FAN 240 360 ONLY W57 BLK 9 Eu su Oa wc 55 LPS2 m a 51 162 WHT 8 refe se WHT POWER EXHAUST 1 DISCRETE OUTPUTS POWER EXHAUST 2 ECONOMIZER 4 20 mA OUTPUT W38 BLU W199 BLK W47 BLU PES2 Lys BLU Kiowa GRA EI Ta 5 4141 WHT 142 PES4 was BLU C HROHH3 GRA CI rc C2 MODULATING POWER EXHAUST FIELD ACCESSORY Fig 46 115 V Control Circuit Schematic 580G H240 360 y E SEE TABLE 68 26 0 02 HK 70 YEL 424 H22 TH KZD we aur 69 TEL COMP 116 6 3 2 BLU 134 H23 w11 BLU TBI FIELD SEE TABLE SUPPLY T 9 4 BLK 7 4 HED 110 VE 0 22 n vt DH 415 COP BUTS 0 023 w78 H23 911 GRO 107 BLK K 479 BLK 2 2679 02 2 YEL 2H H2 3981 IfM 118 BLU 36 tL SEE TABLE B orci He 87 TEL OF MI W129 BLU 1TH KD was BL 100 BLK TH H2 A96
54. essors and or fan motors are thermally protected 6 Three phase motors are protected against primary single phasing conditions 38 The Following Compressors Have Two Parallel Wires Run From TB1 to the Compressors Compressor Wire 06D 537 208 230 3 60 TABLE B The Following Fan Motors Have Two Parallel Wires Run From TB1 to the Fan Motors Indoor Wire 20HP 208230360 Fig 47 Power Schematic 580G H240 360 208 230 3 60 and 460 3 60 3105 BLK Wi16 BLU 038 ALL VOLTAGES ci DS 8 1 D 6 109 YE NY 9 0 VEL comp 4136 Br 2 BL Q FIELD om POWER 3 SUPPLY 3 106 BLES 0 07 314 BLK 73 BLK D reL d G2 n6 YELL 75 YEL 2 BLU 0 4 3 GRD 4107 6 8 01 HED 479 BLK 4112 YEL 0 482 YEL 1H HE 81 YEL FM 3118 BLU 36 me 484 BLU eee OFCI 108 BLK 66 BLK CHK 85 BLK 1037 115 YEL TEL G2H H22 381 YEL Q oni 19 BL 129 BLU 13H H23 mwe BL 4196 RED orca 4122 BLK 100 BLK W96 BLK D 101 TEL 24 K 97 YEL 4130 BLU 13H KI 38 BLU G gt VOLTAGE PLI 8 PL2 8 125 u 52 itt SE 24v CABE
55. ge heat will start im mediately If unit is equipped with 2 heaters second stage heat will energize upon a call for additional heat Check for heating effect at supply diffusers 4 The evaporator fan and heaters will cycle off with no delay after thermostat temperature is satisfied B Gas Heating The gas heat units incorporate two separate systems to pro vide gas heat Each system incorporates its own induced draft motor Integrated Gas Control IGC board 2 stage gas valve manifold etc The systems are operated in parallel for example when there is a call for first stage heat both induced draft motors operate both gas valves are energized and both IGC boards initiate spark All of the gas heating control is performed through the IGC boards The base module board serves only to initiate and terminate heating operation The base module board is powered by 24 vac When the ther mostat or room sensor calls for heating power is sent from the base module board to W on each of the IGC boards light emitting diode LED on the I GC board will be on dur ing normal operation A check is made to ensure that the roll out switches and limit switches are closed and the induced draft motors are not running The induced draft motors are then energized and when speed is proven with the hall effect sensor on the motor the ignition activation period begins The burners will ignite within 5 seconds When ignition occurs the GC board
56. h flame 1 Remove all access panels 3 Make the following inspections a Inspect for shipping and handling damages such as broken lines loose parts disconnected wires etc b Inspect for oil at all refrigerant tubing connections and on unit base Detecting oil generally indicates a refrigerant leak Leak test all refrigerant tubing connections using electronic leak detector halide torch or liquid soap solution c Inspect all field and factory wiring connections Be sure that connections are completed and tight d Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb Verify the following conditions a Make sure that condenser fan blades are correctly positioned in fan orifices Blades should clear fan motor and fan orifice ring b Make sure that return air filters and outdoor air inlet screens are in place c Make sure that the condensate trap is filled with water to ensure proper drainage d Makesure that all tools and miscellaneous loose parts have been removed Loosen the compressor holddown bolts until sideways movement of the washer under each holddown bolt can be obtained Do not loosen completely as bolts are self locking and will maintain adjustment Open compres sor valves Makesurerefrigerant service port caps are tight Each refrigerant system has one suction port located in the top of the compressor motor casing All units also have on
57. harge Cooling Using appropriate cooling charging chart see Fig 43 add or remove refrigerant until conditions of the appropriate chart are met Note that charging chart is different from those normally used An accurate pressure gage and temperature sensing device are required Measure liquid line pressure at the liquid line service valve using pressure gage Connect temperature sensing device to liquid line near the liquid line service valve and insulate it so that outdoor ambient tem perature does not affect reading Indoor air cfm must be within normal operating range of unit Take outdoor ambient tem perature and read the suction pressure gage Refer to appro priate chart to determine correct suction temperature If intersection point on chart is above the curve add refrig erant If intersection point on chart is below curve carefully recover some of the charge Recheck suction pressure as charge is adjusted CIRCUIT 1 ALL OUTDOOR FANS MUST BE OPERA 140 CU 120 ADD CHARGE IF ABOVE CURVE ING LH EDUCE CHARGE IF BELOW CURVE 40 Hi TH 50 100 150 200 250 300 350 400 LIQUID PRESSURE AT LIQUI LVE PSIG LIQUID TEMPERATURE AT LIQUID VALVE BEG F gt CIRCUIT 2 ALL OUTDOOR FANS MUST BE OPERATING 140 TT ADD CHA
58. he initialization software reads DIP switch no 1 to determine it is in the closed position Next DIP switch no 2 is read to determine it is closed for thermostat opera tion The initialization sequence clears all alarms and alerts re maps the input output database for operation sets maxi mum heat stages to 2 and sets maximum cool stages to 3 Power up takes a random 1 to 63 seconds plus 5 minutes The TSTAT function performs a thermostat based control by monitoring Y 1 Y2 W1 W2 and G inputs These functions control stages cool1 cool2 heat1 heat2 and the indoor fan respecti vel y The control module will operate economizer and run diagnos tics to monitor alarms at all times If the thermostat energizes the G input the control module will turn on theindoor fan and open the economizer dampers to minimum position If thermostats are used to deenergize the G input the control module will turn off the indoor fan and close the economizer dampers When cooling G must be energized before cooling can oper ate The control module determines if outdoor conditions are suitable for economizer cooling For the economizer to func tion for outside air cooling the enthalpy must be below the enthalpy set point the outdoor air temperature must be equal to or less than 65 F the SAT supply air temperature ther mistor must not be in alarm and the outdoor air reading is available When these conditions are satisfied the control mod ule
59. here X is the unit control software version number 1 or 2 COM Common D N O LED N C DETERMINE SOFTWARE VERSION HERE Fig 11 Control Board Diagram SIO CONNECTION TO EXPANSION BOARD TERMINAL g LED POWER CONNECTION TERMINAL RED GREEN LED JUMPER CONNECTION FOR VOLTAGE OUTPUT JUMPER CONNECTION FOR CURRENT OUTPUT Fig 12 Indoor Air Quality Sensor Configuration m TBI FELD ua m POWER SN 2 122 I I I ao PER NEC DISCONNECT 1 r 9 EQUIP GND LEGEND EQUIP Equipment NEC National Electrical Code GND Ground TB Terminal Block NOTE TB1 Maximum wire size is 500 MCM Fig 13 Field Power Wiring Connections Operating voltage to compressor must be within voltage range indicated on unit nameplate On 3 phase units voltages be tween phases must be balanced within 2 and the current must be balanced within 10 Use the formula in Table 3 to determine the percentage of voltage imbalance IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components On 208 230 v units transformer 1 is wired for 230 v If 208 230
60. ial service circumstances It is very important that the orientation and position of the top cover be marked on the unit prior to disassembly This will allow proper replacement of the top cover onto the unit and prevent rainwater from leaking into the unit IMPORTANT After servicing is completed make sure door is dosed and relatched properly and that the latches aretight Failure to do so can result in water leakage into the evapo rator section of the unit LATCH BOLT Fig 39 Door Latch CLEANING Inspect unit interior at beginning of each heating and cool ing season and as operating conditions require Remove unit top panel and or side panels for access to unit interior A Evaporator Coil Clean as required with a commercial coil cleaner B Condenser Coil Clean condenser coil annually and as required by location and outdoor air conditions Inspect coil monthly dean as required C Condensate Drain Check and clean each year at start of cooling season n win ter keep drains and traps dry D Filters Clean or replace at start of each heating and cooling season or more often if operating conditions require Refer to Table 1 for type and size NOTE Theunit requires industrial grade throwaway filters capable of withstanding face velocities up to 625 fpm To replace filters open filter access door marked with label Remove inner access panel Remove plastic filter retainer in between filter t
61. installation start up and service Instructions 580G H Sizes 240 360 SINGLE PACKAGE ROOFTOP ELECTRIC COOLING GAS HEATING UNITS Cancels 580G H 240 1 II 580G H 240 2 11 1 97 CONTENTS SAFETY CONSIDERATIONS Page Installation and servicing of air conditioning equipment can SAFETY CONSIDERATIONS 1 be hazardous due to system pressure and electrical compo nents Only trained and qualified service personnel should Mere Support SU URDU UE PUE 2 4 install repair or service air conditioning equipment Rig and Place Unit 2 Untrained personnel can perform basic maintenance func Ill Field Fabricate Ductwork 7 tions of cleaning coils and filters and replacing filters All other IV Unit Duct Connections 7 operations should be performed by trained service personnel V Flue Hood Ay 8 When working on air conditioning equipment observe pre VI Trap Condensate Drain 8 cautions in the literature tags and labels attached tothe unit Gas Piping 8 and other safety precautions that may apply Vill Electrical Connections 9 Follow all safety codes Wear safety glasses and work gloves IX Outdoor Air Inlet Assembly 14 Use quenching cloth for unbrazing operations Have fire X Power Exhaust Barometric Relief extinguishers available for all brazing operations
62. ions for tightness and controls for proper operation each heating and cooling season Service when necessary 6 Check and inspect heating section before each heating season 7 Check and dean vent screen if needed WARNING F ailuretofollow these warnings could re sult in serious personal injury 1 Turn off electrical power to the unit before perform ing any maintenance or service on the unit 2 Useextreme caution when removing panels and parts As with any mechanical equipment personal injury can result from sharp edges etc 3 Never place anything combustible either on or in con tact with the unit 4 Should overheating occur shut off the electrical supply 28 SERVICE WARNING Before beginning any maintenance be sure to turn off power at the main disconnect switch TAG THE SWITCH WITH A SUITABLE WARNING LABEL All unit components can be reached through clearly labelled hinged access doors These doors are not equipped with tie backs soif heavy duty servicing is needed either remove them or prop them open to prevent accidental closure Each door is held closed with 3 latches The latches are se cured to the unit with a single Vin 20 x Y2 in long bolt See Fig 39 To open loosen the latch bolt using a e in wrench Pivot the latch so it is not in contact with the door Open the door To shut reverse the above procedure NOTE Disassembly of the top cover may be required under spec
63. j Replacement 31 phone Follow the gas supplier s instructions IV Evaporator Fan Motor Replacement 31 4 If you cannot reach your gas supplier call the fire V Power Failure 31 department VI Refrigerant Charge 31 Vil Filter Drier 32 VIII Thermostatic Expansion Valve 32 N WARNING Disconnect gas piping from unit when IX Protective Devices 32 pressure testing at pressure greater than 0 5 psig Pres X Relief Devices 32 sures greater than 0 5 psig will cause gas valve dam XI Control Circuits 32 age resulting in hazardous condition If gas valve is XII Compressor Lockout Logic 32 subjected to pressure greater than 0 5 psig it must be XIII Replacement Parts 32 replaced before use When pressure testing field TROUBLESHOOTING 33 41 supplied GaS Piping eit pressures of 0 5 psig or less a Ta nissa jm 33 unit connected to such piping must be isolated by clos Error Code Summary 34 ing the manual gas valve s Input Output Channel Designations 34 START UP CHECKLIST CL 1 CL 2 INSTALLATION I PROVIDE UNIT SUPPORT CAUTION All panels must be in place when rig ging Unit is not designed for handling by fork truck
64. ng Diodes operation A series of quick blinks indicates an alarm Refer There are 3 LEDs red yellow and green on the lower right to Table 12 for a description of alarms The yellow and green hand side of the control board The red light is used to check LEDs have no significance on 580G H units unit operation and alarms A constant pulse is normal unit Table 12 Control Board LED Alarms LED ERROR TROUBLESHOOTING BLINKS CODE DESCRIPTION COMMENTS 1 Normal Operation The control board flashes the red LED in one second intervals when the board is operating properly Make sure DIP switch 3 is closed HF 13 Compressor 1 Safety The high or low pressure safety switch for compressor no 1 has opened for 3 seconds The error will be cleared and compressor no 1 will be allowed to turn on in 15 minutes If the safeties have been tripped 3 times in 90 minutes compressor no 1 will be locked out until the control board has been manually reset HF 14 Compressor 2 Safety The high or low pressure safety switch for compressor no 2 has opened for 3 seconds The error will be cleared and compressor no 2 will be allowed to turn on in 15 minutes If the safeties have been tripped 3 times in 90 minutes compressor no 2 will be locked out until the control board has been manually reset 7 HF 15 Thermostat Failure The thermostat is calling for both heating and cooling at the same time The unit will operate on a first call basis and will automati
65. o be energized IMPORTANT After a prolonged shutdown or service job energize the crankcase heaters for 24 hours before starting the compressors B Evaporator Fan Motor Protection A manual reset calibrated trip magnetic circuit breaker protects against overcurrent Do not bypass connections or increase the size of the breaker to correct trouble Determine the cause and correct it before resetting the breaker If the evaporator fan motor is replaced with a different horsepower motor resizing of the circuit breaker is required Contact Application Engineering C Condenser Fan Motor Protection Each condenser fan motor is internally protected against overtemperature D High and Low Pressure Switches If either switch trips or if the compressor overtemperature switch activates that refrigerant circuit will be automa tically locked out To reset manually move the thermostat setting E Freeze Protection Thermostat FPT Freeze protection thermostats are located on the evaporator coil for each circuit One is located at the top and bottom of each circuit They detect frost build up and turn off the com pressor allowing the coil to clear Once the frost has melted the compressor can be reenergized X RELIEF DEVICES All units have relief devices to protect against damage from excessive pressures i e fire These devices are installed on the suction line liquid line and on the compressor XI CONTROL CIRCUITS
66. oad Amps Ti 13 or HACR circuit breaker 457 Determine maximum deviation from average voltage 457 452 5 v or 464 457 7 v E 457 455 2 2v STE LISTE 4 Maximum deviation is 7 v NOTES Determine percent voltage imbalance 1 In compliance with NEC requirements for multimotor and combina zi STA tion load equipment refer to NEC Articles 430 and 440 the over Z Voltage Imbalance 100 x 457 current protective device for the unit shall be fuse or HACR breaker 1 53 Canadian units may be fuse or circuit breaker LU S fe 2 Unbalanced 3 Phase Supply Voltage This amount of phase imbalance is satisfactory as it is below the Never operate a motor where a phase imbalance in supply voltage is maximum allowable 295 reater than 2 Use the following formula to determine the percent Vollage balance P IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately Voltage Imbalance 100 max voltage deviation from average voltage average voltage 13 THERMOSTAT CONTROL BOX Fig 15 Field Control Thermostat Wiring IX OUTDOOR AIR INLET ASSEMBLY A Economizer NOTE If accessory power exhaust or barometric relief pack ages are being added to the unit install power exhaust or barometric relief before installing economizer hoods Economizer Hood Assembly The economizer hood is shipped in a
67. opper Evaporator coil fin material condenser coil fin material TCircuit 1 uses the lower portion of condenser coil Circuit 2 uses the upper portion All units have intertwined evaporator coils Table 2 Evaporator Fan Motor Data FAN SHEAVE BUSHING SHEAVE MOTOR PITCH DIAMETER SHAN p PITCH DIAMETER DIAMETER in in BUSHING DIAMETER OUTSIDE BELT LENGTH BELT QUANTITY 1 12 717 55 1 125 1B5V124 12 4 59 62 1 38 924 2 50 None 1 375 2B5V86 8 6 2 BX51 54 1 62 1096 2B5V56 B 1 625 1 38 773 1 38 962 1 62 1106 1 38 848 1 62 1059 1 62 1187 BK60H H 1 375 1B5V60 H 1 375 2B5V54 B 1 625 10 1 38 884 15 1 62 1096 1 62 1187 sal cali aon 2BK50 2B5V48 2B5V58 2BK50 2B5V56 2B5V58 ao B 1 625 B 1 625 H 1 375 B 1 625 B 1 625 D NOTE Motor shaft speed is 1750 rpm The fan shaft diameter is 111 4s inches A Positioning Provide clearance around and above unit for airflow safety and service access Fig 2 and 3 Do not install unit in an indoor location Do not locate air inlets near exhaust vents or other sources of contaminated air For proper unit operation adequate combustion and ventila tion air must be provided in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 American National Standards Institute Although unit is weatherproof guard again
68. or in absence of local codes with NEC ANSI Cl latest year All field wiring must comply with NEC and local code requirements C Field Power Supply Unit is factory wired for voltage shown on nameplate See Table 3 for electrical data Field wiring can be brought into the unit from bottom through basepan and roof curb or through side of unit corner post next to control box A NPT knockout for field power wiring a in NPT knockout for 24 control wiring are provided in base pan In the side post there are two 2 in knockouts for the field power wiring See Fig 2 and 3 If control wiring is to be brought in through the side of unit a 78 in diameter hole is provided in the condenser side post next to the control box If disconnect box is mounted to corner post be careful not to drill any screws into the condenser coil Routing Through Bottom of Unit If wiring is brought in through bottom of unit use field supplied watertight conduit to run power wiring from base pan out through bottom 3 2 in hole to the disconnect box and back into unit to the main control box Use strain relief going into control box through 2 2 in diam eter hole provided After wires are in unit control box con nect to power terminal block see Power Wiring section on this page Low voltage wiring must be run in watertight conduit from the basepan to control box and through 1 in diameter hole provided in bottom of
69. otor Table 10 Motor Limitations STANDARD EFFICIENCY MOTORS Maximum Maximum Amps Motor 230 55 Efficiency 7 9 43 8 12 543 91 0 21 9 19 0 14 756 91 0 sss 19 188 E 3588 E ood uw dL wu ey M 7 078 91 7 9 600 12 273 17 553 LEGEND confidence Using your fan motors up to the horsepower ratings shown BHP Brake Horsepower on the Motor Limitations table will not result in nuisance tripping or pre NOTE Extensive motor and electrical testing on the these units has en mature motor failure Unit warranty will not be affected sured that the full horsepower range of the motor can be utilized with Table 11 Air Quantity Limits MINIMUS HEATING MINIMUM COOLING MAXIMUM 2 6 000 10 000 7 500 7 500 12 500 39 8250 8250 13 750 9 000 9 000 75 000 VI MAIN BURNERS For all applications main burners are factory set and should require no adjustment A Main Burner Removal Fig 38 1 Shut off field supplied manual main gas valve Shut off power to unit Remove heating access panel Disconnect gas piping from gas valve inlet Remove wires from gas valve Remove wires from rollout switch Remove sensor wire and ignitor cable from I GC board Remove 2 screws securing manifold bracket to basepan Remove 4 screws that hold the burner support plate flange to the vestibule plate Lift burner assembly out of unit O O N
70. package secured to the outside of the unit and must be field assembled There are 2 hoods on every unit The 580H units are side supply and side return The return duct limits access to economizer filters from below Filter tracks mounting angle without tabs must be installed correctly to allow access to economizer filters from each side NOTE Before assembly of the economizer hood check along the outer edges of the economizer assembly for any seal strip protruding past the flanges Trim the excess seal strip so that it is flush with the economizer assembly flanges Perform the following procedure to assemble the economizer hood 1 a Apply black seal strip provided in package to out side top edge of hood sides Wrap seal strip over to cover top flange 4 hood sides Make certain seal strip covers screw holes Allow strip to overhang in past end opposite mounting flange See Fig 16 b Assemble hood sides top and cross member with gas keted screws provided See Fig 17 c Attach 10 green speed clips provided to hood top d Apply black seal strip to mounting flanges cover holes of hood sides See Fig 18 NOTE Each hood assembly has a slotted side that should be adjacent to the other hood when mounted to the unit e Apply black seal strip to hood top mounting flange Seal strip of hood top mounting flange must press against seal strip of hood side mounting flanges See Fig 19 f Add gray foam strip provided to c
71. py control located inside the outdoor air hood 4 Connect the violet wire from the enthalpy sensor kit to the terminal on the enthalpy control Connect the blue wire from the enthalpy sensor kit to the SR terminal on the terminal control PL4 1 PL4 2 620 ohm JUMPER PL4 4 NOTE Switches shown in high enthalpy state Termi nals 2 and 3 close on enthalpy decrease Fig 27 Wire Connections for Solid State Enthalpy Control HH57AC077 CONTROL POINT CONTROL APPROX DEG AT 50 RH 90 95 100 105 110 321 1351 _ 38 40 51 43 5 RELATIVE HUMIDITY 4 55 0 5 v 75 80 85 90 95 100 105 1 5 149 7 09 331 115 51 18 5 211 24 126 51 29 5 321 1351 381 4051 DRY BULB TEMPERATURE APPROXIMATE FAHRENHEIT CELSIUS RH Relative Humidity Fig 28 Psychrometric Chart for Enthalpy Control 5 Turn the enthalpy control set point potentiometer clock wise past the D setting on the enthalpy control to con figure the control to operate on differential enthalpy 6 Remove the return air enthalpy sensor from the acces sory package Using the screws provided mount the sensor inside the return duct near the unit Do not locate the control too far from the unit or the wires will not reach from the sensor to the control On 580H units the enthalpy sensor can be installed in the return air section of the unit under the return air dampers 7 Route the wires from the en
72. racks by sliding and pulling outward Remove first filter by sliding out opening in filter track Locate filter removal tool which is shipped next to the return air damp ers Use the filter removal tool to remove the rest of the filters E Main Burners At the beginning of each heating season inspect for deterio ration or blockage due to corrosion or other causes Observe the main burner flames and adjust if necessary Refer to Main Burners sections on page 28 Check spark gap See Fig 40 F Flue Gas Passageways The flue collector box and heat exchanger cells may be inspected by removing gas section access panel Fig 2 and 3 flue box cover collector box and main burner assembly Fig 41 and 42 Refer to Main Burners section on page 28 for burner removal sequence If cleaning is required clean all parts with a wire brush Reassemble using new cerafelt high temperature insulation for sealing G Combustion Air Blower Clean periodically to assure proper airflow and heating effi ciency Inspect blower wheel every fall and periodically dur ing heating season For the first heating season inspect blower wheel bi monthly to determine proper cleaning frequency Toinspec blower wheel remove heat exchanger access panel Shine a flashlight into opening to inspect wheel If cleaning is required remove motor and wheel assembly by removing screws holding motor mounting plate to top of combustion fan housing Fig 41 and 42 The mo
73. ross members at bottom tray See Fig 20 TOP FLANGE BLACK SEAL STRIP HOOD SIDE Fig 16 Adding Seal Strip to Top of Hood Sides FILTER HOOD SIDE ECONOMIZER COVER ENTHALPY BRACKET RIGHT HOOD ONLY ACCESSORY ENTHALPY CONTROL NS FILTERS MOUNTING ANGLE HOOD CROSSMEMBER W O TABS SUBE FILTER TRACK BLOCKOFF ASSEMBLY BAFFLE WITH SCREWS NOTE Left side economizer hood has mounting angle without tabs and filter track assembled end on opposite side Fig 17 Economizer Hood Assembly Right Side Economizer Hood Shown Exhaust Mounting Details g Place gray foam strip on inside of slotted hood side between filter and cross member opposite mounting end See Fig 21 h Attach gray foam strip to blockoff baffle on outer face area of flange See Fig 22 2 Removethe screws on each end and along top of damper assembly of unit Remove top 2 screws on each side of filter panel under damper assembly Set hood assembly in place and attach to unit using these screws 3 Attach accessory enthalpy bracket on hood side fur thest from control box end Locate bracket on inside upper right hand corner using hood mounting holes Mount outdoor air thermistor to enthalpy bracket if pur chased Attach and wire enthal py assembly Place quick connects on enthalpy wires 14 MOUNTING FLANGE HOOD SIDE Fig 18 Adding Seal Strip to Mounting Flange of Hood Sides HOOD TOP HOOD SI
74. s H Crankcase Heater Unit main power supply must remain on to provide crank case heater operation The crankcase heater in each compres sor keeps oil free of refrigerant while compressor is off Table 7 Smoke Control Modes DEVICE PRESSURIZATION 100 Power Exhaust all outputs Heat Stages ON SMOKE DETECTOR TB2 CB4 W78 WHT ak 220 RED COM 24V BASE MODULE SAT 18 SUPPLY AIR TEMP SENSOR TRAN2 INDOOR FAN Fig 33 Field Supplied Smoke Detector Wiring 23 I Head Pressure Control Each unit has a fan cycling outdoor thermostat to shut off the outdoor fan motor s at 55 F The head pressure control permits unit to operate with correct condensing tempera tures down to 35 F outdoor air temperature J Motormaster Control The Motormaster 111 Solid State H ead Pressure Control is a field installed accessory fan speed control device actuated by a temperature sensor It is specifically designed for use on Bryant equipment and controls the condenser fan motor speed in response to the saturated condensing temperature F or out door temperatures down to 20 it maintains condensing temperature at 100 F Refer to the accessory Motormaster installation instructions for more information FIELD TEST OPERATION The field test program is initiated by moving up DIP switch no 4 to the On position The outdoor air d
75. s are to outside of part 2 Dimensions are in inches Fig 30 Barometric Relief Damper and Power Exhaust Mounting Details XI ACCESSORIES After all the factory installed options have been adjusted in stall all field installed accessories Refer to the accessory in stallation instructions included with each accessory A Motormaster III Control Installation Install Field F abricated Wind Baffles Wind baffles must be field fabricated for all units to ensure proper cooling cycle operation at low ambient temperatures See Fig 31 for baffle details Use 20 gage galvanized sheet metal or similar corrosion resistant metal for baffles Use field supplied screws to attach baffles to unit Screws should be Ya in diameter and long Holes for wind baffles are pre punched in the unit sheet metal CAUTION To avoid damage to the refrigerant coils and electrical components use recommended screw sizes only The wind baffles attach to flanges formed on the outer sheet metal of the unit where the condenser coil tube sheets attach Install Motormaster Controls Only one Motormaster 111 control is required per unit Motor The circuit no 1 lead compressor outdoor fan motor OFM will need to be changed out in the field to accommodate the Motormaster accessory The replace ment motor part no is HD52AK 652 The no 1 compressor is located at the left side of the unit looking from the compressor en
76. st water from higher level runoff and overhangs B Roof Mount Check building codes for weight distribution requirements Ill FIELD FABRICATE DUCTWORK Secure all ducts to building structure Use flexible duct con nectors between unit and ducts as required nsulate and weath erproof 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 To attach ductwork to roof curb insert ductwork approx imately 10 to 11 in up into the curb Connect ductwork to 14 gage roof curb material using sheet metal screws driven from inside the duct WARNING For vertical supply and return units tools or parts could drop into ductwork and cause an injury Install 90 degree elbow turns in the supply and return ductwork between the unit and the conditioned space If a 90 degree elbow cannot be installed then grilles of sufficient strength and density should be installed to prevent objects from falling into the conditioned space IV UNIT DUCT CONNECTIONS A 580G Units Unit is shipped for through the bottom duct connections Duct work openings are shown in Fig 2 Attach all ductwork to roof curb Air distribution is shown in Fig 5 Refer to installation instructions shipped with accessory roof curb for more information None 1 375 2B5V90 9 1 T 2 5VX530 53 1B5V124 BX59 62
77. thalpy sensor to the return air enthalpy control through the holes on the inside of the hinged filter access panel The holes are blocked by plug buttons which should be removed 8 Use field supplied wire ties to attach the violet wire to the terminal and the blue wire to the SR terminal 9 Replace economizer filters 10 Return power to unit Disable Economizer For applications where the economizer will not be used areas of high humidity the economizer should be disabled To disable the economizer perform the following 1 Turn off power Lock out disconnect 2 Locatethe OAT outdoor air thermistor in the right hand outdoor air damper area 3 Locate the splice connecting the violet wire coming from T24 on the base module board to the red wire coming from T29 on the base module board Remove the wire nut and break the red to violet wire splice 4 Cap off both wires When the connection is broken the base module is fooled into thinking that the enthalpy is not acceptable and economizer operation is disabled NOTE Economizer operation can also be disabled by discon necting the OAT This is not recommended due to the fact that Unoccupied Free Cooling IAQ Purge and Low Ambient Fan Cycle Control are also disabled An OAT failure alarm will also be issued GEAR DRIVEN DIRECT DRIVE S OUTDOORAIR lt DAMPERS wd RETURN AIR es DAMPER gt RETURN AIR 2 SENSOR AIR 580H ONLY y 580H
78. tor scroll and wheel assem bly can be removed from the unit Remove scroll from plate Remove the blower wheel from the motor shaft and dean with a detergent or solvent Replace motor and wheel assembly H Outdoor Air Inlet Screens Clean screens with steam or hot water and a mild detergent Do not use throwaway filters in place of screens Il LUBRICATION A Compressors Each compressor is charged with the correct amount of oil at the factory The correct oil charge is shown in Table 1 If oil is visible in the compressor sight glass check unit for operating readiness as described in Start U p section then start theunit Observe oil level and add oil if required to bring oil level in compressor crankcase up to between and of sight glass during steady operation If oil charge is above 3 sight glass do not remove any oil until the compressor crankcase heater has been energized for at least 24 hours with compressor off When additional oil or a complete chargeis required useonly approved compressor oils Petroleum Specialties Inc Cryol 150 Texaco uos re s Capella WF 32 Witco Chemical Corp Suniso 3GS IMPORTANT Do not use reclaimed oil or oil that has been exposed to the atmosphere Refer to Standard Service Tech niques Manual Chapter 1 Refrigerants section for proce dures to add or remove oil 29 NOTES SPARK GAP
79. trical Code OFM Outdoor Condenser Fan Motor RLA Rated Load Amps Fuse or HACR circuit breaker or Liste LisTEo NOTES 1 In compliance with NEC requirements for multimotor and combina tion load equipment refer to NEC Articles 430 and 440 the over current protective device for the unit shall be fuse or HACR breaker Canadian units may be fuse or circuit breaker 2 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply voltage is greater than 2 Use the following formula to determine the percent voltage imbalance Noltage Imbalance 100x max voltage deviation from average voltage average voltage POWER COMBUSTION EXHAUST FAN MOTOR POWER SUPPLY L FLA MCA Te 0 96 101 8 100 3 125 125 2 23 6 41 0 96 125 4 123 9 150 150 3 0 96 115 9 113 1 150 150 0 23 6 41 0 96 139 5 136 7 175 175 0 96 131 3 127 1 150 150 3 6 41 6 0 96 154 9 150 7 175 175 0 50 49 4 60 6 12 6 23 0 50 62 0 80 0 50 55 8 70 0 12 6 23 0 50 68 4 80 0 50 62 8 80 12 6 23 0 50 75 4 90 0 50 40 5 50 1 12 6 23 0 50 53 1 60 iol lx 0 50 45 4 60 0 126 23 0 50 58 0 70 0 50 51 4 60 0 12 6 23 0 50 64 0 80 EN eojoo oo vul DO EN 229 BRIN D A D gt D
80. unted the economizer hood See Fig 17 The enthalpy setting adjustment is on the en thalpy control For maximum benefit of outdoor air set en thalpy sensor control to A See Fig 27 and 28 Enthalpy Control Installation The outdoor air enthalpy control is installed on the inside panel of the outdoor air hood The enthalpy control should be mounted when the outdoor air hoods are assembled To install the con trol perform the following procedure 1 Turn off all power Ensure disconnect is locked out 2 Remove the economizer inlet filters from the bottom of the right hand economizer hood See Fig 29 16 MOUNTING ANGLE WITHOUT TABS FILTER TRACK ASSEMBLY Fig 23 Mounting Angle Without Tabs Attached to Filter Track Assembly MOUNTING ANGLE WITH TABS Fig 24 Mounting Angle With Tabs Attached to Filter Track Assembly BLACK SEAL STRIP CENTERED FILTER COVER Fig 25 Attaching Seal Strip to Filter Cover REV A 1994550 57 077 ENTHALPY CONTROL 9 o HH57AC078 ENTHALPY SENSOR USED WITH ENTHALPY CONTROL FOR DIFFER ENTIAL ENTHALPY OPERATION Fig 26 Enthalpy Control and Sensor 3 Mount the outdoor air enthalpy sensor inside the right economizer hood on the right side panel of the hood
81. used to enable expansion board operation DIP switch 4 is used to field test the unit DIP switch 5 is used to specify the type of power exhaust Table 4 DIP Switch Configuration SETTING 2 ae 8 Pl 7 89 Expansion Board Operation Thermostat Base Control oui ewe oy LEGEND CV Constant Volume Modulated IN CONJUNCTION Exhaust Exhaust Time Guard Override ON Heat Pump Gas Heat Operation WITH FIELD TEST Set Minimum Damper Position Air Conditioner Operation Time Guard Override OFF Electric Heat NOTES 1 The OPEN side of the DIP switch is marked OPEN When the rocker switch is on the OPEN side of the switch the switch is open 2 When the unit is being field tested DIP switch 4 to OPEN the func tion of DIP switch 6 changes and it is used to set the minimum damper position Table 5 DIP Switch Factory Settings UNT 1 moi amp o 5506 Glosed Closed Closed 0059 Open Closed DIP switch 6 configures the Time Guard override and when used with the field test function sets the mini mum damper position DIP switch 7 configures the unit for gas heat or elec tric heat DIP switch 8 configures the unit for heat pump air conditioner operation 10 Adjust economizer Check that outdoor air damper is closed and return air damper is open IMPORTANT Unit power must be on for 24 hours prior to
82. v unit is to be run with 208 v power supply the trans former must be rewired as follows 1 Remove cap from red 208 v wire 2 Remove cap from spliced orange 230 v wire Discon nect orange wire from black unit power wire 3 Cap orange wire 4 Splice red wire and black unit power wire Cap wires IMPORTANT Becertain unused wires are capped Failureto do so may damage the transformers D Field Control Wiring Install an approved accessory thermostat Control box dia gram is shown in Fig 14 Thermostat Wiring Install an approved accessory thermostat assembly per cur rent price pages according tothe installation instructions in duded with the accessory or these instructions Locate ther mostat assembly on a solid wall in the conditioned space to sense average temperature Route thermostat cable or equivalent single leads of no 18 AWG American Wire Gage colored wire from subbase terminals to low voltage connections as shown on unit label wiring diagram and in Fig 15 NOTE For wire runs up to 50 ft use no 18 AWG insulated wire 35 C minimum For 50 to 75 ft use no 16 AWG insulated wire 35 C minimum For over 75 ft use no 14 AWG insulated wire 35 C minimum All wire larger than no 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat Set heat anticipators settings to 1 for all voltages Settings may be changed slightly to provide a greater degr
83. will continue to monitor the condition of the rollout and limit switches the hall effect sensor as well as the flame sensor If the unit is controlled through a room thermostat set for fan auto 45 seconds after ignition occurs the indoor fan motor will be energized and the outdoor air dampers will open to their minimum posi tion If for some reason the overtemperature limit opens prior tothe start of the indoor fan blower on the next attempt the 45 second delay will be shortened to 5 seconds less than the time from initiation of heat to when the limit tripped Gas will not be interrupted to the burners and heating will con tinue Once modified the fan on delay will not change back to 45 seconds unless power is reset to the control When additional heat is required W2 doses and initiates power to the second stage of the main gas valves When the ther mostat is satisfied W1 and W2 open and the gas valves close interrupting the flow of gas to the main burners If the call for W1 lasted less than 1 minute the heating cycle will not terminate until 1 minute after W1 became active If the unit is controlled through a room thermostat set for fan auto the indoor fan motor will continue to operate for an additional 45 seconds then stop and the outdoor air dampers will close If the over temperature limit opens after the indoor motor is stopped within 10 minutes of W1 becoming inactive on the next cyclethetime will be extended by 15 seconds Th
84. will use economizer as the first stage of cooling When Y1 input is energized the economizer will be modu lated to maintain SAT at the set point temperature The default is 55 F When SAT is above the set point the econo mizer will be 100 open When SAT is below the set point the economizer will modulate between minimum and 100 open position When Y2 is energized the control module will turn on compressor 1 and continue to modulate the econo mizer as described above If the Y2 remains energized and the SAT reading remains above the set point for 15 minutes 21 compressor 2 will turn on If Y2 is deenergized at any time only the last stage of compression that was energized will be turned off If outdoor conditions are not suitable for econo mizer cooling the economizer will go to minimum position and cycle compressors 1 and 2 based on demand from Y 1 and Y 2 respectively The compressors will be locked out when the SAT temperature is too low less than 40 F for compressor 1 and less than 45 F for compressor 2 After a compressor is locked out it can restart after normal time guard period The compressor time delay function maintains a minimum off time of 5 minutes a minimum on time of 10 seconds and a minimum delay before starting the second compressor of 10 seconds When heating the heat stages respond to the demand from W1 and W2 of the thermostat input Heating and cool ing will be mutually locked out on demand on a

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