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Bryant 548D Heat Pump User Manual

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3. ADJUST INDOOR FAN SPEED Adjust indoor fan speed to meet jobsite requirements For units with electric heat required minimum cfm is 2250 for 548D090 2550 for 548D102 and 3000 for 548D120 with the following exceptions UNIT HEATER UNIT REQUIRED UNIT VOLTAGE kW CONFIG MINIMUM URATION CFM 208 230 3200 208 230 3200 Horizontal 548D120 460 50 0 or 3200 Vertical Horizontal 2800 575 or Table 6 shows indoor fan motor data Table 7 shows fan rpm at motor pulley settings for standard and alternate motors Refer to Tables 8 13 to determine fan rpm settings Fan motor pulleys are factory set for speed shown in Table 1 To change fan speeds 1 Shut off unit power supply and tag disconnect 2 Loosen belt by loosening fan motor mounting nuts See Fig 36 and 37 3 Loosen movable pulley flange setscrew see Fig 38 4 Screw movable flange toward fixed flange to increase fan rpm or away from fixed flange to decrease speed Increasing fan rpm increases load on motor Do not exceed maximum speed specified in Table 1 19 5 Set movable flange at nearest keyway of pulley hub and tighten setscrew See Table 1 for speed change for each full turn of pulley flange To align fan and motor pulleys 1 Loosen fan pulley setscrews 2 Slide fan pulley along fan shaft 3 Make angular alignment by loosening motor from mounting plate To adjust belt tension 1 Loosen fan motor mounting plate nuts 2 Units 090 102 S
4. 3 Do not remove compressor terminal cover until all electrical sources are disconnected and tagged 4 Relieve all pressure from system before touch ing or disturbing anything inside compressor terminal box if refrigerant leak is suspected around compressor terminals Use accepted methods to recover refrigerant 5 Never attempt to repair soldered connection while refrigerant system is under pressure 6 Donot use torch to remove any component Sys tem contains oil and refrigerant under pres sure To remove a component wear protective goggles and proceed as follows a Shut off electrical power to unit and install lockout tag b Relieve all pressure from system using both high and low pressure ports Use accepted methods to recover refrigerant Cut component connection tubing with tub ing cutter and remove component from unit d Carefully unsweat remaining tubing stubs when necessary Oil can ignite when exposed to torch flame Proceed as follows to inspect and prepare the unit for initial start up 1 Remove all access panels 2 Read and follow instructions on all WARNING CAU TION and INFORMATION labels attached to or shipped with unit 3 Makethe following inspections a Inspect for shipping and handling damages such as broken lines loose parts or disconnected wires b Inspect for oil at all refrigerant tubing connec tions and on unit base Detecting oil generally indicates a refrigerant leak Lea
5. NOTE Refer to Fig 21 for economizer barometric relief damper characteristics QUICK CONNECTS FOR DEFROST TIMER Fig 10 Defrost Board 4 On size 120 units install vertical discharge block off plate over duct openings See Fig 13 5 Economizer is factory installed in unit and secured with screws See Fig 14 NOTE Besurerear economizer flange is engaged under tabs in vertical return air opening 6 Toconvert to horizontal discharge application a Rotate the economizer 90 degrees until the econ omizer motor faces the outdoor section see Fig 15 b Remove shipping screw and tape from baromet ric damper and rotate the barometric relief damper hinge 90 degrees Barometric relief damper should open vertically to operate properly c Install horizontal discharge block off plate over the opening on the access panel Block off plate MUST beinstalled before installing hood assem bly See Fig 16 7 Remove existing 12 pin blue and yellow wire jumper plug and store Insert 12 pin economizer plug into economizer harness See Fig 14 TT OUTDOOR AIR FILTER ACCESS 8 If ventilation air is not required proceed to Step 9 If OPENING PANEL em Ba Im PANEL ventilation air is required determine the minimum position setting for required airflow See Fig 17 Fig 11 Panel Locations 2 SCREEN SEAL
6. economizer circuit board 2 If the damper does not move check for 24 vac at PL6 1 red wire If 24 vac is not present check wiring see unit label diagram 3 If damper still does not move check for 24 vac at blue terminal of economizer con trol board blue wire If 24 vac is not present replace the economizer control board Incorrect SAT wiring or 1 After verifying that the wiring is correct and the economizer control board is func inoperative SAT tioning properly place the OAT or EC switch in the closed position Place a call for Y1 and open the damper to the fully open position Confirm that the 24 vac terminal of the SAT has 24 vac white wire If 24 vac is not present check wiring see unit label diagram 2 If supply air temperature is less than 52 F 24 vac should be found at terminal T1 on the SAT violet wire If 24 vac not found replace SAT Economizer motor failure If economizer control board and SAT are functioning properly verify that there is a minimum of 18 at the positive motor terminal If a minimum of 18 vdc is present and the motor is still not operating replace the motor Economizer damper Insufficient battery power 1 Check voltage potential across batteries If lower than 14 vdc replace close on does not close on inoperative economizer power loss power supply 9 v alkaline batteries Check this emergency power sup power loss control board ply on a regular basis or whenever the filters are
7. to the flanges Insulate and weather proof all external duct work joints and roof openings with counter flashing and mastic in accordance with applicable codes Ducts passing through an unconditioned space must be insu lated and covered with a vapor barrier If a plenum return is used on a vertical unit the return should be ducted through the roof deck to comply with ap plicable fire codes A minimum clearance to combustibles is not required around ductwork on vertical discharge units On horizontal discharge units with electric heat a minimum clearance of 1 in is required for the first 12 in of ductwork Cabinet return air static should not exceed 0 35 in wg with Durablade econo mizer 0 30 in wg with EconoMi er or 0 45 in wg without economizer N CAUTION Ensure voltage listed on unit data plate agrees with electrical supply provided for the unit Ill STEP 3 INSTALL CONDENSATE DRAIN LINE AND EXTERNAL TRAP Condensate drain connections are located on the bottom and end of the unit Unit discharge connections do not determine the use of drain connections either drain connection can be used in vertical or horizontal applications When using the standard end drain connection make sure the plug Red in the alternate bottom connection is tight before installing the unit To use the bottom drain connection for a roof curb installa tion relocate the factory installed plug Red from the bot tom connection to
8. 24 V 3 2 ECONOMIZER ASSY TWO POSITION DAMPER ASY w Copyright 2000 Bryant Heating amp Cooling Systems LEGEND Adjustable Heat Anticipator R Relay American Wire Gage RVS Reversing Valve Solenoid Contactor Compressor SAT Supply Air Thermostat Capacitor SW1 Switch Fully Open Circuit Breaker SW2 Switch Fully Closed Cooling Capacitor SW3 Switch Minimum Vent Position Crankcase Heater SW4 Switch Maximum Vent Position Compressor Lockout TB Terminal Block Compressor Motor Thermostat Cooling Diode TH Thermostat Heating Defrost Board S TRAN Transformer efrost Thermosta Enthalpy Control Field Splice Economizer x Marked Wire Terminal Marked Emergency Power Supply nine volt battery Equipment Economizer Relay Freeze Up Protection Thermostat Q Terminal Unmarked Fuse Ground Terminal Block Heater Contactor Strip Heat x High Pressure Switch j Heater Relay Splice Indoor Fan Contactor e Indoor Fan Motor Spliced Marked Indoor Fan Motor Overload Switch Factory Wiring Low Pressure Switch Limit Switch Manual Reset Minimum Circuit Amps Motor Outdoor Air Thermostat Outdoor Fan Contactor Outdoor Fan Motor Field Control Wiring wees Field Power Wiring Accessory or Optional Wiring To indicate common potential only Plug E vi represent wiring Plug Assembly Quadruple Terminal
9. 8 5 8 7 0 1 48 16 75 19 25 30 5 45 5 Cleanable 1 20x 25x 1 1 16 x 25 x1 Throwaway 4 16 x 20 x2 15x15 Belt Belt 4000 2 40 2 90 56 56 685 935 835 1085 Ball 2100 2 8 3 8 3 4 4 4 15 85 17 50 15 85 17 50 50 50 4 20 x 20 x2 NOTE The 548D units have a loss of charge switch located in the liquid line avail able as an option or an accessory Standard on 120 units V STEP 5 MAKE ELECTRICAL CONNECTIONS N WARNING Unit cabinet must have an uninter rupted unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur This ground may consist of electrical wire connected to unit ground lug in control compartment or conduit approved for electrical ground when installed in accordance with NEC National Electrical Code ANSI American National Standards Institute NFPA National Fire Protection Association 70 latest year and local electrical codes Failure to follow this warning could result in the installer being liable for personal injury of others A Field Power Supply All units except 208 230 v units are factory wired for the voltage shown on the unit nameplate If the 208 230 v unit is to be connected to a 208 v power supply the transformer must be rewired by disconnecting the black wire from the 230 v terminal on the transformer and connecting it to the 200 v terminal from the transformer Refer to unit label diagr
10. Damper Minimum Position Setting TOP SCREW POSITION SETTING BRACK Fig 18 Durablade Economizer Minimum Position Damper Setting OUTDOOR THERMOSTAT OR AES ORY ENTHALP CONTROL OAT TERMINALS ARE UP TOP UNIT OUTSIDE AIR SCREEN ENTHALPY CONTROL HOOD Fig 19 Outdoor Air Thermostat Enthalpy Control Installation OAT carar 8 RED 3 4 Fig 20 Wiring Connections for Outdoor Air Thermostat 14 PRESSURE DROP in wg 0 30 0 25 0 20 015 0 10 0 05 0 00 50 100 150 200 250 300 350 400 450 500 550 CFM Fig 21 Durablade Economizer Barometric Relief Damper Characteristics C Optional EconoMi er See Fig 22 for EconoMi er component locations 1 To remove the existing unit filter access panel raise the panel and swing the bottom outward The panel is now disengaged from the track and can be removed Remove the indoor coil access panel and discard See Fig 23 Controller should be mounted in vertical position as shown in Fig 22 Assemble the hood assembly as follows Remove the EconoMi er hood from its packaging Locate the outdoor air opening panel See Fig 24 Remove hood assembly shipping brackets located on back sloped side of EconoMi er assembly These brackets are used to retain hood assembly during shipping only Install the 1 s x 3 4 in seal strip on the
11. LRA Locked Rotor Amps MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protection NEC National Electrical Code OFM Outdoor Fan Motor RLA Rated Load Amps c UL Dus Heaters are field installed only TUsed to determine minimum disconnect NEC Heater capacity kW is based on heater voltage of 208 v 240 v or 480 v and 575 v H power distribution voltage to unit varies from rated heater voltage heater kW will vary accordingly ttFuse or HACR circuit breaker llOptional disconnect switch is unavailable Applies to units with FLA greater or equal to 80 NOTES 1 In compliance with NEC requirements for multimotor and combination load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be fuse or HACR breaker 2 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply voltage is greater than 2 Use the following formula to determine the percentage of voltage imbalance 10 Voltage Imbalance max voltage deviation from average voltage average voltage Example Supply voltage is 460 3 60 100 x 452 v EE BC 464 v 2455v Average Voltage 1371 3 457 Determine maximum deviation from average voltage AB 457 452 5v BC 464 457 7 AC 457 455 2 v Maximum deviation is 7 v Determine percent of voltage imbalance 7 96 Voltage Imbalance 1 mE o
12. changed 2 If the close on power loss and economizer control board are functioning properly check for 14 vdc or higher at the blue terminal of the economizer control board blue wire when power is disconnected from unit If 14 vdc is not present replace the control board LEGEND C1 Common Power EC Enthalpy Control IFC Indoor Fan Contactor IFO Indoor Fan On OAT Outdoor Air Thermostat PL Plug SAT Supply Air Thermostat SW Economizer Position Switch 35 Table 16 EconoMi er Troubleshooting PROBLEM CAUSE REMEDY Damper does not open Indoor Fan is Off Check to ensure that 24 vac is present at Terminal C1 Common Power on the IFC Indoor Fan contactor or that 24 vac is present at the IFO Indoor Fan On terminal Check whether 24 vac is present at PL Plug 6 1 red wire and or PL6 3 black wire If 24 vac is not present check wiring see unit label diagram Check proper thermostat connection to G on the connection board No power to Check to ensure that 24 vac is present across Terminals 24 VAC and controller 24V on the control If 24 vac is not present check wiring see unit label diagram If 24 vac is present STATUS light should be on constantly No power to G Terminal If IFM is on check to ensure 24 vac is present on G Terminal of the EconoMi er controller If 24 vac is not present check wiring see unit label diagram Con
13. coils Use of a field supplied motor may affect wire sizing Contact your representative to verify Standard motor drive range 685 to 935 rpm All other rpms require field supplied drive Interpolation is permissible Do not extrapolate Table 10 Fan Performance 548D120 Vertical Discharge Units 548D120 10 TONS STANDARD AND ALTERNATE MOTORS BELT DRIVE External Static Pressure in wg Airflow 548D120 10 TONS STANDARD AND ALTERNATE MOTORS BELT DRIVE cont External Static Pressure in wg 4 1 1 LEGEND standard motor and 2 90 with alternate motor Extensive motor Bhp Brake Horsepower Input to Fan and electrical testing on these units ensures that the full range of Watts Input Watts to Motor the motor can be utilized with confidence Using your fan motors up to the wattage ratings shown will not result in nuisance tripping or premature motor failure Unit warranty will not be affected Values include losses for filters unit casing and wet coils Use of a field supplied motor may affect wire sizing Contact your representative to verify Standard motor drive range 685 to 935 rpm Alternate motor drive range 835 to 1085 rpm All other roms require field supplied drive Interpolation is permissible Do not extrapolate NOTES 1 Boldface indicates field supplied or alternate as appropriate drive is required See Note 7 2 indicates alternate motor and drive are requ
14. energizes electric heater elements if installed Check heating effects at air sup ply grille s If accessory electric heaters do not energize reset limit switch located on indoor fan scroll by depressing button located between terminals on the switch To Shut Unit Off Set system selector switch at OFF position Resetting heat ing selector lever below room temperature temporarily shuts unit off until space temperature falls below thermostat setting XII SAFETY RELIEF A soft solder joint in the suction line at the loss of charge low pressure switch fitting provides pressure relief under abnormal temperature and pressure conditions XIII VENTILATION CONTINUOUS FAN Set fan and system selector switches at ON and OFF posi tions respectively Indoor fan operates continuously to pro vide constant air circulation XIV OPERATING SEQUENCE A Cooling Units Without Economizer When the thermostat calls for cooling terminals G and Y1 are energized The indoor fan contactor IFC outdoor fan contactor OFC RVS1 reversing valve solenoid and compressor contactor no 1 C1 are energized and the indoor fan motor compressor no 1 outdoor fan motors and outdoor fans start The outdoor fan motors run continuously while unit is cooling If the thermostat calls for a second stage of cooling by energizing Y2 compressor contactor no 2 C2 and RVS2 are energized and compressor no 2 starts B Heating Units Without Econo
15. or EC is closed Y1 is called for and damper incorrectly wired or not is at minimum position Confirm 24 vac on gray terminal of the economizer control functioning board gray wire If 24 vac is not present check wiring see unit label diagram 2 Verify that SW1 and SW3 are wired correctly and working properly see unit label diagram 3 Check to ensure that 24 vac exists at PL6 2 blue wire If 24 vac is not present check wiring see unit wiring label diagram 4 Check 24 vac output at PL6 10 white wire If 24 vac is not present replace economizer control board Incorrect SAT wiring or 1 After verifying that the OAT and EC settings and the economizer control board wir inoperative SAT ing are correct check to ensure that the 24 vac terminal of the SAT has 24 vac white wire If OAT EC and control board are functioning and wired properly and no 24 vac exists check wiring see unit label diagram 2 If supply air temperature is greater than 57 F 24 vac should be found at terminal T2 on the SAT pink wire If 24 vac is not present replace SAT Damper does not Incorrect economizer 1 Verify that SW2 and SW4 are wired and working properly see unit label diagram close wiring 2 Check diode D19 If diode is not functioning properly replace economizer control board Incorrect damper actuator 1 After verifying that the wiring is correct modulate the damper to the minimum posi wiring or inoperative tion Remove the calls for G
16. the end connection See Fig 3 The piping for the condensate drain and external trap can be completed after the unit is in place All units must have an external trap for condensate drain age Install a trap at least 4 in deep and protect against freeze up See Fig 4 If drain line is installed downstream from the external trap pitch the line away from the unit at lin per 10 ft of run Do not use a pipe size smaller than the unit connection 3 4 in IV STEP 4 RIG AND PLACE UNIT Inspect unit for transportation damage File any daim with transportation agency Keep unit upright and do not drop Spreader bars are not required if top crating is left on unit Rollers may be used to move unit across a roof Level by using unit frame as a reference See Table 1 and Fig 5 for additional information Operating weight is shown in Table 1andFig 5 Lifting holes are provided in base rails as shown in Fig 5 and 6 Refer to rigging instructions on unit Positioning Maintain dearance around and above unit to provide proper airflow and service access See Fig 6 Position unit on roof curb so that the following clearances are maintained 1 4 dearance between roof curb and base rails on each sideand in duct end of unit 35 16 clearance between roof curb and condenser end see Fig 1 section C C Do not install unit in an indoor location Do not locate unit air inlet near exhaust vents or other sources of contami nated
17. unit and install lock out tag to avoid shock hazard or injury from rotating parts CLEANING Inspect unit interior at the beginning of each heating and cooling season or more frequently as operating conditions require A Indoor Coil 1 Turn unit power off and tag disconnect Remove filter access panel and indoor coil access panel 2 If economizer or accessory two position damper is in stalled remove economizer two position damper by disconnecting economizer plug and removing mount ing screws see Fig 14 15 or 22 Refer to Accessory Economizer or Two Position Damper Installation Instructions for more details 3 Slide filters out of unit 4 Clean coil using a commercial coil cleaner or dish washer detergent in a pressurized spray canister Wash both sides of coil and flush with dean water For best results backflush toward return air section to remove foreign material Caution should be taken as to not overflow the evaporator drain condensate pan Flush condensate pan after completion Reinstall economizer two position damper and filters Reconnect wiring Replace access panels B Outdoor Coils Inspect coils monthly Clean condenser coils annually and as required by location and outdoor air conditions Clean 2 row coils as follows 1 Turn off unit power and tag disconnect 2 Remove top panel screws on outdoor end of unit 3 Remove outdoor coil corner post See Fig 39 To hold
18. 11 A 7 8 10 4 76 5 80 7 80 90 12 0 16 0 91 0 97 5 100 100 208 230 3 60 STD 187 254 14 4 103 0 1 4 5 8 18 6 24 0 113 9 124 0 125 125 24 0 32 0 132 7 145 7 150 150 31 8 42 4 159 8 176 9 175 200 102 81 2 460 3 60 STD 414 508 0 7 2 6 19 3 2011 575 3 60 STD 518 632 44 0 07 2 6 174 0 17 1 40 7 4511 34 0 34 1 62 0 70 52 1 52 1 60 60tt 55 55 300 300 7 8 10 4 21 7 25 0 79 2 83 4 80 84 322 3251 120 160 33 3 38 5 937 002 100 110 93 99 333 338ll 197555 124 0 1 4 5 8 57 0 32 0 66 6 77 0 135 4 148 4 150 150 132 144 366 3771l 31 8 42 4 88 3 102 0 162 5 179 6 175 200 157 172 1388 40211 37 6 50 0 104 4 120 3 182 6 172 4 200 200 175 193 404 42011 208 230 3 60 53 8 53 8 60 60tt 57 57 319 319 7 8 10 4 21 7 25 0 80 9 85 1 90 90 82 86 341 3441 120 160 33 3 38 5 95 4 101 9 100 110 93 101 352 3571l 187 254 17 2 124 0 1 4 7 5 54 0 32 0 66 6 77 0 137 1 150 1 150 175 134 145 385 396ll 31 8 42 4 88 3 102 0 164 2 181 3 175 200 158 174 1407 4211 37 6 50 0 104 4 120 3 184 3 174 1 200 200 177 195 423 43911 508 596 07 26 10 Tons 460 3 60 575 3 60 HEREDES NOTE Legend and Notes for Electrical Data are on page 10 LEGEND AND NOTES FOR TABLES 2A AND 2B LEGEND FLA Full Load Amps HACR Heating Air Conditioning and Refrigeration IFM Motor
19. 11 Install the complete hood assembly on the unit and secure using the screws provided NOTE If optional power exhaust is being installed complete installation of power exhaust at this time See Fig 32 for wiring 12 Remove the indoor fan motor access panel 13 Mount the supply air temperature sensor to the lower left portion of the indoor blower housing with the two 2 screws provided see Fig 33 Connect the violet and pink wires to the corresponding connections on the supply air temperature sensor Replace the indoor fan motor access panel CO2 Control Set Up If a CO2 sensor is not being used proceed tothe next section If a CO2 sensor is being used perform the following 16 1 Determine the value at which you want the minimum position of the dampers to begin opening to allow a greater amount of outdoor air to enter The range is 800 to 1 400 ppm 2 Locate the CO2 SP PPM potentiometer and adjust to the desired set point See Fig 34 12 pin Female Factory Installed Connections 50DK508234 Actuator 50DK508233 Molex Connector Rear of Plug PL6 Red 4 4 Red Blue 21 2 Blue 3 3 Black g 4 Brown amp Q ag Used for 8778 2 RAH Outdoor Air Enthalpy 5 5 E 2 Ion a elle coa 3 a CO2 cq 7 7 S 88 2 COM al PM Orange e EM t
20. 21 29 95041 9 18 85 29 5 75 24 2552 8 8 55 18 5 i 483 70 55 13 H fw 45 7 LI E 414 z60 I 8 5345 50 gt 8 I I I I I 276 40 LI I I LT I LI 30 III II 30 40 50 60 70 80 90 SUCTION LINE TEMPERATURE eB 4 10 16 21 27 32 SUCTION LINE TEMPERATURE Fig 43 Cooling Charging Chart 548D090 3 8 5 2 CIRCUIT 1 CHARGING CHART 8 5 TON 6OHZ CIRCUIT 2 CHARGING CHART 589 100 DEE R 689 100 SEO R ep op eC 0227 125 52 821 90 621 90 115 46 105 41 125 52 115 46 16 95 35 4552 80 105 41 2552 80 8 95 35 8 85 29 z p 85 29 z 483 70 75 24 2 483 70 75 24 D 65 18 D i S i 55 18 2414 60 55 13 2414 Sen 2 iij 45 7 amp amp 24 2 345 250 2 345 250 55 13 S a 2 45 7 18 5276 40 5278 40 Wu 207 30 207 30 20 30 40 50 60 70 80 20 30 40 50 60 70 80 SUCTION LINE TEMPERATURE F SUC
21. 4011 38 34 0 34 1 60 2 6011 58 A 47 295 295 7 8 10 4 21 7 25 0 74 4 78 6 317 320 187 254 124 0 12 016 0 33 3 38 5 88 9 95 4 90 100 328 334ll 24 0 32 0 66 6 77 0 130 6 143 6 150 150 362 372ll 31 8 42 4 88 3 102 0 157 7 174 8 175 175 383 3971I 082303 0 37 6 50 0 104 4 120 3 177 8 167 6 200 175 399 4151 49 0 490 50 50tt 314 314 7 8 10 4 21 7 25 0 76 1 80 8 80 90 336 389ll ALT 124 0 5 12 016 0 33 3 38 5 90 6 97 1 100 100 347 3531 24 0 32 0 66 6 77 0 132 3 145 3 150 150 381 391 31 8 42 4 88 3 102 0 159 4 176 5 175 200 402 416ll 37 6 50 0 104 4 120 3 179 5 169 3 200 175 418 434ll 120 10 Tons 460 3 60 STD 518 HERBES NOTE Legend and Notes for Electrical Data are on page 10 575 3 60 Table 2B Electrical Data Units With Electrical Convenience Outlet VOLTAGE COMPRESSOR DISCONNECT UNIT NOMINAL IFM _RANGE Ee Idee ROWER SUPPIY SIZEt 43 6 43 6 45 45tt 46 46 234 234 7 8 10 4 21 7 25 0 70 7 748 80 80 71 75 256 259 120 160 33 3 38 5 85 2 91 7 90 100 85 91 267 2721 208 230 3 60 STD 187 254 14 5 8 6 24 0 51 6 59 7 108 1 118 2 110 125 106 115 285 294II 24 0 32 0 126 8 139 8 150 150 123 135 300 3111 31 8 42 4 153 9 171 1 175 475 148 164 322 336ll 090 71 2 Tons 460 3 60 STD 414 508 6 7 420 07 26 17 1 20tt 575 3 60 STD 518 632 39 0 0 7 2 6 17 0 38 5 4011 34 0 59 7 60
22. 54 805 CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE
23. 9 00 257 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 con tact your local electric utility company immediately B Field Control Wiring Install an approved accessory thermostat assembly accord ing to installation instructions induded with the accessory Locate thermostat assembly on a solid wall in the condi tioned space to sense average temperature in accordance with thermostat installation instructions Route thermostat cable or equivalent single leads of colored wire from subbase terminals to low voltage connections on unit shown in Fig 8 as described in Steps 1 through 4 below NOTE If using Bryant electronic thermostat set thermostat configuration for non heat pump operation The use of the O terminal is not required to energize the reversing valve in this family of products NOTE For wire runs up to 50 ft use no 18 AWG American Wire Gage insulated wire 35 C minimum For 51 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 1 If unit is mounted on roof curb and accessory thru the curb service plate connection is used route wire through connection plate 2 Pass control wires through
24. ED CANT STRIP FIELD SUPPLIED ROOFING MATERIAL FIELD SUPPLIED SUPPLY AIR OPENING SECTION C C SCALE 1 4 NY I 7 RIGID INSULATION OPENING FOR BASEPAN oco zng FIELD SUPPLIED ENTRY SERVICE BOLT HEADS eal oe art Bel BOLT HEADS A 761 0 0 7 16 07 0 7 16 111 07 2 1 8 BOLT HEADS BOLT HEADS 7 541 PLACE UNIT AS CLOSE TO A 7 PR THIS END OF CURB AS POSSIBLE 07 3 3 16 2331 lt gt 7 gt 22 GAS SERVICE PLATE 1 8 3 16 Kal 513 0 4 5 16 rm 07 0 1 4 t7 INSIDE 4 CINSIDEY CONTROL 25 17 8 3 16 SERVIE 0 4 9 16 EZ 115 5 lt gt RETURN VIEW SUPPLY AIR HEAD OF BOLT TO BE ON INSIDE OF FLANGE 12641 D E NOTE CAMBRIDGEPORT SURE LOCK CORNER FASTENING DEVICE IS ACCEPTABLE ALTERNATE CONSTRUCTION gt ALL CORNERS SEE VIEW Fig 1 Roof Curb Details MAXIMUM ALLOWABLE DIFFERENCE in AB BC AC Fig 2 Unit Leveling Tolerances Il STEP 2 FIELD FABRICATE DUCTWORK On vertical discharge units secure all ducts to roof curb and building structure Do not connect ductwork to unit For hori zontal applications field supplied flanges should be attached to horizontal discharge openings and all ductwork attached
25. Fig 46 Typical Wiring Diagram cont CATALOG NO 5354 805 START UP CHECKLIST Remove and Store in Job File PRELIMINARY INFORMATION MODEL SERIAL NO DATE TECHNICIAN UNIT NO J OB LOCATION JOB NAME Il PRE START UP insert checkmark box as each item is completed O VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS O CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS CHECK THAT RETURN INDOOR AIR FILTERS ARE CLEAN AND IN PLACE O VERIFY THAT UNIT INSTALLATION IS LEVEL O CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS CHECK PULLEY ALIGNMENT AND BELT TENSION PER INSTALLATION INSTRUCTIONS ENSURE BELT TENSION AND BLOWER PULLEYS ARE PROPERLY ALIGNED Ill START UP ELECTRICAL SUPPLY VOLTAGE L1 L2 L2 L3 L3 L1 CIRCUIT NO 1 COMPRESSOR AMPS 11 L2 L3 CIRCUIT NO 2 COMPRESSOR AMPS 11 L2 L3 INDOOR FAN AMPS L1 L2 L3 TEMPERATURES OUTDOOR AIR TEMPERATURE DB dry bulb RETURN AIR TEMPERATURE DB WB wet bulb COOLING SUPPLY AIR DB WB PRESSURES Cooling Mode REFRIGERANT SUCTION CIRCUIT 1 PSIG F REFRIGERANT SUCTION CIRCUIT 2 PSIG F REFRIGERANT DISCHARGE CIRCUIT 1 PSIG F REFRIGERANT DISCHARGE CIRCUIT 2 PSIG F O VERIFY THAT 3 PHASE SCROLL COMPRESSOR IS ROTATING IN CORRECT DIRECTION O VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGES 32 AND 33 Copyright 2000 Bryant Heating amp Cooling Systems CL 1 CATALOG NO 53
26. S WITH 230 VOLT NAMEPLATE MCA UNDER 110 AMPS MAXIMUM WIRE SIZE 2 0 AWG SEE RED POWER PIGTAILS BRN COMP 2 ORN ER POWER SUPPL COMP 1 IEN SINGLE POINT BOX WIRING FOR UNITS WITH 230 VOLT NAMEPLATE MCA BETWEEN 110 AND 151 9 AMPS INGLE POINT CONNECTION BOX DETAIL A ALTERNATE SINGLE POINT BOX OPTIONS F ELECTRIC HEATERS SEE HEATER BRN SCHEMATICS RED BRN FOR INTERNAL BRN WIRING YEL BLK BRN YEL BRN Du CO 52 E OH ET m VICI _ lt VIO BRN ORN m GRA HPS LPS Eh wette We t BLU IN s K ck 8 K LI U LU OPTIONAL Fig 46 Typical Wiring Diagram 37 ECONOMIZER CONTROL BOARD EP52 PL6 R FOR STD UNIT NOTES 1 If any of the original wire furnished must be replaced it must be replaced with type 90 C wire or its equivalent 2 Three phase motors are protected under primary single phasing conditions 3 Thermostat P272 2783 Subbase HH93AZ176 P272 1882 1883 Set Heat anticipator at 8 amp for 1st stage and 3 amp for 2nd stage Use copper conductors only Use copper copper clad aluminum or aluminum conductors HHO7AT172 178 and REMOVED WITH EC om p SW XC ic PNK M MUST D pvc TRIP AMPS VOLTAGE RATING Potter amp Brumfield W28X 1024 3 2
27. SZ 9 9 5 White 2 Black 8 10 10 8 8 Black Yellow Brown a4 88 1 White Gray Connector Cable Not Used White Yellow 21 Switch S1 White Gray NO 23 20 Auxiliary Switch White Blue NG 22 Wire Connections Black Yellow 24 Switch 52 Located within Black Gray 25 70 the Actuator Black Blue 26 Fig 30 EconoMi er Wiring ECONOMISER CONTROLLER VIOLET OUTDOOR OAT AIR COM SENSOR OAH 15V RAT BROWN VIOLET aoe RAH SENSOR 15 SENSOR V 24 CO COM COM VAC DAT COM SUPPLY AIR REM POT TEMPERATURE SENSOR COM LED J COM Fig 31 EconoMi er Sensor Wiring TO FUSED a DISCONNECT a RED GRAY RED YEL a GRAY 88 gg e o Bg UE 2 o Ow amp l 0209 amp SECONDARY SECONDARY GE E E eee Si S vac H FIELD SUPPLIED WIRING LT BLUE GREEN YELLOW 230 VAC 1 PHASE C1 LT BLUE GREEN YELLOW Fig 32 Wiring Diagram for Power Exhaust System SUPPLY AIR TEMPERATURE SENSOR MOUNTING LOCATION SUPPLY AIR TEMPERATURE d4 SENSOR 6 b Fig 33 Supply Air Sensor Mounting Location 18 R2 24 VAC Mechanical Cooling Lockout Det
28. T 2 0 er 1 t8211 Ore SE We igs 0 0 91 11 5 09 1 MEE ud 621 91 1 2 0 d 1 1 071 0 LINA 40 191 2 2 2 ONINSdO Ji Wd 1619 aly 3015110 8 E 02 2 791407 Dud 55399 1 3 1102 004100 T3NYd 55322 5055399002 21812313 ONY 83 018 40106 000 1 X08 1041 05 A 831114 COOH 055392 GENEE IM SEEK ER D m gt k e X000 55322 831114 L 8 25 6 9176 2 0 E 6122 NOTL 901 123 02510 B E 2 721919313 5 H3MOg 7M 1902 y 91 6 8 01 ja 621 A e Ge 1L 2 we a us LNOYS AN Ene cup tec ri za 2315 LAVHI 0 93909 91 2 S 0 8 310 335 83 04 401108 335 jacea 78 8 1 tb 1521 ATddNS 2 4 lt Eet 81815085023 T TWOLLIN3A 1 1 I zen gt 3015 IH9IM mE 1331 8 2 0 6 kag aIv Nvdasva NI Al 10992 591 S9NIN3dO 149811 015 0 91 6 0 rar gt 9181 2 20 1 2 HW NES 3 out NuniJu 2d v tor i PO NUS re eseq eui Jo eu dn 021 104 019 5 5 M3IA 2715 20 1103 40 2 ZOL pue 060 20 lt 601 2 12 1 S jo 1ejueo e9nie 78 poene eue DONT __ em
29. TION LINE TEMPERATURE 1 4 10 16 21 27 1 4 10 16 2 27 SUCTION LINE TEMPERATURE C SUCTION LINE TEMPERATURE CO SODKS083161 Fig 44 Cooling Charging Chart 548D102 758 110 683 100 OUTDOOR TEMP TE UE pc Bg 8 S 105 4i 5 95 35 2552 85 29 5 75 24 wo g 65 18 ip 483 470 55 13 45 7 2 414 260 CHE 5 8 ed 5 345 50 2 N 276 40 HH 30 30 40 50 60 70 80 90 SUCTION LINE TEMPERATURE CP 4 10 16 21 27 32 SUCTION LINE TEMPERATURE C Fig 45 Cooling Charging Chart 548D120 33 TROUBLESHOOTING Refer to Tables 14 16 and Fig 46 for troubleshooting information Table 14 Heating and Cooling Troubleshooting Compressor and Thermostat setting too high Lower thermostat setting below room temperature See problem Excessive head pressure Compressor will not start but outdoor fan runs Compressor motor burned out seized or internal Determine cause Replace compressor overload open Defective overload Determine cause and replace One leg of 3 phase power dead Replace fuse or reset circuit breaker Determine cause Compressor cycles Refrigerant overcharge or undercharge Recover refrigerant evacuate system and other than normally recharge to nameplate aree ng instmosi e Faulty outd
30. air Although unit is weatherproof guard against water from higher level runoff and overhangs After unit is in position remove polyethylene shipping wrap per and rigging skid DRAIN PLUG NOTE Drain plug is shown in factory installed position Fig 3 Condensate Drain Connection MINIMUM PITCH ONE IN PER BASE 10 FT OF LINE TO ROOF DRAIN DRAIN PLUG NOTE Trap should be deep enough to offset maximum unit static dif ference A 4 in trap is recommended Fig 4 External Trap Condensate Drain 3 SECURE ALL SEAL STRIPS IN PLACE BEFORE POSITIONING EE UNIT ON ROOF CURB AS CLOSE 914 1371 TO THIS END AS POSSIBLE SEE DETAIL DUCT END NOTES 1 Dimension in is in millimeters 2 Hook rigging shackles through holes in base rail as shown in detail Holes in base rails are centered around the unit center of grav ity Use wooden top skid when rigging to prevent rigging straps from damaging unit in mm 1054 3 Unit weights do not include economizer See Table 1 for econo 65 438 77 42 1966 5 41 5 1054 42 12 1070 mizer We 15 460 77 42 1966 5 41 5 1054 42 12 1070 N CAUTION All panels must be in place when rigging and lifting Fig 5 Rigging Details suoisuauiig yun eseg 9 614 1 5 30 02 7015 d Nuni3H IV Aide LNOYS 3015 LHOIY xoa 3015 1331 r AD 2S v l 2 0 S
31. am for additional information Pig tails are provided for field wire connections Use factory supplied splices or UL Underwriters Laboratories approved copper al uminum connector TO COMP 2 T ORN When installing units provide a disconnect per the NEC All field wiring must comply with the NEC and local re quirements In Canada electrical connections must be made in accordance with CSA Canadian Standards Association C22 1 Canadian Electrical Code Part One Install field wiring as follows 1 Install conduit through side panel openings For units without electric heat install conduit between discon nect and control box 2 Install power lines to terminal connections as shown in Fig 7 3 For units with electric heat refer to Accessory Instal lation Instructions 4 If thru the bottom control connections are used refer to the accessory installation instructions for informa tion on control wiring Refer to Fig 6 for drilling holes in basepan During operation voltage to compressor terminals must be within range indicated on unit nameplate see Tables 2A and 2B On 3 phase units voltages between phases must be bal anced within 2 and the current within 10 Use the for mula shown in Tables 2A and 2B Note 2 on page 10 to determine the percentage of voltage imbalance Operation on improper line voltage or excessive phase imbalance consti tutes abuse and may cause damage to electrical compo nents Su
32. arometric relief damp ers and ensure dampers move freely GEAR DRIVEN DAMPER ECONOMISER CONTROLLER PLUG ACTUATOR x OUTDOOR AIR TEMPERATURE SENSOR RELIEF DAMPERS Fig 22 EconoMi er Component Locations OUTDOOR AIR FILTER ACCESS OPENING PANEL PANEL Fig 23 Typical Access Panel Locations 15 OUTDOOR AIR OPENING PANEL EXHAUST AIR HOOD TOP SEAL A N X EXHAUST AIR BOTTOM BRACKET Fig 24 Exhaust Air Hood Assembly SCREEN RETAINER EXHAUST AIR HOOD SIDES L EXHAUST AIR SCREEN OUTDOOR AIR OPENING PANEL OUTDOOR AIR HOOD TOP PA SCREEN A RETAINER OUTDOOR AIR p ct RY INLET M SCREENS EXHAUST HOOD OUTDOOR AIR J HOOD SIDES 4 SEAL STRIP Fig 25 Outdoor Air Hood Assembly BLOWER RETURN AIR FILTER BLOCK OFF PLATE OUTDOOR AIR BLOCK OFF PLATE ECONOMISER Fig 27 Return Air Block Off Plate Installation WIRING HARNESS OUTDOOR AIR BLOCK OFF PLATE ECONOMIZER CLIP UNIT FILTER RACK x HVAC UNIT A ECONOMIZER UNIT BASE M S KS ECONOMIZER REAR FLANGE Fig 28 Rear EconoMi er Flange Installation Fig 29 EconoMi er Installed
33. ating Sequence 29 SERVICE iii i boa or bad nidos 30 33 L 0 30 31 Ill Outdoor Fan 32 Economizer 32 V Refrigerant Charge 32 5 34 38 START UP CHECKLIST CL 1 SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical com ponents Only trained and qualified service personnel should install repair or service air conditioning equipment Untrained personnel can perform basic maintenance func tions of cleaning coils and filters and replacing filters All other operations should be performed by trained service per sonnel When working on air conditioning equipment ob serve precautions in the literature tags and labels attached to the unit and other safety precautions that may apply 548D Sizes 090 120 71 2 to 10 Tons Cancels 11 548D 90 1 548D 90 2 10 15 00 Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for unbrazing operations Have fire ex tinguisher available for all brazing operations N WARNING Before performing service or mainte nance operations on unit turn off main power swit
34. ch to unit and tag disconnect with lockout tag Electrical shock could cause personal injury INSTALLATION Unit is shipped in the vertical configuration To convert to horizontal configuration remove side duct opening covers Using the same screws install covers on vertical duct open ings with the insulation side down Seals around duct open ings must be tight STEP 1 PROVIDE UNIT SUPPORT A Roof Curb Assemble and install accessory roof curb in accordance with instructions shipped with curb See Fig 1 Install insulation cant strips roofing felt and counter flashing as shown Duct work must be attached to curb If electric or control power is to be routed through the basepan attach the accessory thru the bottom service connections to the basepan in accordance with the accessory installation instructions Connections must be installed before unit is set on roof curb IMPORTANT The gasketing of the unit to the roof curb is critical for watertightness Install gasket supplied with the roof curb as shown in Fig 1 Improperly applied gasket can also result in air leaks and poor unit performance Curb should be level Unit leveling tolerances are shown in Fig 2 This is necessary for unit drain to function properly Refer to Accessory Roof Curb Installation Instructions for additional information as required B Slab Mount Horizontal Units Only Provide a level concrete slab that extends a minimum of 6 in beyon
35. ch operation would invalidate any applicable warranty FIELD POWER SUPPLY FIELD POWER SUPPLY aren GE EE DE d GE DISCONNECT DISCONNECT pL PERNEC pL PERNEC 208 230 3 60 LEGEND 575 3 60 460 3 60 Contactor COMP Compressor IFC Indoor Fan Contactor National Electrical Code TB Terminal Block Field Wiring Factory Wiring Splice Connection L Factory Supplied Fig 7 Power Wiring Connections Table 2A Electrical Data Units Without Electrical Convenience Outlet VOLTAGE COMPRESSOR DISCONNECT UNT NOMINAL Fm RANGE DG Beete ONE SIZEt 548 PH 40 40tt 41 41 229 229 7 8 10 4 4 j 70 80 251 254 12 0 16 0 i 5 90 90 262 26811 208 230 3 60 STD 187 254 Th Ka 18 6 24 0 7 103 3 113 4 110 125 281 289ll 24 0 32 0 66 6 77 0 122 0 135 0 125 150 296 306ll 31 8 42 4 88 3 102 0 149 1 166 3 150 175 317 3311I 090 71 2 Tons 460 3 60 STD 414 508 6 7 42 0 0 7 2 6 15 4 2011 16 575 3 60 STD 518 632 39 0 0 7 2 6 174 0 36 7 40tt 36 34 0 6011 55 321 321 80 80 343 346 EI 12 0 16 0 90 100 354 360 186254 18 6 24 0 7 109 1 119 2 110 125 373 3811l 24 0 32 0 0 127 9 140 9 150 150 388 398 31 8 42 4 155 0 172 0 175 175 409 42311 102 81 2 460 3 60 STD 414 508 0 7 2 6 17 3 2011 18 575 3 60 STD 518 632 6 4 58 0 0 7 2 6 17 0 17 1 39 0
36. d unit cabinet Install a 6 in gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow NOTE Horizontal units may be installed on a roof curb if required N CAUTION Ensure voltage listed on unit data plate agrees with electrical supply provided for the unit ROOF CURB UNIT SIZE ACCESSORY 548D CRRFCURBOO3A00 1 2 356 090 150 CRRFCURBO004A00 2 0 610 ALT DRAIN HOLE Sj 1 1015 16 583 13 4 44 5 NOTES 1 Roof curb accessory is unassembled Insulated panels 1 in thick polyure thane foam 13 4 Ib density Dimensions in are in millimeters Roof curb 16 gage steel Attach ductwork to curb flanges of duct shipped cO CONTROL 3 4 19 NPT 19 41 4 31 7 NPT 1 EI 12 7 NPT 3 4 19 NPT 19 NPT 11 4 31 7 NPT CONNECTOR PACKAGE ACCESSORY CRBTMPWRO001A00 CRBTMPWR002A00 CRBTMPWR003A00 CRBTMPWR004A00 6 Service clearance 4 ft on each side T 2 Direction of airflow 8 Connector packages CRBTMPWRO001A00 and 002A00 are for thru the curb connections Packages CRBTMPO003A00 and 004A00 are for thru the bottom connections 1 2 12 7 NPT 1 2 12 7 NPT rest on curb UNIT NAIL TYPICAL 4 SIDES GASKET SUPPLIED WITH CURB FIELD SUPPLIED 07 3 5 1625 COUNTER FLASHING FIELD SUPPLIED ROOFING FELT FIELD SUPPLI
37. e desired system operating suction line temperature See Fig 43 45 6 Compare actual suction tube temperature with desired suction tube temperature Using a tolerance of 3 F add refrigerant if actual temperature is more than 3 F higher than proper suction tube tem perature or remove refrigerant if actual temperature is more than 3 F lower than required suction tube temperature B To Use Cooling Charging Charts Take the outdoor ambient temperature and read the suction pressure gage Refer to appropriate chart to determine what the suction temperature should be If suction temperature is high add refrigerant If suction temperature is low carefully recover some of the charge Recheck the suction pressure as charge is adjusted EXAMPLE Fig 43 Outdoor 85 Suction 70 psig Suction Temperature should 49 F Suction Temperature may vary 5 F C Heating Mode Charge Do not attempt to adjust charge by cooling methods while in Heating mode When charging is necessary in Heating mode recover refrigerant and weigh in according to unit data plate refrigerant data 758 110 689 100 OUTDOOR TEMP TE e 125 52 2 ES 45
38. e of the motors can be utilized with confidence Using fan motors up to the horsepower ratings shown in this table will not result in nuisance tripping or premature motor failure Unit warranty will not be affected Table 7 Fan Rpm at Motor Pulley Settings UNIT MOTOR PULLEY TURNS OPEN eae ee eee 815 790 765 740 715 690 665 635 615 590 090 935 04 1085 1060 1035 1010 985 960 935 885 835 Approximate fan rpm shown TIndicates standard motor and drive package Indicates alternate drive package only ttindicates alternate motor and drive package 21 Table 8 Fan Performance 548D090 Vertical Discharge Units STANDARD MOTOR BELT DRIVE External Static Pressure in wg Airflow Cfm STANDARD MOTOR BELT DRIVE cont External Static Pressure in wg Airflow Cfm LEGEND Bhp Brake Horsepower Input to Fan Watts Input Watts to Motor NOTES Boldface indicates field supplied drive is required See Note 7 indicates alternate drive is required 2 3 INN indicates field supplied motor and drive are required 4 Maximum usable watts input is 2120 and maximum continuous bhp is 2 40 Extensive motor and electrical testing on these units ensures that the full range of the motor be utilized with confi dence Using your fan motors up t
39. e rooftop unit connection board 2 Locatethe minimum position MIN POS potentiome ter Turn the potentiometer full CCW to fully dose the outdoor air dampers Turn the potentiometer gradually dockwise CW to the desired position See Fig 34 3 Replace the filter access panel See Fig 11 Ensure the filter access panel slides along the tracks and is securely engaged 4 Calculate the minimum airflow across the EconoMi er a Calculate 96 of outside air using the following formula Outdoor air through EconoMi er Mixture Temp Return Air Temp td Outdoor Temp Return Air Temp b Divide total CFM by percentage outdoor air this gives outdoor air volume in CFM 5 Turn on base unit power NOTE The EconoMi er begins operation three minutes after power up N WARNING PERSONAL INJ URY HAZARD Avoid possible injury by keeping fingers away from damper blades See Fig 35 for barometric relief damper characteristics o 20 800 1000 10 A B 10 m ut OFF CONFIG 30 D 60 1400 1200 60 49 COSP MECH CLG PPM LOCKOUT SP 100 en ECON MIN Fig 34 EconoMi er Control Adjustment Potentiometers Factory Settings 0 5 9 z gt 0 4 H gt 2 02 D 0 1 E 0 0 200 400 600 800 1000 1200 1400 1600 FLOW CUBIC FEET MINUTE Fig 35 Barometric Relief Capacity Vil STEP 7
40. ermine the outdoor air temperature at which you want the mechanical cooling compressors to be disabled Locate the mechanical cooling lockout MECH CLG LOCKOUT potentiometer To disable this feature turn the potentiome ter counterdockwise CCW to the OFF position Otherwise set the value between 10 and 60 F Mechanical cooling will not operate when the outdoor air temperature is below this value SeeFig 34 Dry Bulb Changeover Set Up Determine the dry bulb changeover set point from Table 4 The settings B C and D Locate the ECON SP potenti ometer and set the dry bulb changeover set point See Fig 34 When the OAT is abovethis set point the damper is limited to minimum position setting Table 4 Changeover Set Points SETTINGS A B C D Single Enthalpy Btu Ib Differential Temperature F Not Adjustable Differential Enthalpy Not Adjustable Field installed accessory If a potentiometer fails its setting will default to the values in Table 5 Table 5 Default Potentiometer Settings POTENTIOMETER CO SP PPM MECH CLG LOCKOUT ECON SP MIN POS Ventilation Air Minimum Position Set U p If ventilation air is not required proceed to Step 5 If ventila tion air is required perform the following 1 The indoor fan must be on to set the ventilation air Either put thethermostat in the continuous fan mode or jumper the R and G terminals at th
41. exhaust air hood side panels and the bottom bracket Assemble the exhaust air hood to the outdoor air opening panel as shown in Fig 24 using the screws provided Do not attach hood assembly to unit at this time Install the 1 s x 7 in seal strip the outdoor air hood top and side panels Assemble the outdoor air hood to the outdoor air opening panel as shown in Fig 25 using the screws provided Do not attach hood assembly to the unit as this ti me Slide the outdoor air inlet screens into the screen track on the hood side panels While holding the screens in place fasten the screen retainer to the hood using the screws provided Repeat the process for the barometric exhaust air screen Do not attach completed Fig 26 hood assembly to unit at this ti me Install the return air block off plate over the return air duct opening See Fig 27 Slide the EconoMi er assembly into the rooftop unit See Fig 28 and 29 NOTE Be sure to engage rear EconoMi er flange under tabs in return air opening of the unit base See Fig 28 8 Install the outdoor air block off plate then secure the EconoMi er with the screws provided See Fig 27 and 29 9 Remove and save the 12 pin blue and yellow wire jumper plug from the unit wiring harness located in the upper left corner and insert the EconoMi er plug Refer to wiring diagram Fig 30 and 31 Also refer to Fig 32 if installing an accessory power exhaust 10 Remove shipping tape from b
42. ft INDOOR FAN Quantity Size in Type Drive Nominal Cfm Maximum Continuous Bhp Motor Frame Size Nominal Rpm High Low Fan Rpm Range Motor Bearing Type Maximum Allowable Rpm Motor Pulley Pitch Diameter Min Max in Nominal Motor Shaft Diameter in Fan Pulley Pitch Diameter in Belt Quantity Type Length in Pulley Center Line Distance in Speed Change per Full Turn of Movable Pulley Flange rpm Movable Pulley Maximum Full Turns From Closed Position Factory Setting Factory Speed Setting rpm Fan Shaft Diameter at Pulley in HIGH PRESSURE SWITCH psig Standard Compressor Internal Relief Differential Cutout Reset Auto LOSS OF CHARGE SWITCH psig Cutout Reset Auto FREEZE PROTECTION THERMOSTAT F Opens Closes OUTDOOR AIR INLET SCREENS Quantity Size in RETURN AIR FILTERS Quantity Size in LEGEND Al Aluminum Bhp Brake Horsepower Indoor coil fin material outdoor coil fin material TWeight of 14 in roof curb Requires an accessory or optional controls upgrade kit Hermetic Scroll 2 62 ea Enhanced Copper Tubes Aluminum Lanced Fins Acutrol Feed Device sex 56 590 840 685 935 Ball 2100 2 4 3 4 2 8 3 8 5 7 0 7 0 1 A 48 1 A 48 16 75 19 25 15 75 19 25 50 50 4 16 x 20x2 18 00 Propeller Type 6500 2 22 1 4 1100 600 Centrifugal 1 15 15 Belt 3600 2 40 56 685 935 Ball 2100 2 8 3
43. ie RETAINER HOOD TOP HOOD SIDE SEAL PLATE STRIP SCREEN TRACKS HOOD SIDE ET SCREEN PLATE A CLASP BOTTOM STOP OUTDOOR AIR INLET SCREENS OUTDOOR AIR HOOD UNASSEMBLED HOOD TOP HOOD SIDE PLATE TRACKS FOR AIR INLET SCREEN STOP HOOD SIDES AND TOP ASSEMBLED Fig 12 Outdoor Air Hood Details BLOWER FILTER BLOCK OFF PLATE P N 50DK502257 Fig 13 Vertical Discharge Block Off Plate Size 120 Only ECONOMIZER ECONOMIZER ECONOMIZER TOP BAROMETRIC RELIEF DAMPER SHIPPING ECONOMIZER POSITION MOUNTING HOLES SETTING BRACKET Fig 14 Durablade Economizer Installation ECONOMIZER CONTROL BOARD ORN ECONOMIZER PLUG u WSs SSS A ECONOMIZER MOTOR BAROMETRIC RELIEF DAMPER SHIPPING SCREW POSITION SETTING BRACKET Fig 15 Horizontal Discharge Durablade Economizer Installation BLOCK OFF PLATE Fig 16 Horizontal Discharge Block Off Plate 13 TTT 1 REET EAA AD a Ht yt A LA 7 LLL tA VI NEGATIVE PRESSURE IN UNIT in wg 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 OUTDOOR AIRFLOW cfm x 100 Example Given Negative 0 1 in wg Outdoor Airflow 2 2 2 1100 Determine Setting 6 Fig 17 Durablade Economizer
44. installation start up and service instructions SINGLE PACKAGE ROOFTOP STANDARD EFFICIENCY HEAT PUMP UNITS CONTENTS Page SAFETY CONSIDERATIONS 1 INSTALLATION oa 1 27 Step 1 Provide Unit Support 1 ll Step 2 Field Fabricate Ductwork 3 Step 3 Install Condensate Drain Line and External 3 IV Step4 Rig and Place Unit 3 V Step 5 Make Electrical Connections 7 VI Step 6 Adjust Factory Installed Options 11 VII Step 7 Adjust Indoor Fan Speed 19 28 STARFEUP eR Rn SEN da we 28 30 1 Unit 28 Il Return Air 28 Ill Outdoor Air Inlet 28 IV Compressor 28 V Internal 0 28 VI Refrigerant Service 28 VII High Flow 28 Vill Compressor Rotation 28 IX Adjust Gas 29 X Cooling ices cad A eh ees 29 Xl Heating e e 29 Safety 29 XIII Ventilation Continuous 29 XIV Oper
45. ired EHE indicates field supplied motor and drive are required Maximum usable watts input is 2120 with standard motor and 2615 with alternate motor Maximum continuous bhp is 2 40 with o oo Ro Table 11 Fan Performance 5480090 Horizontal Discharge Units STANDARD MOTOR BELT DRIVE External Static Pressure in wg Airflow Cfm STANDARD MOTOR BELT DRIVE cont Airflow Cfm LEGEND Bhp Brake Horsepower Input to Fan Watts Input Watts to Motor NOTES 1 Boldface indicates field supplied drive is required See Note 7 2 indicates alternate drive is required HEE indicates field supplied motor and drive are required 4 Maximum usable watts input is 2120 and maximum continuous bhp is 2 40 Extensive motor and electrical testing on these units ensures that the full range of the motor be utilized with confidence Using your fan motors up to the wattage ratings shown will not result in nuisance tripping or premature motor failure Unit warranty will not be affected Values include losses for filters unit casing and wet coils Use of a field supplied motor may affect wire sizing Contact your representative to verify Standard motor drive range 590 to 840 rpm Alternate motor drive range 685 to 935 rpm All other rpms require field supplied drive Interpolation is permissible Do not extrapolate Table 12 Fan Perf
46. ischarge block off plate is shipped with the air hood package If unit is to be used for vertical dis charge application discard this plate Assembly 1 Determine if ventilation air is required in building If so determine the minimum amount to be supplied by each unit and record quantity of ventilation air needed for use in Step 8 Remove filter access panel by raising panel and swinging panel outward Panel is now disengaged from track and can be removed Notools are required to remove filter access panel Remove outdoor air opening panel Save panels and screws See Fig 11 Remove optional outdoor air damper hood package from filter section 3 Assemble outdoor air hood top and side plates as AHA cc DISCONNECT BOARD DISCONNECT SWITCH OPTIONAL RACEWAY COMPRESSOR NO 2 HOLE IN END PANEL shown in Fig 12 Install seal strips on hoop top and sides Put aside screen retainer and retainer screw for later assembly Do not attach hood to unit at this time WIRE CONNECTIONS TO LOW VOLTAGE ECTION 1 01 Ko er _ mmm TYPICAL THERMOSTAT CONNECTION BOARD LEGEND Adjustable Heat Anticipator Cooling Compensator Field Wiring Factory Wiring Fig 8 Low Voltage Connections COMPRESSOR NO 1 Fig 9 Typical Field Control Wiring Raceway Table 3 Heat Anticipator Settings UNIT VOLTAGE 1 575 UNIT Ed Co
47. k test all refrig erant 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 Ensure electrical wiring does not come into contact with refrigerant tubing or sharp edges d Inspect coil fins If damaged during shipping and handling carefully straighten fins with a fin comb 4 Verify the following conditions a Make sure that outdoor fan blades are correctly positioned in fan orifice Refer to Outdoor Fan Adjustment section on page 32 for more details b Make sure that air filter s is in place c Make sure that condensate drain trap is filled with water to ensure proper drainage d Make sure that all tools and miscellaneous loose parts have been removed e Ensure belt and blower pulley are properly aligned and at correct tension START UP 1 UNIT PREPARATION Make sure that unit has been installed in accordance with these installation instructions and applicable codes IL RETURN AIR FILTERS Make sure correct filters are installed in unit see Table 1 Do not operate unit without return air filters OUTDOOR AIR INLET SCREEN Outdoor air inlet screen must be in place before operating unit IV COMPRESSOR MOUNTING Compressors are internally spring mounted Do not loosen or remove compressor holddown bolts V INTERNAL WIRING Check all electrical connections in unit control boxes tigh
48. levels should now move totheir normal start up levels NOTE When the compressor is rotating in the wrong direc tion the unit makes an elevated level of noise and does not provide heating cooling IX ADJUST GAS INPUT The gas input to the unit is determined by measuring the gas flow at the meter or by measuring the manifold pressure Manifold pressure should be 3 5 in wg X COOLING To start unit turn on main power supply Set system selector switch at COOL position and fan switch at AUTO position Adjust thermostat to a setting below room temperature Compressor indoor and outdoor fans start on dosure of contactors Check unit charge Refer to Refrigerant Charge section on page 32 Unit must operate for at least 15 minutes before adjusting charge Reset thermostat at a position above room temperature Compressor and outdoor fans will shut off To Shut Off Unit Set system selector switch at OFF position Resetting ther mostat at a position above room temperature shuts unit off temporarily until space temperature exceeds thermostat setting Compressor restart is accomplished by manual rese at the thermostat by turning the selector switch to OFF position and then ON position XI HEATING To start unit turn on main power supply Set thermostat at HEAT position and a setting above room temperature fan at AUTO position First stage of thermostat energizes the indoor fan motor compressor and outdoor fan second stage
49. lide motor mounting plate away from fan scroll for proper belt tension 12 deflection with 5 to 10 Ibs of force and tighten mounting nuts with 10 Ibs torque see Fig 36 Unit 120 Slide motor mounting plate downward to tighten belt tension 1 2 deflection with 5 to 10 Ibs of force Secure motor mounting plate nuts with 10 Ibs of torque See Fig 37 3 Adjust bolt and nut on mounting plate to secure motor in fixed position Realign fan and motor pulleys 1 Loosen fan pulley setscrews 2 Slide fan pulley along fan shaft 3 Make angular alignment by loosening motor from mounting plate MOTOR MOUNTING PLATE NUTS 9 Fig 36 Typical Belt Drive Motor Mounting for Sizes 090 and 102 MOTOR MOUNTING PLATE NUTS HIDDEN Fig 37 Typical Belt Drive Motor Mounting for Size 120 STRAIGHTEDGE MUST MOVABLE BE PARALLEL FLANGE WITH BELT MOTOR AND FAN SHAFTS MUST BE PARALLEL SETSCREWS FIXED FLANGE SINGLE GROOVE Fig 38 Indoor Fan Pulley Adjustment Table 6 indoor Fan Motor Performance UNIT INDOOR FAN UNIT MAXIMUM ACCEPTABLE MAXIMUM ACCEPTABLE MAXIMUM 548D MOTOR VOLTAGE CONTINUOUS BHP OPERATING WATTS AMP DRAW 2 40 2120 Alternate 46 208 230 Standard 2 40 2120 0 208 230 460 2 90 2615 575 LEGEND BHP Brake Horsepower Extensive motor and electrical testing on these units ensures that the full horsepower rang
50. mizer Upon a call for heating through terminal W1 IFC OFC and C2 energized On units equipped for 2 stages of heat when additional heat is needed HC is energized through W2 C Cooling Units With Durablade Economizer When the outdoor air temperature is above the OAT setting and the room thermostat calls for cooling the compressor contactor no 1 and outdoor fan contactor OFC are ener gized to start compressor no 1 and outdoor fan motors RVS1 reversing valve solenoid is energized The indoor fan motor IFM is energized and the economizer damper moves to the minimum position Upon a further call for cooling compressor contactor no 2 will be energized starting com pressor no 2 RVS2 is energized After the thermostat is sat isfied and the IFM is deenergized the damper moves to the fully dosed position When the outdoor air temperature is below the OAT setting and the thermostat calls for Y1 and G the economizer damper moves to the minimum position when the indoor fan starts The first stage of cooling is provided by the econo mizer If the supply air temperature is above 57 F a switch on the supply air thermostat is closed between the T2 ter minal and the 24 vac terminal This causes the damper to continue to modulate open until the supply air temperature falls below 55 F or the damper reaches the fully open position When the supply air temperature is between 55 F and 52 F the supply air thermostat ha
51. n motor is energized and the economizer damper moves to the minimum position If the two position damper is used the outdoor air damper opens to the minimum position whenever the indoor fan opens When the thermostat is satisfied the damper moves to the fully closed position F Defrost When the temperature of the outdoor coil drops below 28 F as sensed by the defrost thermostat DFT2 and the defrost timer is at the end of a timed period adjustable at 30 50 or 90 minutes reversing valve solenoids RVS1 and RVS2 are energized and the OFC is deenergized This switches the position of the reversing valves and shuts off the outdoor fans The electric heaters if installed will be energized The unit continues to defrost until the coil temperature as measured by DFT2 reaches 65 F or the duration of defrost cycle completes a 10 minute period During the defrost mode if circuit 1 defrosts first RVS1 will oscillate between heating and cooling modes until the defrost mode is complete At the end of the defrost cycle the electric heaters if in stalled will be deenergized the reversing valves switch and the outdoor fan motors will be energized The unit will now operate in the heating mode If the space thermostat is satisfied during a defrost cycle the unit will continue in the defrost mode until the time or tem perature constraints are satisfied SERVICE N CAUTION When servicing unit shut off all elec trical power to
52. nection board No power to economizer Check that SW3 is properly making contact with the damper blade Check that motor SWh is in the NC normally closed position Check diode D18 If diode is not functioning properly replace economizer control board Confirm that the economizer control board is grounded properly at PL6 4 brown wire and at brown terminal of the economizer control board brown wire The economizer motor must also be grounded properly at the negative motor terminal brown wire Verify SW1 and SW3 are working and wired properly see unit label diagram Check for 24 vac input at both PL6 1 red wire and PL6 3 black wire If 24 vac not present check unit wiring see unit label diagram If 24 vac is found in both places check for 24 vac at the yellow terminal of the economizer control board yellow wire If 24 vac power is not present replace the economizer control board Economizer motor failure If the indoor fan and economizer motor are energized verify that there is a minimum of 18 vdc at the positive motor terminal If the motor is not operating replace the motor Economizer operation OAT or EC set too high 1 Set at correct temperature 3 F below indoor space temperature limited to minimum 2 Check OAT or EC by setting above outdoor temperature or humidity level If the position OAT or EC switches do not close replace OAT or EC Economizer control board 1 Perform the following tests when OAT
53. nfiguration Amm E 104 160 0 3 NA NA 13 9 16 5 17 0 34 0 548D 248 320 06 27 8 33 0 ps3 Heater capacity kW is based on heater voltage of 208 v 240 v 480 v and 575 v If power distribution voltage to unit varies from rated heater voltage heater kW will vary accordingly Adjust minimum position setting by loosening the screws on the position setting bracket See Fig 18 Slide bracket until the top screw is in the position determined by Fig 17 Tighten screws 9 Remove tape and shipping screw from outdoor air thermostat OAT Fas ten OAT to inside of hood using screws and speed clips provided See Fig 19 Make sure OAT terminals are positioned up 10 Replace outdoor air opening panel using screws from Step 2 Replace filter access panel Ensure the filter access panel slides along the tracks and is securely engaged 11 Fasten hood top and side plate assembly to outdoor air opening panel with screws provided 12 Place knob supplied with economizer on OAT See Fig 19 Set for 3 F below indoor room thermostat setting accessory enthalpy control is used in place of OAT see instructions shipped with EC for installation and adjustment See Fig 19 13 Connect OAT per Fig 20 14 Slide outdoor air inlet screen into screen track on hood side plate While holding screen in place fasten 30 50 90 screen retainer to hood using screws provided
54. o the wattage ratings shown will not result in nuisance tripping or premature motor failure Unit war ranty will not be affected Values include losses for filters unit casing and wet coils Use of a field supplied motor may affect wire sizing Contact your representative to verify Standard motor drive range 590 to 840 rpm Alternate motor drive range 685 to 935 rpm All other rpms require field supplied drive Interpolation is permissible Do not extrapolate Table 9 Fan Performance 548D102 Vertical Discharge Units STANDARD MOTOR BELT DRIVE External Static Pressure in wg Airflow Cfm STANDARD MOTOR BELT DRIVE cont External Static Pressure in wg Airflow 908 2 24 1980 913 2 29 2023 924 2 40 2120 LEGEND Bhp Brake Horsepower Input to Fan Watts Input Watts to Motor NOTES 1 Boldface indicates field supplied drive is required See Note 6 2 EE indicates field supplied motor and drive are required 3 Maximum usable watts input is 2120 and maximum continuous bhp is 2 40 Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with z ep OTE confidence Using your fan motors up to the wattage ratings shown will not result in nuisance tripping or premature motor failure Unit warranty will not be affected Values include losses for filters unit casing and wet
55. oor fan cooling or indoor fan heating motor or Replace capacitor Compressor operates ard aded Air in system Recover refrigerant evacuate system and recharge Outdoor coil dirty or restricted Clean coil or remove restriction Scroll compressor Compressor rotating in the wrong direction Reverse the 3 phase power leads as described in makes excessive noise Start Up page 28 Excessive head Dirty air filter Replace filter pressure Dirty outdoor coi Refrigerant overcharged Remove excess refrigerant Air in system Recover refrigerant evacuate system and recharge Head pressure too low Excessive suction Suction pressure too low Insufficient indoor airflow cooling mode Increase air quantity Check filter and replace if necessary Temperature too low in conditioned area Reset thermostat Field installed filter drier restricted Outdoor ambient temperature below 25 F Install low ambient kit Compressor no 2 Unit in economizer mode Proper operation no remedy necessary will not run Table 15 Durablade Economizer Troubleshooting PROBLEM CAUSE REMEDY Damper does not Indoor fan is off Check to ensure that 24 vac is present at terminal C1 on the IFC or that 24 vac is open present at the IFO terminal Check whether 24 vac is present at PL6 1 red wire and or PL6 3 black wire If 24 vac is not present check wiring see unit label diagram Check proper thermostat connection to G on the con
56. or Stage 1 cooling R to G Y 1 the indoor fan motor IFM is energized and the EconoMi er damper modulates to mini mum position The compressor contactor and OFC are ener gized starting the compressor and outdoor fan motor OFM After the thermostat is satisfied the damper modulates to the fully closed position when the IFM is deenergized When the OAT is below the ECON SP setting and the room thermostat calls for Stage 1 cooling R to G Y1 the EconoMi er modulates to the minimum position when the IFM is energized The EconoMi er provides Stage 1 of cool ing by modulating the return and outdoor air dampers to maintain a 55 F supply air set point If the supply air tem perature SAT is greater than 57 the EconoMi er modu lates open allowing a greater amount of outdoor air to enter theunit If the SAT drops below 53 F the outdoor air damper modulates closed to reduce the amount of outdoor air When the SAT is between 53 and 57 F the EconoMi er maintains its position If outdoor air alone cannot satisfy the cooling requirements of the conditioned space and the OAT is above the MECH CLG LOCKOUT set point the EconoMi er integrates free cooling with mechanical cooling This is accomplished by the strategies below NOTE Compressors have a two minute Minimum On Mini mum Off and I nterstage delay timer 1 If Y1is energized and the room thermostat calls for Y2 2 stage thermostat the compressor number 1 and OFM are ene
57. ormance 548D102 Horizontal Discharge Units STANDARD MOTOR BELT DRIVE External Static Pressure in wg Airflow STANDARD MOTOR BELT DRIVE cont External Static Pressure in wg Airflow Cfm LEGEND Bhp Brake Horsepower Input to Fan Watts Input Watts to Motor NOTES 1 Boldface indicates field supplied drive is required See Note 6 2 indicates field supplied motor and drive are required 3 Maximum usable watts input is 2120 and maximum continuous bhp is 2 40 Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with meo oum confidence Using your fan motors up to the wattage ratings shown will not result in nuisance tripping or premature motor failure Unit warranty will not be affected Values include losses for filters unit casing and wet coils Use of a field supplied motor may affect wire sizing Contact your representative to verify Standard motor drive range 685 to 935 rpm All other rpms require field supplied drive Interpolation is permissible Do not extrapolate Table 13 Fan Performance 548D120 Horizontal Discharge Units STANDARD AND ALTERNATE MOTORS BELT DRIVE Airflow External Static Pressure in wg Cfm STANDARD AND ALTERNATE MOTORS BELT DRIVE cont External Static Pressure in wg Airflow LEGEND Bhp Brake Horsepower Input to Fan Wa
58. position to decrease Refer to the Start Up instructions Verify correct position set point setting of MIN POS If correct is operating correctly Damper does not return to ventilation strategy If a CO2 sensor is being used and the damper position is greater than minimum position controlling minimum position the ventilation control strategy is controlling Refer to the Start Up instructions EconoMi er is operating correctly Damper does not close on Damper travel is Check to ensure the damper is not blocked power loss restricted LEGEND IFM Indoor Fan Motor OAT Outdoor Air Temperature SCHEMATIC 208 230 3 0 YEL BLK YEL BLK EQUIP GND S 9 E P DEEL LA uy SEE NOTE S SEE DETAIL MAXIMUM WIRE SIZE 350 MCM EQUIP GND RELOCATE TO SINGLE POINT BOX WHEN ELECTRIC HEAT OPTION IS USED c2 MAXIMUM WIRE SIZE 2 AWG A AND B SEE NOTE 6 SINGLE POINT B0X WIRING FOR UNITS WITH 230 VOLT NAMEPLATE MCA OVER 173 9 AMPS m a SIs Bye Pa z E BLU IFC DETAIL B ELECTRIC HEATERS A Tuner OFF VIO PNK WHT YEL BLU BLK BRN RED GRA ORN BRN KZD RED C2 YEL BRN ORN BLK H23 y 8LU 21 I BLU ORN CHI SINGLE POINT BOX WIRING FOR UNITS WITH 230 VOLT NAMEPLATE MCA BETWEEN SINGLE POINT BOX WIRING DG 152 AND 173 9 AMPS UNIT
59. rgized The position of the EconoMi er damper is maintained at its current value 2 If Y1 is energized for more then 20 minutes and Y 2 is not energized whether or not a 2 stage thermostat is used compressor no 1 and OFM are energized The position of the EconoMi er damper is maintained at its current value 3 If Y1 is energized and compressor no 1 is already energized and the room thermostat calls for Y2 compressor no 1 continues to operate If Y 2 remains energized for more than 20 minutes compressor no 2 is energized NOTE Compressor no 2 cannot be energized unless there is a signal for Y 2 from the space thermostat 4 f compressor no 2 is energized and the Y2 signal from the thermostat is satisfied compressor no 1 and 2 are deenergized Re asserting Y2 will start com pressor no 1 and after a 20 minute interstage delay compressor no 2 5 If compressor no 1 is energized the thermostat is satisfied compressor no 1 the OFM and IFM are deenergized and the EconoMi er modulates closed When the OAT is below the MECH CLG LOCKOUT set point the compressors remain off E Heating Units With Economizer If Accessory Heater is Installed When the room thermostat calls for heat through terminal W1 the indoor fan contactor outdoor fan contactor C1 and C2 are energized On units equipped for 2 stages of heat when additional heat is needed heater contactor is energized through W2 The indoor fa
60. s open switches between the T2 and 24 vac terminals and between the T1 and 24 vac termi nals This causes the economizer damper to remain in an intermediate open position If the supply air temperature falls below 52 F a switch on the supply air thermostat is dosed between the T1 terminal and the 24 vac terminal This causes the damper to modu late closed until the supply air temperature rises above 55 F or the damper reaches the minimum position When the supply air temperature is between 55 F and 57 F the supply air thermostat has open switches between the T2 and 24 vac terminals This causes the economizer damper to remain in an intermediate open position If the outdoor air alone cannot satisfy the cooling require ments of the conditioned space economizer cooling is in tegrated with mechanical cooling providing second stage cooling Compressor no 1 and outdoor fans will be ener gized and the position of the economizer damper will be determined by the supply air temperature Compressor no 2 is locked out When the second stage of cooling is satisfied the compressor RVS2 and outdoor fan motors will be deenergized The damper position will be determined by the supply air temperature When the first stage of cooling is satisfied the damper will move to fully closed position 29 D Cooling Units With EconoMi er When the Outdoor Air Temperature OAT is above the ECON SP set point and the room thermostat calls f
61. ten as required Ensure wiring does not come into direct contact with refrigerant tubing or sharp edges VI REFRIGERANT SERVICE PORTS Each refrigerant system has 4 Schrader type service gage ports One on the suction line one on the cooling mode liquid line and 2 on the compressor discharge line Be sure that caps on the ports are tight Vil HIGH FLOW VALVES Located on the compressor hot gas and suction tubes are High Flow Valves Large black plastic caps distinguish these valves with O rings located inside the caps These valves cannot be accessed for service in the field Ensure the plastic caps are in place and tight or the possibility of refrigerant leakage could occur Vill COMPRESSOR ROTATION It is important to be certain the scroll compressor is rotating in the proper direction To determine whether or not com pressor is rotating in the proper direction 1 Connect service gages to suction and discharge pres sure fittings 2 Energize the compressor 3 The suction pressure should drop and the discharge pressure should rise as is normal on any start up If the suction pressure does not drop and the discharge pres sure does not rise to normal levels 1 Note that the indoor fan is probably also rotating in the wrong direction 2 Turn off power to the unit and tag disconnect 3 Reverse any two of the unit power leads 4 Turn on power tothe unit Reenergize compressor The suction and discharge pressure
62. the hole provided on unit see connection D in Connection Sizes table in Fig 6 3 Feed wire through the raceway built into the corner post to the 24 v barrier located on the left side of the control box See Fig 9 The raceway provides the UL required dearance between the high and low voltage wiring 4 Connect thermostat wires to screw terminals of low voltage connector see Fig 8 NOTE If thru the bottom power connections are used refer to the accessory installation instructions for information on power wiring Refer to Fig 6 for drilling holes in basepan C Defrost Board The defrost board timer cyde is set to 30 minutes To change the cycle time remove the wire from defrost board connected to the 30 minute quick connect See Fig 10 Connect the wire to the 50 or 90 minute quick connects on the defrost board depending on the desired defrost time D Heat Anticipator Settings For units with electric heat set heat anticipator settings as shown in Table 3 VI STEP 6 ADJUST FACTORY INSTALLED OPTIONS A Disconnect Switch The optional disconnect switch is non fused The switch has the capability of being locked in place for safety purposes SeeFig 9 B Optional Durablade Economizer The optional economizer hood assembly is packaged and shipped in the filter section Damper blades and control boards are installed at the factory and the economizer is shipped in the vertical discharge position NOTE Horizontal d
63. top panel open place coil corner post between top panel and center post See Fig 40 4 Remove device holding coil sections together at return end of outdoor coil Carefully separate the outer coil section to 4 in from the inner coil section SeeFig 41 5 Usea water hose or other suitable equipment to flush down between the 2 coil sections to remove dirt and debris Clean the outer surfaces with a stiff brush in the normal manner 6 Secure the sections together Reposition the coil sec tions and remove the coil corner post from between the top panel and center post Install the coil corner post and coil center post and replace all screws C Condensate Drain Check and dean each year at start of cooling season In win ter keep drain dry or protect against freeze up D Filters Clean or replace at start of each heating and cooling season or more often if operating conditions require it Replacement filters must be same dimensions as original filters E Outdoor Air Inlet Screen Clean screen with steam or hot water and a mild detergent Do not use disposable filters in place of screens F Belts Adjust belt tension and pulley alignment at least twice a year or more frequently as operating conditions require Il LUBRICATION A Compressors Each compressor is charged with correct amount of oil at the factory B Fan Motor Bearings Fan motor bearings are permanently lubricated No further lubrication of o
64. troller fault If STATUS light is flashing one flash the EconoMi er controller is experiencing a fault condition Cycle power to the controller If condition continues replace the EconoMi er controller Thermostat fault If STATUS light is flashing two flashes the EconoMi er controller senses the thermostat is wired incorrectly Check wiring between the thermostat and the connection board in the electrical panel The fault condition is caused by Y2 being energized before Y1 Actuator Fault Check the wiring between the EconoMi er controller and the actuator Hold CONFIG button between three and ten seconds to verify the actuator s operation This process takes three minutes to complete EconoMi er operation limited Minimum position set Verify that the MIN POS 96 is set greater than zero Adjust to minimum position incorrectly MIN POS to 100 to verify operation and then set to correct setting EconoMi er changeover Set at correct value See Table 4 set point set too high or too low Supply air temperature If STATUS light is flashing 4 flashes the supply air temperature sensor is faulty sensor faulty Check wiring or replace sensor Outdoor air temperature sen If STATUS light is flashing 5 flashes the outdoor air temperature sensor is faulty sor faulty Check wiring or replace sensor Damper position Supply air low limit The supply air temperature is less than 45 F causing the minimum less than minimum strategy controlling
65. tts Input Watts to Motor NOTES 1 2 Ro Boldface indicates field supplied or alternate as appropriate drive is required See Note 7 indicates alternate motor and drive are required HES indicates field supplied motor and drive are required Maximum usable watts input is 2120 with standard motor and 2615 with alternate motor Maximum continuous bhp is 2 40 with 27 Qo standard motor and 2 90 with alternate motor Extensive motor and electrical testing on these units ensures that the full range of the motor can be utilized with confidence Using your fan motors up to the wattage ratings shown will not result in nuisance tripping or premature motor failure Unit warranty will not be affected Values include losses for filters unit casing and wet coils Use of a field supplied motor may affect wire sizing Contact your representative to verify Standard motor drive range 685 to 935 rpm Alternate motor drive range 835 to 1085 rpm All other rpms require field supplied drive Interpolation is permissible Do not extrapolate PRE START UP N WARNING Failure to observe the following warn ings could result in serious personal injury 1 Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system 2 Do not operate compressor or provide any elec tric power to unit unless compressor terminal cover is in place and secured
66. uperheat charging chart is attached to the outside of the service access panel The chart indudes the required suction line temperature at given suction line pressures and outdoor ambient temperatures An accurate superheat thermocouple or thermistor type thermometer and a gage manifold are required when using the superheat charging method for evaluating the unit charge Do not use mercury or small dial type thermometers becausethey are not adequatefor this type of measurement NCAUTION When evaluating the refrigerant charge an indicated adjustment to the specified fac tory charge must always be very minimal If a substan tial adjustment is indicated an abnormal condition exists somewhere in the cooling system such as insuf ficient airflow across either coil or both coils Proceed as follows 1 Remove caps from low and high pressure service fittings 2 Using hoses with valve core depressors attach low and high pressure gage hoses to low and high pressure service fittings respectively 3 Start unit in Cooling mode and let unit run until sys tem pressures stabilize 4 Measure and record the following a Outdoor ambient air temperature F db b Evaporator inlet air temperature F wb Suction tube temperature F at low side service fitting d Suction low side pressure psig 5 Using Cooling Charging Charts compare outdoor air temperature F db with the suction line pressure psig to determin
67. utdoor or indoor fan motors is required 31 TOP REMOVE OUTDOOR PANEL SCREWS FAN CONTROL BOX CORNER POST cse mm 4 Bm REMOVE COIL CENTER SCREWS POST OUTDOOR REMOVE COIL COIL CORNER POST Fig 39 Cleaning Outdoor Coil COIL CORNER CENTER BAFFLE TOP PANEL Fig 40 Propping Up Top Panel TOP VIEW TOP PANEL OUTDOOR COIL INNER COIL SECTION CENTER BAFFLE OUTER COIL SECTION RETURN END Fig 41 Separating Coil Sections OUTDOOR FAN ADJUSTMENT Fig 42 1 Shut off unit power supply 2 Remove outdoor fan assembly grille motor motor cover and fan and loosen fan hub setscrews 3 Adjust fan height as shown in Fig 42 Tighten setscrews and replace outdoor fan assembly UNIT VOLTAGE 208 230 V 460 V and 575 V Fig 42 Outdoor Fan Adjustment IV ECONOMIZER ADJUSTMENT Refer to Optional Economizer sections on pages 11 and 15 IMPORTANT Refer to Troubleshooting Tables 14 16 for addi tional information V REFRIGERANT CHARGE A Checking and Adjustment Refrigerant Charge The refrigerant system is fully charged with R 22 refriger ant tested and factory sealed Unit must operate in cooling mode a minimum of 10 minutes before checking charge NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R 22 charge A s

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