Bryant 577D-A User Manual
577D----A
EVOLUTIONR
15 SEER SINGLE--PACKAGED AIR CONDITIONER AND GAS FURNACE
SYSTEM WITH PURONR (R--410A) REFRIGERANT
SINGLE PHASE
2--5 NOMINAL TONS (SIZES 24--60)
Installation Instructions
!
CAUTION
EQUIPMENT OPERATION HAZARD
Failure to follow this caution may result in improper unit
operation.
OAT sensor must be field installed. See Accessory
Installation for more details.
!
CAUTION
EQUIPMENT OPERATION HAZARD
Failure to follow this caution may result in improper unit
operation.
This Evolutionr unit is designed for use with an Evolution
User Interface.
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 2.........................
INTRODUCTION 2...................................
RECEIVING AND INSTALLATION 2--13.................
Check Equipment 2..................................
Identify Unit 2....................................
Inspect Shipment 2.................................
Provide Unit Support 2...............................
Roof Curb 2......................................
Slab Mount 3.....................................
Provide Clearances 3.................................
Rig and Place Unit 3.................................
Inspection 3......................................
Rigging/Lifting of Unit 9............................
Select and Install Ductwork 9...........................
Configuring Units for Downflow (Vertical) Discharge 10...
Provide for Condensate Disposal 10.....................
Install Flue Hood 11..................................
Install Gas Piping 11.................................
Install Electrical Connections 12........................
High--Voltage Connections 12........................
Routing Power Leads Into Unit 12.....................
Connecting Ground Lead to Ground Screw 12...........
Routing Control Power Wires 13.....................
Accessory Installation 13............................
Special Procedures for 208 -- v Operation 13..............
PRE-- START--UP 16...................................
START--UP 16--29.....................................
Unit Start--Up and Troubleshooting 16...................
Sequence of Operation 23.............................
Check for Refrigerant Leaks 28.........................
Start--Up Adjustments 28..............................
A09032
Fig. 1 -- Unit 577D----A
Checking Cooling and Heating Control Operation 28......
Checking and Adjusting Refrigerant Charge 28...........
Refrigerant Charge 29..............................
No Charge 29.....................................
Low Charge Cooling 29.............................
To Use Cooling Charging Charts 29....................
Non--Communicating Emergency Cooling/Heating Mode 29..
MAINTENANCE 31--34................................
Air Filter 31........................................
Indoor Fan and Motor 31..............................
Inducer Blower 31...................................
Limit Switch 31.....................................
Burner Ignition 31...................................
Main B urners 31....................................
Inducer Pressure Switch 32............................
Outdoor Coil, Indoor Coil, and Condensate Drain Pan 32.....
Outdoor Fan 32.....................................
Electrical Controls and Wiring 32.......................
Refrigerant Circuit 33.................................
Indoor Airflow 33...................................
Pressure Switches 33.................................
L o s s -- o f -- C h a r g e S w i t c h 3 3............................
High--Pressure Switches 33............................
Copeland Scroll Compressor (Puron
Refrigerant System 33................................
Refrigerant 33....................................
Compressor Oil 33.................................
Servicing Systems on Roofs with Synthetic Materials 33....
Liquid-- Line Filter Drier 34..........................
Puron (R--410A) Refrigerant Charging 34...............
TROUBLESHOOTING 34..............................
FINAL CHECKS 35...................................
CARE AND MAINTENANCE 35........................
START--UP CHECKLIST 39............................
®
Refrigerant) 33........
1
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. consult local
building codes, the current editions of the National Fuel Gas Code
(NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code
(NEC) NFPA 70.
In Canada refer to the current editions of the National Standards of
Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation codes, and Canadian Electrical Code CSA C22.1
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these
577D-- --A
signal words: DANGER, WARNING, and CAUTION. Th ese
words are u sed with the safety--alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be
more than one disconnect switch. Turn off accessory heater
power switch if applicable.
!
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal
injury or equipment damage.
Puron (R--410A) systems operate at higher pressures than
standard R-- 22 systems. DO NOT use R--22 service
equipment or components on Puron (R--410A) equipment.
Ensure service equipment is rated for Puron (R--410A).
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
When removing access panels or performing maintenance
functions inside your unit, be aware of sharp sheet metal
parts and screws. Although special care is taken to reduce
sharp edges to a minimum, be extremely careful when
handling parts or reaching into the unit.
INTRODUCTION
The 577D----A packaged unit is a fully self--contained combination
Category I gas heating/electric air conditioner designed for outdoor
installation (See Fig. 1). Standard units are shipped in a
horizontal--discharge configuration for installation on a rooftop, or
on cement slab (See Fig. 4 for roof curb dimensions). Standard
units can be converted to downflow (vertical) discharge
configurations for rooftop applications.
Models with an N in the thirteenth position of the model number
are dedicated Low NOx units designed for California installations.
These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/joule or less as
shipped from the factory and must be installed in California Air
Quality Management Districts or any other regions in North
America where a Low NOx rule exists.
In gas heating mode, this unit is designed for a minimum
continuous return--air temperature of 55_F(13_C) db and a
maximum continuous return--air temperature of 80_F(27_C) db.
Failure to follow these return--air temperature limits may affect
reliability of heat exchangers, motors, and other components.
NOTE: Low NOx requirements apply only to natural gas
installations.
RECEIVING AND INSTALLATION
Check Equipment
IDENTIFY UNIT
The unit model number and serial number are printed on the unit
.
informative plate. Check this information against shipping papers.
INSPECT SHIPMENT
Inspect for shipping damage before removing packaging material.
If unit appears to be damaged or is torn loose from its anchorage,
have it examined by transportation inspectors before removal.
Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in transit.
Check all items against shipping list. Immediately notify the
nearest distributor office if any item is missing. To prevent loss or
damage, leave all parts in original packages until installation.
If the unit is to be mounted on a curb in a downflow application,
review “Configuring Units for Downflow Discharge” to determine
which method is to be used to remove the downflow panels before
rigging and lifting into place. The panel removal process may
require the unit to be on the ground.
Provide Unit Support
IMPORTANT: The unit must be secured to the curb by installing
screws through the bottom of the curb flange and into the unit base
rails. When installing large base units onto the common curb, the
screws must be installed before allowing the full weight of the unit
to rest on the curb. A minimum of six screws are required for large
base units. Failure to secure unit properly could result in an
unstable unit. See Warning near Rigging/Lifting information and
accessory curb instructions for more details.
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate, if required.
ROOF CURB
Install accessory roof curb in accordance with instructions shipped
with curb (See Fig. 4). Install insulation, cant strips, roofing, and
flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is
critical for a water tight seal. Install gasketing material supplied
with the roof curb. Improperly applied gasketing also can result in
air leaks and poor unit performance.
Curb should be level to within 1/4 in. (6.35 m) (See Fig. 2). This is
necessary for unit drain to function properly. Refer to accessory
roof curb installation instructions for additional information as
required.
2
A
C
MAXIMUM ALLOWABLE
B
A-B
(6.35)
1/4
Fig. 2 -- Unit Leveling Tolerances
Installation on older “G” series roof curbs.
Two accessory kits are available to aid in installing a new “G”
series unit on an old “G” roof curb.
1. Accessory kit number CPADCURB001A00, (small chassis)
and accessory kit number CPADCURB002A00, (large
chassis) includes roof curb adapter and gaskets for the
perimeter seal and duct openings. No additional
modifications to the curb are required when using this kit.
2. An alternative to the adapter curb is to modify the existing
curb by removing the outer horizontal flange and use
accessory kit number CPGSKTKIT001A00 which includes
spacer blocks (for easy alignment to existing curb) and
gaskets for the perimeter seal and duct openings. This kit is
used when existing curb is modified by removing outer
horizontal flange.
!
UNIT/STRUCTURAL DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Ensure there is sufficient clearance for saw blade when cutting
the outer horizontal flange of the roof curb so there is no
damage to the roof or flashing.
CAUTION
OPTIONAL
RETURN
AIR
OPENING
DIFFERENCE in. (mm)
1/4
B-C
(6.35)
A-C
1/4
OPTIONAL
SUPPLY
AIR
OPENING
(6.35)
A07925
Provide Clearances
The required minimum service clearances are shown in Fig. 5 and
6. Adequate ventilation and outdoor air must be provided. The
outdoor fan draws air through the outdoor coil and discharges it
through the top fan grille. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
corner or under an overhead obstruction. The minimum clearance
under a partial overhang (such as a normal house overhang) is 48
in. (1219 mm) above the unit top. The maximum horizontal
extension of a partial overhang must not exceed 48 in. (1219 mm).
IMPORTANT: Do not restrict outdoor airflow. An air restriction
at either the outdoor--air inlet or the fan discharge may be
detrimental to compressor life.
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting or other combustible materials. Slab-- mounted units
should be at least 4 in. (102 mm) above the highest expected water
and runoff levels. Do not use unit if it has been under water.
Rig and Place Unit
Rigging and handling of this equipment can be hazardous for
many reasons due to the installation location (roofs, elevated
structures, etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment,
and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the
lifts to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting
kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
Inspection
Prior to initial use, and at monthly intervals, all rigging shackles,
clevis pins, and straps should be visually inspected for any
damage, evidence of wear, structural deformation, or cracks.
Particular attention should be paid to excessive wear at hoist
hooking points and load support areas. Materials showing any kind
of wear in these areas must not be used and should be discarded.
577D-- --A
!
WARNING
2˝
(50.8mm)
EVAP. COIL COND. COIL
A07926
Fig. 3 -- Slab Mounting Detail
SLAB MOUNT
Place the unit on a solid, level concrete pad that is a minimum of 4
in. (102 mm) thick with 2 in. (51 mm) above grade. The slab
should extend approximately 2 in. (51 mm) beyond the casing on
all 4 sides of the unit (See Fig. 3). Do not secure the unit to the slab
except when required by local codes.
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Never stand beneath rigged units or lift over people.
!
WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
When straps are taut, the clevis should be a minimum of 36
in. (914 mm) above the unit top cover.
3
HVAC unit
base rails
Anchor screw
Flashing field
supplied
Roofing material
field supplied
Cant strip
field supplied
HVAC unit
basepan
Sealing
Gasket
Roofcurb
Wood nailer*
Roofcurb*
Insulation
(field supplied)
B
G
C
F
A
H
D
Dashed lines show cross support
location for large basepan units.
E
A09413
*Provided with roofcurb
SMALL/COMMON CURB
A09090
ROOF CURB DETAIL
577D-- --A
B
C
G
SUPPLY
AIR
SMALL
BASE
UNIT
H
A
F
RETURN
E
AIR
LARGE
BASE
UNIT
D
UNIT PLACEMENT ON
LARGE CURB
A09415
COMMON CURB
SMALL OR LARGE BASE UNIT
A09094
A
UNIT
SIZE
Small
or
Large
Large
NOTES:
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
3. Roof curb is made of 16--gauge steel.
4. Attach ductwork to curb (flanges of duct rest on curb).
5. Insulated panels: 1--in. (25.4 mm) thick fiberglass 1 lb. density.
CATALOG
NUMBER
CPRFCURB010A00
CPRFCURB011A00
CPRFCURB012A00
CPRFCURB013A00
(mm)
(279)
(356)
(279)
(356)
B (small / common
IN.
11
14
11
14
base)
IN. (mm)*
B(large
base)
IN. (mm)*
10 (254)
14 (356)
14 (356)
Fig. 4 -- Roof Curb Dimensions
A09414
C
IN.
(mm)
16
(406)
D
IN.
(mm)
47.8
(1214)
E
IN.
(mm)
32.4
(822)
43.9
(1116)
F
IN.
(mm)
2.7 (69)
G
IN. (mm)HIN. (mm)
30.6 (778)
46.1 (1170)
42.2 (1072)
4
577D-- --A
Fig. 5 -- 577D----A24--30 Unit Dimensions
5
A09556
577D-- --A
Fig. 6 -- 577D----A36--60 Unit Dimensions
6
A09557
Table 1 – Physical Data -- Unit 577D----A
UNIT SIZE 24040 24060 30040 30060 36060 36090 42060 42090
NOMINAL COOLING CAPACITY (ton) 2 2 2 --- 1 / 2 2 --- 1 / 2 3 3 3 --- 1 / 2 3 --- 1 / 2
NOMINAL HEATING CAPACITY (Btu) 40,000 60,000 40,000 60,000 60,000 90,000 60,000 90,000
SHIPPING WEIGHT (lb)
COMPRESSORS
Quantity
REFRIGERANT : PURON (R --- 410A)
Quantity (lb)
REFRIGERANT METERING DEVICE TXV
OUTDOOR COIL
Rows...Fins/in.
Face Area (sq ft )
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
Motor Hp (Rpm)
INDOOR COIL
Rows...Fins/in.
Face Area (sq ft )
(kg)
Size 2Ton 2Ton 3Ton 3Ton 3Ton 3Ton 4Ton 4Ton
(mm)
(kg)
INDOOR FAN
Nominal Airflow (Cfm)
Comfort Variable based on Comfort Roll back (see User Interface instructions for more information).
Efficiency 700 700 875 875 1050 1050 1225 1225
Max 800 800 1000 1000 1200 1200 1400 1400
Furnace (gas ht.) airflow ---Low Stage 475 727 475 727 745 875 745 875
Furnace (gas ht.) airflow ---High Stage 844 1120 844 1120 1120 1410 1120 1410
Size (in.)
(mm)
Motor HP 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4
FURNACE SECTION*
Burner Orifice No. (Qty...Drill Size)
Natural Gas (Factory Installed)
Propane Gas
HIGH--- PRESSURE SWITCH (psig)
C u t --- o u t
Reset (Auto)
HIGH--- PRESSURE SWITCH 2 (psig)
(Compressor Solenoid)
C u t --- o u t
Reset (Auto)
L O S S --- O F --- C H A R G E /
LOW---PRESSURE SWITCH
(Liquid Line) (psig)
C u t --- o u t
Reset (auto)
RETURN-- -AIR FILTERS Throwaway†
(in.)
(mm)
Continued next page.
426
193
10.1
4.6
2...21
13.6
2700
22
559
1/8 (825)
3...17
3.7
10x10
254x254
2...44
2...55
431
196
10.1
4.6
2...21
13.6
2700
22
559
1/8 (825)
3...17
3.7
10x10
254x254
3...44
3...55
20x24x1
508x610x25
433
196
11.3
5.1
2...21
15.3
2700
22
559
1/8 (825)
3...17
3.7
10x10
254x254
2...44
2...55
438
199
2 --- S t a g e S c r o l l
11.3
5.1
2...21
15.3
2700
22
559
1/8 (825)
3...17
3.7
10x10
254x254
3...44
3...55
1
670 ±10
470 ± 25
565 ± 15
455 ± 15
23 ± 5
55 ± 5
522
237
9.5
4.3
2...21
17.5
2800
22
559
1/8 (825)
3...17
4.7
11x10
279x254
3...44
3...55
24x30x1
610x762x25
530
240
9.5
4.3
2...21
17.5
2800
22
559
1/8 (825)
3...17
4.7
11x10
279x254
3...38
3...53
544
247
13.8
6.3
2...21
19.4
2800
22
559
1/8 (825)
3...17
4.7
11x10
279x254
3...44
3...55
24x36x1
610x914x25
552
250
13.8
6.3
2...21
19.4
2800
22
559
1/8 (825)
3...17
4.7
11x10
279x254
3...38
3...53
577D-- --A
7
UNIT SIZE 48090 48115 48130 60090 60115 60130
Table 1—Physical Data (Con’t) -- Unit 577D----A
NOMINAL COOLING CAPACITY (ton) 4 4 4 5 5 5
NOMINAL HEATING CAPACITY (Btu) 90,000 115,000 130,000 90,000 115,000 130,000
SHIPPING WEIGHT (lb)
COMPRESSORS
Quantity
REFRIGERANT : PURON (R --- 410A)
Quantity (lb)
REFRIGERANT METERING DEVICE TXV
Size 4Ton 4Ton 4Ton 5Ton 5Ton 5Ton
OUTDOOR FAN
Nominal Cfm
Diameter (in.)
Motor Hp (Rpm)
OUTDOOR COIL
Rows...Fins/in.
Face Area (sq ft )
INDOOR COIL
Rows...Fins/in.
Face Area (sq ft )
INDOOR FAN
Nominal Airflow (Cfm)
Comfort Variable based on Comfort Roll back (see User Interface instructions for more information).
577D-- --A
Efficiency 1400 1400 1400 1750 1750 1750
Max 1600 1600 1600 2000 2000 2000
Furnace (gas ht.) airflow--- Low Stage 815 1215 1255 845 1215 1255
Furnace (gas ht.) airflow--- High Stage 1385 1885 1875 1300 1910 1920
Size (in.)
Motor HP (RPM) 3/4 3/4 3/4 1 1 1
FURNACE SECTION*
Burner Orifice No. (Qty...Drill Size)
Natural Gas (Factory Installed)
Propane Gas
HIGH--- PRESSURE SWITCH (psig)
C u t --- o u t
Reset (Auto)
HIGH--- PRESSURE SWITCH 2 (psig)
(Compressor Solenoid)
C u t --- o u t
Reset (Auto)
L O S S --- O F --- C H A R G E /
LOW---PRESSURE SWITCH
(Liquid Line) (psig)
C u t --- o u t
Reset (auto)
RETURN-- -AIR FILTERS Throwaway†(in.)
(mm)
(kg)
(mm)
(mm)
(kg)
*Based on altitude of 0 to 2000 ft (0 to 610 m).
{Recommended filter sizes for field---installed air filter grilles mounted on the wall or ceiling of the conditioned structure. Required filter sizes shown are based on
the larger of the AHRI (Air Conditioning, Heating and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/minute for throwaway
type or 450 ft/minute for high ---capacity type. Air filter pressure drop for non ---standard filters must not exceed 0.08 IN. W.C.
558
253
15.3
6.9
3300
22
559
1/4 (1100)
2...21
19.4
3...17
5.7
11x10
279x254
3...38
3...53
558
253
15.3
6.9
3300
22
559
1/4 (1100)
2...21
19.4
3...17
5.7
11x10
279x254
3...33
3...51
558
253
15.3
6.9
3300
22
559
1/4 (1100)
2...21
19.4
3...17
5.7
11x10
279x254
3...31
3...49
2 --- S t a g e S c r o l l
1
670 ± 10
470 ± 25
565 ± 15
455 ± 15
23 ± 5
55
± 5
24x36x1
610x914x25
609
276
15.8
7.2
3300
22
559
1/3 (1110)
2...21
23.3
4...17
5.7
11x10
279x254
3...38
3...53
609
276
15.8
7.2
3300
22
559
1/3 (1110)
2...21
23.3
4...17
5.7
11x10
279x254
3...33
3...51
609
276
15.8
7.2
3300
22
559
1/3 (1110)
2...21
23.3
4...17
5.7
11x10
279x254
3...31
3...49
8
CAUTION - NOTICE TO RIGGERS
PRUDENCE - AVIS AUX MANIPULATEUR
PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.
Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition
ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.
DUCTS
MINIMUM HEIGHT: 36" (914.4 mm)
HAUTEUR MINIMUM
UNIT HEIGHT
HAUTEUR D'UNITÉ
SEE DETAIL A
VOIR DÉTAIL A
CABINET MODEL
Small 577D------A24 426 193
Small 577D------A30 433 196
Large
NOTE: See dimensional drawing for corner weight distribution.
Rigging/Lifting of Unit (See Fig. 7)
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Large base units must be secured to common curb before
allowing full weight of unit to rest on curb. Install screws
through curb into unit base rails while rigging crane is still
supporting unit.
DETAIL A
VOIR DÉTAIL A
577D------A36 522 237
577D------A42 544 247
577D------A48 558 253
577D------A60 609 276
Fig. 7 -- Suggested Rigging
Select and Install Ductwork
The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
non--residence type air conditioning and ventilating systems,
NFPA 90A or residence type, NFPA 90B and/or local codes and
ordinances.
Select and size ductwork, supply-- air registers, and return air grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supply-- and return-- air openings
on the side of the unit.
SEAL STRIP MUST BE IN
PLACE BEFORE PLACING
UNIT ON ROOF CURB
BANDE SCELLANT DOIT ÊTRE
EN PLACE AVANT DE PLACER
L'UNITÉ SUR LA BASE DE TOIT
50CY502286 2.0
RIGGING WEIGHT
lb kg
577D-- --A
A09079
Lifting holes are provided in base rails as shown in Fig. 5 and 6.
1. Leave top shipping skid on the unit for use as a spreader bar
to prevent the rigging straps from damaging the unit. If the
skid is not available, use a spreader bar of sufficient length
to protect the unit from damage.
2. Attach shackles, clevis pins, and straps to the base rails of
the unit. Be sure materials are rated to hold the weight of the
unit (See Fig. 7).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted level
with the ground.
After the unit is placed on the roof curb or mounting pad, remove
the top skid.
!
WARNING
PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal
injury or death.
For vertical supply and return units, tools or parts could
drop into ductwork, therefore, install a 90 degree turn in the
return ductwork between the unit and the conditioned space.
If a 90 degree elbow cannot be installed, then a grille of
sufficient strength and density should be installed to prevent
objects from falling into the conditioned space.
When designing and installing ductwork, consider the following:
1. All units should have field--supplied filters or accessory
filter rack installed in the return-- air side of the unit.
Recommended sizes for filters are shown in Table 1.
9
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
ensure weather tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
connector between ductwork and unit discharge connection. If
flexible duct is used, insert a sheet metal sleeve inside duct. Heat
resistant duct connector (or sheet metal sleeve) must extend 24 -- in.
(610 mm) from electric heater element.
3. Size ductwork for max possible air flow (See Table 1).
4. Seal, insulate, and weatherproof all external ductwork. Seal,
insulate and cover with a vapor barrier all ductwork passing
through conditioned spaces. Follow latest Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA) and Air Conditioning Contractors Association
(ACCA) minimum installation standards for residential
heating and air conditioning systems.
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration--isolate duct openings in wall or roof
according to good construction practices.
577D-- --A
6. Read unit rating plate for any required clearances around
ductwork.
Configuring Units for Downflow (Vertical) Discharge
!
WARNING
Basepan
Downflow
(Vertical)
Supply
Knockout
Horizontal Duct Covers
A09076
Basepan
Downflow
(Vertical)
Return
Knockout
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be
more than one disconnect switch.
1. Open all electrical disconnects before starting any service
work.
2. Remove horizontal (metal) duct covers to access vertical
(downflow) discharge duct knockouts in unit basepan. (See
Fig. 8.)
!
CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Collect ALL screws that were removed. Do not leave screws
on rooftop as permanent damage to the roof may occur.
To remove downflow return and supply knockout covers, break
front and right side connecting tabs with a screwdriver and
hammer. Push cover down to break rear and left side tabs.
NOTE: These panels are held in place with tabs similar to an
electrical knockout. Reinstall horizontal duct covers (see Fig. 8)
shipped on unit from factory. Insure openings are air and
watertight.
The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
nonresidence--type air conditioning and ventilating systems, NFPA
90A or residence-- type, NFPA 90B; and/or local codes and
ordinances.
Adhere to the following criteria when selecting, sizing, and
installing the duct system:
1. Units are shipped for horizontal duct installation (by
removing duct covers).
A09077
Fig. 8 -- Supply and Return Duct Opening
2. Select and size ductwork, supply--air registers, and
return--air grilles according to American Society of Heating,
Refrigeration and Air Conditioning Engineers (ASHRAE)
recommendations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
ensure weather--tight and airtight seal.
4. All units must have field--supplied filters or accessory filter
rack installed in the return--air side of the unit.
Recommended sizes for filters are shown in Table 1.
5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.
6. Adequately insulate and weatherproof all ductwork located
outdoors. Insulate ducts passing through unconditioned
space, and use vapor barrier in accordance with latest issue
of Sheet Metal and Air Conditioning Contractors National
Association (SMACNA) and Air Conditioning Contractors
of America (ACCA) minimum installation standards for
heating and air conditioning systems. Secure all ducts to
building structure.
7. Flash, weatherproof, and vibration isolate all openings in
building structure in accordance with local codes and good
building practices.
Provide for Condensate Disposal
NOTE: Ensure that condensate--water disposal methods comply
with local codes, restrictions, and practices.
The units dispose of condensate through a 3/4 --in. NPT female
fitting that exits on the compressor end of the unit. Condensate
water can be drained directly onto the roof in rooftop installations
(where permitted) or onto a gravel apron in ground level
installations. Install a field-- supplied condensate trap at end of
condensate connection to ensure proper drainage. Make sure that
10
the outlet of the trap is at least 1 in. (25 mm) lower than the
drain--pan condensate connection to prevent the pan from
overflowing. Prime the trap with water. When using a gravel apron,
make sure it slopes away from the unit.
If the installation requires draining the condensate water away from
the unit, install a field--supplied 2--in. (51 mm) trap at the
condensate connection to ensure proper drainage. Condensate trap
is available as an accessory or is field--supplied. Make sure that the
outlet of the trap is at least 1 in. (25 mm) lower than the unit
drain--pan condensate connection to prevent the pan from
overflowing. Connect a drain tube using a minimum of
field-- supplied 3/4 --in. PVC or field--supplied 3/4 --in. copper pipe
at outlet end of the 2 --in. (51 mm) trap (See Fig. 9). Do not
undersize the tube. Pitch the drain tube downward at a slope of at
least 1 in. for every 10 ft. (3 m) of horizontal run. Be sure to check
the drain trough for leaks. Prime the trap at the beginning of the
cooling season start--up.
Install Flue Hood
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
The venting system is designed to ensure proper venting.
The flue hood assembly must be installed as indicated in
this section of the unit installation instructions.
Install the flue hood as follows:
1. This installation must conform with local building codes
and with the National Fuel Gas Code (NFGC), NFPA
54/ANSI Z223.1 (in Canada, CAN/CSA B149.1, and
B149.2) or latest revision. Refer to provincial and local
plumbing or wastewater codes and other applicable local
codes.
2. Remove flue hood from shipping location (inside the return
section of the blower compartment--See Fig. 8). Remove the
return duct cover to locate the flue hood. Remove two
screws on flue panel. Place flue hood assembly over flue
panel. Orient screw holes in flue hood with holes in the flue
panel.
3. Secure flue hood to flue panel by inserting a single screw on
the top and the bottom of the hood.
TRAP
OUTLET
1-in. (25 mm) min.
2-in. (51 mm) min.
A09052
Fig. 9 -- Condensate Trap
Install Gas Piping
The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2--in.
FPT gas inlet on the gas valve.
Install a gas supply line that runs to the heating section. Refer to
Table 2 and the current edition of NFGC in the U.S. and the current
NSCNGPIC in Canada. Do not use cast--iron pipe. It is
recommended that a black iron pipe is used. Check the local utility
for recommendations concerning existing lines. Size gas supply
piping for 0.5 IN. W.C. maximum pressure drop. Never use pipe
smaller than the 1/2-- in. FPT gas inlet on the unit gas valve.
For natural gas applications, the gas pressure at unit gas connection
must not be less than 4.0 IN. W.C. or greater than 13 IN. W.C.
while the unit is operating. For propane applications, refer to
propane conversion kit instructions.
A 1/8-- in. (3.2 mm) NPT plugged tapping, accessible for test gauge
connection, must be installed immediately upstream of the gas
supply connection to the gas valve and downstream of manual
equipment shutoff valve.
When installing the gas supply line, observe local codes pertaining
to gas pipe installations. Refer to the NFPA 54/ANSI Z223.1--2009
(in Canada, CAN/CSA B149.1).
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a licensed
plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 in. (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T-- handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
In the absence of local building codes, adhere to the following
pertinent recommendations:
1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in.
(6.35 mm) for every 15 ft (4.6 m) of length to prevent traps.
Grade all horizontal runs downward to risers. Use risers to
connect to heating section and to meter.
2. Protect all segments of piping system against physical and
thermal damage. Support all piping with appropriate straps,
hangers, etc. Use a minimum of one hanger every 6 ft. (1.8
m). For pipe sizes larger than 1/2 in., follow
recommendations of national codes.
3. Apply joint compound (pipe dope) sparingly and only to
male threads of joint when making pipe connections. Use
only pipe dope that is resistant to action of liquefied
petroleum gases as specified by local and/or national codes.
Never use Teflon tape.
4. Install sediment trap in riser leading to heating section (See
Fig. 10). This drip leg functions as a trap for dirt and
condensate.
5. Install an accessible, external, manual main shutoff valve in
gas supply pipe within 6 ft (1.8 m) of heating section.
6. Install ground--joint union close to heating section between
unit manual shutoff and external manual main shut off
valve.
7. Pressure test all gas piping in accordance with local and
national plumbing and gas codes before connecting piping
to unit.
NOTE: Pressure test the gas supply system after the gas supply
piping is connected to the gas valve. The supply piping must be
disconnected from the gas valve during the testing of the piping
systems when test pressure is in excess of 0.5 psig. Pressure test the
gas supply piping system at pressures equal to or less than 0.5 psig.
The unit heating section must be isolated from the gas piping
system by closing the external main manual shutoff valve and
slightly opening the ground--joint union.
577D-- --A
11
OUT
IN
TEE
NIPPLE
Install Electrical Connections
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
The unit cabinet must have an uninterrupted, unbroken
electrical ground. This ground may consist of an electrical
wire connected to the unit ground screw in the control
compartment, or conduit approved for electrical ground
when installed in accordance with NEC, NFPA 70 National
Fire Protection Association (latest edition) (in Canada,
Canadian Electrical Code CSA C22.1) and local electrical
codes.
CAP
C99020
Fig. 10 -- Sediment Trap
577D-- --A
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in fire, explosion,
personal injury, death and/or property damage.
S Connect gas pipe to unit using a backup wrench to avoid
S Never purge a gas line into a combustion chamber. Never
S Use proper length of pipe to avoid stress on gas control
S If a flexible connector is required or allowed by authority
S If codes allow a flexible connector, always use a new
8. Check for gas leaks at the field--installed and
!
WARNING
damaging gas controls.
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections.
manifold.
having jurisdiction, black iron pipe shall be installed at
furnace gas valve and extend a minimum of 2 in. (51 mm)
outside furnace casing.
connector. Do not use a connector which has previously
serviced another gas appliance.
factory--installed gas lines after all piping connections have
been completed. Use a commercially available soap solution
made specifically for the detection of leaks (or method
specified by local codes and/or regulations).
HIGH--VOLTAGE CONNECTIONS
The unit must have a separate electrical service with a
field-- supplied, waterproof disconnect switch mounted at, or within
sight from, the unit. Refer to the unit rating plate, NEC and local
codes for maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.
The field--supplied disconnect may be mounted on the unit over
the high--voltage inlet hole (See Fig. 5 and 6).
NOTE: Field supplied disconnect switch box should be
positioned so that it does not cover up any of the unit gas
combustion supply air louvers.
Operation of unit on improper line voltage constitutes abuse and
may cause unit damage that could affect warranty.
!
UNIT COMPONENT DAMAGE HAZARD
Failure to follow this caution may result in damage to the
unit being installed.
1. Make all electrical connections in accordance with NEC
NFPA 70 (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part 1 and applicable
local codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between
field-- supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high--voltage power to unit is within
operating voltage range indicated on unit rating plate.
4. Insulate low--voltage wires for highest voltage contained
within conduit when low--voltage control wires are in
same conduit as high--voltage wires.
5. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit,
etc.
CAUTION
ROUTING POWER LEADS INTO UNIT
Use only copper wire between disconnect and unit. The high
voltage leads should be in a conduit until they enter the duct panel;
conduit termination at the duct panel must be watertight. Run the
high--voltage leads through the power entry knockout on the
power entry side panel. See Fig. 5 and 6 for location and size. For
single-- phase units, connect leads to the black and yellow wires.
CONNECTING GROUND LEAD TO GROUND SCREW
Connect the ground lead to the chassis using the ground screw on
the control plate near the inducer switch (See Fig. 12).
12
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