Bryant 579F User Manual

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installation, start-up and service instructions

SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNITS

CONTENTS

Page

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

I. Step 1 — Provide Unit Support. . . . . . . . . . . . . . . . . 1

II. Step 2 — Rig and Place Unit. . . . . . . . . . . . . . . . . . . 3

III. Step 3 — Field Fabricate Ductwork . . . . . . . . . . . . . 8

IV. Step 4 — Make Unit Duct Connections . . . . . . . . . . 8

V. Step 5 — Install Flue Hood and Wind Baffle . . . . . . 8

VI. Step 6 — Trap Condensate Drain . . . . . . . . . . . . . . . 8

VII. Step 7 — Orifice Change. . . . . . . . . . . . . . . . . . . . . . 9

VIII. Step 8 — Install Gas Piping . . . . . . . . . . . . . . . . . . 10

IX. Step 9 — Make Electrical Connections . . . . . . . . . 10

X. Step 10 — Make Outdoor-Air Inlet

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

XI. Step 11 — Install Outdoor-Air Hood. . . . . . . . . . . . 11

XII. Step 12 — Install All Accessories . . . . . . . . . . . . . 13

XIII. Step 13 — Adjust Factory-Installed Options. . . . . 14

XIV. Step 14 — Install Humidistat for Optional

Perfect Humidity™ Dehumidification Package . . . 21

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-28

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-37

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . .38-42

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

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

Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters . A ll other o perations should be performed by trained service per sonnel. When working on air-conditi oning equipme nt, obser v e precautions in the literature, tags and labels attached to the unit, and other safety prec au tions that may a pp ly.

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

WARNING: Before performing service or maintenance operations on unit, turn off main power switch to unit and install lockout tag on disconnect switch. Electrical shock could cause personal injury.

579F

Dura

Cancels: II 579F-180-7 II 579F-180-8

WARNING:

1. Improper installation, adjustment, alteration, service, or maintena nce c an caus e pr ope rty dam age, personal injury, or loss of life. Refer t o the User’s Information Manual provided with this unit for more details.

2. Do not store or use gasoline or other flammable vapors and liquids in the vi cinity of this or any other appliance.

What to do if yo u sm ell gas:

1. DO NOT try to light any appliance.

2. DO NOT touch any elec trical switch, or use an y phone in your building.

3. IMMEDIATELY call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

4. If you cannot reach your gas supplier, call the fire department.

WARNING: Disconnect gas piping from unit when pressure testing at pressure greater than 0.5 psig. Pressures greater than 0.5 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure grea ter than 0.5 psig, it must be replaced before use. When pressure testing fieldsupplied gas piping at pressures of 0.5 psig or less, a unit connected to such piping must be isolated by closing the manual gas valve(s).

IMPORTANT: Units have high ambient operating limits. If limits are exceeded, the units will automatically lock the compressor out of operation. Manual reset will be required to restart the compressor.

INSTALLATION

I. STEP 1 — PROVIDE UNIT SUPPORT

A. Roof Curb

Assemble and install accessory roof curb or horizontal adapter roof curb in accordance with instructions shipped with this accessory. See Fig. 1 and 2. Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork can be installed to roof curb or horizontal adapter roof curb before unit is set in place. Cur b or ada pt er roof curb shou ld b e le ve l. This is necessary to permit unit drain to function properly. Unit leveling tolera nce is ± tion. Refer to Accessory Roof Curb or Horizontal Adapter Roof Curb Installation Instructions for additi onal information as required. When accessory roof curb or horizontal adapter roof curb is used, unit may be installed on class A, B, or C roof covering material.

/16 in. per linear ft in any direc-

Pac

Series

Sizes 180-300

15 to 25 Tons

3/15/06

DESCRIPTION

CURB

HEIGHT

PKG. NO. REF.

Fig. 1 — Roof Curb Details

CRRFCURB010A00 1′− 2″ (305) Standard Curb 14″ High

CRRFCURB011A00 2′-0″ (610) Standard Curb for Units Requiring High Installation

CRRFCURB012A00 2′-0″ (610) Side Supply and Return Curb for High Installation

—2—

3 1/2"

2" X 1/4 SUPPORT TYP. STITCH WELDED

FULLY INSULATED SUPPLY PLENUM 1" INSULATION 1 1/2 # DENSITY, STICK PINNED & GLUED

NOTE: CRRFCURB013A00 is a fully factory preassembled horizontal adapter and includes an insulated transition duct. The pressure drop through the adapter curb is negligible.

For horizontal return applications: The power exhaust and barometric

relief dampers must be installed in the return air duct.

Fig. 2 — Horizontal Supply/Return Adapter Installation (579F180-240)

IMPORTANT: The gasketing of the un it to the roof curb or

adapter roof curb is critical for a watertight seal. Install gasket with the roof curb or adapter as shown in Fig. 1. Improperly applied gasket can also result in air leaks and poor unit performance.

B. Alternate Unit Support

When the curb or ada pter cannot be used, install unit on a noncombustible surface. Support unit with sleepers, using unit curb support area. If sleepers cannot be used, support long sides of unit with a minimum of 3 equally spaced 4-in. x 4-in. pads on each side.

II. STEP 2 — RIG AND PLACE UNIT

Inspect unit for transportation damage. File any claim with transportation agency.

Do not drop unit; keep uprig ht. Use spreader bars over unit to prevent sling or cable damage. Rollers may be used to move unit across a roof. Level by using unit frame a s a reference; leveling tolerance is ±

/16 in. per linear ft in a ny di re ction. See Fig. 3 for additional information. Unit operating weight is shown in Table 1.

Four lifting holes are provided in ends of unit base rails as shown in Fig. 3. Refer to rigging instructions on unit.

14 3/4"

ACCESSORY

PACKAGE NO.

CRRFCURB013A00

12" WIDE STANDING SEAM PANELS

CURB

HEIGHT

1′-11″

(584)

DESCRIPTION

Pre-Assembled, Roof Curb,

Horizontal Adapter

23"

A. Positioning

Maintain clearance, per Fig. 4 and 5, around and above unit to provide minimum distance from combustible materials, proper airflow, and service access.

Do not install unit in an indoor l ocation. Do not locate unit air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute).

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

Locate mechanical draft system flue assembly at least 4 ft from any opening through which combustion products could enter the buil ding, and at le ast 4 ft fr om any adj acen t buil ding. When unit is located adjacent to public walkways, flue assembly must be at least 7 ft above grade.

B. Roof Mount

Check building codes for weight distribution requirements. Unit operating weight is shown in Table 1.

Instructions continued on page 8.

—3—

NOTES:

1. Dimensions in ( ) are in millimeters.

2. Refer to Fig. 4 and 5 for unit operating weights.

3. Remove boards at ends of unit and runners prior to rigging.

4. Rig by inserting hooks into unit base rails as shown. Use corner post from packaging to protect coil from damage. Use bumper boards for spreader bars on all units.

5. Weights do not include optional EconoMi$erIV. Add 90 lb (41 kg) for EconoMi$erIV weight.

6. Weights given are for aluminum evaporator and condenser coil plate fins.

CAUTION: All panels must be in place when rigging

UNIT 579F

MAXIMUM

SHIPPING WEIGHT

lb kg Ft-in. mm Ft-in. mm 180 1775 805 6-11 216 1875 850 6-11 240 1985 900 6-11 300 2135 968 6-11

Fig. 3 — Rigging Details

DIMENSIONS

/22121 3-5 1041

/22121 3-3 991

/22121 3-2 965

—4—

DIM A DIM B DIM C

CORNER

″ (8) on each side

CORNER

WEIGHT

ECONOMI$ERIV

lb kg lb kg lb kg lb kg lb kg lb kg ft-in. mm ft-in. mm ft-in. mm

WEIGHT

STD UNIT

UNIT

•Top: 6′-0″ (1829) to assure proper condenser fan operation.

grounded surfaces.

• Local codes or jurisdiction may prevail.

power exhaust as stated in Note #6, a removable fence or barricade

• Bottom: 14″ (356) to combustible surfaces (when not using curb).

• Control box side: 3′-0″ (914) to ungrounded surfaces, non-combustible.

• Control box side: 3′-6″ (1067) to block or concrete walls, or other

requires no clearance.

for top cover drip edge.

7. With the exception of clearance for the condenser coil and the damper/

8. Dimensions are from outside of corner post. Allow 0′-

4′-0″ (1219) if conditions permit coil removal from the top.

•Rear: 7′-0″ (2134) for coil removal. This dimension can be reduced to

•4′-0″ (1219) to combustible surfaces, all four sides (includes between

NOTES:

1. Refer to print for roof curb accessory dimensions.

2. Dimensions in ( ) are in millimeters.

3. Center of Gravity.

4. Direction of airflow.

5. Ductwork to be attached to accessory roof curb only.

6. Minimum clearance:

579F180 1650 748 90 41 423 192 386 175 403 183 438 199 3-5 1041 3-5 1041 1-10 559

579F216 1800 816 90 41 432 196 410 186 461 209 472 214 3-3 991 3-7 1092 1- 8 508

exhaust if so equipped.

units).

• Right side: 4′-0″ (1219) for proper operation of damper and power

• Front: 4′-0″ (1219) for control box access.

• Left side: 4′-0″ (1219) for proper condenser coil airflow.

Fig. 4 — Base Unit Dimensions; 579F180,216

—5—

DIM A DIM B DIM C

CORNER

WEIGHT

ECONOMI$ERIV

″ (8) on each

4′-0″ (1219) if conditions permit coil removal from the top.

•4′-0″ (1219) to combustible surfaces, all four sides (includes between

• Rear: 7′-0″ (2134) for coil removal. This dimension can be reduced to

NOTES:

1. Refer to print for roof curb accessory dimensions.

2. Dimensions in ( ) are in millimeters.

3. Center of Gravity.

4. Direction of airflow.

5. Ductwork to be attached to accessory roof curb only.

6. Minimum clearance:

exhaust if so equipped.

units).

• Right side: 4′-0″ (1219) for proper operation of damper and power

• Front: 4′-0″ (1219) for control box access.

• Left side: 4′-0″ (1219) for proper condenser coil airflow.

grounded surfaces.

• Bottom: 14″ (356) to combustible surfaces (when not using curb).

• Control box side: 3′-0″ (914) to ungrounded surfaces, non-combustible.

• Control box side: 3′-6″ (1067) to block or concrete walls, or other

• Local codes or jurisdiction may prevail.

power exhaust as stated in Note #6, a removable fence or barricade

7. With the exception of clearance for the condenser coil and the damper/

requires no clearance.

side for top cover drip edge.

8. Dimensions are from outside of corner post. Allow 0′-

•Top: 6′-0″ (1829) to assure proper condenser fan operation.

WEIGHT

STD UNIT

UNIT

lb kg lb kg lb kg lb kg lb kg lb kg ft-in. mm ft-in. mm ft-in. mm

579F240 1850 839 90 41 443 201 406 184 476 216 525 238 3-2 965 3-5 1041 1-8 508

579F300 2000 907 90 41 471 214 428 194 526 239 574 260 3-2 965 3-5 1041 1-8 508

Fig. 5 — Base Unit Dimensions; 579F240,300

—6—

Table 1 — Physical Data

NOMINAL CAPACITY (tons) 15 18 20 25 OPERATING WEIGHT (lb) 1650 1800 1850 2000

EconoMi$erIV 90 90 90 90 Roof Curb 200 200 200 200

COMPRESSOR/MANUFACTURER Scroll, Copeland

Quantity...Model (Ckt 1, Ckt 2) 2...SR*942AE Number of Refrigerant Circuits 2222

Stages of Capacity Control (%) 50/50 60/40 52/48 56/44 Oil (oz) (Ckt 1, Ckt 2) 90, 90 110, 72 110, 110 112, 110

REFRIGERANT TYPE R-22

Expansion Device TXV Operating Charge (lb-oz) Circuit 1* 10-13 15-2 16-3 21-0 Circuit 2 10- 5 11-5 14-8 15-4

CONDENSER COIL Cross-Hatched

Rows...Fins/in. 2...17 3...15 3...15 4...15 Total Face Area (sq ft) 21.7 21.7 21.7 21.7

CONDENSER FAN Propeller Type

Nominal Cfm 10,500 9250 13,650 12,500 Quantity...Diameter (in.) 3...22 3...22 2...30 2...30 Motor Hp...Rpm Watts Input (Total) 1100 1100 3400 3400

EVAPORATOR COIL Cross-Hatched

Rows...Fins/in. 2...17 3...15 3...15 4...15 Total Face Area (sq ft) 17.5 17.5 17.5 17.5

EVAPORATOR FAN Centrifugal Type

Quantity...Size (in.) 2...10 x 10 2...12 x 12 2...12 x 12 2...12 x 12 Type Drive Belt Belt Belt Belt Nominal Cfm 6000 7200 8000 10,000 Motor Hp 3.7 5 7.5 10 Motor Nominal Rpm 1725 1745 1745 1740

Maximum Continuous Bhp 4.25 5.90 Motor Frame Size 56H 184T 213T 215T

Fan Rpm Range Low-Medium Static 891-1179 910-1095 1002-1225 1066-1283

Motor Bearing Type Ball Ball Ball Ball Maximum Allowable Rpm 1550 1550 1550 1550 Motor Pulley Pitch Diameter Low-Medium Static 3.1/4.1 4.9/5.9 5.4/6.6 4.9/5.9

Min/Max (in.) High Static 3.7/4.7 4.9/5.9 5.4/6.6 4.9/5.9 Nominal Motor Shaft Diameter (in.) Fan Pulley Pitch Diameter (in.) Low-Medium Static 6.0 9.4 9.4 8.0

Nominal Fan Shaft Diameter (in.) 1 Belt, Quantity...Type...Length (in.) Low-Medium Static 1...BX...42 1...BX...50 1...BX...54 2...BX...50

Pulley Center Line Distance (in.) 13.5-15.5 13.3-14.8 14.6-15.4 14.6-15.4 Speed Change per Full Turn of

Movable Pulley Flange (rpm) Movable Pulley Maximum Full Turns

From Closed Position 6666 Factory Speed Pulley Setting 3.5 3.5 3.5 3.5 Factory Speed Setting (rpm) Low-Medium Static 1035 1002 1120 1182

FURNACE SECTION (Low Heat/High Heat)

Rollout Switch Cutout Temp (F)† 190 190 190 190

Burner Orifice Diameter (in. ...drill size)

Natural Gas Thermostat Heat Anticipator Setting (amps)

208/230 v Stage 1 0.98 0.98 0.98 0.98

460 v Stage 1 0.80 0.80 0.80 0.80

Gas Input Stage 1 206,000/270,000 206,000/270,000 206,000/270,000 206,000/270,000

Efficiency (Steady State) (%) 81 81 81 81 Temperature Rise Range 15-45/20-50 15-45/20-50 15-45/20-50 15-45/20-50 Manifold Pressure (in. wg)

Natural Gas 3.3 3.3 3.3 3.3 Gas Valve Quantity 1111 Field Gas Connection Size (in.-FPT)

HIGH-PRESSURE SWITCH (psig)

Cutout 426 Reset (Auto) 320

LOW-PRESSURE SWITCH (psig)

Cutout 27 Reset (Auto) 44

FREEZE PROTECTION THERMOSTAT (F)

Opens 30 ± 5 Closes 45 ± 5

OUTDOOR-AIR INLET SCREENS Cleanable

Quantity...Size (in.) 2...20 x 25 x 1

RETURN-AIR FILTERS Throwaway**

Quantity...Size (in.) 4...20 x 20 x 2

POWER EXHAUST

LEGEND

Bhp — Brake Horsepower TXV — Thermostatic Expansion Valve

*Circuit 1 uses the lower portion of condenser coil and lower portion of evaporator coils;

and Circuit 2 uses the upper portion of both coils.

UNIT 579F 180 216 240 300

/2...1050

1...SM120

1...SR*782*AE

Aluminum Pre-Coated, or Copper Plate Fins

/8-in. Copper Tubes, Aluminum Lanced or Copper Plate Fins, Face Split

/8-in. Copper Tubes, Aluminum Lanced,

/2...1050 1...1075 1...1075

1...SM120

1...SM110

8.7 [208/230 v]

9.5 [460 v]

1...SM161

1...SM120

10.2 [208/230 v]

11.8 [460 v]

High Static 1227-1550 1069-1287 1193-1458 1332-1550

High Static 5.2 8.0 7.9 6.4

11/

17/

13/

17/

13/

17/

High Static 1...BX...42 1...BX...48 1...BX...50 2...BX...47

Low-Medium Static 48 37 37 36 High Static 55 34 44 45

High Static 1389 1178 1328 1470

0.1285...30/

0.136...29

0.1285...30/

0.136...29

0.1285...30/

0.136...29

0.1285...30/

0.136...29

Stage 2 0.44 0.44 0.44 0.44

Stage 2 275,000/360,000 275,000/360,000 275,000/360,000 275,000/360,000

1...20 x 20 x 1

/2 Hp, 208/230-460 v Motor Direct Drive, Propeller-Fan (Factory-Wired for 460 v)

†Rollout switch is manual reset.

**The 579F300 units requires 2-in. industrial-grade filters capable of handling face veloc-

ities of up to 625 ft/min (such as American Air Filter no. 5700 or equivalent).

NOTE: The 579F180-300 units have a low-pressure switch (standard) located on the suction side.

4...16 x 20 x 2

—7—

III. STEP 3 — FIELD FABRICATE DUCTWORK

Secure all ducts to building structure. Use flexible duct connectors between unit and ducts as required. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and m asti c i n acc ordance with applicable codes.

Ducts passing through a n unc ondit i one d spa ce must be insulated and covered with a vapor barrier.

IV. STEP 4 — MAKE UNIT DUCT CONNECTIONS

Unit is shipped for thru-the-bottom duct connections. Ductwork openings are shown in Fig. 1, 4, and 5. Duct connections are shown in Fig. 6. Field-fabricated concentric ductwork may be connected as shown in Fig. 7 and 8. Attach all ductwork to roof curb and roof curb basepans.

V. STEP 5 — INSTALL FLUE HOOD AND WIND BAFFLE

Flue hood and wind baffle are shipped secured under main control box. To install, secure flue hood to access panel. See Fig. 9. The wind baffle is then installed over the flue hood.

NOTE: Whe n properly insta lled, flue hoo d will line up with combustion fan housing. See Fig. 10.

VI. STEP 6 — TRAP CONDENSATE DRAIN

See Fig. 11 for drain location. One

/4-in. half coupling is provided inside unit evaporator section for condensate drain connection. An 8 diameter pipe nipple, coupled to standard

/2-in. x 3/4-in. diameter and 2-in. x 3/4-in.

/4-in. diameter elbows, provide a straight path down through hole in unit base rails (see Fig. 12). A trap at leas t 4-in. deep must be used.

NOTE: Do not drill in this area; damage to basepan may result in water leak.

Fig. 6 — Air Distribution — Thru-the-Bottom

NOTE: Dimensions A, A′, and B′ are obtained from field-supplied ceil-

ing diffuser.

Shaded area indicates block-off panels.

Fig. 8 — Concentric Duct Details

WIND BAFFLE

NOTE: Do not drill in this area; damage to basepan may result in water leak.

Fig. 7 — Concentric Duct Air Distribution

Fig. 9 — Flue Hood Location

—8—

INDUCED DRAFT MOTOR

VII. STEP 7 — ORIFICE CHANGE

This unit is factory assembled for heating operation using natural gas at an elevation from sea level to 2000 ft. This unit uses orifice type LH32RFn nn, wher e “nnn” i ndicates th e orifice size based on drill size diameter in thousands of an inch.

A. High Elevation (Above 2000 ft)

Use accessory high altitude kit when installing this unit at an elevation of 2000 to 7000 ft. For elevations above 7000 ft, refer to Table 2 to identify the correct orifice size for the elevation. See Table 3 for the nu mber of orifi ces re quired for each unit size. Purc hase the se orifi ces f rom your lo cal Bryant dealer. Fo llow in structions in ac cessory I nstallati on Ins tructions to install the correct orif ices.

Table 2 — Altitude Compensation*

COMBUSTION FAN HOUSING

MAIN BURNER SECTION

HEAT EXCHANGER SECTION

Fig. 10 — Combustion Fan Housing Location

3/4" FPT DRAIN CONNECTION

1-3/8" DRAIN HOLE

Fig. 11 — Condensate Drain Details (579F180 Shown)

ELEVATION (ft)

0-1,999 30 29

2,000 30 29 3,000 31 30 4,000 31 30 5,000 31 30 6,000 31 30 7,000 32 31 8,000 32 31 9,000 33 31

10,000 35 32

*As the height above sea level increases, there is less oxygen per cubic

foot of air. Therefore, heat input rate should be reduced at higher altitudes. Includes a 4% input reduction per each 1000 ft.

†Orifices available through your Bryant dealer.

NATURAL GAS ORIFICE†

Low Heat High Heat

Table 3 — Orifice Quantity

UNIT ORIFICE QUANTITY 579F180 Low Heat 5 579F210 Low Heat,

579F240 Low Heat, 579F300 Low Heat, 579F180 High Heat

579F210 High Heat, 579F240 High Heat, 579F300 High Heat

B. Conversion To LP (Liquid Propane) Gas

Use accessory LP gas conversion kit when converting this unit for use with LP fuel usage for elevations up to 7000 ft. For elevations above 7000 ft, refer to Table 4 to identify the correct orifice size for the elevation. See Table 3 for the number of orifices required for each unit size. Purchase these orifices from your local Bryant deale r. Follow instructions in acce ssory Installation Instructions to install the correc t orific es.

Table 4 — LP Gas Conversion*

Fig. 12 — Condensate Drain Piping Details

ELEVATION (ft) LP GAS ORIFICE†

0-1,999 36

2,000 37 3,000 38 4,000 38 5,000 39 6,000 40 7,000 41 8,000 41 9,000 42

10,000 43

*As the height above sea level increases, there is less oxygen per

cubic foot of air. Therefore, heat input rate should be reduced at higher altitudes. Includes a 4% input reduction per each 1000 ft.

†Orifices available through your Bryant dealer.

—9—

VIII. STEP 8 — INSTALL GAS PIPING

Unit is equipped for use with natural gas. Installation must conform with local bu ilding codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1.

Install field-supplied manual gas shutoff valve with a

/8-in. NPT pressure tap for test gage connection at unit. Field gas piping must include sediment trap and union. See Fig. 13.

WARNING: Do not pressure test gas supply while connected to unit. Always disconnect union before servicing.

IMPORTANT: Natural gas pressure at unit gas connection must not be less than 5.5 in. wg or greater than 13.5 in. wg.

Size gas-supply piping for 0.5-in. wg maximum pressure drop. Do not use supply pipe smaller than unit gas connection.

Fig. 13 — Field Gas Piping

IX. STEP 9 — MAKE ELECTRICAL CONNECTIONS

A. Field Power Supply

Unit is factory wired for voltage sh own on nameplate. When installing units, provide a disconnect per NEC

(National Electrical Code) of adequate size (see Table 5). All field wiring must comply with NEC and local

requirements. Route power ground lines through control box end panel or

unit basepan (see Fig. 4 and 5) to connections as shown on unit wiring diagram and Fig. 14.

CAUTION: The correct power phasing is critical in the operation of the scroll compressors. An incorrect phasing will cause the compressor to rotate in the wrong direction. This m ay lead to prematu re comp ressor failure.

WARNING: The unit must be electrically grounded in accordance with local codes and NEC ANSI/NFPA 70 (National Fire Protection Association).

Field wiring must confirm to temperature limitations for type “T” wire. All field wiring must comply with NEC and local require ments.

Transformer no. 1 is wi r ed for 230 -v uni t. If 2 08/ 230-v unit is to be run with 208-v power supply, the tran sformer must be rewired as follows:

1. Remove cap from red (208 v) wire.

2. Remove cap from orange (230 v) spliced wire.

3. Replace orange wire with red wire.

4. Recap both wires.

IMPORTANT: BE CERTAIN UNUSED WIRES ARE CAPPED. Failure to do so may damag e the transformers.

Operating voltage to compressor must be within voltage range indicated on unit nameplate. On 3-phase units, voltages between phases must be balanced within 2%.

Unit failure as a res ult of ope ra tio n o n imp ro per line volt age or excessive phase imbalance constitutes abuse and may cause damage to electrical components.

B. Field Control Wiring

Install a Bryant-approved accessory thermostat assembly according to installation instructions included with accessory. Locate thermostat assembly on a solid interior wall in the conditioned space to sense average temperature.

Route thermostat cable or equivalent single leads of colored wire from sub bas e t ermin als through conduit in unit to low-voltage connection s as sho wn on unit la be l wi ring diagram and in Fig. 15.

NOTE: For wire runs up to 50 ft, use no. 18 AWG (American Wire Gage) insulated wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG insulated wire (35 C minimum). For over 75 ft, use no. 14 AWG insulated wire (35 C minimum). All wire larger than no. 18 AWG cannot be directly connected a t the thermos tat and wi ll req uire a j unction box and s plice a t the thermostat.

Set heat anticipator settings as follows:

VOLTAGE W1 W2

208/230

460

0.98

0.80

0.44

Settings may be changed slightly to provide a greater degree of comfort for a particular installation.

C. Optional Non-Fused Disconnect

On units with the optional non-fused disconnect, incoming power will be wired into the disconnect switch. Refer to Fig. 16 for wiring for 100 and 200 amp disconnect switches. Units with an MOCP (maximum overcurrent protection) under 100 will use the 100 amp disconnect switch. Units with an MOCP over 100 will use the 200 amp disconnect switch. Refer to the applicable disconnect wiring diagram.

To prevent breakage during shipping, the disconnect handle and shaft are shipped and packaged inside the unit control box. Install the disconnect handle before unit operation. To install the handle and shaft, perform the following procedure:

1. Open the co ntro l box door and remov e th e han d le a nd shaft from shipping location.

2. Loosen the Allen bolt located on the disconnect switch. The bolt is locat ed on the sq uare hole a nd is used to hold the shaft in place. The shaft cannot be inserted until the Allen bo lt is moved.

3. Insert the disconnect shaft into the square hole on the disconnect switch. The end of the shaft is specially cut and the shaft can only be inserted in the correct orientation.

4. Tighten the Allen bolt to lock the shaft into position.

5. Close the control box door.

6. Attach the handle to the external access door with the two screws provided. When the handle is in the ON position, the handle will be vertical. When the handle is in the OFF position, the handle will be horizontal.

—10—

7. Turn the handle to the OFF position and close the door. The handle should fit over th e end of the shaft when the door is closed.

8. The handle must be in the OFF position to open the control box door.

D. Optional Convenience Outlet

On units with optional convenience outlet, a 115-v GFI (ground fault interrupt) convenience outlet receptacle is provided for field wiring. Field wiring should be run through

the

/8-in. knockout provided i n the basepan ne ar the return

air opening.

LEGEND

EQUIP — Equipment GND — Ground NEC — National Electrical Code TB — Terminal Block

NOTE: The maximum wire size for TB1 is 2/0.

Fig. 14 — Field Power Wiring Connections

THERMOSTAT ASSEMBLY

REMOVABLE JUMPER

RED

Y1 Y2

BLU

PNK

W1Y2

ORN

VIO

BLK

BRN

WHT

Fig. 15 — Field Control Thermostat Wiring

6T3 4T2 2T1 LOAD

X. STEP 10 — MAKE OUTDOOR-AIR INLET ADJUSTMENTS

A. Manual Outdoor-Air Damper

All units (except those equipped with a factory-installed economizer) have a manual outdoor-air damper to provide ventilation air.

Damper can be preset to admit up to 25% outdoor air into return-air compartment. To adjust, loosen securing screws and move damper to desired setting, then retighten screws to secure damper (Fig. 17).

XI. STEP 11 — INSTALL OUTDOOR-AIR HOOD

The outdoor-air hood is common to 25% air ventilation and EconoMi$erIV. If EconoMi$erIV is used, all electrical connections have been made an d adjusted at th e factory. Assemble and install hood in the field.

IMPORTANT: If the unit is equipped with the optional EconoMi$erIV component, move the outdoor-air temperature sensor prior to installing the outdoor-air hood. See the Optional EconoMi$erIV section for more inform ation.

NOTE: The hood top panel, upper and lower filter retainers, hood drain pan, baffle (size 300), and filter support bracket are secured opposite the condenser end of the unit. The screens, hood side panels, remaining section of filter support bracket, seal strip, and hardware are in a package located inside the return-air filter access panel (Fig. 18).

1. Attach seal strip to upper filter retainer. See Fig. 19.

2. Assemble hood top panel, side panels, upper filter retainer, and drain pan (see Fig. 20).

3. Secure lower filter retainer and support bracket to unit. See Fig. 20. Leave screws loose on size 300 units.

4. Slide baffle (size 300) behind lower filter retainer and tighten screws.

5. Loosen sheet metal screws for top panel of base unit located above o utdoor-air inlet opening, and remove screws for hood side panels located on the sides of the outdoor-air inlet opening.

6. Match notches in hood top panel to unit top panel screws. Insert hood flange between top panel flange and unit. Tighten screws.

7. Hold hood side panel flanges flat against unit, and install screws removed in Step 5.

8. Insert outdoor-air inlet screens and spacer in channel created by lower filter retainer and filter support bracket.

5L3 3L2 1L1 LINE

NOTE: The disconnect takes the place of TB-1 as shown on the unit wiring diagram label and the component arrangement label.

Fig. 16 — Optional Non-Fused Disconnect Wiring Fig. 17 — Standard 25% Outdoor-Air Section Details

—11—

Table 5 — Electrical Data

UNIT 579F

180

(15 Tons)

216

(18 Tons)

240

(20 Tons)

300

(25 Tons)

FLA — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration IFM — Indoor (Evaporator) Fan Motor LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection NEC — National Electrical Code, U.S.A. OFM — Outdoor (Condenser) Fan Motor RLA — Rated Load Amps

*Fuse or HACR circuit breaker.

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. Canadian units may be fuse or circuit breaker.

2. Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is

NOMINAL VOLTAGE

(3 Ph, 60 Hz)

208/230 187 253 25.6 190 25.6 190 3 0.5 1.7 3.7 10.5/11.0

460 414 508 13.5 95 13.5 95 3 0.5 0.8 3.7 4.8

208/230 187 253 33 237 23 184 3 0.5 1.7 5.0 15.8/15.8

460 414 508 16.2 130 10.2 90 3 0.5 0.8 5.0 7.9

208/230 187 253 33 237 29.5 237 2 1 6.6 7.5 25.0/25.0

460 414 508 16.2 130 14.1 130 2 1 3.3 7.5 13.0

208/230 187 253 47.5 265 33.0 237 2 1 6.6 10.0 28.0/28.0

460 414 508 22.9 145 16.2 130 2 1 3.3 10.0 14.6

greater than 2%.

of voltage imbalance. % Voltage Imbalance

= 100 x

max voltage deviation from average voltage

VO LTAGE

RANGE

Min Max RLA LRA RLA LRA Qty Hp

LEGEND

Use the following formula to determine the percent

average voltage

COMPRESSOR

No. 1 No. 2

OFM IFM

FLA

Hp FLA FLA LRA FLA MCA MOCP*

(ea)

Example: Supply voltage is 460-3-60.

Determine maximum deviation from average voltage.

(AB) 457 – 452 = 5 v (BC) 464 – 457 = 7 v

(AC) 457 – 455 = 2 v Maximum deviation is 7 v. Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x

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

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

POWER

EXHAUST

— — 0.57 74/74 90/ 90

4.6 18.8 0.57 78/79 100/100 — — 0.30 38 50

2.3 6.0 0.30 40 50 — — 0.57 85/85 110/110

4.6 18.8 0.57 90/90 110/110 — — 0.30 41 50

2.3 6.0 0.30 43 50 — — 0.57 109/109 125/125

4.6 18.8 0.57 114/114 125/125 — — 0.30 54 70

2.3 6.0 0.30 56 70 — — 0.57 134/134 175/175

4.6 18.8 0.57 135/135 175/175 — — 0.30 66 80

2.3 6.0 0.30 68 90

AB = 452 v BC = 464 v AC = 455 v

Average Voltage =

COMBUSTION

FAN MOTOR

452 + 464 + 455

1371

457

POWER SUPPLY

457

= 1.53%

—12—

Fig. 18 — Outdoor-Air Hood Component Location

Fig. 19 — Seal Strip Location

BAFFLE (300 ONLY)

LOWER FILTER RETAINER

FILTER SUPPORT BRACKET

HOOD SIDE

HOOD TOP PANEL

PANELS (2)

BAFFLE (300 ONLY)

LOWER FILTER RETAINER

FILTER SUPPORT BRACKET

XII. STEP 12 — INSTALL ALL ACCESSORIES

After all the factory-installed options have been adjusted, install all field-instal led accessories. Refer to the accessory installation instructions included with each accessory.

A. Motormaster® I Control Installation (579F180 and 216 Only)

Install Field-Fabricated Wind Baffles Wind baffles must be field-fabricated for all units to ensure

proper cooling cycle operation at low ambient temperatures. See Fig. 21 for baffle det ails. Use 20-gage, galva nized sheet metal, or similar corrosion-resistant metal for baffles. Use field-supplied screws to attach baffles to unit. Screws should

/4-in. diameter and 5/8-in. long. Drill required screw holes

for mounting baffles.

CAUTION: To avoid damage to the refrigerant coils and electrical components, use recommended screw sizes only. Use care when drilling holes.

Install Motormaster I Controls Only one Motormaster I control is required per unit. The

Motormaster I control must be used in conjunction wi th the Accessory 0° F Low Ambient Kit (purchased separately). The Motormaster I device controls ou tdoor fan no. 1 while outdoor fans no. 2 and 3 are sequenced off by the Accessory 0° F Low Ambient Kit.

Accessory 0° F Low Ambient Kit

Install the Access ory 0° F Low Ambi ent Kit per instru ction supplied with accessory.

Sensor Assembly

Install the sensor assembly in the location shown in Fig. 22.

Motor Mount

To ensure proper fan height, replace the existing motor mount with the new motor mount provided with accessory.

Transformer (460-v Units Only)

On 460-v units, a transformer is required. The transformer is provided with the accessory and must be field-installed.

Motormaster I Control

Recommended mounting location is on the inside of the panel to the left of the control box. The control should be mounted on th e i nside of th e pan el, ver ticall y, with leads p rotruding from bottom of extrusion.

B. Motormaster® V Control Installation

Install Field-Fabricated Wind Baffles Wind baffles must be field-fabricated for all units to ensure

/4-in. diameter and 5/8-in. long. Drill required screw holes

for mounting baffles.

CAUTION: To avoid damage to the refrigerant coils and electrical components, use recommended screw sizes only. Use care when drilling holes.

HOOD DRAIN PAN

UPPER FILTER RETAINER

Fig. 20 — Outdoor-Air Hood Details

—13—

NOTE: Dimensions in ( ) are in mm.

Fig. 21 — Wind Baffle Details

Install Motormaster V Controls The Motormaster V control is a motor speed control device

which adjusts condenser fan motor speed in response to declining liquid refrigerant pressure. A properly applied Motormaster V control extends the operating range of aircondition ing systems and permits operation at lower outdoor ambient temperatures.

The minimum ambient temperatures at which the unit will operate are:

Standard Unit Unit with Low Ambient Kit Unit with MMV Control

40 25 –20

TEMPERATURE OPERATING LIMITS — F°

To operate down to the ambient temperatures listed, Motormaster V controls (Fig. 23) must be added. Fieldfabricated and installed wind baffles are also r equired for all units (see Fig. 21). The Motormaster V control permits operation of the unit to an ambient temperature of –20 F. The control regulates the speed of 3-phase fan motors that are compatible with the control. These motors are factory installed.

See Table 6 for the Motormaster V control accessory package usage. Table 7 shows applicable voltages and motors. Replacement of a motor IS NOT REQUIRED ON CUR- RENT PRODUCTION UNITS since the control is co mpatible with the factory-installed fan motors. Only field wiring control is required.

Install the Motormast er V control per instru ctions supplied with accessory .

Table 6 — Motormaster V Control Package Usage

UNIT VOLTAGE ITEM DESCRIPTION

579F180-300

208/230 CRLOWAMB015A00

460 CRLOWAMB016A00

SENSOR LOCATION

HAIRPIN END

NOTE: All sensors are located on the eighth hairpin up from the bottom.

579F180 579F216

SENSOR LOCATION

HAIRPIN END

Fig. 22 — Motormaster® I Sensor Locations

Table 7 — Applicable Voltages and Motors

VOLTAGE C OM PATIBL E MOTOR

208/230-3-60 HD52AK654

460-3-60 HD52AK654

XIII. STEP 13 — ADJUST FACTORY-INSTALLED OPTIONS

A. Optional EconoMi$erIV

See Fig. 24 and 25 for EconoMi$erIV component locations. NOTE: These instructions are for installing the optional

EconoMi$erIV only. Refer to the accessory EconoMi$erIV installation instructions when field installing an EconoMi$erIV accessory.

To complete installation of t he optional EconoMi$erIV, perform the following procedure.

1. Remove the EconoMi $erIV hood. Ref er to Step 11 — Install Outdoor-Air Hood on page 11 for info rmation on removing and in stalling the outdoor-air hood.

2. Relocate outdoor air temperature sensor from shipping position to operation pos ition on EconoMi $erIV. See Fig. 24.

IMPORTANT: Failure to relocate the sensor w ill res ult in the EconoMi$erIV not operating properly.

3. Re-install economizer hood.

4. Install all EconoMi$erIV accessories. EconoMi$erIV wiring is shown in Fig. 26.

Outdoor air leakage is shown in Table 8. Return air pressure drop is shown in Tabl e 9.

—14—

FROM FUSE BLOCK

Table 8 — Outdoor Air Damper Leakage

BLK

YEL

BLU

13B

13C

12 13A

256

TO PRESSURE TRANSDUCER

TO MOTOR(S)

Fig. 23 — Motormaster® V Control

OUTDOOR AIR TEMPERATURE SENSOR (INSTALLED OPERATION POSITION)

SCREWS

ECONOMI$ERIV

FRAME

TOP

SCREWS

LOW TEMPERATURE COMPRESSOR LOCKOUT SWITCH

Fig. 24 — EconoMi$erIV Component Locations —

End View

SUPPLY AIR TEMPERATURE SENSOR LOCATION

ECONOMI$ERIV

ACTUATOR

CONTROLLER

FLANGE AND SCREWS (HIDDEN)

1 R

R T

a V 4 2

O C

c a V

X E

t e

V 0

1 V 2

s o

V C

V 0

V 2

V C

Q A

e r

l o

+ R S

DAMPER STATIC PRESSURE (in. wg)

0.2 0.4 0.6 0.8 1.0 1.2

LEAKAGE (cfm) 35 53 65 75 90 102

Table 9 — Return Air Pressure Drop (in. wg)

CFM

4500 5000 5400 6000 7200 7500 9000 10,000 11,250

0.040 0.050 0.060 0.070 0.090 0.100 0.110 0.120 0.140

B. EconoMi$erIV Standard Sensors

Outdoor Air Temperature (OAT) Sensor The outdoor air temperature sensor (HH57AC074) is a 10 to

20 mA device used to measure the outdoor-air temperature. The outdoor-air temperat ure is used t o determine whe n the EconoMi$erIV can be used for free cooling. The sensor must be field-reloca ted. See Fig. 24. The operati ng range of temperature measurement is 40 to 100 F.

Supply Air Temperature (SAT) Sensor The supply air temperature sensor is a 3 K thermistor

located at the inlet of the indoor fan. See Fig. 25. This sensor is factory installed. The operating range of temperature measurement is 0° to 158 F. See Tabl e 10 for sensor temper ature/resistance values.

The temperature sensor looks like an eyele t terminal with wires running to it. The sensor is located in the “crimp end” and is sealed from moisture.

Low Temperature Compressor Lockout Switch The EconoMi$erIV is equipped with an ambient tempera-

ture lockout switch located in the outdoor airstream which is used to lock out the compressors below a 42 F ambient temperature. See Fig. 24.

Table 10 — Supply Air Sensor Temperature/

Resistance Values

TEMPERATURE (F) RESISTANCE (ohms)

–58 200,250 –40 100,680 –22 53,010

–4 29,091 14 16,590 32 9,795 50 5,970 68 3,747 77 3,000

86 2,416 104 1,597 122 1,080 140 746 158 525 176 376 185 321 194 274 212 203 230 153 248 116 257 102 266 89 284 70 302 55

Fig. 25 — EconoMi$erIV Assembled in Unit —

Side View

—15—

DCV — Demand Controlled Ventilation IAQ — Indoor Air Quality LALS— Low Temperature Compressor

OAT — Outdoor-Air Temperature POT — Potentiometer

LEGEND

Lockout Switch

Potentiometer Default Settings: Power Exhaust Middle Minimum Pos. Fully Closed DCV Max. Middle DCV Set Middle Enthalpy C Setting

Fig. 26 — EconoMi$erIV Wiring

NOTES:

1. 620 ohm, 1 watt 5% resistor should be removed only when using differential enthalpy or dry bulb.

2. If a separate field-supplied 24 v transformer is used for the IAQ sensor power supply, it cannot have the secondary of the transformer grounded.

3. For field-installed remote minimum position POT, remove black wire jumper between P and P1 and set control minimum position POT to the minimum position.

C. EconoMi$erIV Control Modes

Determine the EconoMi$erIV control mode before set up of the control. Some modes of operation may require different sensors. Refer to Table 11. The EconoMi$erIV is supplied from the factory with a supp ly air tem perature s ensor, a low temperature compressor lockout switch, and an outdoor air temperature sensor . This allows for operation of the EconoMi$erIV with outdoor air dry bulb changeover control. Additional accessories can be added to allow for different types of changeover control and operation of the EconoMi$erIV and unit.

Outdoor Dry Bulb Changeover The standard controller is shipped from the factory config-

ured for outdoor dry bulb changeover control. The outdoor air and supply air temperature sensors are included as standard. For this control mode, the outdoor temperature is compared to an adjus table set point se lected on the con trol. If the outdoor-air temperature is above the set point, the EconoMi$erIV will ad just the outdoor-air dampers to minimum position. If the outdoor-air temperature is below the set point, the position of the outdoor-air dampers will be controlled to provid e free c oo lin g using outdoor air. When in this mode, the LED next to the free cooling set point pote ntiometer will be o n. Th e chang eover te mperatu re set point is con trolled by the free cooling set poi nt potenti ometer locate d on the control. See Fig. 27. The scale on the potenti omet er is A, B, C, and D. See Fig. 28 for the corresponding temp erature changeover values.

Differential Dry Bulb Control For differential dry bulb control the standard outdoor dry

bulb sensor is used in conjunction with an additional accessory return air sensor (part number CRTEMPSN002A00). The accessory sensor must be mounted in the return airstream. See Fig. 29.

In this mode of operation, the outdoor-air temperature is compared to the return-air temper ature and the lower temperature airstream is used for cooling. When using this mode of changeover control, turn the free cooling/enthalpy set point potentiometer fully clockwise to the D sett ing. See Fig. 27.

Outdoor Enthalpy Changeover For enthalpy control, accessory enthalpy sensor (part num-

ber HH57AC078) is required. Replace the standard outdoor dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. See Fig. 24. When the outdoor air enthalpy rises above the outdoor enthalpy changeover set point, the outdoor-air damper moves to its minimum position. The outdoor enthalpy changeover set point is set with the ou tdoor enthalpy set poi nt potentiometer on the EconoMi$er IV controller. The set points are A, B, C, and D. See Fig. 30. The factory-installed 620-ohm jumper must be in place across terminals SR and SR+ on the EconoMi$erIV controller. See Fig. 26 and 31.

—16—

Table 11 — EconoMi$erIV Sensor Usage

APPLICATION

ECONOMI$ERIV WITH OUTDOOR AIR

DRY BULB SENSOR

ECONOMI$ERIV WITH SINGLE

ENTHALPY SENSOR

Accessories Required Accessories Required

Outdoor Air Dry Bulb None. The outdoor air dry bulb sensor is factory installed. CRTEMPSN002A00*

Differential Dry Bulb CRTEMPSN002A00* (2) CRTEMPSN002A00*

Single Enthalpy HH57AC078 None. The single enthalpy sensor is factory installed.

Differential Enthalpy

for DCV Control using a

Wall-Mounted CO

for DCV Control using a

Duct-Mounted CO

*CRENTDIF004A00 and CRTEMPSN002A00 accessories are used on many different base units. As such, these kits may contain parts that will not be needed

for installation.

†CGCDXSEN004A00 is an accessory CO

**CGCDXASP001A00 is an accessory aspirator box required for duct-mounted applications.

Sensor

sensor.

HH57AC078

and

CRENTDIF004A00*

CGCDXSEN004A00

CGCDXSEN004A00†

CGCDXASP001A00**

and

CRENTDIF004A00*

1 R

Va 4 2

4 2

et S V 10

n i

1 P

1 T

n e

p O

V 0 1

F E

V 2

V C

Q A

+ O

e e

+ R S

Fig. 27 — EconoMi$erIV Controller Potentiometer

and LED Locations

LED ON

LED OFF

LED ON

LED OFF

LED ON

LED OFF

LED ON

LED OFF

100

DEGREES FAHRENHEIT

Fig. 28 — Outside Air Temperature

Changeover Set Points

IAQ

SENSOR

RETURN AIR

TEMPERATURE

OR ENTHALPY

SENSOR

Fig. 29 — Return Air Temperature or Enthalpy

Sensor Mounting Location

Differential Ent halpy Control For differential enthalpy control, the EconoMi$erIV con troller

uses two enthalpy sensors (HH57AC078 and CRENTDIF004A00), one in the outside air and one in the return airstream on the EconoMi$erIV frame. The EconoMi$erIV controller compare s the ou tdoor a ir enth al py to the return air enthalpy to determine EconoMi$erIV use. Th e controller selects the lower enthalpy air (retur n or outdoor) for cooling. For example, when the outdoor air has a lower enthalpy than the return air and is below the set point, the EconoMi$erIV opens to bring in outdoor air for free cooling.

Replace the standard outside air dry bulb temperature sensor with the acc essor y enth alpy senso r in th e same mou nting location. See Fig. 24. Mount th e return air enthalpy sen sor in the return airstream . See Fig. 29. The outdoor enthalpy changeover set point is set with the outdoor enthalpy set point potentiometer on th e EconoMi$erIV controller. When using this mode of chan ge ov er contr ol , tu rn th e enth alp y set point potentiometer fully clockwise to the D setting.

NOTE: Remove 620-ohm resistor if differential enthalpy sensor is installed.

—17—

Fig. 30 — Enthalpy Changeover Settings

AQ1

SO+

SR+

EXH

2V 10V

EXH

2V 10V

DCV

2V 10V

Free Cool

Open

Min Pos

DCV

Max

DCV

Set

TR1

24 Vac

Vac

COM

HOT

EF1

Fig. 31 — EconoMi$erIV Controller

Indoor Air Quality (IAQ) Sensor Input The IAQ input can be used for demand control ventilation

control based on the level of CO

measured in the spa ce or

return air duct. Mount the accessory IAQ sensor according to manufacturer

specifications. The IAQ sensor should be wired to the AQ and AQ1 terminals of the controller. Adjust the DCV potentiometers to correspond to the DCV voltage output of the indoor air quality sensor at the user-determined set point. See Fig. 32.

If a separate field-supplied transformer is used to power the IAQ sensor, the sensor must not be grounded or the EconoMi$erIV control board will be damaged.

Exhaust Set Point Adjustment The exhaust set point will determine when the exhaust fan

runs based on d am p er po sit i on ( if accessory power exhaust is installed). The set point is modified with the Exhaust Fan Set Point (EXH SET) potentiometer. See Fig. 27. The set point represents the damper position above which the exhaust fan will be turned on. When there is a call for exhaust, the E con o Mi $er I V co ntro ller provides a 45 ± 15 sec ond delay before exhaust fan activation to allow the dampers to open. This delay allows the damper to reach the appropriate position to avoid unnecessary fan overload.

Minimum Position C o ntrol There is a minimum damper position potentiometer on the

EconoMi$erIV controller. See Fig. 27. The minimum damper position maintains the minimum airflow into the building during the occupied period.

When using demand ventilation, the minimum damper position represents the minimum ventilation position for VOC (volatile organic compound) ventilation requirements. The maximum demand ventilation position is used for fully occupied ventilation.

When demand ventilation control is not being used, the minimum position potentiometer should be used to set the occupied ventilation position. The maximum demand ventilation position should be turned fully clock wi se.

—18—

Adjust the minimum position potentiometer to allow the minimum amount of outdoor air, as required by local codes, to enter the building. Make minimum position adjustments with at least 10° F temperature difference between the outdoor and return-air temperatures.

To determine the minimum position setting, perform the following proced ur e :

1. Calculate the appropriate mixed-air temperature using the following formula:

= Outdoor-Air Temperature

)+ (TR x

100 100

) = T

OA = Percent of Outdoor Air

= Return-Air Temperature

RA = Percent of Return Air T

= Mixed-Air Temperature

As an example, if local codes require 10% outdoor air during occupied conditions, outdoor-air temperature is 60 F, and return-air temperature is 75 F.

(60 x .10) + (75 x .90) = 73.5 F

2. Disconnect the supply-air sensor from terminals T and T1.

3. Ensure that the factory-installed jumper is i n place across terminals P and P1. If remote damper positioning is being used, make sure that the terminals are wired accor din g to Fig. 26 and that t he mi nim um position potentiometer is turned fully clockwise.

4. Connect 24 vac across terminals TR and TR1.

5. Carefully adjust the minim um posit ion po tentiome ter until the measured mixed-air temperature matches the calculated va lue.

6. Reconnect the supply air sensor to terminals T and T1.

Remote control of the EconoMi$erIV damper is desirable when requiring additional temporary ventilation. If a field-supplied remote potentiometer (Ho neywell pa rt numbe r S963B1128 ) is wired to the EconoMi$ erIV controller, the minimum position of the damper can be controlled from a remote location.

To control the minimum damper position remotely, remove the factory-insta lled jumper on the P and P1 terminals on the EconoMi$erIV controller. Wire the field-supplied potentiometer to the P and P1 terminal s on the EconoMi $erIV controller. See Fig. 31.

Damper Movement Damper movement from full open to full closed (or vice

versa) takes 2

/2 minutes. Thermostats The EconoMi$erIV control works with conventional thermo-

stats that have a Y1 (cool stage 1), Y2 (cool stage 2), W1 (heat stage 1), W2 (heat stage 2), and G (fan). The EconoMi$erIV control does not support space temperature sensors. Connections are made at the thermostat terminal connection board located in the main control box.

Occupancy Control The factory default configuration for the EconoMi$erIV con-

trol is occupied mode. Occupied status is provided by the black jumper from terminal TB2-9 to terminal TB2-10. When unoccupied mode is desired, install a field-supplied timeclock function in place of the jumper between terminals TB2-9 and TB2-10. See Fig. 26. When the timeclock contacts are closed, the EconoMi$erIV control will be in occupied

mode. When the timecl ock contacts are open (remo ving the 24-v signal from terminal N), the EconoMi$erIV will be in unoccupied mode.

Demand Controlled V enti lation (DCV) When using the EconoMi$erIV for demand controlled venti-

lation, there are some equipment selection criteria which should be considered. When selecting the heat capacity and cool capacity of the equipment, the maximum ventilation rate must be evaluated for design conditio ns. The maximum damper position must be calculated to provide the desired fresh air.

Typically the maximum ventilation rate will be ab out 5 to 10% more than the typical cfm required per person, using normal outside air design criteria.

A proportional anticipatory strategy should be taken with the following conditions: a zone with a large area, varied occupancy, and equipmen t that cannot exceed the req uired ventilation rate at design con diti ons. Exceedin g the req uir ed ventilation rate means the equipment can co ndition air a t a maximum ventilation rate that is greater than the required ventilation rate for maximum occupancy. A proportionalanticipatory strategy will cause the fresh air supplied to increase as the room CO

level increases even though the

CO2 set point has not been reached. By the time the CO level reaches the set point, the damper will be at maximum ventilation and should maintain the set point.

In order to have the CO

sensor control the economizer damper

in this manner, first determine the damper voltage output for minimum or base ventilation. Base ve ntilation is t he ventilation required to remove contaminants during unoccupied periods. The following equation may be used to determine the percent of outside-air entering the building for a given damper position. For best results there should be at least a 10 degree difference in outside and return-air temperatures.

(TO x

= Outdoor-Air Temperature

)+ (TR x

100 100

) = T

OA = Percent of Outdoor Air TR = Return-Air Temperature RA = Percent of Return Air

= Mixed-Air Temperature

Once base ventilation has been determined, set the minimum damper position potentiometer to the correct position.

CO SENSOR MAX RANGE SETTING

6000

5000

4000

3000

2000

1000

RANGE CONFIGURATION (ppm)

2345678

DAMPER VOLTAGE FOR MAX VENTILATION RATE

800 ppm 900 ppm 1000 ppm 1100 ppm

Fig. 32 — CO2 Sensor Maximum Range Setting

—19—

The same equation can be used to determine the occupied or maximum ventilation rate to the building. For example, an output of 3.6 volts t o the ac tuat o r pro vide s a ba se ve ntil at io n rate of 5% and an output of 6.7 volts provides the maximum ventilation rate of 20% (or bas e plu s 15 cfm pe r pers on). Use Fig. 32 to determine the maximum setting of the CO

sensor.

For example, a 1100 ppm set point relates to a 15 cfm per person design. Use the 1100 ppm curve on Fig. 32 to find the point when the CO

sensor output will be 6.7 volts. Line up

the point on the graph with the left side of the chart to determine that the range configuration for the CO

sensor should

be 1800 ppm. T he EconoMi$erIV control ler will output the

6.7 volts fro m the CO

sensor to the actuator when the CO

concentration in th e sp ace is a t 11 00 ppm. Th e DCV se t point may be left at 2 volts since the CO

sensor voltage wi ll be

ignored by the Econo Mi$erIV controller until it rises above the 3.6 volt setting of the minimum position potentiometer.

Once the fully occupied damper position has been determined, set the maximu m da mpe r de ma nd co nt ro l ve nt il atio n potentiometer to this position. Do not set to the maximum position as this can result in over-ventilation to the space and potential high-humidity levels.

Sensor Con figuration

The CO2 sensor has preset standard voltage settings that can be selected anytime afte r the sensor is powere d up. See Table 12 .

Use setting 1 or 2 f or Bryant equip ment. See Table 12.

1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.

2. Press Mode twice. The STDSET Menu will appear.

3. Use the Up/Down button to select the preset number. See Table 12.

4. Press Enter to lock in the selection.

5. Press Mode to exit and resume normal operation.

The custom settings of the CO

sensor can be changed any-

time after the sensor is en ergized. Follow the steps belo w to change the non-standard settings:

1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.

2. Press Mode twice. The STDSET Menu will appear.

3. Use the Up/Down button to toggle to the NONSTD menu and press Enter.

4. Use the Up/Down button to toggle through each of the nine variables, starting with Altitude, until the desired setting is reached.

5. Press Mode to move through the variables.

6. Press Enter to lock in the selection, then press Mode to continue to the next variable.

Dehumidification of Fresh Air with DCV Control Information from ASHRAE indicates that the largest humid-

ity load on any zone is the fresh air introduced. For some applications, a field-supplied energy recovery unit can be added to reduce the moisture content of the fresh air being brought into the building when the enthalpy is high. In most cases, the normal heating and cooling processes are more than adequate to remove the humidity loads for most commercial applications.

If normal roof top heating and cooling operation is not adequate for the outdoor humidity level, an energy recovery unit and/or a dehumidification option should be considered.

Tab l e 1 2 — CO

SETTING EQUIPMENT OUTPUT

Interface w/Standard

2 Proportional Any

Building Control System

3 Exponential Any

5 Proportional 20

Economizer

6 Exponential 15

7 Exponential 20

8 Health & Safety Proportional —

Parking/Air Intakes/

Loading Docks

LEGEND

ppm — Parts Per Million

Proportional Any

Proportional 15

Proportional —

Sensor Standard Settings

VENTILATION

RATE

(cfm/Person)

ANALOG

OUTPUT

0-10V

4-20 mA

2-10V

7-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

0-10V

4-20 mA

CONTROL RANGE

(ppm)

0-2000 1000 50

0-2000 1100 50

0-1100 1100 50

0- 900 900 50

0-1100 1100 50

0- 900 900 50

0-9999 5000 500

0-2000 700 50

OPTIONAL

RELAY SETPOINT

(ppm)

RELAY

HYSTERESIS

(ppm)

—20—

XIV. STEP 14 — INSTALL HUMIDISTAT FOR OPTIONAL PERFECT HUMIDITY™ DEHUMIDIFICATION PACKAGE

Perfect Humidity dehumidification package operation can be controlled by field installation of a Bryant-approved humidistat. To install the humidistat perform the following procedure:

1. Locate humidistat on a solid interior wall in the conditioned space. Location should be a well ventilated area to sense average humidity.

2. Route thermostat cable or equivalent single leads of colored wire from humidistat terminal s through conduit in unit to the low voltage connection on the 2-pole terminal strip (TB3) as shown in Fig. 33 and Fig. 34. See Fig. 35 for operational diagram.

Fig. 34 — Typical Perfect Humidity™

Dehumidification Package Control Box

LEGEND

CB — Circuit Breaker LLSV — Liquid Line Solenoid Valve LPS — Low-Pressure Switch TB — Terminal Block TRAN — Transformer

Fig. 33 — Typical Wiring Perfect Humidity Dehumidification Package Humidistat (460 V Unit Shown)

—21—

Fig. 35 — Perfect Humidity™ Dehumidification Package Operation Diagram (Single Circuit Shown)

START-UP

Use the following information and Start-Up Checklist on page CL-1 to check out unit PRIOR to start-up.

I. UNIT PREPARATION

Check that unit has been installed in accordance with these installation instructions and all applicable codes.

II. COMPRESSOR MOUNTING

Do not loosen or remove compressor holddown bolts.

III. REFRIGERANT SERVICE PORTS

Each refrigerant system has a total of 3 Schrader-type service gage ports. One port is lo cated on the suction line, one on the compre ssor discha rge line, and one on the liqui d line. In addition Schrader-type valves are located underneath the low-pressure switches. Be sure that caps on the ports are tight.

IV. COMPRESSOR ROTATION A. 579F180 and 216 Only

The unit is equipped with a Phase Monitor Relay (PMR) board located in the control box. The PMR device will not allow the unit to run if field power is connected incorrectly. To determine if the Phase Monitor Relay is preventing the unit from starting, check to see if the red LED is blinki ng. If the LED is blinking, the 3-ph ase fiel d power has been wired incorrectly. A solid light means that field power connections are correct.

B. 579F240 and 300 Only

It is important to b e certain th e compress ors are rota ting in the proper direction. To determine whether or not compressors are rotating in the proper direction:

1. Connect service gages to suct ion and discharge pressure 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 pressure does not rise to normal levels:

1. Note that the evaporator fan is probably also rotating in the wrong direction.

2. Turn off power to the unit.

3. Reverse any two of the incoming power leads.

4. Turn on power to the unit.

5. Energize each compre ssor.

The suction and discharge pressure levels should now move to their normal start-up levels.

NOTE: When compre ssors are rotatin g in the wrong direction, the unit will have increased noise levels and will not provide heating and cooling.

After a few minutes of r eve rse o p erati on , t he s cro ll com pres sor internal overload protection will open, which will activate the unit’s lockout and requires a manual reset. Reset is accomplished by turning the thermostat on and off.

—22—

V. INTERNAL WIRING

Check all electrical conne c tio ns in uni t co ntrol boxe s; tig hte n as required.

VI. CRANKCASE HEATER (Size 300 and Units with Perfect Humidity™ Dehumidification Package Only)

Crankcase heater(s) is energized as long as there is power to the unit and the compressor is not operating.

IMPORTANT: Unit power must b e on for 24 hours prio r to start-up. Otherwise, damage to the comp ressor may result.

VII. EVAPORATOR FAN

Fan belt and variable pulleys are factory-installed. See Tables 13-18 for fan performance data. Be sure that fans rotate in the proper dire ction. See Table 19 for air quantity limits. See Tables 20-22 for static pressure information for accessories and options. See Table 23 for fan rpm at various motor pulley settings. See Tables 24 and 25 for EvaporatorFan Motor Data and Efficiency. To alter fan performance, see Evaporator Fan Performance Ad ju st me nt se cti on on page 30.

A 3

/2-in. bolt and threaded plate are included in the installer’s packet on 579F216-300 units. They can be added to the motor support channel below the motor mounting plate to aid in raising the fan motor.

VIII. CONDENSER-FANS AND MOTORS

Condenser fans and motors are factory set. Refer to Condenser-Fan Adjustment section on page 31 as required. Be sure that fans rotate in the proper direction.

IX. RETURN-AIR FILTERS

Check that correct filters are installed in filter tracks (see Table 1). Do not operate unit without return-air filters.

X. OUTDOOR-AIR INLET SCREENS

Outdoor-air inlet screens must be in place before op erating unit.

XI. GAS HEAT

Verify gas pressures before turning on heat as follows:

1. Turn off manual gas stop.

2. Connect pressure gage to supply gas pressure tap (see Fig. 13).

3. Connect pressure gage to manifold pressure tap on gas valve.

4. Turn on manual gas stop and set thermostat to HEAT position. Adjust set point to several degrees above the current room te mpe ratu re to ens ure a heat demand. After the unit has run for several minutes, verify that incoming pressure is 5.5 in. wg or greater, and that the manifold pressure is 3.3 in. wg. If manifold pressure must be adjusted, refer to Gas Valve Adjustment section on page 32.

5. After unit has been in operation for 5 minutes, check temperature rise across the heat exchangers. See unit informative plate for correct rise limits of the heat supplied. Air quantities may need to be adjusted to bring the actual rise to within the allowable limits.

Table 13 — Fan Performance — 579F180 (Low Heat Units)

AIRFLOW

(cfm)

4500 809 1.53 1317 906 1.74 1502 994 1.96 1690 1078 2.18 1882 1156 2.41 2077 1230 2.64 2275 4800 850 1.76 1516 942 1.98 1706 1027 2.20 1899 1107 2.43 2094 1183 2.66 2293 1255 2.89 2495 5100 892 2.01 1733 979 2.24 1928 1061 2.46 2125 1138 2.70 2325 1211 2.93 2528 1281 3.17 2733 5400 934 2.28 1970 1017 2.52 2169 1096 2.75 2371 1170 2.99 2575 1241 3.22 2781 1309 3.47 2990 5700 976 2.58 2225 1058 2.82 2429 1132 3.06 2635 1204 3.30 2843 1272 3.54 3053 1338 3.79 3266 6000 1019 2.90 2500 1096 3.14 2709 1168 3.38 2919 1238 3.63 3131 1304 3.88 3345 1368 4.13 3562 6300 1063 3.24 2795 1136 3.49 3008 1206 3.74 3223 1273 3.99 3439 1337 4.24 3657 — — — 6600 1106 3.61 3111 1177 3.86 3329 1244 4.11 3547 1309 4.37 3767 — — — — — — 6900 1150 4.00 3448 1218 4.26 3670 — — — — — — — — — — — — 7200 —— — —— — —— — —— — —— — —— — 7500 —— — —— — —— — —— — —— — —— —

AIRFLOW

(cfm)

4500 1301 2.87 2477 1369 3.11 2683 1434 3.35 2891 1497 3.47 2997 1497 3.60 3103 4800 1324 3.13 2700 1390 3.37 2909 1454 3.62 3120 1515 3.74 3226 1515 3.87 3334 5100 1349 3.41 2942 1413 3.66 3153 1475 3.90 3367 1535 4.03 3475 1535 4.16 3584 5400 13743.71320214373.96341614984.213633—————— 5700 14024.04348114634.293699————————— 6000 ——————————————— 6300 ——————————————— 6600 ——————————————— 6900 ——————————————— 7200 ——————————————— 7500 ———————————————

Bhp — Brake Horsepower FIOP — Factory-Installed Option Watts — Input Watts to Motor

NOTES:

1. Standard low-medium static drive range is 891 to 1179 rpm. Alternate highstatic drive range is 1227 to 1550. Other rpms require a field-supplied drive.

2. Maximum continuous bhp is 4.25 and the maximum continuous watts are

3775. Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

LEGEND

0.20.40.60.81.01.2

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

1.4 1.6 1.8 1.9 2.0

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

3. Static pressure losses (i.e., EconoMi$erIV) must be added to external static pressure before entering Fan Performance table.

4. Interpolation is permissible. Do not extrapolate.

5. Fan performance is based on wet coils, clean filters, and casing losses. See Table 20 for accessory/FIOP static pressure information.

6. Extensive motor and drive testing on these units ensures that the full horsepower and watts range of the motor can be utilized with confidence. Using the fan motors up to the watts or bhp rating shown will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.

7. Use of a field-supplied motor may affect wiring size. Contact your local Bryant representative for details.

—23—

Table 14 — Fan Performance — 579F216 and 240 (Low Heat Units)

AIRFLOW

(cfm)

5,500 755 2.27 1908 831 2.58 2171 901 2.91 2443 968 3.24 2723 1031 3.58 3009 1091 3.93 3302 6,000 810 2.72 2287 881 3.04 2556 947 3.37 2833 1010 3.71 3116 1070 4.05 3406 1127 4.40 3702 6,500 866 3.22 2710 932 3.55 2985 994 3.88 3266 1054 4.23 3554 1111 4.57 3847 1166 4.93 4146 7,000 923 3.78 3177 985 4.11 3458 1044 4.45 3744 1100 4.80 4036 1155 5.15 4333 1207 5.51 4635 7,500 980 4.39 3690 1038 4.73 3976 1094 5.07 4267 1148 5.43 4564 1200 5.78 4864 1250 6.15 5170 8,000 1038 5.06 4251 1093 5.40 4542 1146 5.75 4838 1197 6.11 5138 1246 6.47 5443 1294 6.84 5752 8,500 1096 5.78 4859 1148 6.13 5156 1198 6.49 5456 1247 6.85 5761 1294 7.22 6070 1340 7.59 6382 9,000 1154 6.56 5517 1204 6.92 5818 1251 7.28 6123 1298 7.65 6432 1343 8.02 6745 1388 8.40 7062 9,500 1213 7.40 6224 1260 7.77 6531 1306 8.13 6840 1350 8.51 7154 1394 8.88 7471 1436 9.26 7791

10,000 1272 8.30 6983 1317 8.67 7294 1360 9.05 7608 1403 9.43 7926 1445 9.81 8247 1486 10.19 8570

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

0.2 0.4 0.6 0.8 1.0 1.2

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(cfm)

5,500 1149 4.28 3602 1204 4.65 3907 1258 5.02 4217 1284 5.20 4375 1309 5.39 4533 6,000 1183 4.76 4003 1236 5.13 4310 1288 5.50 4622 1313 5.68 4780 1337 5.87 4939 6,500 1219 5.29 4450 1270 5.66 1459 1320 6.03 5073 1344 6.22 5232 1368 6.41 5391 7,000 1258 5.88 4942 1307 6.25 5253 1355 6.62 5569 1378 6.81 5729 1402 7.00 5890 7,500 1299 6.52 5480 1346 6.89 5794 1392 7.27 6113 1415 7.46 6273 1437 7.65 6435 8,000 1341 7.21 6065 1387 7.59 6383 1392 7.97 6704 1453 8.16 6866 1475 8.36 7028 8,500 1385 7.97 6699 1429 8.35 7019 1472 8.73 7343 1493 8.93 7506 1514 9.12 7670 9,000 1431 8.78 7382 1473 9.15 7705 1515 9.55 8032 1535 9.75 8196 — — — 9,500 14789.658114151910.048441—————————

10,000 ———————————————

Bhp — Brake Horsepower FIOP — Factory-Installed Option Watts — Input Watts to Motor

NOTES:

LEGEND

1. Standard low-medium static drive range for size 216 is 910 to 1095 rpm. Standard low-medium static drive range for size 240 is 1002 to 1225 r pm. Alternate high-static drive range for size 216 is 1069 to 1287. Alternate highstatic drive range for size 240 is 1193 to 1458 rpm. Other rpms require a field-supplied drive.

2. Maximum continuous bhp for size 216 is 5.90. Maximum continuous bhp for size 240 is 8.7 (208/230 v) or 9.5 (460 v). The maximum continuous watts for size 216 is 5180. The maximum continuous watts for size 240 is 7915

1.4 1.6 1.8 1.9 2.0

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

(208/230 v) or 8640 (460 v). Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.

3. Static pressure losses (i.e.,EconoMi$erIV) must be added to external static pressure before entering Fan Performance table.

4. Interpolation is permissible. Do not extrapolate.

5. Fan performance is based on wet coils, clean filters, and casing losses. See Table 21 for accessory/FIOP static pressure information.

7. Use of a field-supplied motor may affect wiring size. Contact your local Bryant representative for details.

Table 15 — Fan Performance — 579F300 (Low Heat Units)

AIRFLOW

(cfm)

7,000 941 3.35 2769 1002 3.80 3140 1061 4.27 3528 1117 4.76 3934 1171 5.27 4356 1224 5.80 4794 7,500 999 4.05 3348 1057 4.53 3742 1112 5.02 4152 1166 5.54 4579 1218 6.07 5020 1268 6.63 5478 8,000 1058 4.85 4007 1113 5.35 4424 1165 5.87 4856 1216 6.41 5304 1266 6.97 5766 1314 7.55 6243 8,500 1117 5.74 4750 1169 6.28 5190 1219 6.83 5645 1268 7.40 6114 1315 7.98 6597 1361 8.58 7094 9,000 1177 6.75 5583 1226 7.31 6047 1274 7.89 6524 1320 8.48 7015 1365 9.09 7520 1410 9.72 8037

9,500 1237 7.98 6511 1284 8.46 6999 1329 9.07 7499 1374 9.69 8012 1417 10.33 8538 1459 10.98 9076 10,000 1297 9.12 7450 1342 9.74 8051 1385 10.37 8574 1428 11.02 9110 1469 11.68 9657 1510 12.36 10217 10,500 1358 10.49 8674 1400 11.14 9209 1442 11.80 9755 1483 12.47 10314 1523 13.16 10883 — — — 11,000 1418 12.00 9919 1459 12.67 10478 — — — — — — — — — — — — 11,250 1449 12.80 10585 — — — — — — — — — — — — — — —

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

0.2 0.4 0.6 0.8 1.0 1.2

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(cfm)

7,000 1274 6.35 5248 1323 6.92 5718 1371 5.54 6204

7,500 1316 7.20 6960 1364 7.79 6437 1410 6.41 6939

8,000 1360 8.14 6734 1406 8.76 7239 1450 7.40 7759

8,500 1406 9.20 7605 1449 9.83 8129 1492 8.48 8666

9,000 1453 10.36 8568 1495 11.02 9111 1536 9.69 9667

9,500 1501 11.64 9627 1541 12.32 10190 — — — 10,000 ————————— 10,500 ————————— 11,000 ————————— 11,250 —————————

LEGEND

Bhp — Brake Horsepower FIOP — Factory-Installed Option Watts — Input Watts to Motor

NOTES:

1. Standard low-medium static drive range is 1066 to 1283 rpm. Alternate highstatic drive range is 1332 to 1550. Other rpms require a field-supplied drive.

2. Maximum continuous bhp is 10.2 (208/230 v) or 11.8 (460 v) and the maximum continuous watts are 9510 (208/230 v) or 11,000 (460 v). Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

1.4 1.6 1.8

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

—24—

3. Static pressure losses (i.e., EconoMi$erIV) must be added to external static pressure before entering Fan Performance table.

4. Interpolation is permissible. Do not extrapolate.

5. Fan performance is based on wet coils, clean filters, and casing losses. See Table 21 for accessory/FIOP static pressure information.

7. Use of a field-supplied motor may affect wiring size. Contact your local Bryant representative for details.

Table 16 — Fan Performance — 579F180 (High Heat Units)

AIRFLOW

(cfm)

4500 819 1.55 1335 914 1.76 1518 1001 1.98 1705 1083 2.20 1894 1160 2.42 2088 1234 2.65 2284 4800 861 1.78 1538 951 2.00 1726 1035 2.22 1916 1113 2.45 2110 1188 2.68 2307 1259 2.91 2507 5100 904 2.04 1759 989 2.26 1952 1069 2.49 2147 1145 2.72 2345 1218 2.95 2545 1287 3.17 2749 5400 947 2.32 1999 1028 2.55 2197 1105 2.78 2396 1179 3.01 2598 1248 3.25 2802 1315 3.49 3009 5700 990 2.62 2259 1068 2.85 2461 1142 3.09 2665 1213 3.33 2871 1280 3.57 3079 1345 3.81 3289 6000 1034 2.94 2539 1109 3.18 2745 1180 3.42 2953 1248 3.67 3163 1313 3.91 3375 1376 4.16 3589 6300 1078 3.29 2840 1150 3.54 3050 1218 3.78 3262 1284 4.03 3476 1348 4.28 3692 — — — 6600 1123 3.67 3161 1192 3.91 3376 1258 4.16 3592 — — — — — — — — — 6900 1167 4.06 3504 1234 4.32 3723 — — — — — — — — — — — — 7200 —— — —— — —— ——— — —— ——— —

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

0.2 0.4 0.6 0.8 1.0 1.2

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(cfm)

4500 1304 2.88 2484 1371 3.12 2688 1435 3.36 2895 1467 3.48 2999 1497 3.60 3104 4800 1327 3.14 2711 1393 3.38 2917 1456 3.62 3126 1486 3.75 3232 1517 3.87 3338 5100 1353 3.43 2955 1417 3.67 3165 1478 3.92 3377 1508 4.04 3484 1537 4.16 3592 5400 1380 3.73 3219 1442 3.98 3432 1502 4.23 3646 1531 4.35 3755 — — — 5700 14084.06350314684.313718————————— 6000 ——————————————— 6300 ——————————————— 6600 ——————————————— 6900 ——————————————— 7200 ———————————————

Bhp — Brake Horsepower FIOP — Factory-Installed Option Watts — Input Watts to Motor

NOTES:

LEGEND

1. Standard low-medium static drive range is 891 to 1179 rpm. Alternate highstatic drive range is 1227 to 1550. Other rpms require a field-supplied drive.

2. Maximum continuous bhp is 4.25 and the maximum continuous watts are

3775. Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.

1.4 1.6 1.8 1.9 2.0

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

3. Static pressure losses (i.e., EconoMi$erIV) must be added to external static pressure before entering Fan Performance table.

4. Interpolation is permissible. Do not extrapolate.

5. Fan performance is based on wet coils, clean filters, and casing losses. See Table 20 for accessory/FIOP static pressure information.

7. Use of a field-supplied motor may affect wiring size. Contact the local Bryant representative for details.

Table 17 — Fan Performance — 579F216 and 240 (High Heat Units)

AIRFLOW

(cfm)

5,500 795 2.43 2043 866 2.74 2306 934 3.07 2578 998 3.40 2856 1059 3.74 3142 1117 4.08 3434 6,000 854 2.92 2452 921 3.24 2722 984 3.57 3998 1044 3.90 3281 1102 4.25 3570 1158 4.60 3865 6,500 914 3.46 2909 977 3.79 3184 1036 4.12 3465 1093 4.46 3752 1148 4.81 4045 1201 5.16 4343 7,000 975 4.06 3414 1034 4.39 3695 1090 4.73 3981 1144 5.08 4272 1196 5.43 4569 1246 5.79 4870 7,500 1037 4.72 3969 1092 5.06 4255 1145 5.41 4546 1196 5.76 4842 1256 6.12 5142 1294 6.48 5447 8,000 1099 5.44 4575 1150 5.79 4866 1201 6.14 5162 1249 6.50 5462 1297 6.86 5766 1343 7.22 6075 8,500 1161 6.22 5232 1210 6.57 5529 1258 6.93 5829 1304 7.29 6134 1349 7.66 6443 1393 8.03 6755 9,000 1223 7.07 5943 1270 7.43 6245 1315 7.79 6550 1360 8.16 6869 1403 8.53 7171 1445 8.90 7487 9,500 1286 7.98 6708 1331 8.34 7014 1374 8.71 7324 1416 9.08 7638 1457 9.46 7954 1498 9.84 8274

10,000 1349 8.95 7528 1392 9.32 7839 1433 9.70 8154 1473 10.07 8471 — — — — — —

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

0.2 0.4 0.6 0.8 1.0 1.2

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(cfm)

5,500 1173 4.44 3732 1227 4.80 4036 1279 5.17 4345 1304 5.35 4502 1329 5.54 4629 6,000 1211 4.95 4165 1263 5.32 4471 1313 5.69 4782 1337 5.87 4939 1361 6.06 5097 6,500 1252 5.53 4646 1302 5.89 4954 1350 6.26 5267 1373 6.56 5425 1396 6.64 5584 7,000 1295 6.16 5176 1343 6.52 5487 1389 6.90 5802 1412 7.09 5961 1434 7.28 6121 7,500 1340 6.85 5756 1386 7.22 6070 1431 7.60 6387 1452 7.79 6547 1474 7.98 6709 8,000 1388 7.60 6388 1431 7.97 6704 1474 8.35 7024 1495 8.54 7186 1516 8.74 7348 8,500 1436 8.41 7071 1478 8.79 7390 1520 9.17 7713 1540 9.37 7876 — — — 9,000 14869.28780715279.678130————————— 9,500 153810.228597————————————

10,000 ———————————————

LEGEND

Bhp — Brake Horsepower FIOP — Factory-Installed Option Watts — Input Watts to Motor

NOTES:

1.4 1.6 1.8 1.9 2.0

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

(208/230 v) or 8640 (460 v). Do not adjust motor rpm such that motor maximum bhp and/or watts is exceeded at the maximum operating cfm.

3. Static pressure losses (i.e., EconoMi$erIV) must be added to external static pressure before entering Fan Performance table.

4. Interpolation is permissible. Do not extrapolate.

5. Fan performance is based on wet coils, clean filters, and casing losses. See Table 21 for accessory/FIOP static pressure information.

7. Use of a field-supplied motor may affect wiring size. Contact your local Bryant representative for details.

—25—

Table 18 — Fan Performance — 579F300 (High Heat Units)

AIRFLOW

(cfm)

7,000 992 4.05 3,348 1051 4.44 3,668 1106 4.83 3995 1160 5.24 4331 1212 5.65 4675 1262 6.08 5026 7,500 1055 4.77 3,947 1110 5.17 4,277 1162 5.58 4615 1214 6.00 4960 1263 6.43 5312 1311 6.86 5672 8,000 1118 5.58 4,610 1170 5.99 4,950 1220 6.41 5298 1268 6.84 5653 1315 7.27 6014 1361 7.72 6382 8,500 1182 6.46 5,339 1231 6.88 5,690 1278 7.31 6047 1324 7.75 6411 1369 8.20 6782 1413 8.66 7158 9,000 1246 7.42 6,136 1292 7.86 6,498 1337 8.30 6865 1381 8.75 7239 1424 9.21 7618 1466 9.68 8003

9,500 1310 8.47 7,005 1354 8.92 7,377 1397 9.38 7754 1439 9.84 8137 1480 10.31 8525 1520 10.79 8918 10,000 1374 9.61 7,947 1416 10.07 8,329 1457 10.54 8715 1497 11.02 9107 1537 11.50 9504 — — — 10,500 1439 10.84 8,964 1479 11.32 9,356 1518 11.79 9752 — — — — — — — — — 11,000 1503 12.17 10,059 1542 12.65 10,460 — — — — — — — — — — — — 11,250 1536 12.86 10,636 — — — — — — — — — — — — — — —

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

0.2 0.4 0.6 0.8 1.0 1.2

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(cfm)

7,000 1311 6.51 5385 1359 6.96 5751 1405 6.00 6124

7,500 1358 7.30 6039 1403 7.76 6412 1448 6.84 6792

8,000 1406 8.17 6767 1560 8.63 7137 1492 7.75 7524

8,500 1456 9.12 7541 1498 9.59 7929 1539 8.75 8323

9,000 1507 10.15 8393 1548 10.63 8790 — — —

9,500 ————————— 10,000 ————————— 10,500 ————————— 11,000 ————————— 11,250 —————————

Bhp — Brake Horsepower FIOP — Factory-Installed Option Watts — Input Watts to Motor

NOTES:

LEGEND

1. Standard low-medium static drive range is 1066 to 1283 rpm. Alternate highstatic drive range is 1332 to 1550. Other rpms require a field-supplied drive.

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

1.4 1.6 1.8

Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts

Table 19 — Air Quantity Limits

UNIT

579F

180 4500 3800 3800 7,500 216 5400 4750 5450 9,000 240 6000 4750 5450 10,000 300 7000 4750 5450 11,250

MINIMUM COOLING

CFM

MINIMUM

HEATING CFM

Low Heat High Heat

MAXIMUM

CFM

Table 20 — Accessory/FIOP Static Pressure*

(in. wg) — 579F180

3. Static pressure losses (i.e., EconoMi$erIV) must be added to external static pressure before entering Fan Performance table.

4. Interpolation is permissible. Do not extrapolate.

5. Fan performance is based on wet coils, clean filters, and casing losses. See Table 21 for accessory/FIOP static pressure information.

7. Use of a field-supplied motor may affect wiring size. Contact your local Bryant representative for details.

Table 18 — Accessory/FIOP Static Pressure*

(in. wg) — 579F216-300

COMPONENT

5000 6000 7200 9000 10,000 11,250

EconoMi$erIV 0.06 0.07 0.09 0.11 0.12 0.14

LEGEND FIOP — Factory-Installed Option

*The static pressure must be added to external static pressure. The

sum and the evaporator entering-air cfm should then be used in conjunction with the Fan Performance tables to determine blower rpm and watts.

CFM

COMPONENT

4500 5000 6000 7200 7500

CFM

EconoMi$erIV 0.04 0.05 0.07 0.09 0.10

LEGEND FIOP — Factory-Installed Option

*The static pressure must be added to external static pressure. The

sum and the evaporator entering-air cfm should then be used in conjunction with the Fan Performance tables to determine blower rpm and watts.

—26—

Table 22 — Perfect Humidity™ Dehumidification

Package Static Pressure Drop (in. wg)

UNIT SIZE

579F

UNIT NOMINAL

TONS

180 15 .040 .071 .111 216 18 .058 .102 .160 240 20 .071 .126 .197 300 25 .111 .197 .308

CFM PER TON

300 400 500

Table 23 — Fan Rpm at Motor Pulley Settings*

UNIT 579F

MOTOR PULLEY TURNS OPEN

44 180† †† †† 1179 1150 1121 1093 1064 1035 1006 978 949 920 891 180** †† †† 1550 1522 1488 1455 1422 1389 1356 1323 1289 1256 1227

216† †† †† 1095 1077 1058 1040 1021 1002 984 965 947 928 910 216** †† †† 1287 1265 1243 1222 1200 1178 1156 1134 1112 1091 1069 240† †† †† 1225 1209 1187 1165 1143 1120 1098 1076 1053 1031 1002 240** †† †† 1458 1434 1407 1381 1354 1328 1301 1275 1248 1222 1193 300† †† †† 1283 1269 1247 1225 1203 1182 1160 1138 1116 1095 1066 300** †† †† †† †† 1551 1524 1497 1470 1443 1415 1388 1361 1332

*Approximate fan rpm shown.

†Indicates standard low/medium static drive package.

**Indicates alternate high static-drive package.

††Due to belt and pulley size, pulley cannot be set to this number of

turns open.

NOTE: For speeds not listed above, field-supplied drives are required.

Table 24 — Evaporator-Fan Motor Data

UNIT 579F

180

216

240

300

BHP — Brake Horsepower BkW — Brake Kilowatts

*Extensive motor and electrical testing on these units ensures that the full horsepower (brake kilowatt) range

of the motors can be utilized with confidence. Using the fan motors up to the horsepower (brake kilowatt) ratings shown in this table will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.

NOTE: All indoor-fan motors 5 hp and larger meet the minimum efficiency requirements as established by the Energy Policy Act of 1992 (EPACT) effective October 24, 1997.

UNIT

VOLTAGE

MAXIMUM ACCEPTABLE

CONTINUOUS BHP*

MAXIMUM ACCEPTABLE

CONTINUOUS BkW*

MAXIMUM ACCEPTABLE

OPERATING WATTS

208/230 4.25 3.17 3,775 10.5

460 4.25 3.17 3,775 4.8

208/230

460 7.9

5.90 4.40 5,180

208/230 8.70 6.49 7,915 22.0

460 9.50 7.08 8,640 13.0

208/230 10.20 7.61 9,510 28.0

460 11.80 8.80 11,000 14.6

LEGEND

MAXIMUM

AMP DRAW

15.8

Table 25 — Evaporator-Fan Motor Efficiency

UNIT

579F 180 (3.7 Hp) 85.8 216 (5 Hp) 87.5 240 (7.5 Hp) 88.5 300 (10 Hp) 89.5

NOTE: All indoor-fan motors 5 hp and larger meet the minimum effi-

ciency requirements as established by the Energy Policy Act of 1992 (EPACT) effective October 24, 1997.

MOTOR EFFICIENCY

(%)

—27—

XII. OPERATING SEQUENCE

A. Cooling, Units Without Economizer

When thermostat calls for cooling, terminals G and Y1 are energized. The indoor (evaporator) fan contactor (IFC), compressor contactor no. 1 (C1) and outdoor-fan contactor (OFC) are energized , and evaporator-fan motor, compressor no. 1, and both condenser fans start. The condenser-fan motors run continuously while unit is cooling. If the thermostat calls for a second st age of cooling by energizi ng Y2, compre ssor contactor no. 2 (C2) is energized and compressor no. 2 starts.

When the thermostat is satisfied, C1 and C2 are deenergized and the compressors and outdoor (condenser) fan motors (OFM) shut off. After a 30-second delay, the indoor (evaporator) fan motor (IFM) shuts off. If the thermostat fan selector switch is in the ON position, the evaporator-fan motor will run continuously.

B. Heating, Units Without Economizer

When the thermostat call s for heatin g, terminal W1 is energized. In order to prevent thermostat sh ort-cycling, the unit is locked into the Heating mode for at least 1 minute when W1 is energized. The induced-draft motor (IDM) is then energized and the burner ignition sequence begins. The indoor (evaporator) fan motor (IFM) is energized 45 seconds after a flame is ignited. On units equipped for two stages of heat, when addition al heat is needed, W2 is e nergized and the high-fire solen oid on the main ga s valve (MGV) is energized. When the thermostat is satisfied and W1 and W2 are deenergized, the IFM stops after a 45-second time-off delay.

C. Cooling, Units With EconoMi$erIV

When free cooling is not avail able, the compressors will be controlled b y th e zone ther mosta t. Wh en f ree co oling is a vai lable, the outdoor-air damper is modulated by the EconoMi$erIV control to provide a 50 to 55 F supply-air temperature into the zone. As the supply-air temperature fluctuates above 55 or be lo w 50 F, the dampers wil l be modulated (open or close) to bring the supply-air temperature back within the set point limits.

For EconoMi$erIV operation, there must be a thermostat call for the fan (G). This will move the damper to its minimum position during the occupied mode.

Above 50 F supply-air temperature, the dampers will modulate from 100% o pen to the minimum open po sition. From 50 F to 45 F supply-air temperature, the dampers will maintain at the minimum open position. Below 45 F the dampers will be completely shut. As the supply-air temperature rises, the dampers will com e ba ck ope n to the m inim u m ope n po si tion once the supply-air temperature rises to 48 F.

If optional power exhaust is installed, as the outdoor-air damper opens and c loses, the power exhaust fan will be e nergized and deenergized.

If field-installed accessory CO

sensors are connecte d to the

EconoMi$erIV control, a demand controlled ventilation strategy will begin to operate. As the CO increases abov e the CO

set point, the minimum position of

level in the zone

the damper will be increased proportionally. As the CO2 level decreases because of the increase in fresh air, the outdoor-air damper will be propo rtionally closed. Damper position will follow the higher de mand condition from DCV mode or fr ee cooling mode.

Damper movement from full closed to full open (or vice versa) will take between 1

/2 and 21/2 minutes.

If free cooling c an be used as determin ed from the appr opriate changeover command (switch, dry b ulb, enthalpy curv e, differential dry bulb, or differential enthalpy), a call for

cooling (Y1 closes at the thermostat) will cause the control to modulate the dampers open to maintain the supply a ir temperature set point at 50 to 55 F.

As the supply-air temperature drops below the set point range of 50 to 55 F, the control will modulate the outdoor-air dampers closed to maintain the proper supply-air temperature.

D. Heating, Units With EconoMi$erIV

When the room the rmostat calls for heat, the heating controls are energized as described in the Heating, Units Without Economizer s ection. When the indoor fan is energiz ed, the economizer damper moves to the minimum position. When the indoor fan is off, the economizer damper is fully closed.

SERVICE

WARNING: Before performing service or mainte-

nance operations on unit. Turn off main power switch to unit and install lockout tag or disconnect switch. Electrical shock could cause personal injury.

I. CLEANING

Inspect unit inte rior (see Fig. 36) at beginning of e ach heating and cooling season and as operating conditions require. Remove unit top panel and/or side panels for access to unit interior.

A. Main Burner

At the beginning of each heating season, inspect for deterioration or blockag e due to cor rosion or ot her causes. Obs erve the main burner f lames. Refer to Main Burners section on page 33.

B. Flue Gas Passageways

The flue collector box and heat exchanger cells may be inspected by removing heat exchanger access panel (Fig. 4 and 5), flue box cover, and main burner assembly. Refer to Main Burners section on page 33 for burner removal sequence. If cleaning is required, remove heat exchanger baffles and clean tubes with a wire brush.

Use caution with ceramic heat exchanger baffles. When installing retaining clip, be sure the center leg of the clip extends inward toward baffle. See Fig. 37.

INDUCED DRAFT MOTOR

COMBUSTION FAN HOUSING

LEGEND

IGC — Integrated Gas Controller

INTEGRATED GAS UNIT CONTROLLER (HIDDEN)

MAIN BURNER SECTION

FLUE BOX COVER

VIEW PORT

CONTROL BOX ACCESS PANEL

IGC FAULT CODE LABEL

MAIN GAS VALV E

Fig. 36 — Typical Gas Heating Section

—28—

CERAMIC BAFFLE

CLIP

HEAT EXCHANGER TUBES

NOTE: One baffle and clip will be in each upper tube of the heat exchanger.

Fig. 37 — Removing Heat Exchanger

Ceramic Baffles and Clips

C. Combustion-Air Blower

Clean periodically to assure proper airflow and heating efficiency. Inspect blower wheel every fall and peri odically during heating season. For the first heating season, inspect blower wheel bi-monthly to determine pro per c lea ning fre quenc y.

To inspect blower wheel, remove heat exchanger access panel. Shine a flashlight into opening to inspect wheel. If cleaning is required, remove motor and wheel assembly by removing screws holding motor mounting plate to top of combustion fan housing. The motor and wheel assembly will slide up and out of the fan housing. Remove the blower wheel from the motor shaft and clean with a detergent or solvent. Replace motor and wheel assembly.

D. Coil Maintenance and Cleaning Recommendation

Routine cleaning of coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and removal of harmful residues will greatly increase the life of the coil and extend the life of the unit. The following maintenance and cleaning procedures are recommended as part of the routine maintenance activities to extend the life of the coil.

Remove Surface Loaded Fibers Surface loaded fibers or dirt should be removed with a vac-

uum cleaner. If a vacuum cleaner is not available, a soft nonmetallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges can be easily bent over and damage to the coating of a protected coil) if the tool is applied across the fins.

NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleanin g efforts more difficult. Surface loaded fibers must be co mpl etely remo ved p rior to us ing lo w velocity clean water rinse.

Periodic Clean Water Rinse A periodic clean water rinse i s very beneficial for coils th at

are applied in coastal or industrial environments. However, it is very important t hat the water rinse is made with ver y low velocity water stream to avoid damaging the fin edges. Monthly cleaning as described below is recommended.

Routine Cleaning of Coil Surfaces Monthly cleaning with Totaline® environmentally sound coil

cleaner is essential to extend the life of coils. This cleaner is available from Replacement parts division as part number

P902-0301 for a one gallon container, and part number P902-0305 for a 5 gallon container. It is recommended that all coils, including standard aluminum, pre-coated, copper/copper or E-coated coils be cle aned w ith the Totaline environme ntally sound coil cleaner as described below. Coil cleaning should be part of the unit’s regularly scheduled maintenance pro cedures to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the envi ronm ent.

Avoid the use of:

• Coil brighteners

• Acid cleaning prior to painting

• High pressure washers

• Poor quality water for cle aning Totaline environmentally sound co il cleaner is non-flammable ,

hypoallergenic, nonbacterial, and a USDA accepted biodegradable agent that will not harm the coil or surrounding components such as el ectrica l wiring, painted m etal sur faces, or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.

Totaline Environmentally Sound Coil Cleaner Application Equipment

•2

/2 gallon garde n sp rayer

• Water rinse with low velocity spray nozzle CAUTION: Harsh chemicals, household bleach or

acid or basic cleaners should not be used to clean outdoor or indoor coi ls of any kin d. These cle aners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in contact. If there is dirt below the surface of the coil, use the Totaline environmentally sound coil cleaner as described above.

CAUTION: High velocity water from a pressure

washer, garden hose, or compressed air should never be used to clean a coil. Th e force of the water or air jet will bend the f in edges and increase airsi de pressure drop. Reduced unit performance or nuisance unit shutdown may occur.

Totaline Environmentally Sound Coil Cleaner Application Instructions

1. Proper eye protection such as safety glasses is recommended during mixing and application.

2. Remove all surface loaded fibers and dirt with a vacuum cleaner as described above.

3. Thoroughly wet f inn ed s urf ac es wi th cl ean water an d a low velocity garden hose, being careful not to bend fins.

4. Mix Totaline environmentally sound coil cleaner in a

/2 gallon garden sprayer according to the instructions included with the cleaner. The optimum solution temperature is 100 F.

NOTE: Do NOT

USE water in excess of 130 F, as the enzy-

matic activity will be destroyed.

5. Thoroughly apply Totaline environmentally sound coil cleaner solution to all coil surfaces including finned area, tube sheets and coil headers.

6. Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize potential for fin damage.

—29—

7. Ensure cleaner thoroughly penetrates deep into finned areas.

8. Interior and exterior finned areas must be thoroughly cleaned.

9. Finned surfaces should remain wet with cleaning solution for 10 minutes.

10. Ensure surfaces are not allowed to dry before rinsing. Reapplying cleaner as needed to ensure 10-minute saturation is achieved.

11. T horoughl y rinse all surface s with low velocity cl ean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle.

E. Condensate Drain

Check and clean each year at start of cooling season. In winter, keep drains and traps dry. During periods of low outdoor temperatures, add anti-freeze to the condensate trap to prevent freezing. Follow all precautions on anti-freeze labeling.

F. Filters

Clean or replace at start of each heating and cooling season, or more often if operating conditions require. Refer to Table 1 for type and size.

NOTE: The 579F300 unit requires industrial grade throwaway filters capable of withstanding face velocities up to 625 fpm. Ensure that replacement filters for the 579F300 units are rated for 625 fpm.

G. Outdoor-Air Inlet Screens

Clean screens with steam or hot water and a mild detergent. Do not use throwaway filters in place of screens.

II. LUBRICATION A. Compressors

Each compressor is charged with the correct amount of oil at the factory. Conventional white oi l (Sontext 200LT) is used. White oil is compatible with 3GS oil, and 3GS oil may be used if the additi on of oil is requi red. See c ompressor n ameplate for original oil ch arge. A complete recharge should be four ounces less tha n the original oil charge. When a compressor is exchanged in the field it is possible that a major portion of the oil from the repla ced compressor m ay still be in the system. While this will not affect the reliability of the replacement compressor, the extra oil will add rotor drag and increase power usa ge. To remove this excess oil, a n access valve may be ad de d to the lower port io n o f t he suc t io n l ine at the inlet of the compress or. The compressor should then be run for 10 minutes, shut down, and the access valve opened until no oil flows . Th is shou ld be r epeate d twice to make sure the proper oil level has been achieved.

B. Fan Shaft Bearings

For size 180 units, bearings are permanently lubricated. No field lubrication is required. Fo r size 216-300 units, lubricate bearings at least every 6 months with suitable bearing grease. Extended grease line is provided for far side fan bearing (opposite drive side). Typical lubric ants are g ive n belo w:

C. Condenser and Evaporator-Fan Motor Bearings

The condenser-fan and evaporator-fan motors have permanently sealed bearings, so no field lubrication is necessary.

III. EVAPORATOR FAN PERFORMANCE ADJUSTMENT (Fig. 38-40)

Fan motor pulleys are factory set for speed shown in Table 1. To change fan speeds:

1. Shut off unit power supply.

2. a. Size 180 Only: Loosen belt by loosening carriage nuts holding motor mount assembly to fan scroll side plates (A and B).

b. Size 216-300 Only: Loosen nuts on the 2 carriage

bolts in the motor mounting base. Install jacking bolt and plate under motor base (bolt and plate are shipped in installer’s packet). Using bolt and plate, raise motor to top of slide and remove belt. Secure motor in this position by tightening the nuts on the carriage bolts.

3. Loosen movable-pulley flange setscrew (see Fig. 38).

4. Screw movable flange toward fixed flange to increase

speed and away from fixed flange to decrease speed. Increasing fa n speed i ncreases load on mo tor. Do not exceed maximum speed specified in Table 1.

5. See Table 19 for air quantity limits.

6. 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.)

7. Replace and tighten belts. See Belt Tension Adjust-

ment section on page 31.

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.

MANUFACTURER LUBRICANT

Texaco Regal AFB-2*

Mobil Mobilplex EP No. 1

Sunoco Prestige 42

Texaco Multifak 2

*Preferred lubricant because it contains rust and oxidation inhibitors.

Fig. 38 — Evaporator-Fan Pulley and Adjustment

—30—

IV. EVAPORATOR FAN SERVICE AND REPLACEMENT

A. 579F180 Units (See Fig. 39)

NOTE: To remove belts only, follow Steps 1-6.

1. Remove filter and supply-air section panels.

2. Remove unit top panel.

3. Loosen carriage nuts A and B holding motor mount assembly to fan scroll side plates.

4. Loosen screw C.

5. Rotate motor mount assembly (with motor attached) as far as pos sible away from evaporator coil.

6. Remove belt.

7. Rotate motor mount assembly back past original position toward evaporator coil.

8. Remove motor mounting nuts D and E (both sides).

9. Lift motor up through top of unit.

10. Reverse above procedure to reinstall motor.

11. Check and adjust belt tension as necessary.

B. 579F216-300 Units (See Fig. 40)

The 579F216-300 units use a fan motor mounting system that features a slide-out motor mounting plate. To replace or service the motor, slide out the bracket.

1. Remove the evaporator-fan access panel and the heating control access panel.

2. Remove the cent er pos t (locate d betwe en the evapor ator fan and heating control access panels) and all screws securing it.

3. Loosen nuts on the 2 carriage bolts in the motor mounting base.

4. Using jacking bolt under motor base, raise motor to top of slide and remove belt. Secure motor in this position by tightening the nuts on the carriage bolts.

5. Remove the belt drive.

6. Remove jacking bolt and tapped jacking bolt plate.

7. Remove the 2 screws that secure the motor mounting plate to the motor support channel.

8. Remove the 3 screws from the end of the motor support channel that interfere with the motor slide path.

9. Slide out the motor and motor mounting plate.

10. Disconnect wiring connections and remove the 4 mounting bolts.

11. Rem ove the motor.

12. To install the new motor, reverse Steps 1- 11.

V. BELT TENSION ADJUSTMENT

To adjust belt tension:

1. Loosen fan motor bolts.

2. a. Size 180 Units: Move motor mounting plate up or down for proper belt tension (

/2 in. deflection with one

finger).

b. Size 216-300 Units:

Turn motor jacking bolt to move moto r mo untin g plate up or down for proper belt tension (

/8 in. deflection at midspan with one finger [9 lb force]).

3. Tighten nuts.

4. Adjust bolts and nut on mounting plate to secure motor in fixed position.

VI. CONDENSER-FAN ADJUSTMENT

A. 579F180,216 Units (Fig. 41)

1. Shut off unit power supply.

2. Remove access panel(s) closest to the fan to be adjusted.

3. Loosen fan hub setscrews.

4. Adjust fan height on shaft using a straightedge placed across the fan orifice.

5. Tighten setscrews and replace panel(s).

6. Turn on unit power.

Fig. 39 — 579F180 Evaporator-Fan Motor Adjustment

NOTE: A 31/2-in. bolt and threaded plate are included in the installer’s packet.

They should be added to the motor support channel below the motor mounting plate to aid in raising the motor. The plate par t number is 50DP503842. The adjustment bolt is

/8-16 x 21/2 in. LG.

Fig. 40 — 579F216-300 Evaporator-Fan Motor Section

—31—

B. 579F240,300 Units (Fig. 42)

1. Shut off unit power supply.

2. Remove fan top-grille assembly and loosen fan hub screws.

3. Adjust fan height on unit, using a straightedge placed across the fan orifice.

4. Tighten setscrews and replace rubber hubcap to prevent hub from rusting to motor shaft.

5. Fill hub recess with permagum if rubber hubcap is missing.

VII. POWER FAILURE

Dampers have a spring return. In event of power failure, dampers will return to fully closed position until power is restored. Do not manually operate economizer motor.

VIII. REFRIGERANT CHARGE

Amount of refrigerant charge is listed on unit nameplate and in Table 1. Refer to GTAC II; Module 5; Charging, Recovery, Recycling, and Reclamation section for charging methods and procedures. Unit panels must be in place when unit is operating during charging procedure.

NOTE: Do not use recycled refrigerant as it may contain contaminants.

A. No Charge

Use standard evacuating techniques. After evacuating system, weigh in the specifi ed amount of refrigerant (refer to Table 1).

B. Low Charge Cooling

Using cooling charging chart (see Fig. 43), add or remove refrigerant until conditions of the chart ar e met. Note that charging chart is different from those normally used. An accurate pressure gage and temperature-sensing device is required. Chargin g is accomplished by ens uring the proper amount of liquid subcooling. Measure liquid line pressure at the liquid line service valve using pressure gage. Connect temperature sensing device to the liquid line near the liquid line service valve and insulate it so that outdoor ambient temperature does not affect reading.

NOTE: Dimensions are in inches.

Fig. 41 — Condenser Fan Adjustment, 579F180,216

NOTE: Dimensions are in inches (millimeters).

Fig. 42 — Condenser-Fan Adjustment, 579F240,300

BOTH CIRCUITS

REDUCE CHARGE IF BELOW CURVE

150

200

250

300

350

400

140

120

100

LIQUID TEMPERATURE AT LIQUID VALVE (DEG F)

ALL OUTDOOR FANS MUST BE OPERATING

ADD CHARGE IF ABOVE CURVE

100

LIQUID PRESSURE AT LIQUID VALVE (PSIG)

Fig. 43 — Cooling Charging Chart

C. To Use the Cooling Charging Chart

Use the above tempe rature and pre ssure readings, and find the intersection point on the cooling charging chart. If intersection point on chart is above line, add refrigerant. If intersection point on chart is below line, carefully recover some of the charge. Recheck suction pressure as charge is adjusted.

NOTE: Indoor-air cfm must be within normal operating range of unit. All o utdoor fans must be operating.

The TXV (thermostatic expansion valve) i s set to maintain between 15 and 20 degrees of superheat at the compressors. The valves are factory set and should not require re-adjustment.

D. Perfect Humidity™ System Charging

The system charge for units with the Perfect Humidity option is greater than that of the standard unit alone. The charge for units with this option is indicated on the unit nameplate drawing. To charge systems using the Perfect Humidity dehumidification package, fully evacuate, recover, and re-charge th e system to th e nameplate specified cha rge level. To check or adjust refrigerant charge on systems using the Perfect Humidity dehumidification package, charge per the standard subcooling charts. The subcooler MUST be deenergized to use the charging charts. The charts reference a liquid pressure (psig) and temperature at a point between the condenser coil and the subcooler coil. A tap is provided on the unit to measure liquid pressure entering the subcooler (leaving the cond enser).

IX. GAS VALVE ADJUSTMENT

A. Natural Gas

The gas valve opens and closes in response to the thermostat or limit control.

When power is supplied to valve terminals D1 and C2, the main valve opens to its preset position.

The regular factory setting is stamped on the valve body (3.3 in. wg).

To adjust regulator:

1. Set thermostat at setting for no call for heat.

2. Turn main gas valve to OFF position.

3. Remove

/8-in. pipe plug from manifold or gas valve pressure tap connection. Install a suitable pressuremeasuring device.

—32—

4. Set main gas valve to ON pos ition.

5. Set thermostat at setting to call for heat.

6. Remove screw cap covering regulator adjustment screw (See Fig. 44).

7. Turn adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

8. Once desired pressure is established, set thermostat setting for no call for heat, turn off main gas valve, remove pressure-measuring device, and replace

/8-in. pipe plug and screw cap.

X. MAIN BURNERS

For all applications, main burners are factory set and should require no adjustment.

A. Main Burner Removal

1. Shut off (field-supplied) manual main gas valve.

2. Shut off power to unit.

3. Remove unit control box acce ss panel, burn er section access panel, and center post (Fig. 4 and 5).

4. Disconnect gas piping from gas valve inlet.

5. Remove wires from gas valve.

6. Remove wires from rollout switch.

7. Remove sensor wire and ignitor cable from IGC board.

8. Remove 2 screws securing manifold bracket to basepan.

9. Remove 2 screws that hold the burner support plate flange to the vestib ule plate.

10. Lift burner assembly out of unit.

B. Cleaning and Adjustment

1. Remove burner rack from unit as described in Main Burner Removal section above.

2. Inspect burners, and if dirty, remove burners from rack.

3. Using a soft brush, clean burners and crossover port as required.

4. Adjust spark gap. See Fig. 45.

5. Reinstall burners on rack.

6. Reinstall burner rack as described above.

XI. FILTER DRIER

Replace whenever refrigerant system is exposed to atmosphere.

XII. PROTECTIVE DEVICES

A. Compressor Protection

Phase Protection On 579F180 and 216 units, the phase monitor relay (PMR)

will monitor the sequence of the 3-phase electrical system to provide phase re versal protection. The PMR will also mo nitor the 3-phase voltage inputs to provide phase loss protection for the 3-phase device.

Overcurrent Each compressor has internal line break motor protection,

except the circuit no. 1 on the 579F300 units. Compressor no. 1 on the 579F300 unit uses an electronic module, located with the compressor junction box, to provide motor protection. This electron ic modu le mo ni to rs wi nd ing an d d ischa rge temperatures. If these temperatures reach the trip values, the module interrupts th e control line and causes the compressor to switch off.

Crankcase Heater Only the 579F300 unit and units with optional Perfect

Humidity dehumidification system are equipped with a 70-watt crankcase heater to prevent absorption of liquid refrigerant by oil in the crankcase when the compressor is idle. The crank case heater i s energized whenever ther e is a main power to the unit and the compressor is not energized.

IMPORTANT: After a prolonged shutdown or servicing, energize the crankcase heaters for 24 hours before starting the compressors.

Compressor Lockout If any of the safeties (high-pressure, low-pressure, freeze

protection thermostat, compressor internal thermostat) trip, or if there is loss of power to the compressors, the cooling lockout (CLO) will lock the compressors of f. To reset, manually move the thermostat setting.

B. Evaporator-Fan Motor Protection

A manual reset, calibrated trip, magnetic circuit breaker protects against ov ercurrent. Do not bypass connections or increase the size of the breaker to correct trouble. Determine the cause and correct it before r esetting the breaker.

C. Condenser-Fan Motor Protection

Each condenser-fan motor is internally protected against overtemperature.

D. High-Pressure and Low-Pressure Switches

If either switch trips, or if the compressor overtemperature switch activates, that refrigerant circuit will be automatically locked out by the CLO. To reset, manually move the thermostat setting.

E. Freeze Protection Thermostat (FPT)

An FPT is located on the top and bottom of the evaporator coil. They detect fro st build-up and turn off the compressor, allowing the coil to clear. Once the frost has melted, the compressor can be reenergize d by resetting the compressor lockout.

XIII. RELIEF DEVICES

All units have relief devices to protect against damage from excessive pressu res (i.e., fire). Th ese devices protect the high and low side.

XIV. CONTROL CIRCUIT, 24-V

This control circuit is protected against overcurrent by a

3.2 amp circuit breaker. Breaker can be reset. If it trips, determine cause of trouble before re setting. See Fig. 46 and 47 for typical wiring diagrams.

XV. REPLACEMENT PARTS

A complete list of repl acement parts may be obtained from any Bryant distributor upon request.

XVI. DIAGNOSTIC IGC LEDs

The IGC boar d has LEDs for diagno stic purposes. Refer t o Troubleshooting section on page 38.

Fig. 44 — Gas Valve

—33—

XVII. OPTIONAL HINGED ACCESS DOORS

When the optional service package is ordere d or the if the hinged access doors option is ordered, the unit will be provided with external and internal hinged a ccess doors to facilitate service.

Four external hinged access doors are provided. All external doors are provide d with 2 larg e

/4 turn latches with folding bail-type handles. (Compressor access doors have one latch.) A single door is provided for filter and drive access. One door is provided for control box access. The control box access door is interlocked with the non-fused disconnect w hich must be

SEE

DETAIL

"C"

579F180 (Low Heat)

SEE

DETAIL

"C"

in the OFF position to open the door. Two doors are provided for access to the compressor compartment.

Two internal access doors are provided inside the filter/drive access door. The filter access door (on the left) is secured by 2 small

/4 turn latches with folding bail-type handles. This door must be opened prior to opening the drive access door. The drive access door is shipped with 2 sheet metal screws holding the door closed. Upon initial opening of the door, these screws may be removed and discarded. The door is then held shut by the filter access door, which closes over it.

SEE

DETAIL

"C"

579F216-300 (Low Heat) AND 579F180 (High Heat)

579F216-300 (High Heat)

Fig. 45 — Spark Gap Adjustment

—34—

Fig. 46 — Typical Wiring Schematic (579F180, 208/230-V Shown)

—35—

Fig. 47 — Typical Component Arrangement (579F240, 208/230-V Shown)

—36—

LEGEND AND NOTES FOR FIG. 46 AND 47

LEGEND

AHA — Adjustable, Heat Anticipator BRK W/AT — Breaks With Amp Turns C—Contactor, Compressor CAP — Capacitor CB — Circuit Breaker CC — Cooling Compensator CLO — Compressor Lockout COMP — Compressor Motor CTD — Compressor Time Delay DM — Damper Motor DU — Dummy Terminal EQUIP — Equipment FU — Fuse GND — Ground HPS — High-Pressure Switch IAQ — Indoor Air Quality Sensor IDM — Induced Draft Motor IFC — Indoor-Fan Contactor IFM — Indoor-Fan Motor IFR — Indoor Fan Relay IGC — Integrated Gas Unit Controller L—Light LALS — Low Ambient Temperature

LPS — Low-Pressure Switch LS — Limit Switch MGV — Main Gas Valve NEC — National Electrical Code OAT — Outdoor Air Temperature Sensor OCCUP — Occupancy Sensor OFC — Outdoor Fan Contactor OFM — Outdoor Fan Motor PL — Plug Assembly PMR — Phase Monitor Relay

NOTES:

1. Compressor and/or fan motors thermally protected; three phase motors protected against primary singlephasing conditions.

2. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent.

3. TRAN1 is wired for 230-v operation. If unit is 208-v, disconnect the BLK wires from the ORN TRAN wire and reconnect to the RED TRAN wire. Apply wirenuts to wires.

4. CB1, 2 Must Trip Amps are equal to or less than 156% FLA, IFCB 140%.

5. The CLO locks out the compressor to prevent short cycling on compressor overload and safety devices. Before replacing CLO, check these devices.

6. Jumpers are omitted when unit is equipped with economizer.

7. Number(s) indicates the line location of used contacts. A bracket over (2) numbers signifies a single-pole, double-throw contact. An underlined number signifies a normally closed contact. A plain (no line) number signifies a normally open contact.

8. Remove jumper between RC & RH.

9. 620 Ohm, 1 watt, 5% resistor should be removed only when using differential enthalpy or dry bulb.

10. If a separate field-supplied 24-v transformer is used for the IAQ sensor power supply, it cannot have the secondary of the transformer grounded.

11. OAT sensor is shipped inside unit and must be relocated in the field for proper operation.

12. For field-installed remote minimum position POT, remove black wire jumper between P and P1 and set control minimum position POT to the minimum position.

Compressor Lockout Switch

QT — Quadruple Terminal RAT — Return Air Temperature Sensor RS — Rollout Switch SN — Sensor SW — Switch TB — Terminal Block TC — Thermostat Cooling TH — Thermostat Heating TRAN — Transformer

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Splice

Factory Wiring Field Wiring Option/Accessory Wiring To indicate common potential only;

not to represent wiring.

Economizer Motor

Remote POT Field Accessory

OAT Sensor

Disch Air Sensor

RAT Accessory Sensor

Low Ambient Lockout Switch

—37—

TROUBLESHOOTING

I. UNIT TROUBLESHOOTING

Refer to Tables 26-2 8 and Fig. 48.

II. ECONOMI$ERIV TROUBLSHOOTING

See Table 29 for EconoMi$erIV logic. A functional view of the Econ oMi$erIV is shown in Fig. 49.

Typical settings, sensor ranges, and jumper positions are also shown. An EconoMi$erIV simulator program is available from Bryant to help with EconoMi$erIV training and troubleshooting.

A. EconoMi$erIV Preparation

This procedure is used to prepare the EconoMi$erIV for troubleshooting. No troubleshooting or testing is done by performing the following procedure.

NOTE: This procedure requires a 9-v battery, 1.2 kilo-ohm resistor, and a 5.6 kilo-ohm resistor which are not supplied with the EconoM i$ er IV.

IMPORTANT: Be sure to record the positions of al l potentiometers before star ting troubleshooting.

1. Disconnect power at TR and TR1. All LEDs should be off. Exhaust fan contac ts should be open.

2. Disconnect device at P and P1.

3. Jumper P to P1.

4. Disconnect wires at T and T1. Place 5.6 kilo-ohm resistor across T and T1.

5. Jumper TR to 1.

6. Jumper TR to N.

7. If connected, remove sensor from terminals SO and +. Connect 1.2 kilo-ohm 4074EJM checkout resistor across terminals S

8. Put 620-ohm resistor across terminal s S

and +.

9. Set minimum position, DCV set point, and exhaust potentiometers fully CCW (counterclockwise).

10. Set DCV maximum position potentiometer fully CW (clockwise).

11. Set enthalpy potentiometer to D.

12. Apply power (24 vac) to terminals TR and TR1.

B. Differential Enthalpy

To check differential enthalpy:

1. Make sure EconoM i$erIV prepar ation procedu re has been performed.

2. Place 620-ohm resistor across S

3. Place 1.2 kilo-ohm resistor across S

and +.

and +. The Free

Cool LED should be lit.

4. Remove 620-ohm resistor across S

and +. The Free

Cool LED should turn off.

5. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

C. Single Enthlapy

To check single enthalpy:

1. Make sure EconoM i$erIV prepar ation procedu re has been performed.

2. Set the enthalpy potentiometer to A (fully CCW). The Free Cool LED should be lit .

3. Set the enthalpy potentiometer to D (fully CW). The Free Cool LED should turn off.

4. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

D. DCV (Demand Controlled Ventilation) and Power Exhaust

To check DCV and Power Exhaust:

1. Make sure EconoMi $erIV preparat ion procedure h as been performed.

2. Ensure terminals A Q and AQ 1 a r e op en . The LED for both DCV and Exhaust should be off. The actuator should be fully closed.

3. Connect a 9-v battery to AQ (positive node) and AQ1 (negative node). The LED for both DCV and Exhaust should turn on. The a ctua tor s hou ld dri ve to be tween 90 and 95% open.

4. Turn the Exhaust potentiometer CW until the Exhaust LED turns off. The LED should turn off when the potentiometer is approximately 90%. The actuator should remain in position.

5. Turn the DCV set point potentiometer CW until the DCV LED turns off. The DCV LED should turn off when the potentiometer is approximately 9 v. The actuator should drive fully closed.

6. Turn the DCV and Exhaust potentiometers CCW until the Exhaust LED turns on. The exhaust contacts will close 30 to 120 seconds afte r the Exhaust LED turns on.

7. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

E. DCV Minimum and Maximum Position

To check the DCV minimum and maximum position:

1. Make sure EconoMi $erIV preparat ion procedure h as been performed.

2. Connect a 9-v battery to AQ (positive node) and AQ1 (negative node). Th e DCV LED should turn on. The actuator should drive to between 90 and 95% open.

3. Turn the DCV Maximum Position potentiometer to midpoint. The actuator should drive to between 20 and 80% open.

4. Turn the DCV Maximum Position potentiometer to fully CCW. The actuator should drive fully closed.

5. Turn the Minimum Position potentiometer to midpoint. The actua tor should drive to betwee n 20 and 80% open.

6. Turn the Minimum Position Potentiometer fully CW. The actuator should drive fully open.

7. Remove the jumper from TR and N. The actuator should drive fully closed.

8. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

F. Supply-Air Input

To check supply-air input:

1. Make sure EconoMi $erIV preparat ion procedure h as been performed.

2. Set the Enthalpy potentiometer to A. The Free Cool LED turns on. The actuator should drive to between 20 and 80% open.

3. Remove the 5.6 kilo-ohm resistor and jumper T to T1. The actuator should drive fully open.

4. Remove the jumper across T and T1. The actuator should drive fully closed.

5. Return EconoMi$erIV settings and wiring to normal after completing troubleshooting.

—38—

G. EconoMi$erIV Troubleshooting Completion

This procedure is used to r eturn the Eco noMi $erI V to o pera tion. No troubleshooting or testing is done by performing the following proced ur e.

1. Disconnect power at TR and TR1.

2. Set enthalpy potentiometer to previous setting.

3. Set DCV maximum position potenti ometer to previous setting.

4. Set minimum position, DCV set point, and exhaust potentiometers to previous settings.

5. Remove 620-ohm resistor from terminals S

and +.

6. Remove 1.2 kilo-ohm checkout resistor from terminals S

and +. If used, reconnect sensor from terminals S

and +.

7. Remove jumper from TR to N.

8. Remove jumper from TR to 1.

9. Remove 5.6 kilo-ohm resistor from T and T1. Reconnect wires at T and T1.

10. Remov e jumper from P to P1. Recon nect device at P and P1.

11. Apply power (24 vac) to terminals TR and TR1.

Table 26 — Cooling Service Analysis

Compressor and Condenser Fan Will Not Start.

Compressor Will Not Start but Condenser Fan Runs.

Compressor Cycles (other than normally satisfying thermostat).

Compressor Operates continuously.

Excessive Head Pressure. Dirty air filter. Replace filter.

Head Pressure Too Low. Low refrigerant charge. Check for leaks, repair, and recharge.

Excessive Suction Pressure.

Suction Pressure Too Low. Dirty air filter. Replace filter.

LEGEND TXV — Thermostatic Expansion Valve

PROBLEM CAUSE REMEDY

Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Defective thermostat, contactor, transformer, or control

relay. Insufficient line voltage. Determine cause and correct. Incorrect or faulty wiring. Check wiring diagram and rewire correctly. Thermostat setting too high. Lower thermostat setting below room temperature. Three phase power incorrectly connected (579F180 and 216

only). Indicated by flashing red LED on Phase Monitor Relay (PMR) board (see Control Box Component Arrangement for location).

Faulty wiring or loose connections in compressor circuit. Check wiring and repair or replace. Compressor motor burned out, seized, or internal overload

open. Defective overload. Determine cause and replace. Compressor locked out Determine cause for safety trip and reset lockout. One leg of 3-phase power dead. Replace fuse or reset circuit breaker.

Refrigerant overcharge or undercharge. Recover refrigerant, evacuate system, and recharge

Defective compressor. Replace and determine cause. Insufficient line voltage. Determine cause and correct. Blocked condenser. Determine cause and correct. Defective overload. Determine cause and replace. Defective thermostat. Replace thermostat. Faulty condenser-fan motor. Replace. Restriction in refrigerant system. Locate restriction and remove. Dirty air filter. Replace filter. Unit undersized for load. Decrease load or increase unit size. Thermostat set too low. Reset thermostat. Low refrigerant charge. Locate leak, repair, and recharge. Air in system. Recover refrigerant, evacuate system, and recharge. Condenser coil dirty or restricted. Clean coil or remove restriction.

Dirty condenser coil. Clean coil. Refrigerant overcharged. Recover excess refrigerant. Faulty TXV. 1. Check TXV bulb mounting and secure tightly to suction line.

Air in system. Recover refrigerant, evacuate system, and recharge. Condenser air restricted or air short-cycling. Determine cause and correct.

Restriction in liquid tube. Remove restriction. High heat load. Check for source and eliminate. Faulty TXV. 1. Check TXV bulb mounting and secure tightly to suction line.

Refrigerant overcharged. Recover excess refrigerant.

Low refrigerant charge. Check for leaks, repair, and recharge. Metering device or low side restricted. Remove source of restriction. Faulty TXV. 1. Check TXV bulb mounting and secure tightly to suction line.

Insufficient evaporator airflow. Increase air quantity. Check filter and replace if necessary. Temperature too low in conditioned area. Reset thermostat. Field-installed filter drier restricted. Replace.

Replace component.

Correct field power phasing.

Determine cause. Replace compressor.

Determine cause.

to nameplate.

2. Replace TXV if stuck open or closed.

—39—

Table 27 — Heating Service Analysis

PROBLEM CAUSE REMEDY

Burners Will Not Ignite.

Inadequate Heating. Dirty air filter. Clean or replace filter as necessary.

Poor Flame Characteristics.

Burners Will Not Turn Off.

LEGEND GR — Ground

Misaligned spark electrodes. Check flame ignition and sensor electrode positioning.

No gas at main burners. Check gas line for air; purge as necessary. After purging

Water in gas line. Drain water and install drip leg to trap water. No power to furnace. Check power supply, fuses, wiring, and circuit breaker. No 24 v power supply to control circuit. Check transformer. Transformers with internal overcurrent

Miswired or loose connections. Check all wiring and wire nut connections. Burned-out heat anticipator in thermostat. Replace thermostat. Broken thermostat wires. Run continuity check. Replace wires if necessary.

Gas input to unit too low. Check gas pressure at manifold. Clock gas meter for

Unit undersized for application. Replace with proper unit or add additional unit. Restricted airflow. Clean filter, replace filter, or remove any restrictions. Blower speed too low. Install alternate motor, if applicable, or adjust pulley to

Limit switch cycles main burners. Check rotation of blower, thermostat heat anticipator

Too much outdoor air. Adjust minimum position.

Incomplete combustion (lack of combustion air) results in:

Aldehyde odors, CO, sooting flame, or floating flame.

Unit is locked into Heating mode for a one minute minimum.

Adjust as needed.

gas line of air, allow gas to dissipate for at least 5 minutes before attempting to relight unit.

Check gas valve.

protection require a cool-down period before resetting. Check 24-v circuit breaker; reset if necessary.

input. If too low, increase manifold pressure or replace with correct orifices.

increase fan speed.

settings, and temperature rise of unit. Adjust as needed.

Check economizer operation. Check all screws around flue outlets and burner

compartment. Tighten as necessary. Cracked heat exchanger. Overfired unit — reduce input, change orifices, or adjust

gas line or manifold pressure. Check vent for restriction. Clean as necessary. Check orifice to burner alignment. Wait until mandatory one minute time period has

elapsed or power to unit.

Table 28 — Perfect Humidity™ Dehumidification Subcooler Service Analysis

PROBLEM CAUSE REMEDY

Subcooler Will Not Energize No power to subcooler control transformer. Check power source. Ensure all wire connections

No power from subcooler control transformer to liquid line three-way valve.

Liquid line three-way valve will not operate. 1. Solenoid coil defective; replace.

Subcooler Will Not Deenergize Liquid Line three-way valve will not close. Valve is stuck open; replace. Low System Capacity Low refrigerant charge or frosted coil. 1. Check charge amount. See system charging

are tight.

1. Fuse open; check fuse. Ensure continuity of wiring.

2. Subcooler control low-pressure switch open. Cycle unit off and allow low-pressure switch to reset. Replace switch if it will not close.

3. Transformer bad; check transformer.

2. Solenoid valve stuck closed; replace.

section.

2. Evaporator coil frosted; check and replace subcooler control low-pressure switch if necessary.

—40—

LEGEND IGC — Integrated Gas Unit Controller NOTE: Thermostat Fan Switch in the “AUTO”

position.

Fig. 48 — IGC Control (Heating and Cooling)

—41—

Table 29 — EconoMi$erIV Input/Output Logic

INPUTS OUTPUTS

Demand Control

Ventilation (DCV)

Below set (DCV LED Off)

Above set (DCV LED On)

*For single enthalpy control, the module compares outdoor enthalpy

to the ABCD set point.

†Power at N terminal determines Occupied/Unoccupied setting:

24 vac (Occupied), no power (Unoccupied).

**Modulation is based on the supply air sensor signal.

††Modulation is based on the DCV signal.

High (Free Cooling LED Off)

Low (Free Cooling LED On)

High (Free Cooling LED Off)

Low (Free Cooling LED On)

Enthalpy*

Outdoor Return

Low On On On On Minimum position Closed

High On On On Off Modulating** (between min.

Low On On On On Modulating†† (between min.

High On On On Off Modulating*** Modulating†††

Y1 Y2

On Off On Off Off Off Off Off

On Off Off Off Off Off Off Off Minimum position Closed

On Off On Off Off Off Off Off

On Off Off Off Off Off Off Off

Compressor N Terminal†

Stage1Stage

position and full-open)

position and DCV maximum)

***Modulation is based on the greater of DCV and supply air sensor

signals, between minimum position and either maximum position (DCV) or fully open (supply air signal).

†††Modulation is based on the greater of DCV and supply air sensor

signals, between closed and either maximum position (DCV) or fully open (supply air signal).

Occupied Unoccupied

Damper

Modulating** (between closed and full-open)

Modulating†† (between closed and DCV maximum)

Fig. 49 — EconoMi$erIV Functional View

—42—

Air quantity limits

Altitude compensation 9 Burner spark gap 34 Changeover set points 17, 18 Charging chart, refrigerant 32 Clearance 5,6 CO2 sensor Configuration 20 Settings 19, 20 Combustion blower wheel 29 Compressor Lockout 15, 33 Lubrication 30 Mounting 22 Rotation 22 Concentric duct 8 Condensate drain Cleaning 30 Location 8, 9 Condenser coil 7 Cleaning 29 Condenser fan 7 Adjustment 31, 32 Control circuit Wiring 10 Convenience outlet 11 Crankcase heater 23, 33 Demand ventilation control 19 Dehumidification 20 Dimensions 2, 3, 5, 6 Ductwork 8 EconoMi$erIV 14-20 Control mode 16 Controller wiring 16 Damper movement 19 Demand ventilation control 19 Dry bulb changeover 16 Enthalpy changeover 16 Troubleshooting 38, 39, 42 Usage 17 Wiring 16 Electrical connections 10 Electrical data 12 Enthalpy changeover set points 18 Error codes 41 Evaporator coil 7 Cleaning 29 Evaporator fan motor Efficiency 27 Lubrication 30 Motor data 27 Performance 23-26 Pulley adjustment 30 Pulley setting 27 Speed 7 Filter Cleaning 30 Size 7 Filter drier 33 Flue collector box 28 Flue gas passageways 28 Flue hood 8 Freeze protection thermostat 7, 33 Gas connection 7 Gas input 7 Gas piping 10 Gas pressure 1, 10 Heat anticipator settings 7, 10 Heat exchanger 7 High-pressure switch 7, 33 Hinged access doors 34 Horizontal adapter roof curb 3 Humidistat 21 Indoor air quality sensor 18 Integrated gas controller Error codes 41 Liquid propane 9 Low-pressure switch 7, 33

INDEX

Main burners 9, 28, 33 Manual outdoor air damper 11 Motormaster® I control 13, 14 Motormaster V control 13-15 Mounting Compressor 22 Unit 3 Natural gas 7, 32 Non-fused disconnect 10, 11 Operating sequence 28 Cooling 28 EconoMi$erIV 28 Heating 28 Outdoor air hood 11 , 13 Outdoor air temperature sensor 15 Outdoor air inlet screens Cleaning 30 Dimensions 7 Perfect Humidity™ dehumidification 21, 22, 26, 32, 40 Physical data 7 Power supply 10 Wiring 11 Pressure, drop Economizer 26 Perfect Humidity 26 Pressure switches High pressure 7 Low pressure 7 Refrigerant Charge 32 Type 7 Refrigerant service ports 22 Replacement parts 33 Return air filter 7, 23 Return air temperature sensor 17 Rigging unit 3, 4 Roof curb Assembly 1 Dimensions 2, 3 Leveling tolerances 2 Weight 7 Safety considerations 1 Service 28-37 Start-up 22-28 Start-up checklist CL-1 Supply-air temperature sensor 15 Thermostat 11 Troubleshooting 38-42 Weight Corner 5, 6 EconoMi$erIV 5-7 Maximum 4 Unit 5-7 Wind baffle 8, 13, 14 Wiring EconoMi$erIV 16 Humidistat 21 Non-fused disconnect 11 Power connections 11 Thermostat 11 Unit 35, 36

—43—

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence

A large selection of product, theory, and skills programs are available, using po pular video-based formats and materials. All include video and/or slides, plus companion book.

Classroom Service Training which includes “hands-on” experience with the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting and fewer callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Trai ning [ ] Classroom Service Training

—44—

START-UP CHECKLIST

MODEL NO.:

SERIAL NO.:

DATE: TECHNICIAN:

I. PRE-START-UP



VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT



VERIFY INSTALLATION OF INDOOR FAN MOTOR ADJUSTMENT BOLT AND PLATE (579F216-300 ONLY)



VERIFY INSTALLATION OF OUTDOOR AIR HOOD



VERIFY INSTALLATION OF FLUE HOOD AND WIND BAFFLE



VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS



VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT



CHECK GAS PIPING FOR LEAKS



CHECK THAT FILTERS AND SCREENS ARE CLEAN AND IN PLACE



VERIFY THAT UNIT IS LEVEL



CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SETSCREW IS TIGHT



VERIFY THAT FAN SHEAVES ARE ALIGNED AND BELTS ARE PROPERLY TENSIONED



VERIFY THAT SCROLL COMPRESSORS ARE ROTATING IN THE CORRECT DIRECTION



VERIFY THAT CRANKCASE HEATER HAS BEEN ENERGIZED FOR 24 HOURS (SIZE 300 AND UNITS WITH PERFECT HUMIDITY™ DEHUMIDIFICATION SYSTEM ONLY)

II. START-UP

ELECTRICAL

SUPPLY VOLTAGE L1-L2 L2-L3 L3-L1

CUT ALONG DOTTED LINE

COMPRESSOR AMPS — COMPRESSOR NO. 1 L1 L2 L3

— COMPRESSOR NO. 2 L1 L2 L3

SUPPLY FAN AMPS

EXHAUST FAN AMPS

TEMPERATURES

OUTDOOR-AIR TEMPERATURE F DB (Dry-Bulb) RETURN-AIR TEMPERATURE

F DB F WB (Wet-Bulb) COOLING SUPPLY AIR F GAS HEAT SUPPLY AIR

PRESSURES

GAS INLET PRESSURE IN. WG GAS MANIFOLD PRESSURE STAGE NO. 1 REFRIGERANT SUCTION CIRCUIT NO. 1 REFRIGERANT DISCHARGE CIRCUIT NO. 1



VERIFY REFRIGERANT CHARGE USING CHARGING CHART ON PAGE 32.

IN. WG STAGE NO. 2 IN. WG PSIG CIRCUI T NO. 2 PSIG PSIG CIRCUI T NO. 2 PSIG

GENERAL



ECONOMI$ERIV MINIMUM VENT AND CHANGEOVER SETTINGS TO JOB REQUIREMENTS

CUT ALONG DOTTED LINE

Bryant 579F User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual