Installation and servicing of air-conditioning equ ipment can
be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should
install, repair , or service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained se rvice personnel. When working on air-conditioning equipment, observe
precautions in the literature, tags and labels attached to the
unit, and other safety pre c au ti ons th at ma y a ppl y.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire extinguishers available for all brazing operations.
WARNING: Before performing service or maintenance operations on unit, turn off main power switch to
unit and install lockout tag to disconnect switch. Electrical shock could cause personal injury.
580F
Dura
Cancels: II 580F-180-2II 580F-180-3
WAR NING:
1. Improper installation, adjustment, alteration, service, or maintenance can cause property damage,
personal injury, or loss of life. Refer to 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 vicinity of this or any
other appliance.
What to do if you smell gas:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switch, or use any
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 sup plier, call the fire
department.
WAR NING: Disconnect gas piping from unit when
pressure testing at p ressure 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 greater than 0.5 psig, it must be replaced
before use. When pressure testing field-supplied gas piping at pressures of 0.5 psig or less, a unit connected to
such piping must be isolated by closing th e manual gas
valve(s).
IMPORTANT: Units have high ambient operating limits. If
limits are exceeded, the units will au tomatically 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 or install accessory roof curb or horizontal adapter
roof curb in accordance with instructions shipped with this
accessory. See Fig. 1A, 1B, 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. Curb or adapter roof curb shoul d be level.
This is necessary to permit unit drain to function properly.
Unit leveling tolerance is ±
tion. Refer to Accessory Roof Curb or Horizontal Adapter Roof
Curb Installation Instructions for additional 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.
1
/16 in. per linear ft in any direc-
Instructions continued on page 4.
Pac
Series
Sizes 180-300
15 to 25 Tons
3/15/06
DESCRIPTION
CURB
HEIGHT
Fig. 1A — Roof Curb Details — 580F180-240
PKG. NO. REF.
CRRFCURB012A002′-0″ (610) Side Supply and Return Curb for High Installation
CRRFCURB010A001′− 2″ (305) Standard Curb 14″ High
CRRFCURB011A002′-0″ (610) Standard Curb for Units Requiring High Installation
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.
IMPORTANT: The gasketing of the unit 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. 1A and
1B. 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 upr ight. Use sprea der 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 ±
1
/16 in. per linear ft in any direction. 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.
NOTE: On 58 0F300 unit s, the lower forklift braces mus t be
removed prior to setting unit on roof curb.
14 3/4"
6"
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. 4-6, around and above unit to
provide minimum distance from combustible materials,
proper airflow, and service access.
Do not install unit in an indoor location. Do not locate air
inlets near exhaust vents or other sources of contaminated air .
For proper unit operation, adequate combustion and 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 t o 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 11.
—4—
NOTES:
1. Dimensions in ( ) are in millimeters.
2. Refer to Fig. 4-6 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.
Rows...Fins/in.4...154...154...153...15 (2 coils)
Total Face Area (sq ft)21.721.721.743.4
CONDENSER FANPropeller Type
Nominal Cfm10,50010,50014,20021,000
Quantity...Diameter (in.)3...223...222...306...22
Motor Hp...Rpm
Watts Input (Total)1100110034002200
EVAPORATOR COILCross-Hatched
Rows...Fins/in.4...154...154...154...15
Total Face Area (sq ft)17.517.517.517.5
EVAPORATOR FANCentrifugal Type
Quantity...Size (in.)2...12 x 122...12 x 122...12 x 122...12 x 12
Type D riv eBeltBeltBeltBelt
Nominal Cfm60007200800010,000
Motor Hp557.510
Motor Nominal Rpm1745174517451740
Maximum Continuous Bhp6.135.90
Motor Frame Size184T184T213T215T
Nominal Rpm High/Low——— —
Fan Rpm RangeLow-Medium Static873-1021910-10951002-11511066-1283
Motor Bearing TypeBallBallBallBall
High Static1025-12001069-12871193-13691332-1550
Maximum Allowable Rpm1550155015501550
Motor Pulley Pitch DiameterLow-Medium Static4.9/5.94.9/5.95.4/6.64.9/5.9
Min/Max (in.)High Static4.9/5.94.9/5.95.4/6.64.9/5.9
Nominal Motor Shaft Diameter (in.)1
Fan Pulley Pitch Diameter (in.)Low-Medium Static9.49.49.48.0
High Static8.08.07.96.4
Nominal Fan Shaft Diameter (in.)1
Belt, Quantity...Type...Length (in.)Low-Medium Static1...BX...501...BX...501...BX...532...BX...50
High Static1...BX...481...BX...481...BX...502...BX...47
Pulley Center Line Distance (in.)13.3-14.813.3-14.814.6-15.414.6-15.4
Speed Change per Full Turn of
Movable Pulley Flange (rpm)
Low-Medium Static37373736
High Static44344445
Movable Pulley Maximum Full Turns
*The ZRU140KC compressor is a tandem compressor, consisting of a ZR72KC (25% total capac-
ity) and a ZR68KC (24% total capacity).
†Circuit 1 uses the lower portion of the condenser coil and lower portion of the evaporator coils;
and Circuit 2 uses the upper portion of both coils.
**Pulley has 6 turns. Due to belt and pulley size, movable pulley cannot be set to 0 to 1
open.
††Pulley has 6 turns. Due to belt and pulley size, movable pulley cannot be set to 0 to
1
/2 turns
1
/2 turns
open.
***Rollout switch is manual reset.
†††A Liquid Propane kit is available as an accessory.
¶The 580F300 unit requires 2-in. industrial-grade filters capable of handling face velocities up to
625 ft/min (such as American Air Filter no. 5700 or equivalent).
NOTE: The 580F units have a low-pressure switch (standard) located on the suction side.
—10—
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 an unconditioned space 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 and 4-6. Duct connections
are shown in Fig. 7. Field-fabricated concentric ductwork
may be connected as shown in Fig. 8 and 9. 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. 10. 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. 11.
VI. STEP 6 — TRAP CONDENSATE DRAIN
See Fig. 12 for drain location. One
3
/4-in. half coupling is provided inside unit evaporator section for condensate drain
connection. An 8
diameter pipe nipple, coupled to standard
1
/2-in. x 3/4-in. diameter and 2-in. x 3/4-in.
3
/4-in. diameter
elbows, provide a straight path down through hole in unit
base rails (see Fig. 13). A trap at least 4-in. de ep must be
used.
NOTE: Do not drill in this area; damage to basepan may result in water
leak.
Fig. 7 — Air Distribution — Thru-the-Bottom
NOTE: Dimensions A, A′, B, and B′ are obtained from field-supplied
ceiling diffuser.
Shaded areas indicate block-off panels.
Fig. 9 — Concentric Duct Details
WIND
BAFFLE
NOTE: Do not drill in this area; damage to basepan may result in water
leak.
Fig. 8 — Concentric Duct Air Distribution
Fig. 10 — Flue Hood Location
—11—
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 acc essory I nstallati on Ins tructions to install the correct orif ices.
580F240 Low Heat,
580F300 Low Heat,
580F180 High Heat
580F210 High Heat,
580F240 High Heat,
580F300 High Heat
6
7
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 corre ct orific es.
*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.
—12—
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
1
/8-in.
NPT pressure tap for test gage co nnection at unit. Field gas
piping must include sediment trap and union. See Fig. 14.
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. 14 — Field Gas Piping
IX. STEP 9 — MAKE ELECTRICAL CONNECTIONS
A. Field Power Supply
Unit is factory wired for voltage shown on unit nameplate.
When installing units, provide a disconnect per NEC
(National Electrical Code) requirements of adequate size
(Table 5).
All field wiring must comply with NEC and local
requirements.
Route power and ground lines through control box end
panel or unit basepan (see Fig. 4-6) to connections as shown
on unit wiring diagram and Fig. 15.
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 may lead to premature compressor failure.
WARNING: The unit must be electrically grounded
in accordance with local codes and NEC ANSI/ NF PA 70
(National Fire Protection Association).
Field wiring must conform 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 unit. If 2 08/230-v unit is
to be run with 208-v power supply, the transfo rmer 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 damage 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-approv ed acces sory ther mosta t assemb ly (or
light commercial Thermidistat™ device for units equipped
with Perfect Humidity™ option) according to the 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 subbase terminals through conduit in uni t to lowvoltage connections as shown on unit label wiring diagram
and in Fig. 16.
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:
VOLTAGEW1W2
208/2300.980.44
4600.800.44
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. 17 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 disconnec t handle before unit operation. To
install the handle and shaft, perform the following procedure:
1. Open the co nt ro l b ox do or and r e mo ve t he handle and
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.
—13—
D. Optional Convenience Outlet
On units with optional convenience outlet, a 115-v GFI
(ground fault interrupt) convenience outl et rece ptacle is pr ovided for field wiring. Field wiring should be run thro ugh th e
7
/8-in. knockout provided in the basepan near the return air
opening.
THERMOSTAT ASSEMBLY
REMOVABLE JUMPER
RC
RH
Y1Y2
W1
W2
GC
L
X
LEGEND
EQUIP — Equipment
GND— Ground
NEC— National Electrical Code
TB— Te rm i n al B o a r d
NOTE: The maximum wire size for TB1 is 2/0.
Fig. 15 — Field Power Wiring Connections
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.
7. Turn the handle to the OFF position and close the
door. The handle should fit over the end of the sha ft
when the door is closed.
8. The handle must be in the OFF position to open the
control box door.
R
RED
Y1
BLU
PNK
W1Y2
ORN
W2
VIO
C
BRN
X
WHT
G
BLK
Fig. 16 — Field Control Thermostat Wiring
6T3 4T2 2T1 LOAD
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. 17 — Optional Non-Fused Disconnect Wiring
—14—
Table 5 — Electrical Data
UNIT
580F
LEGEND
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
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.
Never operate a motor where a phase imbalance in supply voltage is
greater than 2%.
Min Max RLA LRA RLA LRA RLA LRA Qty Hp FLA (ea) HpFLAFLA LRAFLAMCAMOCP*
Use the following formula to determine the percent voltage
COMPRESSOR
No. 1No. 1ANo. 2
OFMIFM
% Voltage Imbalance
= 100 x
EXAMPLE: Supply voltage is 460-3-60.
Determine maximum deviation from average voltage.
Maximum deviation is 7 v.
Determine percent 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 your local electric utility company immediately.
max voltage deviation from average voltage
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
POWER
EXHAUST
——0.5782/82110/110
4.618.80.5786/86110/110
——0.304150
2.36.00.304350
——0.5787/87110/110
4.618.80.5792/92110/110
——0.304450
2.36.00.304760
——0.57124/124 150/150
4.618.80.57129/129 150/150
——0.306180
2.36.00.306380
——0.57138/138 175/175
4.618.80.57143/143 150/175
——0.306480
2.360.306680
average voltage
AB = 452 v
BC = 464 v
AC = 455 v
Average Voltage =
= 1.53%
=
= 457
7
457
COMBUSTION
FAN MOTOR
452 + 464 + 455
3
1371
3
POWER
SUPPLY
X. STEP 10 — MAKE OUTDOOR-AIR INLET ADJUSTMENTS
A. Manual Outdoor-Air Damper
All units (except those equipped with a factory-installed
EconoMi$erIV ) h ave a ma nual out door-air damper to provide
ventilation air.
Damper can be preset to admit up to 25% outdoor air into
return-air compartment. To adjust, loosen securing screws
and move damper to desired setting, then retighten screws
to secure damper (Fig. 18).
XI. STEP 11 — INSTALL OUTDOOR-AIR HOOD
The outdoor-air hood is common to 25% air ventilation and
EconoMi$erIV. If EconoMi$erIV is factory installed, all
electrical connections have been made and adjusted at the
factory. Assemble and install hood in the field.
Fig. 18 — Standard 25% Outdoor-Air Section Details
—15—
IMPORTANT: If the unit is equipped with the optional
EconoMi$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. 19).
1. Attach seal strip to upper filter retainer. See Fig. 20.
2. Assemble hood top panel, side panels, upper filter
retainer, and drain pan (see Fig. 21).
3. Secure lower filter retainer and support bracket to
unit. See Fig. 21. Leave screws loose on size 300 units.
5. Loosen sheet metal screws for top pa nel 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. Inser t hood flange betw een top panel flan ge
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.
9. Attach remaining section of filter support bracket.
XII. STEP 12 — INSTALL ALL ACCESSORIES
After all the factory-installed options have been adjusted,
install all field-installed accessories. Refer to the accessory
installation instructions included with each accessory.
A. Motormaster® I Control (–20 F) Installation (580F180
and 210 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. 22 for baffle details. Use 20-gage, galvanized sheet
metal, or similar corrosion-resistant metal for baffles. Use
field-supplied screws to attach baffles to uni t. Scre ws shou ld
1
be
/4-in. diameter and 5/8-in. long. Drill required screw holes
for mounting baffles.
Fig. 19 — Outdoor-Air Hood Component Location
Fig. 20 — Seal Strip Location
BAFFLE
LOWER FILTER
RETAINER
FILTER SUPPORT
BRACKET
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
One Motormaster I control is required on size 180 and 210
units. The Motormaster I control must be used in conjunction
with the accessory fan motor sequencing kit and winter start
kit (purchased separately). The Motormaster I device controls
outdoor fan no. 1 while outdoor fans no. 2 and 3 are sequenced
off by the accessory fan motor sequencing kit.
Accessory Fan Motor Sequencing Kit — Install the access ory
fan motor sequencing kit per instruction supplied with accessory (purchased separately).
Winter Start Time Delay Relay Kit — Install the kit per
the instructions supplied with the accessory (purchased
separately).
Sensor Assembl y — Install the sensor assembly in the location shown in Fig. 23.
HOOD SIDE
HOOD TOP
PANEL
HOOD DRAIN PAN
UPPER FILTER RETAINER
NOTE: The outdoor-air hood comes with a baffle which is used on
size 300 units only, discard baffle for size 180-240 units.
PANELS (2)
FILTER SUPPORT
BRACKET
Fig. 21 — Outdoor-Air Hood Details
—16—
BAFFLE
(300 ONLY)
LOWER
FILTER
RETAINER
Motor Mount — To ensure proper fan height, replace the
existing motor mount with the new motor m ount 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 con trol box. The
control should be mounted on the inside of the panel, vertically, with leads protruding from bottom of extrusion.
B. Motormaster V Control Installation (580F240 and 300)
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. 22 for baffle details. Use 20-gage, galvanized sheet
metal, or similar corrosion-resistant metal for baffles. Use
field-supplied screws to attach baffles to unit. Screws should
1
be
/4-in. diameter and 5/8-in. long. Drill required screw holes
for mounting baffles.
CAUTION: To avoid damage to the ref rigerant coils
and electrical components, use recommended screw
sizes only. Use care when drilling holes.
Install Motormaster V Controls
The Motormaster V control is a m otor 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 airconditioning systems and permits operation at lower outdoor
ambient te mp eratures.
The minimum ambient temperatures at which the unit will
operate are:
TEMPERATURE OPERATING LIMITS — F°
Standard
Unit
4025–20
Unit with
Low Ambient Kit
Unit with
MMV Control
NOTE: Dimensions in ( ) are in mm.
Fig. 22 — Wind Baffle Details
To operate down to the ambient temperatures listed,
Motormaster V controls (Fig. 24) must be added. Fieldfabricated and installed wind baffles are also required for all
units (see Fig. 22) . The M oto rma st er V con tr ol pe rmi ts op er a tion 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 motor or fan blade IS NOT REQUIREDON CURRENT PRODUCTION UNITS since the control is
compatible with the factory-installed fan motors. Only field
wiring control is re quired.
Install the Motormaste r V control per inst ructions supplied
with accessory .
Table 6 — Motormaster V Control Package Usage
UNITVOLTAGEITEM DESCRIPTION
580F180-300
208/230CRLOWAMB015A00
460CRLOWAMB016A00
Table 7 — Applicable Voltages and Motors
VOLTAGECOMPATIBLE MOTO R
208/230-3-60HD52AK654
460-3-60HD52AK654
SENSOR
LOCATION
HAIRPIN END
580F180580F210
NOTE: All sensors are located on the eighth hairpin up from the
bottom.
SENSOR
LOCATION
HAIRPIN END
Fig. 23 — Motormaster I Sensor Locations
—17—
FROM FUSE BLOCK
BLK
YEL
BLU
ECONOMI$ERIV
SUPPLY AIR
TEMPERATURE SENSOR
LOCATION
B
13B
13C
12 13A
2
256
TO PRESSURE
TRANSDUCER
2
3
1
TO MOTOR(S)
Fig. 24 — Motormaster® V Control
XIII. STEP 13 — ADJUST FACTORY-INSTALLED OPTIONS
A. Optional EconoMi$erIV
See Fig. 25 and 26 for EconoMi$erIV component locations.
NOTE: These instructions are for installing the optional
EconoMi$erIV only. Refer to the accessory EconoMi$erIV or
EconoMi$er2 installation instructions when fie ld installing an
EconoMi$erIV or EconoMi$er2 accessory.
To complete installation of the optional EconoMi$erI V, perform the following procedure.
1. Remove the EconoMi$erIV hood. Refer to Step 11 —
Install Outdoor-Air Hood on page 15 for information
on removing and installing the outd oor-air hood.
2. Relocate outdoor air temperature sensor from shipping position to operation po sition on Ec onoMi$erIV.
See Fig. 25.
IMPORTANT: Failure to relocate the sensor will result in the
EconoMi$erIV not ope r ating properly.
3. Re-install economizer hood.
OUTDOOR AIR
TEMPERATURE SENSOR
(INSTALLED OPERATION
POSITION)
LOW TEMPERATURE
COMPRESSOR
LOCKOUT SWITCH
SCREWS
ECONOMI$ERIV
FRAME
TOP
SCREWS
Fig. 25 — EconoMi$erIV Component Locations —
End View
ACTUATOR
CONTROLLER
FLANGE
AND SCREWS
(HIDDEN)
1
TR
R
T
c
a
V
4
2
M
O
C
4
2
_
c
a
V
T
O
H
H
X
E
+
t
e
S
V
0
2
1
V
2
1
1
N
5
N
n
H
i
X
M
E
s
o
P
4
n
P1
e
p
P
O
3
V
C
1
D
x
a
1
EF
T
M
T
V
0
1
EF
V
2
V
C
D
V
t
C
e
D
S
V
1
0
Q
1
A
Q
A
V
2
+
e
O
e
r
S
C
F
l
o
O
o
S
C
B
D
+
R
S
A
R
S
Fig. 26 — EconoMi$erIV Assembled in Unit —
Side View
4. Install all EconoMi$erIV accessories. EconoMi$erIV
wiring is shown in Fig. 27.
Outdoor air leakage is shown in Table 8. Return air pressure
drop is shown in Tabl e 9.
Outdoor Air Temperature (OAT) Sensor
The outdoor air temperature sensor (HH57AC074) is a 10 to
20 mA device used to me asure the outdoor-air tempera ture.
The outdoor-air tempera ture is used t o determine whe n the
EconoMi$erIV can be used for free cooling. The sensor must
be field-relo cated. See Fig. 25. The operat ing range of temperature measurement is 40 to 100 F.
Supply Air Temperature (SAT) Sensor
The supply air temperature sensor is a 3 K thermistor
located at the inlet of the indoor fan. See Fig. 26. This sensor
is factory installed. The operating range of temperature
measurement is 0° to 158 F. See Tabl e 10 for sensor temper ature/resistance values.
The temperature sensor looks like an eyele t terminal with
wires running to it. The sensor is located in the “crimp end”
and is sealed from moisture.
Low Temperature Compressor Lockout Switch
The EconoMi$erIV is equipped with an ambient tempera-
ture lockout switch located in the outdoor air stream which
is used to lockout the co mpresso rs belo w a 42 F ambie nt te mperature. See Fig. 25.
—18—
LEGEND
DCV — Demand Controlled Ventilation
IAQ — Indoor Air Quality
LALS— Low Temperature Compressor
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.
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 supply air temperature sensor, 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 shippe d from the factory config-
ured for outdoor dry bulb changeover control. The outdoor
air and su pply air temperature sensors are included as standard. For this control mode, the outdoor temperature is compared to an adjustable set point selected on the control. If the
outdoor-air temperature is above the set point, the
EconoMi$erIV will adjust the outdoor-air dampers to minimum position. If the outdoor-air temperature is below the set
point, the position of the outdoor-air dampers will be controlled to provid e fr ee co o lin g us ing out do or ai r. When in this
mode, the LED next to the free cooling set point potentiometer will be on. The changeover temp erature set poi nt is controlled by the free cooling set poi nt potentiomete r located on
the control. See Fig. 28. The scal e on the p otentio meter i s A,
B, C, and D. See Fig. 29 for the corresponding temp erature
changeover values.
—19—
Table 11 — EconoMi$erIV Sensor Usage
ECONOMI$ERIV WITH OUTDOOR AIR
APPLICATION
DRY BULB SENSOR
Accessories RequiredAccessories Required
Outdoor Air Dry BulbNone. The outdoor air dry bulb sensor is factory installed.CRTEMPSN002A00*
Single EnthalpyHH57AC078None. The single enthalpy sensor is factory installed.
Differential Enthalpy
for DCV Control using a
CO
2
Wall-Mounted CO
for DCV Control using a
CO
2
Duct-Mounted CO2 Sensor
*CRENTDIF004A00 and CRTEMPSN002A00 accessories are used on many different base units. As such, these kits may contain parts that will not be needed for
installation.
†CGCDXSEN004A00 is an accessory CO
**CGCDXASP001A00 is an accessory aspirator box required for duct-mounted applications.
Sensor
2
sensor.
2
HH57AC078
and
CRENTDIF004A00*
CGCDXSEN004A00
CGCDXSEN004A00†
and
CGCDXASP001A00**
ECONOMI$ERIV WITH SINGLE
ENTHALPY SENSOR
CRENTDIF004A00*
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. 30.
In this mode of operation, the outdoor-air temperature is
compared to the return-air temperature 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 setting. See Fig. 28.
ber HH57AC078) is required. Replace the standard outdoor
dry bulb temperature sensor with the accessory enthalpy
sensor in the same mounting location. See Fig. 25. 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$er IV controller. The set points are A, B,
C, and D. See Fig. 31. The factory-installed 620-ohm jumper
must be in place across terminals SR and SR+ on the
EconoMi$erIV controller. See Fig. 25 and 32.
Differential Ent halpy Control
For differential enthalpy control, the EconoMi$er IV cont rolle r
uses two enthalpy sensors (HH57AC078 and
CRENTDIF004A00), one in the outside air and one in the
return airstream on the EconoMi$erIV frame. The
EconoMi$erIV controller compares t he outdoor air enthalp y to
the return air entha lpy to dete rmine Econo Mi$erIV use. The
controller s elects the lower enthal py air (return or outdoor)
—20—
for cooling. For example, when the outdoor air has a lower
enthalpy than the return air and is below the set point, the
EconoMi$erIV opens to bring in outdoor air for free c ooling.
Replace the standard outside air dry bulb temperature sensor with the ac ces sory enth alpy senso r in t he same mou nting
location. See Fig. 25. Mount the return air enthalpy sensor
in the return airstream. See Fig. 30. The outdoor enthalpy
changeover set point is set with the outdoor enthalpy set
point potentiomete r on the EconoMi$erIV c ontroller. W hen
using this mode of changeover control, turn the enthalpy set
point potentiometer fully clockwise to the D setting.
NOTE: Remove 620-ohm resistor if differential enthalpy sensor is installed.
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 space or
2
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. 33.
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 w hen the exhaust fan
runs based on dam p er position (if acce ssory power exha ust is
installed). The set point is modified with the Exhaust Fan
Set Point (EXH SET) potentiometer. See Fig. 28. 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. 28. 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.
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.
CONTROL
CURVE
4
1
2
1
A
B
C
D
8
1
6
1
CONTROL POINT
APPROX. °F (°C)
AT 50% RH
73 (23)
70 (21)
67 (19)
63 (17)
LPY
HA
26
NT
E
4
2
2
2
0
2
40
(4)
35
(2)
—
85
(29)90(32)95(35)
46
4
4
42
40
IR
8
3
Y A
6
DR
3
D
N
U
4
3
PO
R
32
E
P
TU
30
B
28
60
(16)
55
(13)
B
50
C
(10)
45
D
(7)
70
(21)
0
0
1
65
(18)
A
80
(27)
75
(24)
0
9
80
70
0
6
50
0
4
TIVE HUM
RELA
0
3
100
(38)
IDITY (
20
105
110
(41)
(43)
)
%
0
1
B
C
D
35
40
45
50
55
60
65
70
75
(2)
(4)
(7)
(10)
(13)
(16)
(18)
(21)
APPROXIMATE DRY BULB TEMPERATURE— °F (°C)
(24)
80
(27)
Fig. 31 — Enthalpy Changeover Set Points
—21—
A
85
(29)90(32)95(35)
100
(38)
105
(41)
110
(43)
HIGH LIMIT
CURVE
TR1
N1
P1
T1
AQ1
SO+
SR+
EXH
2V10V
EXH
Open
2V10V
DCV
2V10V
Free
Cool
B
A
Min
Pos
DCV
Max
DCV
C
D
Set
Set
N
P
T
AQ
SO
SR
TR
24
24 Vac
Vac
COM
HOT
_
+
12
5
4
3
EF1
EF
Fig. 32 — EconoMi$erIV Controller
CO SENSOR MAX RANGE SETTING
2
6000
5000
4000
3000
2000
1000
RANGE CONFIGURATION (ppm)
0
2345678
DAMPER VOLTAGE FOR MAX VENTILATION RATE
800 ppm
900 ppm
1000 ppm
1100 ppm
Fig. 33 — CO2 Sensor Maximum Range Setting
To determine the minimum position setting, perform the
following proced ur e :
1. Calculate the appropriate mixed-air temperature
using the following formula:
(T
T
OA
x
O
= Outdoor-Air Temperature
O
)+ (TR x
100100
RA
) = T
M
OA = Percent of Outdoor Air
T
= Return-Air Temperature
R
RA = Percent of Return Air
= Mixed-Air Temperature
T
M
As an example, if local codes require 10% outdoor air
during occupied conditions, outdoor-air temperature
is 60 F, and return-air temperature is 75 F.
(60 x .10) + (75 x .90) = 73.5 F
2. Disconnect the supply-air sensor from terminals T and
T1.
3. Ensure that the factory-installed jumper is i n place
across terminals P and P1. If remote damper positioning is being used, make sure that the terminals
are wired accor din g to Fig. 27 and that t he mi nimu m
position potentiometer is turned fully clockwise.
4. Connect 24 vac across terminals TR and TR1.
5. Carefully adjust the minimum position potentiometer
until the measured mixed-air temperature matches
the calculated value.
6. Reconnect the supply air sensor to terminals T and T1.
Remote control of the EconoMi$erIV damper is desirable when
requiring additional temporary ventilation. If a field-supplied
remote potentiometer (H oneywel l part num ber S963B1 128) 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-install ed 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 $erIV controller. See Fig. 30.
Damper Movement
Damper movement from full open to full closed (or vice
versa) takes 21/2 minutes.
Thermostats
The EconoMi$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 red
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. 27. Whe n t he tim e clock c ont ac ts ar e cl os ed,
the EconoMi$erIV control will be in occupied mode. When
the timeclock contacts are open (removing the 24-v signal
from terminal N), the Econo Mi$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 equipment that cannot exceed the requ ired
ventilation rate at design con dition s. Exceeding th e requ ired
ventilation rate means the equipment can co ndition air a t a
maximum ventilation rate that is gre ater than the requ ired
ventilation rate for maximum occupancy. A proportionalanticipatory strategy will cause the fresh air supplied to
increase as the room CO
set point has not been reached. By the time the CO
CO
2
level increases even though the
2
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
2
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
2
—22—
percent of outside-air entering the building for a given damper
position. For best results there should be a t least a 10 degre e
difference in outside and return-air temperatures.
OA
(TO x
T
= Outdoor-Air Temperature
O
)+ (TR x
100100
RA
) = T
M
OA = Percent of Outdoor Air
TR = Return-Air Temperature
RA = Percent of Return Air
TM = Mixed-Air Temperature
Once base ventilation has been determined, set the mini-
mum damper position potentiometer to the correct position.
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. 33 to determine the maximum setting of the CO2 sensor.
For example, a 1100 ppm set point relates to a 15 cfm per
person design. Use the 1100 ppm curve on Fig. 33 to find the
point when the CO
sensor output will be 6.7 volts. Line up
2
the point on the graph with the left side of the chart to determine that the range configuration for the CO
sensor sho uld
2
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
2
concentration in the spac e is a t 1100 ppm . The D CV set point
may be left at 2 volts since the CO
sensor voltage wi ll be
2
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 con t 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.
CO
Sensor Configurati on
2
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 for Bryant equipment. 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-
2
time after the s ensor is energiz ed. Follow the s teps 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
2
Information from ASHRAE indicates that the largest humidity 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
SETTINGEQUIPMENTOUTPUT
1
Interface w/Standard
2ProportionalAny
Building Control System
3ExponentialAny
4
5Proportional20
Economizer
6Exponential15
7Exponential20
8Health & SafetyProportional—
Parking/Air Intakes/
9
Loading Docks
LEGEND
ppm — Parts Per Million
ProportionalAny
Proportional15
Proportional—
Sensor Standard Settings
2
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
—23—
CO
CONTROL RANGE
2
(ppm)
0-2000100050
0-2000100050
0-2000110050
0-1100110050
0- 90090050
0-1100110050
0- 90090050
0-99995000500
0-200070050
OPTIONAL
RELAY SETPOINT
(ppm)
RELAY
HYSTERESIS
(ppm)
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 in a well ventilated area to sense aver age humidity.
2. Route thermostat cable or equivalent single leads of
colored wire from humidistat terminals through conduit in unit to the low voltage connection on the
2-pole terminal strip (TB3) as shown in Fig. 34 and
Fig. 35. See Fig. 36 for operation diagram.
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
Compressors are internally spring mounted. Do not loosen or
remove compressor holddown bolts.
III. GAS PIPING
Check gas piping for leaks.
WARNING: Disconnect gas piping from unit when
leak testing at pressure greater than
1
sures greater than
/2 psig will cause gas valve damage
1
/2 psig. Pres-
resulting in hazardous condition. If gas valve is subjected to pressure greater than
1
/2 psig, it must be
replaced before use. When pressure testing fieldsupplied gas piping at pressures of
1
/2 psig or less, a
unit connected to such piping must be isolated by manually closing the gas valve .
IV. 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.
V. COMPRESSOR ROTATION
It is important to be c ertain the c ompressors are rotating in
the proper direction. To determine whether or not co mpressors are rotating in the proper direction:
1. Connect service gages to suct ion and discharge pressure fittings.
2. Energize the compressor .
3. The suction pr essure 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 in coming power leads.
4. Turn on power to the compressor.
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 o f re vers e o per ation , th e s cro ll co m pressor 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.
VI. INTERNAL WIRING
Check all electrical conne c tion s in unit c o ntrol b oxe s; tig hte n
as required.
VII. CRANKCASE HEATER
Crankcase heater(s) is energized as long as there is power to
the unit and the compressor is not operating.
IMPORTANT: Unit power must be on for 24 hours prior to
start-up. Otherwise, damage to compressor may result.
VIII. EVAPORATOR FAN
Fan belt and variable pulleys are factory-installed. See
Tables 13-20 for fan performance data. Be sure that fans
rotate in the proper direction. See Table 21 for air quantity
limits. See Table 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 evaporator fan
motor data. To alter fan performance, see Evaporator Fan
Performance Adjustment section on page 35.
NOTE: A 3
1
/2-in. bolt and threaded plate are included in the
installer’s packet. They can be added to the motor support
channel below the motor mounting plate to aid in raising the
fan motor.
IX. CONDENSER-FANS AND MOTORS
Condenser fans and motors are factory set. Refer to
Condenser-Fan Adjustment section on page 36 as required.
Be sure that fans rotate in the proper direction.
X. RETURN-AIR FILTERS
Check that correct f ilters are installed in filter tr acks (see
Table 1). Do not operate unit without return-air filters.
XI. OUTDOOR-AIR INLET SCREENS
Outdoor-air inlet screens must be in place befo re operatin g
unit.
XII. 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. 14).
3. Connect pressure gage to manifold pressure tap on
gas valve.
4. Turn on manual gas stop and set thermostat to
HEAT position. After the unit has run for several
minutes, verify that incoming pressure is 5.5 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 37.
5. After unit has be en in oper ation f or 5 minu tes, 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.
—26—
Table 13 — Fan Performance — 580F180275 (Low Heat Units)*
Refer to page 32 for general Fan Performance Data notes.
NOTE: Maximum continuous bhp for the standard motor is 6.13. The
maximum continuous watts is 5180. Do not adjust motor rpm such that
motor maximum bhp and/or watts is exceeded at the maximum operating cfm. See Table 24 for more information.
—27—
Table 14 — Fan Performance — 580F180360 (High Heat Units)*
Refer to page 32 for general Fan Performance Data notes.
NOTE: Maximum continuous bhp for the standard motor is 6.13. The
maximum continuous watts is 5180. Do not adjust motor rpm such that
motor maximum bhp and/or watts is exceeded at the maximum operating cfm. See Table 24 for more information.
—28—
Table 15 — Fan Performance — 580F210275 (Low Heat Units)*
Refer to page 32 for general Fan Performance Data notes.
NOTE: Maximum continuous bhp is 5.90. The maximum continuous
watts is 5180. Do not adjust motor rpm such that motor maximum bhp
and/or watts is exceeded at the maximum operating cfm. See Table 24
for more information.
Table 16 — Fan Performance — 580F210360 (High Heat Units)*
Refer to page 32 for general Fan Performance Data notes.
NOTE: Maximum continuous bhp is 5.90. The maximum continuous
watts is 5180. Do not adjust motor rpm such that motor maximum bhp
and/or watts is exceeded at the maximum operating cfm. See Table 24
for more information.
—29—
Table 17 — Fan Performance — 580F240275 (Low Heat Units)*
Refer to page 32 for general Fan Performance Data notes.
NOTE: Maximum continuous bhp for the standard motor is 8.7 (for 208/
230-v units) and 9.5 (for 460-v units). The maximum continuous watts is
7915 (for 208/230-v units) and 8640 (for 460-v units). Do not adjust
motor rpm such that motor maximum bhp and/or watts is exceeded at
the maximum operating cfm. See Table 24 for additional information.
—30—
Table 18 — Fan Performance — 580F240360 (High Heat Units)*
Refer to page 32 for general Fan Performance Data notes.
NOTE: Maximum continuous bhp for the standard motor is 8.7 (for 208/
230-v units) and 9.5 (for 460-v units). The maximum continuous watts is
7915 (for 208/230-v units) and 8640 (for 460-v units). Do not adjust
motor rpm such that motor maximum bhp and/or watts is exceeded at
the maximum operating cfm. See Table 24 for more information.
—31—
Table 19 — Fan Performance — 580F300275 (Low Heat Units)*
*Standard low-medium static drive range is 1066 to 1283 rpm. Alternate
high-static drive range is 1332 to 1550. Other rpms require a field-supplied
drive.
AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)
1.41.61.8
Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts
Refer to this page for general Fan Performance Data notes.
NOTE: Maximum continuous bhp is 10.20 (208/230 v) or 11.80 (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. See Table 24 for more information.
Table 20 — Fan Performance — 580F300360 (High Heat Units)*
Bhp — Brake Horsepower
Watts — Input Watts to Motor
*Standard low-medium static drive range is 1066 to 1283 rpm. Alternate
high-static drive range is 1332 to 1550. Other rpms require a field-supplied
drive.
AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)
1.41.61.8
Rpm Bhp Watts Rpm Bhp Watts Rpm Bhp Watts
GENERAL NOTES FOR FAN PERFORMANCE DATA TABLES
1. Static pressure losses (i.e., EconoMi$erIV) must be added to
external static pressure before entering Fan Performance table.
2. Interpolation is permissible. Do not extrapolate.
3. Fan performance is based on wet coils, clean filters, and
casing losses. See Table 24 for Accessory/FIOP Static Pressure
information.
4. Extensive motor and drive testing on these units ensures that the
full horsepower and watts range of the motor can be utilized with
Refer to this page for general Fan Performance Data notes.
NOTE: Maximum continuous bhp is 10.20 (208/230 v) or 11.80 (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. See Table 24 for more information.
confidence. Using 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.
5. Use of a field-supplied motor may affect wire size. Contact your
Bryant representative for details.
††Due to belt and pulley size, pulley cannot be set to this number of turns open.
MOTOR PULLEY TURNS OPEN
22
1
/
2
33
1
/
2
44
1
/
2
55
1
/
2
6
Table 24 — Evaporator-Fan Motor Data
UNIT
580F
180
210
240
300
LEGEND
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 your fan motors up to the horsepower (brake
UNIT
VOLTAGE
208/230
4607.9
208/230
4607.9
MAXIMUM ACCEPTABLE
CONTINUOUS BHP
6.134.575,180
5.904.405,180
MAXIMUM ACCEPTABLE
208/2308.706.597,91522.0
4609.507.088,64013.0
208/23010.207.619,51028.0
46011.808.8011,00014.6
Table 25 — Evaporator-Fan Motor Efficiency
UNIT 580FMOTOR EFFICIENCY (%)
5 Hp87.5
7.5 Hp88.5
10 Hp89.5
NOTE: All indoor-fan motors 5 hp and larger meet the mini-
mum efficiency requirements as established by the Energy
Policy Act of 1992 (EPACT) effective October 24, 1997.
CONTINUOUS BkW*
OPERATING WATTS
kilowatt) ratings shown in this table will not result in nuisance tripping
or premature motor failure. Unit warranty will not be affected.
MAXIMUM ACCEPTABLE
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.
MAXIMUM
AMP DRAW
15.8
15.8
—33—
XIII. 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 c on tr o l to p rov id e a 50 to 5 5 F supply-air temperature into the zone. As the supply-air temperature fluctuates above 55 o r below 50 F, the dampers will be modu lated
(open or close) to bring the supply-air temperature back
within the set point limits.
For EconoMi$erIV operation, there must be a thermostat
call for the fan (G). This will move the damper to its minimum position during the occupied mode.
Above 50 F supply-air temperature, the dampers will modulate from 100% o pen to the minimum open po sition. From
50 F to 45 F supply-air temperature, the dampers will maintain at the minimum open position. Below 45 F the dampers
will be completely shut. As the supply-air temperature rises,
the dampers will com e ba ck ope n to the m inim u m ope n po si tion once the supply-air temperature rises to 48 F.
If optional power exhaust is installed, as the outdoor-air
damper opens and c loses, the power exhaust fan will be e nergized and deenergized.
If field-installed accessory CO
sensors are connecte d to the
2
EconoMi$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
2
level in the zone
2
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
1
/2 and 21/2 minutes.
If free cooling can be used as determined from the appropriate changeover command (switch, dr y bulb, enthalpy curve,
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 sectio n. Whe n the indo or fan i s running, the
economizer damp er 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 on disconnect switch.
Electrical shock could cause personal injury.
I. CLEANING
Inspect unit i nterior at beginn ing of each heating and cooling season an d a s oper ating conditi o ns re q ui re. Re mo ve uni t
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 37.
B. Flue Gas Passageways
The flue collector box and heat exchanger cells may be
inspected by removing heat exch anger access panel (Fig. 4-
6), flue box cover, and main burner assembly (Fig. 10 and
11). Refer to Main Burners section on page 37 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.
C. Combustion-Air Blower
Clean periodica lly to assur e proper airf low and he ating efficiency. Inspect blower wheel every fall and periodically
during heating season. For the first heating season,
inspect blower whee l bi-monthly to determi ne proper cleaning frequenc 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 clea n with a detergent or s olvent.
Replace motor and wheel assembly.
D. Evaporator Coil
Clean as required with commercial coil cleaner.
—34—
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
E. Condenser Coil
Clean condenser coil annually and as required by location
and outdoor-air conditions. Inspect coil monthly — clean as
required.
F. Condensate Drain
Check and clean each year at start of cooling season. In
winter, keep drains and traps dry.
G. 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 580F300 unit requires industrial grade throwaway filters capable of withstanding face velocities up to
625 fpm. Ensure that replacement filters for the 580F300
units are rated for 625 fpm.
H. Outdoor-Air Inlet Screens
Clean screens with steam or hot water and a mild detergent.
Do not use throwaway filters in place of screens.
II. LUBRICATION
A. Compressors
Each compressor is charged with the correct amount of oil at
the factory. Conventional white oil (Sontex 200LT) is used.
White oil is compatible with 3GS oil, and 3GS oil may be
used if the addi tion of oil is requi red. See c ompress or nameplate for original oil ch arge. A complete recharge should be
four ounces less than the original oil charge. When a
compressor is exchanged in the field it is possible that a
major portion of the oil from the replaced compressor may
still be in the sy st e m. W hi le t his wi ll no t affe c t th e r e li abi li ty
of the replacement com pressor, the extra oil will add r otor
drag and increase power usage. To remove this excess oil, an
access valve may be added to the lower portion of the suction
line at the inlet of the compressor. The compressor should
then be run for 10 minutes, shut down and the access valve
opened until no oil flows. This should be repeated twice to
make sure the proper oil level has been achieved.
B. Fan Shaft Bearings
Lubricate bearings at least every 6 months with suitable
bearing grease. Extended grease li ne is provided for far si de
fan bearing (opposite drive side). Typical lubricants are
given below:
MANUFACTURERLUBRICANT
TexacoRegal AFB-2*
MobilMobilplex EP No. 1
SunocoPrestige 42
TexacoMultifak 2
*Preferred lubricant because it contains rust and oxidation inhibitors.
C. Condenser and Evaporator-Fan Motor Bearings
The condenser an d ev apo rator-fan motors have perma nen tl y
sealed bearings , so no field lubr icat i on is nece ssa ry.
III. EVAPORATOR FAN PERFORMANCE ADJUSTMENT
(Fig. 38 and 39)
Fan motor pulleys are factory set for speed shown in Table 1.
To change fan speeds:
1. Shut off unit power supply.
2. 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 m otor 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.
See Table 21 for air quantity limits.
5. Set movable flange at nearest keyway of pulley hub
and tighten setscrew. (See Table 1 for speed change
for each full turn of pulley flange.)
6. Replace and tighten belts. See Belt Tension Adjustment section below.
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.
IV. EVAPORATOR FAN SERVICE AND REPLACEMENT
The 580F units use a fan motor mounting system that features a slide-out motor mounting plate. See Fig. 39. 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 center post (located betw een the evapo rator 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.
—35—
Fig. 38 — Evaporator-Fan Pulley and 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 part number
is 50DP503842. The adjustment bolt is
3
/8-16 x 13/4-in. LG.
Fig. 39 — 580F180-300 Evaporator-Fan Motor Section
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. Remove 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. Turn motor jacking bolt to move motor mounting
plate up or down for proper belt tension (
3
/8 in. deflec-
tion 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. 580F180, 210, 300 UNITS (Fig. 40)
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.
B. 580F240 Units (Fig. 41)
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 replac e rubber hubcap to pr event 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. Uni t 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 standar d evacuating technique s. After evac uating system, weigh in th e specified amount of refri gerant (refer to
Table 1).
B. Low Charge Cooling
Using cooling charging chart (see Fig. 42), 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. Chargi ng 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.
—36—
NOTE: Dimensions are in inches.
Fig. 40 — Condenser Fan Adjustment, 580F180, 210, 300
NOTE: Dimensions are in inches.
Fig. 41 — Condenser Fan Adjustment, 580F240
BOTH CIRCUITS
REDUCE CHARGE IF BELOW CURVE
150
200
250
300
350
400
140
120
100
80
60
LIQUID TEMPERATURE AT LIQUID VALVE (DEG F)
40
50
ALL OUTDOOR FANS MUST BE OPERATING
ADD CHARGE IF ABOVE CURVE
100
LIQUID PRESSURE AT LIQUID VALVE (PSIG)
Fig. 42 — 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 char gi ng char t. I f in tersection 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 outdoor fans must be operating.
The TXV (thermostatic expansion valve) is 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 the nameplate sp ecified charge
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 s ubcooler coil. A tap is provided
on the unit to measure liquid pressure entering the subcooler (leaving the condenser).
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
1
/8-in. pipe plug from manifold or gas valve
pressure tap connection. Install a suitable pressuremeasuring device.
4. Set main gas valve to ON posit ion.
5. Set thermostat at setting to call for heat.
6. Remove screw cap covering regulator adjustment
screw (see Fig. 43).
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
1
/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 access panel, burner section
access panel, and center post (Fig. 4-6).
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 hol d the burner support plate
flange to the vestibule plate.
INLET PRESSURE TAP
(PLUGGED)
1/8 - 27 N.P.T. THDS.
ON
OFF
W-1
RECEPTACLE TERMINAL
REGULATOR
ADJUSTMENT SCREW
(REMOVE COVER)
D-1
D-2
C1
C2
PILOT
ADJ.
W-2
OUTLET PRESSURE
TAP (PLUGGED)
1/8-27 N.P.T. THDS.
RECEPTACLE AND
TAB COMBINATION
TERMINAL
PILOT CONNECTION
FOR 1/4” O.D. TUBING
(PLUGGED)
Fig. 43 — Gas Valve
B. Cleaning and Adjustment
1. Remove burner rack from unit as described in Main
Burner Removal section on page 37.
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. 44.
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
Overcurrent
Each compressor has internal line break motor prot ection.
Crankcase Heater
All units are equipped with a 70 -watt crankcase heater to
prevent absorption of liquid refrig erant by oil in the crankcase when the compressor is idle. The crankcase heater is
energized whenever there is main power to the uni t and the
compressor is not energized.
IMPORTANT: After 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 i nternal thermostat) t rip,
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 corre ct 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 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). These devices protec t 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. 45 and
46 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 CONTROL LEDs
The unit control boards have LEDs for diagnostic purposes.
Refer to Troubleshooting section on page 43.
XVII. OPTIONAL HINGED ACCESS DOORS
When the optional hinged access doors option is ordered, the
unit will be provided with external and internal hinged
access doors to facilitate service.
Four external hinged access doors are provided on size 180240 units. Two external hinged doors are provided on size
300 units. All external doors are provided with 2 large
1
/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 a ccess door is interlocked with the
non-fused disconnect which must be in the OFF position to
open the door. Two doors are provided on 580F 180- 240 un its
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
1
/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.
—38—
SEE
DETAIL
"C"
SEE
DETAIL
"C"
SEE
DETAIL
"C"
580F180275 (Low Heat)
580F180360 (High Heat) AND 580F210275-300275 (Low Heat)
580F210360-300360 (High Heat)
Fig. 44 — Spark Gap Adjustment
—39—
Fig. 45 — Typical Wiring Schematic (580F240, 208/230 V Shown)
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
NOTES:
1. Compressor and/or fan motor(s) thermally protected three-phase motors protected against primary single
phasing conditions.
2. If any of the original wire furnished must be replaced, it must be replaced with Type 90° C or its equivalent.
3. Jumpers are omitted when unit is equipped with economizer.
4. IFCB must trip amps is equal to or less than 140% FLA.
5. On TRAN1 use BLK lead for 460-v power supply and ORN lead for 575-v power supply.
6. The CLO locks out the compressor to prevent short cycling on compressor overload and safety devices;
before replacing CLO check these devices.
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. Plain (no line) number
signifies a normally open contact.
8. 620 Ohm, 1 watt, 5% resistor should be removed only when using differential enthalpy or dry bulb.
9. 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.
10. OAT sensor is shipped inside unit and must be relocated in the field for proper operation.
11. 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.
—42—
TROUBLESHOOTING
I. UNIT TROUBLESHOOTING
Refer to Tables 26-2 8 and Fig. 47.
II. ECONOMI$ERIV TROUBLSHOOTING
See Table 29 for EconoMi$erIV logic.
A functional view of the Econ oMi$erIV is shown in Fig. 48.
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 contacts 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 termin al s S
and +.
O
and +.
R
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 Econ oMi$erIV prepa ration procedu re has
been performed.
2. Place 620-ohm resistor across S
3. Place 1.2 kilo-ohm resistor across S
and +.
O
and +. The Free
R
Cool LED should be lit.
4. Remove 620-ohm resistor across S
and +. The Free
O
Cool LED should turn off.
5. Return EconoMi$erIV settings and wiring to normal
after completing troubleshooting.
C. Single Enthlapy
To check single enthalpy:
1. Make sure Econ oMi$erIV prepa ration procedu re has
been performed.
2. Set the enthalpy potentiometer to A (fully CCW). The
Free Cool LED should be lit .
3. Set the enthalpy potentiometer to D (fully CW). The
Free Cool LED should turn off.
4. Return EconoMi$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 $erIV prepara tion procedure has
been performed.
2. Ensure terminals AQ and AQ1 are open . The LED for
both DCV and Exhaust should be off. The actuator
should be fully closed.
3. Connect a 9-v battery to AQ (positive node) and AQ1
(negative node). The LED for both DCV and Exhaust
should turn on. The a ctua tor s hou ld dri ve to be tween
90 and 95% open.
4. Turn the Exhaust potentiometer CW until the
Exhaust LED turns off. The LED should turn off
when the potentiometer is approximately 90%. The
actuator should remain in position.
5. Turn the DCV set point potentiometer CW until the
DCV LED turns off. The DCV LED should turn off
when the potentiometer is approximately 9 v. The
actuator should drive fully closed.
6. Turn the DCV and Exhaust potentiometers CCW
until the Exhaust LED turns on. The exhaust contacts will close 30 to 120 seconds afte r the Exhaust
LED turns on.
7. Return EconoMi$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 $erIV prepara tion procedure has
been performed.
2. Connect a 9-v battery to AQ (positive node) and AQ1
(negative node). Th e DCV LED should turn on. The
actuator should drive to between 90 and 95% open.
3. Turn the DCV Maximum Position potentiometer to
midpoint. The actuator should drive to between 20
and 80% open.
4. Turn the DCV Maximum Position potentiometer to
fully CCW. The actuator should drive fully closed.
5. Turn the Minimum Position potentiometer to midpoint. The act uator should drive to be tween 20 and
80% open.
6. Turn the Minimum Position Potentiometer fully CW.
The actuator should drive fully open.
7. Remove the jumper from TR and N. The actuator
should drive fully closed.
8. Return EconoMi$erIV settings and wiring to normal
after completing troubleshooting.
F. Supply-Air Input
To check supply-air input:
1. Make sure EconoMi $erIV prepara tion procedure has
been performed.
2. Set the Enthalpy potentiometer to A. The Free Cool
LED turns on. The actuator should drive to between
20 and 80% open.
3. Remove the 5.6 kilo-ohm resistor and jumper T to T1.
The actuator should drive fully open.
4. Remove the jumper across T and T1. The actuator
should drive fully closed.
5. Return EconoMi$erIV settings and wiring to normal
after completing troubleshooting.
—43—
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 +.
R
6. Remove 1.2 kilo-ohm checkout resistor from terminals
S
and +. If used, reconnect sensor from terminals S
O
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. Reconnect device at P
and P1.
11. Apply power (24 vac) to terminals TR and TR1.
Table 26 — Perfect Humidity™ Dehumidification Subcooler Service Analysis
PROBLEMCAUSEREMEDY
Subcooler Will Not EnergizeNo 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 DeenergizeLiquid Line three-way valve will not close.Valve is stuck open; replace.
Low System CapacityLow 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.
O
Table 27 — Heating Service Analysis
PROBLEMCAUSEREMEDY
Burners Will Not
Ignite.
Inadequate Heating.Dirty air filter.Clean or replace filter as necessary.
Poor Flame
Characteristics.
Burners Will Not Turn
Off.
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.
—44—
Table 28 — Cooling Service Analysis
PROBLEMCAUSEREMEDY
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.
LEGEND
TXV — Thermostatic Expansion Valve
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.
Faulty wiring or loose connections in compressor circuit.Check wiring and repair or replace.
Compressor motor burned out, seized, or internal over-
load open.
Defective overload.Determine cause and replace.
Compressor locked outDetermine 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
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
Refrigerant overcharged.Recover excess refrigerant.
Dirty air filter.Replace filter.
Low refrigerant charge.Check for leaks, repair, and recharge.
Metering device or low side restricted.Remove source of restriction.
Faulty TXV.1. Check TXV bulb mounting and secure tightly to
Insufficient evaporator airflow.Increase air quantity. Check filter and replace if
Temperature too low in conditioned area.Reset thermostat.
Field-installed filter drier restricted.Replace.
Replace component.
Determine cause. Replace compressor.
Determine cause.
to nameplate.
suction line.
2. Replace TXV if stuck open or closed.
suction line.
2. Replace TXV if stuck open or closed.
suction line.
2. Replace TXV if stuck open or closed.
necessary.
—45—
LEGEND
IGC — Integrated Gas Unit Controller
NOTE: Thermostat Fan Switch in the “AUTO”
position.
Fig. 47 — IGC Control (Heating and Cooling)
—46—
Table 29 — EconoMi$erIV Input/Output Logic
INPUTSOUTPUTS
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*
OutdoorReturn
LowOn OnOnOnMinimum positionClosed
HighOn OnOnOffModulating** (between min.
LowOn OnOnOnModulating†† (between min.
HighOn OnOnOffModulating***Modulating†††
Y1 Y2
On OffOnOff
Off OffOffOff
On OffOffOff
Off OffOffOffMinimum positionClosed
On OffOnOff
Off OffOffOff
On OffOffOff
Off OffOffOff
CompressorN Terminal†
Stage1Stage
2
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).
Motormaster® I control 16, 17
Motormaster V control 17, 18
Mounting
Compressor 26
Unit 4
Natural gas 10, 37
Non-fused disconnect 13, 14
Operating limits 17
Operating sequence 34
Cooling 34
EconoMi$erIV 34
Heating 34
Outdoor air hood 15, 16
Outdoor air inlet screens
Cleaning 35
Dimensions 10
Outdoor air temperature sensor 18
Perfect Humidity™ dehumidification
package 24, 25, 37, 44
Physical data 9, 10
Power exhaust 10
Power supply 13
Wiring 14
Pressure, drop
EconoMi$erIV 33
Pressure switches
High pressure 10
Low pressure 10
Refrigerant
Charge 36
Type 9
Refrigerant service ports 26
Replacement parts 38
Return air filter 10, 26
Return air temperature sensor 20
Rigging unit 4, 5
Roof curb
Assembly 1
Dimensions 2-4
Leveling tolerances 2, 3
Safety considerations 1
Service 34-42
Service ports 26
Start-up 26-34
Start-up checklist CL-1
Supply-air temperature sensor 18
Thermostat 14
Troubleshooting 43-47
Weight
Corner
6-8
EconoMi$erIV 6-9
Maximum 5
Unit 6-9
Wind baffle 11, 16, 17
Wiring
EconoMi$erIV 19
Humidistat 24
Power connections 14
Thermostat 14
Unit 40, 41
—48—
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your knowledge of the equipment
discussed in this manual, including:
• Unit Familiarizat ion• Maintenance
• Installation Overview• Operating Sequence
A large selection of product, theory, and skills programs are available, using popular 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
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