Bryant 580G User Manual

installation, start-up and service instructions

SINGLE PACKAGE ROOFTOP ELECTRIC COOLING/GAS HEATING UNITS

Cancels: II 580G,H-240-1 II 580G,H-240-2

580G,H

Sizes 240-360

11/1/97

CONTENTS

Page

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

INSTALLATION ................................ 2-20

I. Provide Unit Support ...................... 2

II. Rig and Place Unit ........................ 2

III. Field Fabricate Ductwork ................... 7

IV. Unit Duct Connections ..................... 7

V. Flue Hood ................................ 8

VI. Trap Condensate Drain ..................... 8

VII. Gas Piping ............................... 8

VIII. Electrical Connections ..................... 9

IX. Outdoor-Air Inlet Assembly ................ 14

X. Power Exhaust/Barometric Relief

Damper Hood ........................... 18

XI. Accessories ............................ 19

PRE-START-UP ................................20,21

START-UP ....................................21-28

I. Cooling Section Start-Up and

Adjustments ............................ 21

II. Heating Section Start-Up and

Adjustments ............................ 22

III. Field Test Operation ...................... 24

IV. Indoor Airﬂow and Airﬂow

Adjustments ............................ 24

V. Gas Valve Adjustment .................... 25

VI. Main Burners ........................... 28

VII. Power Exhaust Operation .................. 28

VIII. Head Pressure Control ................... 28

IX. Low Ambient Kit ......................... 28

CARE AND MAINTENANCE ..................... 28

SERVICE .....................................29-32

I. Cleaning ............................... 29

II. Lubrication ............................. 29

III. Evaporator Fan Service and

Replacement ............................ 31

IV. Evaporator-Fan Motor Replacement ........ 31

V. Power Failure ........................... 31

VI. Refrigerant Charge ....................... 31

VII. Filter Drier .............................. 32

VIII. Thermostatic Expansion Valve (TXV) ........ 32

IX. Protective Devices ....................... 32

X. Relief Devices ........................... 32

XI. Control Circuits ......................... 32

XII. Compressor Lockout Logic ............... 32

XIII. Replacement Parts ....................... 32

TROUBLESHOOTING ...........................33-41

I. Diagnostic LEDs ......................... 33

II. Error Code Summary ..................... 34

III. Input/Output Channel Designations ......... 34

START-UP CHECKLIST ....................CL-1, CL-2

SAFETY CONSIDERATIONS

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

Untrained personnel can perform basic maintenance functions of cleaning coils and ﬁlters and replacing ﬁlters.Allother operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply.

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:

nance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.

WARNING:

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 supplier, call the ﬁre

department.

WARNING:

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

Before performing service or mainte-

Disconnect gas piping from unit when

INSTALLATION

I. PROVIDE UNIT SUPPORT

CAUTION:

All panels must be in place when rig-

ging. Unit is not designed for handling by fork truck.

A. Roof Curb

Assemble and install accessory roof curb in accordance with instructions shipped with the curb. Accessory roof curb and information required to ﬁeld fabricate a roof curb or horizontal adapter are shown in Fig. 1. Install insulation, cant strips, rooﬁng, and counter ﬂashing as shown. Ductwork can be secured to roof curb before unit is set in place.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a leak-proof seal. Install gasket supplied with the roof curb as shown in Fig. 1. Improperly applied gasket can result in air leaks and poor unit performance.

Curb should be level. This is necessary to permit unit drain to function properly. Unit leveling tolerance is shown in Fig 1. Refer to Accessory Roof Curb Installation Instructions for additional information as required. When accessory roof curb is used, unit may be installed on class A, B, or C roof covering material.

NOTES:

1. Unless otherwise speciﬁed, all dimensions are to outside of part.

2. Roof curb accessory is shipped disassembled.

3. All roof curb parts are to be 16 ga galvanized steel.

4. Dimensions are in inches.

NOTE: On retroﬁt jobs, ductwork may be attached to old unit instead of roof curb. Be careful not to damage ductwork when removing old unit.

B. Alternate Unit Support

When the preferred curb or adapter cannot be used, support unit with sleepers using unit curb or adapter support area. If sleepers cannot be used, support long sides of unit (refer to Fig. 2 and 3) with 3 equally spaced 4-in. x 4-in. pads on each side. Unit may sag if supported by corners only.

II. RIG AND PLACE UNIT

Inspect unit for transportation damage. File any claim with transportation agency. Keep unit upright, and do not drop. Use spreader bars over unit to prevent sling or cable damage. Rollers may be used to move unit across a roof. Level by using unit frame as a reference; leveling tolerance is shown in. Fig. 1. See Fig. 4 for additional information. Unit weight is shown in Table 1.

Four lifting lugs are provided on the unit base rails as shown in Fig. 4. Refer to rigging instructions on unit.

(Copy continued on page 7.)

NOTE: To prevent standing water in the drain pan of the indoor section and the heat exchangers, UNIT CAN ONLY BE PITCHED AS SHOWN.

UNIT LEVELING TOLERANCES

Deg. in. Deg. in.

*From edge of unit to horizontal.

DIMENSIONS*

(Degrees and Inches)

1.0 2.9 .50 .75

Fig. 1 — Roof Curb (Sizes 240-360)

—2—

NOTES:

1. Weights include economizer (STD).

2. Center of gravity.

3. Do not locate adjacent units with ﬂue discharge facing economizer inlet. Min. clearances to be:

Adjacent Units: 158-09 Top of Units: No Overhang Condenser Coil: 48-09 Economizer Side: 68-09 Heat Side: 48-09 FilterAccess Side: 108-09 (For Removalof Evaporator Coil)

4. For smaller service andoperational clearances, contact Carrier Application Engineering department.

5. Bottom ducts designed to be attached to accessory roof curb. If unit is mounted on dunnage, it is recommended the ducts be supported by braces as done on accessory roof curb.

UNIT SIZE

580G

OPERATING

WEIGHT

lb ft-in. ft-in. 1 2 3 4

240 350 4176 6- 0 240 525 4256 6- 1 300 350 4262 5- 9 300 525 4342 5-10 324 350 4262 5- 9 324 525 4342 5-10 360 350 4262 5- 9 360 525 4342 5-10

Fig. 2 — Base Unit Dimensions, 580G240-360

⁄83-63⁄

⁄163-611⁄

⁄83-8 899 899 1232 1232

⁄83-85⁄

⁄83-8 899 899 1232 1232

⁄83-85⁄

⁄83-8 899 899 1232 1232

⁄83-85⁄

CORNER WEIGHT

(lb)

879 954 1220 1124 917 973 1218 1148

929 916 1240 1257

—3—

NOTES:

1. Weights include economizer (STD).

2. Center of gravity.

3. Do not locate adjacent units with ﬂue discharge facing economizer inlet. Min. clearances to be:

Adjacent Units: 158-09 Top of Units: No Overhang Condenser Coil: 48-09 Economizer Side: 68-09 Heat Side: 48-09 Filter Access Side: 108-09 (For Removal of Evaporator Coil)

4. For smaller service and operational clearances, contact Application Engineering department.

5. Dimensions are in inches.

6. For side supply/return applications a single return and supply ductwork connection is recommended for covering both return and both supply openings.

UNIT SIZE

580H

OPERATING

WEIGHT

lb ft-in. ft-in. 1 2 3 4

240 350 4176 6- 0 240 525 4256 6- 1 300 350 4262 5- 9 300 525 4342 5-10 324 525 4262 5- 9 324 525 4342 5-10 360 350 4262 5- 9 360 525 4342 5-10

Fig. 3 — Base Unit Dimensions, 580H240-360

⁄83-63⁄

⁄163-611⁄

⁄83-8 899 899 1232 1232

⁄83-85⁄

⁄83-8 899 899 1232 1232

⁄83-85⁄

⁄83-8 899 899 1232 1232

⁄83-85⁄

CORNER WEIGHT

(lb)

879 954 1220 1124 917 973 1218 1148

929 916 1240 1257

—4—

CAUTION: NOTICE TO RIGGERS: ALL PANELS

MUST BE IN PLACE WHEN RIGGING. NOTE: Rig with four cables and spread with two 92 in.

(2337 mm) spreader bars. Maintain a distance of 74 in. (1880 mm) from top of unit to eyehook.

NOTE:

Add 32 lb (14.5 kg) for domestic crating. Add 312 lb (142 kg) for export crating. Add 220 lb (100 kg) for copper condenser coil. Add 250 lb (113 kg) for power exhaust.

UNIT

580G,H

240 350 4176 1894 240 525 4256 1930 73.3 1862 42.7 1085 300 350

360 350 300 525

360 525

WEIGHT A B C

lb kg in. mm in. mm in. mm

72.4 1839 42.4 1072

4262 1933 69.6 1768 44.0 1118324 350

4342 1969 70.1 1781 44.3 1125324 525

87.68 2227

Fig. 4 — Rigging Label

—5—

Table 1 — Speciﬁcations

UNIT 580G,H 240 300 324 360 NOMINAL CAPACITY (tons) 20 25 27 30 OPERATING WEIGHT (lb)

Unit

Al/Al* (Lo Heat/Hi Heat) 4176/4256 4262/4342 4262/4342 4262/4342 Al/Cu* (Lo Heat/Hi Heat) 4396/4476 4482/4562 4482/4562 4482/4562 Roof Curb (14-in. curb) 365 365 365 365

COMPRESSOR

Type Ckt 1 06D328 06D328 06D537 06D537

Ckt 2 06D818 06D328 06D328 06D537

Number of Refrigerant Circuits 22 2 2

Oil (oz) (Ckt 1, Ckt 2) 115, 88 115 ea. 115 ea. 115 ea.

REFRIGERANT TYPE R-22

Operating Charge (lb-oz)

Circuit 1† 25-0 25-0 25-0 25-0 Circuit 2 31-0 25-0 25-0 25-0

CONDENSER COIL Cross-Hatched

Quantity 11 1 1 Rows...Fins/in. 4...15 4...15 4...15 4...15 Total Face Area (sq ft) 33.3 33.3 33.3 33.3

CONDENSER FAN Propeller Type

Nominal Cfm 13,420 13,420 13,420 13,420 Quantity...Diameter (in.) 2...30 2...30 2...30 2...30 Motor Hp (1075 Rpm) 11 1 1

EVAPORATOR COIL Cross-Hatched

Rows...Fins/in. 4...15 4...15 4...15 4...15 Total Face Area (sq ft) 31.7 31.7 31.7 31.7

EVAPORATOR FAN Centrifugal Type

Quantity...Size (in.) 2...20x15 2...20x15 2...20x15 2...20x15 Type Drive Belt Belt Belt Belt Nominal Cfm 8,000 10,000 11,000 12,000 Motor Hp 5 10** 15 7.5 10** 15 10 15** 20 10 15** 20 Motor Frame Size

Standard S184T S215T D254T S213T S215T D254T S215T D254T S256T S215T D254T S256T

High Efficiency S184T S215T S254T S213T S215T S254T S215T S254T S256T S215T S254T S256T Motor Bearing Type Ball Ball Ball Ball Maximum Allowable Rpm 1200 1200 1200 1200 Motor Pulley Pitch Diameter 4.8 4.4 5.7 5.4 6.1 5.5 4.4 4.9 5.9 4.4 5.7 5.9 Nominal Motor Shaft Diameter (in.) 1 Fan Pulley Pitch Diameter (in.) 12.4 8.6 9.1 12.4 11.1 8.7 9.4 8.1 8.7 9.0 9.1 8.7 Nominal Fan Shaft Diameter (in.) 115⁄ Belt, Quantity...Type Belt, Length (in.) Pulley Center Line Distance (in.) 16.0-18.7 15.6-18.4 15.0-17.9 15.6-18.4 15.0-17.9 15.6-18.4 15.0-17.9 15.6-18.4 15.0-17.9 Factory Speed Setting (rpm) 717 924 1096 773 962 1106 848 1059 1187 884 1096 1187

FURNACE SECTION

Rollout Switch Cutout Temp (F)†† 225 225 225 225 Burner Oriﬁce Diameter

(in. ...drill size)

Natural Gas Std .111...34 .111...34 .111...34 .111...34

Liquid Propane Alt .089...43 .089...43 .089...43 .089...43 Thermostat Heat Anticipator

Setting (amps)

Stage 1 0.1 0.1 0.1 0.1

Stage 2 0.1 0.1 0.1 0.1 Gas Input (Btuh) Stage 1 Low 262,500 262,500 262,500 262,500

Efficiency (Steady State) (%) 82 82 82 82 Temperature Rise Range 15-45/35-65 15-45/35-65 15-45/35-65 15-45/35-65 Manifold Pressure (in. wg)

Natural Gas Std 3.5 3.5 3.5 3.5

Liquid Propane Alt 3.5 3.5 3.5 3.5 Gas Valve Quantity 22 2 2 Field Gas Connection Size

(in.-FPT)

HIGH-PRESSURE SWITCH (psig)

Cutout 426 426 426 426 Reset (Auto.) 320 320 320 320

LOW-PRESSURE SWITCH (psig)

Cutout 77 7 7 Reset (Auto.) 22 22 22 22

RETURN-AIR FILTERS

Quantity...Size (in.) 10...20x24x2 10...20x24x2 10...20x24x2 10...20x24x2

OUTDOOR-AIR FILTERS 8...16×25

Quantity...Size (in.) 4...20×25

POWER EXHAUST Direct Drive, 3-Speed, Single Phase Motor (Factory Wired for High Speed), Forward-Curved Fan

Motor, Quantity...Hp 4...1 Fan, Diameter...Width (in.) 11...10

High 394,000 394,000 394,000 394,000

Stage 2 Low 350,000 350,000 350,000 350,000

High 525,000 525,000 525,000 525,000

⁄

13⁄

15⁄

1...BX59622...BX51542...5VX530531...BX59621...5VX590592...5VX530532...BX52552...5VX500502...5VX530532...BX51542...5VX530532...5VX530

1.5 1.5 1.5 1.5

LEGEND

Al — Aluminum Cu — Copper

*Evaporator coil ﬁn material/condenser coil ﬁn material. †Circuit 1 uses the lower portion of condenser coil; Circuit 2 uses the upper portion. All

units have intertwined evaporator coils.

⁄89 Copper Tubes, Aluminum Lanced, Aluminum Pre-Coated, or Copper Plate Fins

⁄89 Copper Tubes, Aluminum Plate Fins, Intertwined Circuits

13⁄

15⁄

13⁄

15⁄

115⁄

**Motor and drive shown will deliver approximately 2.5 in. net external static. For more

fan motor data, see Table 2.

††Rollout switch is manual reset.

115⁄

13⁄

15⁄

115⁄

—6—

Table 2 — Evaporator Fan Motor Data

UNIT

MOTOR

SIZE

580G,H

240

300

324

360

NOTE: Motor shaft speed is 1750 rpm. The fan shaft diameter is 1

MOTOR

SHAFT

10 1.38 924 2BK50 4.4 None-1.375 2B5V86 8.6 B-1.9375 (2) BX51 54 5.21 15 1.62 1096 2B5V56 5.7 B-1.625 2B5V90 9.1 B-1.9375 (2) 5VX530 53 6.00

7.5 1.38 773 BK60H 5.4 H-1.375 1B5V124 12.4 B-1.9375 BX59 62 6.48 10 1.38 962 1B5V60 6.1 H-1.375 1B5V110 11.1 B-1.9375 5VX590 59 7.37 15 1.62 1106 2B5V54 5.5 B-1.625 2B5V86 8.7 B-1.9375 (2) 5VX530 53 6.12

10 1.38 848 2BK50 4.4 None-1.375 2B5V94 9.4 B-1.9375 (2) BX52 55 5.27 15 1.62 1059 2B5V48 4.9 B-1.625 2B5V80 8.1 B-1.9375 (2) 5VX500 50 6.63 20 1.62 1187 2B5V58 5.9 B-1.625 2B5V86 8.7 B-1.9375 (2) 5VX530 53 7.31

10 1.38 884 2BK50 4.4 H-1.375 2B5V90 9.0 B-1.9375 (2) BX51 54 5.24 15 1.62 1096 2B5V56 5.7 B-1.625 2B5V90 9.1 B-1.9375 (2) 5VX530 53 6.00 20 1.62 1187 2B5V58 5.9 B-1.625 2B5V86 8.7 B-1.9375 (2) 5VX530 53 7.31

DIA. (in.)

5 1.12 717 BK55 4.8 None-1.125 1B5V124 12.4 B-1.9375 BX59 62 5.10

FAN SHAFT SPEED

(rpm)

MOTOR SHEAVE

MOTOR

SHEAVE

PITCH

DIAMETER

(in.)

DIAMETER

⁄16inches.

BUSHING

(in.)

A. Positioning

Provide clearance around and above unit for airﬂow, safety, and service access (Fig. 2 and 3).

Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air.

For proper unit operation, adequate combustion and 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 isweatherproof,guardagainst water from higher level runoff and overhangs.

B. Roof Mount

Check building codes for weight distribution requirements.

FAN

SHEAVE

FAN

SHEAVE

PITCH

DIAMETER

(in.)

BUSHING

DIAMETER

(in.)

BELT

(QUANTITY)

OUTSIDE

BELT

LENGTH

BELT

TENSION

(lb at

.24 in.)

B. 580H Units

Remove shipping covers from supply and return air openings.Attachﬁeld-suppliedductworkto unit. Use a single duct over both return openings and a single duct over both supply openings. See Fig. 3 for duct opening dimensions. Secure all ducts to the building structure. See Fig. 6. Use ﬂexible duct connectors between unit and ducts as required.

Install accessory barometric relief or power exhaust in the ﬁeld-fabricated return ductwork. Refer to Power Exhaust/Barometric Relief Damper Hood section for more information.

III. FIELD FABRICATE DUCTWORK

Secure all ducts to building structure. Use ﬂexible duct connectors betweenunitandducts as required. Insulate and weatherproof all external ductwork, joints, and roof openings with counter ﬂashing andmasticinaccordance with applicable codes.

Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier.

To attach ductwork to roof curb, insert ductwork approximately 10 to 11 in. up into the curb. Connect ductwork to 14-gage roof curb material using sheet metal screws driven from inside the duct.

WARNING:

For vertical supply and return units, tools or parts could drop into ductwork and cause an injury. Install 90 degree elbow turns in the supply and return ductwork between the unit and the conditioned space. If a 90 degree elbow cannot be installed, then grilles of sufficient strength and density should be installed to prevent objects from falling into the conditioned space.

IV. UNIT DUCT CONNECTIONS A. 580G Units

Unit is shipped for through-the-bottom duct connections. Ductwork openings are shown in Fig. 2. Attach all ductwork to roof curb. Air distribution is shown in Fig. 5. Refer to installation instructions shipped with accessory roof curb for more information.

Fig. 5 — Air Distribution — Thru-the-Bottom

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

—7—

V. FLUE HOOD

Flue hood is shipped inside gas section of unit. To install, secure ﬂue hood to access panel. See Fig. 7.

NOTE: When properly installed, ﬂue hood will line up with combustion fan housing. See Fig. 8.

Fig. 7 — Flue Hood Location

Fig. 9 — Condensate Drain Connections

(Typical Roof Curb or

Slab Mount Shown)

Condensate pans are sloped sothatwaterwillcompletelydrain from the condensate pan to comply with indoor air quality guidelines.

VII. GAS PIPING

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

Install manual gas shutoff valve with a

⁄8-in. NPT pressure tap for test gage connection at unit. Field gas piping must include sediment trap and union. See Fig. 10.

WARNING:

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

Fig. 8 — Combustion Fan Housing Location

VI. TRAP CONDENSATE DRAIN

See Fig. 2, 3, and 9 for drain location. Condensate drain is open to the atmosphere and must be trapped. Install a trapped drain at the drain location. One 1-in. NPT coupling is provided inside unit evaporator section for condensate drain connection. A trap at least 4-in. deep must be used. Trap must be installed to prevent freeze-up.

Natural gas pressure at unit gas connection must not be less than 5 in. wg or greater than 13.5 in. wg.

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

Fig. 10 — Field Gas Piping

—8—

VIII. ELECTRICAL CONNECTIONS A. Controls Options

The standard constant volume (CV) units, as shipped, are operable as stand-alone units, using a standard (mechanical or electronic) 2-stage heat, 2-stage cool thermostat.

Withastandard thermostat (programmable is optional), heating and cooling operation is set by space temperature. The standard DDC (direct digital controls) are installed in the control box. The DDC control board diagram is shown in Fig. 11.

Features with Thermostat Control of Unit

• two-stage heating

• two-stage cooling

• control of unit using Y1, Y2, W1, W2, and G thermostat inputs

• control of the indoor fan

• outdoor-air temperature/supply-air temperature monitoring

• control of modulating economizer damper to provide free cooling when outdoor conditions are suitable, using supplyair temperature as a control point

• control of the economizer damper and indoor fan to obtain unoccupied free cooling

• provide power exhaust output to an external power exhaust controller

• support a ﬁeld test for ﬁeld checkout

• control of 2 stages of CV power exhaust

• compressor time delay for power up and minimum off and on times

An electronic expansion board may be ﬁeld-installed to provide the following features:

• control of modulating economizer damper to maintain indoor air quality (IAQ) when outdoor conditions are suitable

NOTE: The IAQ sensor must be set for current output (4 to 20 mA). This requires removing the sensor cover and removing a jumper on the sensor. See Fig. 12.

• provide discrete inputs for fan status, ﬁlter status, ﬁeldapplied status, and demand limit

• provide an output for the external alarm light indicator

• provide power exhaust ﬁre outputs for directcontrolofpower exhaust stages during ﬁre or smoke control modes

• control of smoke control modes including evacuation, smoke purge, pressurization, and ﬁre shutdown (non-modulating or modulating power exhaust required)

B. Power Wiring

Units are factory wiredforthevoltageshownon the unit nameplate. The main terminal block is suitable for use with aluminum or copper wires.

When installing units, provide a disconnect per NEC (National Electrical Code) of adequate size (MOCP [maximum overcurrent protection]ofunitis on the informative plate). All ﬁeld wiring must comply with NEC and all local codes. Size wire based on MCA (minimum circuit amps) on the unit informative plate. See Fig. 13 for power wiring connections to the unit power terminal block and equipment ground.

The main power terminal block is suitable for use with aluminum or copper wire. See Fig. 13. Units have circuit breakers for compressors, fan motors, and control circuit. If required by local codes, provide an additional disconnect, per NEC and

local codes requirements, of adequate size (Table 3). Whenever external electrical sources are used, unit must be electrically grounded in accordance with local codes, or in absence of local codes, with NEC, ANSI C1-latest year.

All ﬁeld wiring must comply with NEC and local code requirements.

C. Field Power Supply

Unit is factory wired for voltage shown on nameplate. See Table 3 for electrical data.

Field wiring can be brought into the unit from bottom (through basepan and roof curb) or through side of unit (corner post next to control box).

⁄2-in. NPT knockout for ﬁeld power wiring and a3⁄4-in.

A3 NPT knockout for 24-v control wiring are provided in base-

pan. In the side post, there are two 2

⁄2-in. knockouts for the

ﬁeld power wiring. See Fig. 2 and 3. If control wiring is to be

brought in through the side of unit, a

⁄8-in. diameter hole is

provided in the condenser side post next to the control box. If disconnect box is mounted to corner post, be careful not to

drill any screws into the condenser coil. Routing Through Bottom of Unit

If wiring is brought in through bottom of unit, use ﬁeldsupplied watertight conduit to run power wiring from base-

pan out through bottom 3

⁄2-in. hole to the disconnect box and

back into unit to the main control box.

Use strain relief going into control box through 2

⁄2-in. diameter hole provided. After wires are in unit control box, connect to power terminal block (see Power Wiring section on this page).

Low-voltage wiring must be run in watertight conduit from the basepan to control box and through 1-in. diameter hole provided in bottom of unit control box. Field-supplied strain relief must be used going into the box. After wiring is in control box, make connections to proper terminals on terminal blocks (see Field Control Wiring section on page 11).

Install conduit connector in unit basepan or side panel openings provided. Route power and ground lines through connector to connections in unit control box as shown on unit wiring diagram and Fig. 13.

Routing Through Side of Unit Route power wiring in ﬁeld-supplied watertight conduit into

unit through 2

⁄2-in. hole. Strain relief (ﬁeld supplied) must

be used in hole. Use ﬁeld-supplied strain relief going into control box through

⁄2-in. diameter hole provided. After wires are in unit con-

2 trol box, connect to power terminal block (see Power Wiring section on this page).

Bring low-voltage control wiring through factory-drilled

⁄8-in. diameter hole in condenser side post. Use strain relief

going into

⁄8-in. diameter hole in bottom of unit control box.

After wiring is in control box, make connection to proper terminals on terminal blocks (see Field Control Wiring section on page 11).

WARNING:

The unit must be electrically grounded in accordance with local codes and NEC ANSI/NFPA70 (National Fire Protection Association).

—9—

—10—

Fig. 11 — Control Board Diagram

LEGEND

COM — Common R—Relay D—Diode SIO — Serial Input/Output LED — Light-Emitting Diode SW — Switch N.C. — Normally Closed T—Terminal N.O. — Normally Open

*Where X is the unit control software version number (1 or 2).

JUMPER CONNECTION FOR VOLTAGE OUTPUT

JUMPER CONNECTION FOR CURRENT OUTPUT

Fig. 12 — Indoor Air Quality Sensor Conﬁguration

3. Cap orange wire.

4. Splice red wire and black unit power wire. Cap wires.

IMPORTANT: Becertain unused wires are capped. Failure to do so may damage the transformers.

D. Field Control Wiring

Install an approved accessory thermostat. Control box diagram is shown in Fig. 14.

Thermostat Wiring Install an approved accessory thermostat assembly (per cur-

rent price pages) according to the installation instructions included with the accessory, or these instructions. Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature.

Route thermostat cable or equivalent single leads of no. 18AWG (American Wire Gage) colored wire from subbase terminals to low-voltage connections as shown on unit label wiring diagram and in Fig. 15.

NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated wire (35 C minimum). For 50 to 75 ft, use no. 16 AWG insulated wire (35 C minimum). For over 75 ft, use no. 14 AWG insulated wire (35 C minimum). All wire larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.

Set heat anticipators settings to .1 for all voltages. Settings may be changed slightly to provide a greater degree of comfort for a particular installation.

LEGEND

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

NOTE: TB1 Maximum wire size is 500 MCM.

Fig. 13 — Field Power Wiring Connections

Operating voltage to compressor must be within voltage range indicated on unit nameplate. On 3-phase units, voltages between phases must be balanced within 2% and the current must be balanced within 10%.

Use the formula in Table 3 to determine the percentage of voltage imbalance.

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

Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components.

On 208/230-v units, transformer no. 1 is wired for 230-v. If 208/230-v unit is to be run with 208-v power supply ,the transformer must be rewired as follows:

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

2. Remove cap from spliced orange (230-v) wire. Disconnect orange wire from black unit power wire.

LEGEND

C—Compressor/Contactor CB — Circuit Breaker DIP — Dual In-Line Package FU — Fuse HR — Heater Relay IF — Indoor Fan OF — Outdoor Fan PEC — Power Exhaust Controller TB — Terminal Block TRAN — Transformer

Fig. 14 — Control Box Diagram

—11—

Table 3— Electrical Data — 580G,H240-360

UNIT SIZE

580G,H

240

300

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.

2. Unbalanced 3-Phase Supply Voltage

Never operate a motor where aphaseimbalance in supply voltage is greater than 2%.

voltage imbalance. % Voltage Imbalance

= 100 x

NOMINAL VOLTAGE

(3 Ph 60 Hz)

208/230 187 254 39.1 228 25.6 160 2 1 5.3

460 414 508 19.9 114 11.5 80 2 1 2.7

575 518 632 16.0 91 9.6 64 2 1 2.4

208/230 187 254 39.1 228 39.1 228 2 1 5.3

460 414 508 19.9 114 19.9 114 2 1 2.7

575 518 632 16.0 91 16.0 91 2 1 2.4

max voltage deviation from average voltage

VOLTAGE

RANGE

Min Max RLA LRA RLA LRA Qty Hp

LEGEND

Use the following formula to determine the percent

average voltage

COMPRESSOR

No. 1 No. 2

OFM IFM

FLA

Hp FLA FLA LRA FLA MCA MOCP*

(ea)

5 10 15

5 7.6 10 14.0 15 21.0

5 6.1 10 11.0 15 17.0

7.5 10 15

7.5 11.0 10 14.0 15 21.0

7.5 9.0 10 11.0 15 17.0

EXAMPLE: Supply voltage is 460-3-60.

Determine maximum deviation from average voltage.

(AB) 457 − 452=5v (BC) 464 − 457=7v (AC) 457 − 455=2v

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.

POWER

EXHAUST

16.7/

— — 0.96 101.8/100.3 125/125

15.2

23.6 41.6 0.96 125.4/123.9 150/150

30.8/

— — 0.96 115.9/113.1 150/150

28.0

23.6 41.6 0.96 139.5/136.7 175/175

46.2/

— — 0.96 131.3/127.1 150/150

42.0

23.6 41.6 0.96 154.9/150.7 175/175 — — 0.50 49.4 60

12.6 23.6 0.50 62.0 80 — — 0.50 55.8 70

12.6 23.6 0.50 68.4 80 — — 0.50 62.8 80

12.6 23.6 0.50 75.4 90 — — 0.50 40.5 50

12.6 23.6 0.50 53.1 60 — — 0.50 45.4 60

12.6 23.6 0.50 58.0 70 — — 0.50 51.4 60

12.6 23.6 0.50 64.0 80

24.2/

— — 0.96 122.8/120.6 150/150

22.0

23.6 41.6 0.96 146.4/144.2 175/175

30.8/

— — 0.96 129.4/126.6 150/150

28.0

23.6 41.6 0.96 153.0/150.2 175/175

46.2/

— — 0.96 144.8/140.6 175/175

42.0

23.6 41.6 0.96 168.4/164.0 200/200 — — 0.50 61.2 80

12.6 23.6 0.50 73.8 90 — — 0.50 64.2 80

12.6 23.6 0.50 76.8 90 — — 0.50 71.2 90

12.6 23.6 0.50 83.8 100 — — 0.50 49.8 60

12.6 23.6 0.50 62.4 70 — — 0.50 51.8 60

12.6 23.6 0.50 64.4 80 — — 0.50 57.8 70

12.6 23.6 0.50 70.4 80

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

Average Voltage =

COMBUSTION

FAN MOTOR

= 1.53%

452 + 464 + 455

1371

= 457

457

POWER SUPPLY

—12—

Table 3— Electrical Data — 580G,H240-360 (cont)

UNIT SIZE

580G,H

324

360

*Fuse or HACR circuit breaker.

NOTES:

2. Unbalanced 3-Phase Supply Voltage

Never operate a motor where aphaseimbalance in supply voltage is greater than 2%.

voltage imbalance. % Voltage Imbalance

= 100 x

NOMINAL VOLTAGE

(3 Ph 60 Hz)

208/230 187 254 57.1 266 39.1 228 2 1 5.3

460 414 508 25.6 120 19.9 114 2 1 2.7

575 518 632 20.5 96 16.0 91 2 1 2.4

208/230 187 254 57.1 266 57.1 266 2 1 5.3

460 414 508 25.6 120 25.6 120 2 1 2.7

575 518 632 20.5 96 20.5 96 2 1 2.4

max voltage deviation from average voltage

VOLTAGE

RANGE

Min Max RLA LRA RLA LRA Qty Hp

LEGEND

Use the following formula to determine the percent

average voltage

COMPRESSOR

No. 1 No. 2

OFM IFM

FLA

Hp FLA FLA LRA FLA MCA MOCP*

(ea)

10 15 20 10 14.0 15 21.0 20 27.0 10 11.0 15 17.0 20 22.0 10 15 20 10 14.0 15 21.0 20 27.0 10 11.0 15 17.0 20 22.0

EXAMPLE: Supply voltage is 460-3-60.

Determine maximum deviation from average voltage.

(AB) 457 − 452=5v (BC) 464 − 457=7v (AC) 457 − 455=2v

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.

POWER

EXHAUST

30.8/

— — 0.96 151.9/149.1 200/200

28.0

23.6 41.6 0.96 175.5/172.7 225/225

46.2/

— — 0.96 167.3/163.1 200/200

42.0

23.6 41.6 0.96 190.9/186.7 225/225

59.4/

— — 0.96 180.5/175.1 225/225

54.0

23.6 41.6 0.96 204.1/198.7 250/250 — — 0.50 71.3 90

12.6 23.6 0.50 83.9 100 — — 0.50 78.3 100

12.6 23.6 0.50 90.9 110 — — 0.50 84.3 100

12.6 23.6 0.50 96.9 110 — — 0.50 57.4 70

12.6 23.6 0.50 70.0 90 — — 0.50 63.4 80

12.6 23.6 0.50 76.0 90 — — 0.50 68.4 80

12.6 23.6 0.50 81.0 100

30.8/

— — 0.96 169.9/167.1 225/200

28.0

23.6 41.6 0.96 193.5/190.7 250/225

46.2/

— — 0.96 185.3/181.1 225/225

42.0

23.6 41.6 0.96 208.9/204.7 250/250

59.4/

— — 0.96 198.5/193.1 250/250

54.0

23.6 41.6 0.96 222.1/216.7 275/250 — — 0.50 77.0 100

12.6 23.6 0.50 89.6 110 — — 0.50 84.0 100

12.6 23.6 0.50 96.6 110 — — 0.50 90.0 110

12.6 23.6 0.50 102.6 125 — — 0.50 61.9 80

12.6 23.6 0.50 74.5 90 — — 0.50 67.9 80

12.6 23.6 0.50 80.5 100 — — 0.50 72.9 90

12.6 23.6 0.50 85.5 100

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

Average Voltage =

COMBUSTION

FAN MOTOR

= 1.53%

452 + 464 + 455

1371

= 457

457

POWER SUPPLY

—13—

TOP FLANGE

Fig. 15 — Field Control Thermostat Wiring

IX. OUTDOOR-AIR INLET ASSEMBLY A. Economizer

NOTE: If accessory power exhaust or barometric relief pack-

ages are being added to the unit, install power exhaust or barometric relief before installing economizer hoods.

BLACK SEAL STRIP

HOOD SIDE

Fig. 16 — Adding Seal Strip to Top of Hood Sides

Economizer Hood Assembly The economizer hood is shipped in a package secured to the

outside of the unit and must be ﬁeld assembled. There are 2 hoods on every unit. The 580H units are side supply and side return. The return duct limits access to economizer ﬁlters from below. Filter tracks (mounting angle without tabs) must be installed correctly to allow access to economizer ﬁlters from each side.

NOTE: Before assembly of the economizer hood, check along the outer edges of the economizer assembly for any seal strip protruding past the ﬂanges. Trim the excess seal strip so that it is ﬂush with the economizer assembly ﬂanges.

Perform the following procedure to assemble the economizer hood:

a. Apply black seal strip (provided in package) to out-

1. side top edge of hood sides. Wrap seal strip over to cover top ﬂange (4 hood sides). Make certain seal strip

covers screw holes.Allowstrip to overhang

⁄8in. past

end opposite mounting ﬂange. See Fig. 16.

b. Assemble hood sides, top, and cross member with gas-

keted screws provided. See Fig. 17.

c. Attach 10 green speed clips (provided) to hood top. d. Apply black seal strip to mountingﬂanges(coverholes)

of hood sides. See Fig. 18.

NOTE: Each hood assembly has a slotted side that should be adjacent to the other hood when mounted to the unit.

e. Apply black seal strip to hood top mounting ﬂange.

Seal strip of hood top mounting ﬂange must press against seal strip of hood side mounting ﬂanges. See Fig. 19.

f. Add gray foam strip (provided) to cross members at

bottom tray. See Fig. 20.

NOTE: Left side economizer hood has mounting angle withouttabs and ﬁlter track assembled end on opposite side.

Fig. 17 — Economizer Hood Assembly

(Right-Side Economizer Hood Shown)

Exhaust Mounting Details

g. Place gray foam strip on inside of slotted hood side

between ﬁlter and cross member opposite mounting end. See Fig. 21.

h. Attach gray foam strip to blockoff baffle on outer face

area of ﬂange. See Fig. 22.

2. Remove the screws on each end and along top of damper assembly of unit. Remove top 2 screws on each side of ﬁlter panel under damper assembly. Set hood assembly in place and attach to unit using these screws.

3. Attach accessory enthalpy bracket on hood side furthest from control box end. Locate bracket on inside upper righthandcornerusing hood mounting holes. Mount outdoor-air thermistor to enthalpy bracket (if purchased).Attachandwireenthalpy assembly. Place quick connects on enthalpy wires.

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