Bryant 580G User Manual

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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.

—14—

HOOD SIDE (SLOTTED)

MOUNTING FLANGE

HOOD SIDE

Fig. 18 — Adding Seal Strip to Mounting Flange

of Hood Sides

HOOD SIDE

HOOD TO

HOOD TOP

Fig. 21 — Adding Foam Strip to Hood Side

BLOCKOFF BAFFLE

Fig. 19 — Add Seal Strip to Hood Top Mounting Flange

GRAY FOAM STRIP

CROSS MEMBER

GRAY FOAM STRIP

Fig. 22 — Adding Foam Strip To

Blockoff Baffle

Fig. 20 — Adding Foam Strip to Cross Member

—15—

4. Remove screws along bottom of damper assembly. Locate and mount blockoff baffle using these screws.

5. Assemble 2 ﬁlter tracks side-by-side with the assembled ends together.

a. Attach mounting angle (without tabs) to the as-

sembled end of the ﬁlter track. See Fig. 23.

b. Attach 6 green clips (provided) to mounting angles.

Engagement section of clip faces inside of rack.

c. Attach remaining mounting angle (with tabs) to other

end of the ﬁlter track with no. 10 screws provided. See Fig. 24.

a. Place ﬁlter track assembly in bottom of hood by plac-

ing tabbed end into slotted side (with tab on bottom) and attaching opposite end to hood with speed clips and gasketed screws provided. Tabscan be hand bent after inserted into the side.

NOTE: The ﬁlter track assembly end with screws should face away from the other hood when mounted on the unit.

NOTE: Tabs from both ﬁlter tracks will be in the same space. After one ﬁlter track has been inserted into board, bend the tabs so they will not interfere with installation of the second hood.

b. Attach black seal strip to ﬁlter cover.Sealstripshould

be applied to ﬂange (coveringholes)andcenteroflarge ﬂange. See Fig. 25.

8. Slide two 20 x 25-in. ﬁlters into cross members of hood assembly. Attach ﬁlter cover over ﬁlters with screws and speed clips provided.

Minimum Damper Position Setting Setting of the outdoor air damper position is performed in

conjunction with a shortened version of the ﬁeld run test. This is performed by ﬁrst opening DIP switch no. 4 then no. 6.

The outdoor-air damper closes. The control allows 90 seconds for the damper to close in case it is in the full open position. Next, the indoor-fan contactor will energize. The outdoor air damper will remain at 0% for 30 seconds. It will then move to the 10% position for another 30 seconds. This will be repeated at every 10% increment for 30 seconds until the damper reaches 100% open. Close DIP switch no. 4 during the 30 seconds immediately after the desired outdoor air minimum damper position. The 30-second time period is to allow time where DIP switch no. 4 can be closed. The default value of the minimum outdoor air damper position is 20%. If the desired minimum position is 30%, allow the damper position to go to 10% for 30 seconds, then 20% for 30 seconds, and when it reaches 30% close DIP switch no. 4 during the 30-second period following the 30% position.

The minimum outdoor air damper position is now set. Close DIP switch no. 6.

B. Economizer Settings

Accessory Enthalpy Control (Fig. 26) The control (HH57AC077) is mounted in the economizer hood.

See Fig. 17. The enthalpy setting adjustment is on the enthalpy control. For maximum beneﬁt of outdoor air, set enthalpy sensor control to A. See Fig. 27 and 28.

Enthalpy Control Installation The outdoor air enthalpycontrolisinstalledonthe inside panel

of the outdoorairhood.The enthalpy control should be mounted when the outdoor air hoods are assembled. To install the control, perform the following procedure:

1. Turn off all power. Ensure disconnect is locked out.

2. Remove the economizer inlet ﬁlters from the bottom of the right hand economizer hood. See Fig. 29.

MOUNTING ANGLE (WITHOUT TABS)

FILTER TRACK ASSEMBLY

Fig. 23 — Mounting Angle (Without Tabs)

Attached to Filter Track Assembly

MOUNTING ANGLE (WITH TABS)

Fig. 24 — Mounting Angle (With Tabs)

Attached to Filter Track Assembly

BLACK SEAL STRIP (CENTERED)

FILTER COVER

Fig. 25 — Attaching Seal Strip to Filter Cover

—16—

HH57AC077 ENTHALPY CONTROL

NOTE: Switches shown in high enthalpy state. Terminals 2 and 3 close on enthalpy decrease.

Fig. 27 — Wire Connections for Solid-State

Enthalpy Control (HH57AC077)

C7400A1004

HH57AC078 ENTHALPY SENSOR (USED WITH

ENTHALPY CONTROLFOR DIFFERENTIAL ENTHALPY OPERATION)

Fig. 26 — Enthalpy Control and Sensor

3. Mount the outdoor air enthalpy sensor inside the right

economizer hood on the right side panel of the hood, adjacent to the outdoor-air thermistor.

4. Locate the red, violet, and brown wires near the out-

door air thermistor. Remove the splice from the red and violet wires. Remove the cap from the brown wire.

5. Install a

⁄4-in. push on terminal (ﬁeld-supplied) on the

violet and brown wires.

6. Connect a

⁄4-in. push on terminal (ﬁeld-provided) to one

end of a 18-gage, 6-in. jumper wire (ﬁeld-provided). Con-

nect the other end to the red wire and attach a

⁄4-in.

push on connector (ﬁeld-provided).

7. Connect the red wire with the jumper to terminal TR1.

Connect the jumper to terminal 2. Connect the brown wire to terminal TR. Connect the violet wire to terminal 3. All connections are on the enthalpy control.

8. Replace the economizer ﬁlters.

9. Return power to unit.

Accessory Differential Enthalpy Control (Fig. 26) The control (HH57AC077), in conjunction with the accessory

enthalpy sensor (HH57AC078), controls economizer operation according to the differential enthalpy. The control is mounted in the economizer hood. The sensor is mounted in the return duct (580G) or the return air plenum (580H).

Differential Enthalpy Sensor Installation To install the control, perform the following procedure:

1. Turn off all power. Ensure disconnect is locked out.

2. Remove the economizer inlet ﬁlters from the bottom of the right hand economizer hood.

3. Remove the factory-installed, 620-ohm jumper between terminals SR and + on the enthalpy control located inside the outdoor air hood.

4. Connect the violet wire from the enthalpy sensor kit to the + terminal on the enthalpy control. Connect the blue wire from the enthalpy sensor kit to the SR terminal on the terminal control.

CONTROL

CURVE

RH — Relative Humidity

CONTROL POINT

(APPROX. DEG.)

A 73 (23) B 70 (21) C 67 (19) D 63 (17)

AT 50% RH

Fig. 28 — Psychrometric Chart for Enthalpy Control

5. Turntheenthalpycontrolsetpointpotentiometerclockwise past the ‘‘D’’setting on the enthalpy control to conﬁgure the control to operate on differential enthalpy.

6. Remove the return-air enthalpy sensor from the accessory package. Using the screws provided, mount the sensor inside the return duct near the unit. Do not locate the control too far from the unit, or the wires will not reach from the sensor to the control. On 580H units, the enthalpy sensor can be installed in the return air section of the unit, under the return air dampers.

7. Route the wires from the enthalpy sensor to the return air enthalpy control through the holes on the inside of the hinged ﬁlter access panel. The holes are blocked by plug buttons which should be removed.

—17—

8. Use ﬁeld-supplied wire ties to attach the violet wire to the + terminal and the blue wire to the SR terminal.

9. Replace economizer ﬁlters.

10. Return power to unit. Disable Economizer For applications where the economizer will not be used

(areas of high humidity), the economizer should be disabled. To disable the economizer, perform the following:

1. Turn off power. Lock out disconnect.

2. Locate the OAT(outdoorairthermistor)intherighthand

outdoor air damper area.

3. Locate the splice connecting the violet wire coming from

T24 on the base module board to the red wire coming from T29 on the base module board. Remove the wire nut and break the red to violet wire splice.

4. Cap off both wires. When the connection is broken, the

base module is fooled into thinking that the enthalpy is not acceptable and economizer operation is disabled.

NOTE: Economizer operation can also be disabled by disconnecting the OAT. This is not recommended due to the fact that Unoccupied Free Cooling, IAQ Purge, and Low Ambient Fan Cycle Control are also disabled. An OAT failure alarm will also be issued.

X. POWER EXHAUST/BAROMETRIC RELIEF DAMPER HOOD

All electrical connections have been made and adjusted at the factory. The power exhaust blowers and barometric reliefdampers are shipped assembled and tilted back into the unit for shipping. Brackets and extra screws are shipped in shrink wrap around the dampers. If ordered, each unit will have 4 power exhaust blowers and motors or 4 barometric relief dampers.

1. Remove 9 screws holding each damper assembly in place. See Fig. 30. Each damper assembly is secured with 3 screws on each side and 3 screws along the bottom. Save screws.

2. Pivot each damper assembly outward until edges of damper assembly rest against inside wall of unit.

CAUTION:

Be careful when tilting blower assembly. Hoods and blowers are heavy and can cause injury if dropped.

3. Secure each damper assembly to unit with6screwsacross top (3 screws provided) and bottom (3 screws from Step 1) of damper.

4. With screws saved from Step 1, install brackets on each side of damper assembly.

5. Remove tape from damper blades.

NOTE: Partitionsshown indicate both sidesupply (580H) and vertical supply (580G) units.

Fig. 29 — Economizer Details

—18—

NOTES:

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

2. Dimensions are in inches.

Fig. 30 — Barometric Relief Damper and Power Exhaust Mounting Details

XI. 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. MotormasterT III Control Installation

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. 31 for baffle details. Use 20-gage, galvanized sheet metal, or similar corrosion-resistant metalforbaff les.Use ﬁeldsupplied screws to attach baffles to unit. Screws should be

⁄4-in. diameter and5⁄8-in. long. Holes for wind baffles are pre-

punched in the unit sheet metal.

CAUTION:

To avoid damage to the refrigerant coils and electrical components, use recommended screw sizes only.

The wind baffles attach to ﬂanges formed on the outer sheet metal of the unit where the condenser coil tube sheets attach.

Install Motormaster III Controls Only one Motormaster III control is required per unit. Motor — The circuit no. 1 (lead compressor) outdoor-fan

motor (OFM) will need to be changed out in the ﬁeld to accommodate the Motormaster III accessory. The replacement motor part no. is HD52AK652.

The no. 1 compressor is located at the left side of the unit looking from the compressor end.

Sensor — Install the sensor for thermistor input control in the location shown in Fig. 32. Connect sensor leads to the violet and grey control signal leads on the Motormaster III control.

Signal Selection Switch — Remove the cover of the Motormaster III control. Set the switch to accept the thermistor sensor input signal. Set the frequency to match the unit power supply (60 Hz).

BOTH SIDES

77.7

0.312 DIA HOLES

17.167 BETWEEN HOLES (TYPICAL)

4.62

NOTE: All dimensions are in inches. Material: 20 gage galvanized steel or other non-corrosive material.

CROSS-BREAK

78.7

0.5

Fig. 31 — Motormaster III Baffle Details

Motormaster III Control — The recommended mounting location is in the indoor fan section, mounted on the panel that separates the indoor and outdoor sections.

Electrical Connections

WARNING:To avoid possibility of electrical shock and personal injury, turn off all power to unit before making electrical connections.

When replacing the OFM, reconnect the black, yellow, and blue wires from the outdoor fan contactor to the black, yellow, and blue wires of the Motormaster III control. Run new wires from the red, orange, and brown wires to the leads of the new OFM. Connect the green wire from the control to ground.

NOTE: On all 575-v units, 2 transformers (part no. HT01AH851) must be used for each Motormaster III control to lower the supply voltage to the control to 460-v. Transformers can be mounted anywhere outside the control box.

—19—

Fig. 32 — Low Ambient Kit Sensor Location

PRE-START-UP

WARNING:

ings could result in serious personal injury:

1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.

3. Do not remove compressor terminal cover until all electrical sources have been disconnected.

4. Remove and reclaim refrigerant from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals.

5. Never attempt to repair soldered connection while refrigerant system is under pressure.

6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows:

a. Shut off electrical power to unit. b. Remove and reclaim refrigerant from system. c. Cut component-connecting tubing with tubing

d. Carefully unsweat remaining tubing stubs when

Proceed as follows to inspect and prepare the unit for initial start-up:

1. Remove all access panels.

2. Read and follow instructions on all WARNING, CAUTION, andINFORMA TIONlabels attached to, or shipped with, unit.

Failure to observe the following warn-

cutter and remove component from unit.

necessary. Oil can ignite when exposed to torch ﬂame.

3. Make the following inspections: a. Inspect for shipping and handling damages such as

broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections

and on unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connections usingelectronicleakdetector,halidetorch, or liquid-soap solution.

c. Inspect all ﬁeld- and factory-wiring connections. Be

sure that connections are completed and tight.

d. Inspect coil ﬁns. If damaged during shipping and

handling, carefully straighten ﬁns with a ﬁn comb.

4. Verify the following conditions: a. Make sure that condenser-fan blades are correctly

positioned in fan oriﬁces. Blades should clear fan

motor and fan oriﬁce ring.

b. Make sure that return-air ﬁlters and outdoor-air

inlet screens are in place.

c. Make sure that the condensate trap is ﬁlled with

water to ensure proper drainage.

d. Make sure that all toolsandmiscellaneouslooseparts

have been removed.

5. Loosen the compressor holddown bolts until sideways movement of the washer under each holddown bolt can be obtained. Do not loosen completely as bolts are selflocking and will maintain adjustment. Open compressor valves.

6. Make sure refrigerant service port caps are tight. Each refrigerant system has one suction port located in the top of the compressor motor casing. All units also have one service port on the liquid line valve and one on the compressor discharge valve.

7. Crankcase heaters are energized as long as there is power to the unit, except when the compressors are operating.

IMPORTANT: Unit power must be on for 24 hours prior to start-up. Otherwise, damage to compressor may result.

8. Ensure that the suction, discharge, and liquid line service valves are open. Damage to the compressor could result if they are left closed.

9. Check Direct Digital Controls DIP (dual-in-line package) switch conﬁguration. The Direct Digital Control (DDC) board must be conﬁgured for each application. The DDC board is conﬁgured through the DIP switches located on the board. There are 8 DIP switches which conﬁgure 8 differentapplicationsoftheDDC.See Table 4. DIP switch 1 is on the left of the block. DIP switch 8 is on the right of the block. To open a DIP switch, push the switch up with suitable tool (smallblade screwdriver).To close a DIPswitch,push the switch down. Factory settings are shown in Table 5.

The DIP switch conﬁgurations for the unit control software are as follows:

• DIP switch 1 should be set to closed (CV operation)

• DIP switch 2 should be set to closed (thermostat)

• DIP switch 3 is used to enable expansion board

operation

• DIP switch 4 is used to ﬁeld test the unit

• DIP switch 5 is used to specify the type of power

exhaust

—20—

Table 4 — DIP Switch Conﬁguration

SETTING 1 2 3 4 5 6 7 8

Time GuardT Override ON

IN CONJUNCTION

WITH FIELD TEST —

Set Minimum

Damper Position

Time Guard

Override OFF

Gas Heat

Electric Heat

Heat Pump

Operation

Air Conditioner

Operation

OPEN ——

CLOSED CV

LEGEND

CV — Constant Volume

Thermostat

Used

Expansion

Board

Operation

Base Control

Board Only

Field Test

OFF

Modulated

Power

Exhaust

Power

Exhaust

NOTES:

1. TheOPEN side of the DIPswitch is marked ‘‘OPEN.’’When the rocker switch is on the ‘‘OPEN’’ side of the switch, the switch is open.

2. When the unit is being ﬁeld-tested (DIP switch 4 to OPEN), the function of DIPswitch 6 changes andit is used to settheminimum damper position.

Table 5 — DIP Switch Factory Settings

UNIT 12345678

580G,H Closed Closed Closed Closed Closed Closed Open Closed

• DIP switch 6 conﬁgures the Time Guard override and, when used with the ﬁeld test function, sets the minimum damper position

• DIP switch 7 conﬁgures the unit for gas heat or electric heat

• DIP switch 8 conﬁgures the unit for heat pump or air conditioner operation

10. Adjust economizer. Check that outdoor-air damper is closed and return-air damper is open.

IMPORTANT: Unit power must be on for 24 hours prior to start-up. Otherwise, damage to compressor may result.

11. The optional non-modulating power exhaust is a two-

stage design where the operation of the exhaust fans is linked to economizer position. When the supply fan is running and the economizer is 25% open, the base module closes contacts, activating 2 exhaust fans. When the economizer position reaches75%open,thebase module activates the other 2 exhaust fans. The fans will turn off when the economizer closes below the same points.

START-UP

I. COOLING SECTION START-UP AND ADJUSTMENTS

CAUTION:

Complete the required procedures given in the Pre-Start-Up section on page 20 before starting the unit.

Do not jumper any safety devices when operating the unit.

Do not operate the compressor when the outdoor temperature is below 40 F (unless accessory low ambient kit is installed).

Do not rapid-cycle the compressor. Allow 5 minutes between ‘‘on’’ cycles to prevent compressor damage.

A. Checking Cooling Control Operation

Start and check the unit for proper cooling control operation as follows:

Place SYSTEM switch in COOL position and FAN switch in AUTO. position. Set cooling control below room temperature.

Observe that compressor, condenser fan motor, and evaporator blower motors start. Observe that cooling cycle shuts down when control setting is satisﬁed.

B. Cooling Sequence of Operation

On power up, the control module will activate the initialization software. The initialization software reads DIP switch no. 1 to determine it is in the closed position. Next, DIP switch no. 2 is read to determine it is closed for thermostat operation. The initialization sequence clears all alarms and alerts; re-maps the input/output database for operation; sets maximum heat stages to 2; and sets maximum cool stages to 3. Power up takes a random 1 to 63 seconds plus 5 minutes.

The TSTAT function performs a thermostat based control by monitoring Y1, Y2, W1, W2 and G inputs. These functions control stages: cool1, cool2, heat1, heat2 and the indoor fan, respectively.

The control module will operate economizer and run diagnostics to monitor alarms at all times.

If the thermostat energizes the G input, the control module will turn on the indoor fan and open the economizer dampers to minimum position. If thermostats are used to deenergize the G input, the control module will turn off the indoor fan and close the economizer dampers.

When cooling, G must be energized before cooling can operate. The control module determines if outdoor conditions are suitable for economizer cooling. For the economizer to function for outside air cooling: the enthalpy must be below the enthalpy set point; the outdoor-air temperature must be equal to or less than 65 F; the SAT (supply-air temperature) thermistor must not be in alarm; and the outdoor air reading is available. When these conditions are satisﬁed,thecontrolmodule will use economizer as the ﬁrst stage of cooling.

When Y1 input is energized, the economizer will be modulated to maintain SAT at the set point temperature. The default is 55 F. When SAT is above the set point, the economizer will be 100% open. When SAT is below the set point, the economizer will modulate between minimum and 100% open position. When Y2 is energized, the control module will turn on compressor 1 and continue to modulate the economizer as described above. If the Y2 remains energized and the SAT reading remains above the set point for 15 minutes,

—21—

compressor 2 will turn on. If Y2 is deenergized at any time, only the last stage of compression that was energized will be turned off. If outdoor conditions are not suitable for economizer cooling, the economizer will go to minimum position and cycle compressors 1 and 2 based on demand from Y1 and Y2 respectively. The compressors will be locked out when the SAT temperature is too low (less than 40 F for compressor 1 and less than 45 F for compressor 2.) After a compressor is locked out, it can restart after normal time-guard period.

The compressor time delay function maintains a minimum off time of 5 minutes, a minimum on time of 10 seconds, and a minimum delay before starting the second compressor of 10 seconds.

When heating, the heat stages respond to the demand from W1 and W2 of the thermostat input. Heating and cooling will be mutually locked-out on demand on a ﬁrst call basis. The heating and the cooling functions cannot operate simultaneously.

C. Cooling Capacity Control

The cooling capacity staging is shown in Table 6.

Table 6 — Cooling Capacity Staging Table,

Units with 2 Compressors

STAGES 0

Compressor 1 Off Off On On Compressor 2 Off Off Off On

NOTE: On units which require additional unloading, add suction pres-

sure unloaders to compressor no. 1 only.

ECONOMIZER

II. HEATING SECTION START-UP AND ADJUSTMENTS

CAUTION:

Complete the required procedures given in the Pre-Start-Up section on page 20 before starting unit. Do not jumper any safety devices when operating the unit.

Verify gas pressures before turning on heat as follows:

a. Turn off manual gas stop. b. Connect pressure gage to supply gas tap (See Fig. 10

on page 8).

c. Connect pressure gage to manifold pressure tap on

gas valve.

d. Supply gas pressure mustnotexceed13.5 in. wg. Check

pressure.

e. Turnonmanual gas stop and set thermostat to HEAT

position. After the unit has run for several minutes, verify that incoming pressure is 5.0 in. wg or greater, and that the manifold pressure is 3.5 in. wg. If manifold pressure must be adjusted, refer to Gas Valve Adjustment section on page 25.

A. Checking Heating Control Operation

Start and check the unit for proper heating control operation as follows:

1. Turn on manual gas stop.

2. Set thermostat setting to HEAT position.

3. The evaporator fan and ﬁrst-stage heat will start immediately. If unit is equipped with 2 heaters, secondstage heat will energize upon a call for additional heat. Check for heating effect at supply diffusers.

4. The evaporator fan and heaters will cycle off with no delay after thermostat temperature is satisﬁed.

B. Gas Heating

The gas heat units incorporate two separate systems to provide gas heat. Each system incorporates its own induced draft motor,Integrated Gas Control (IGC) board, 2-stage gas valve, manifold, etc. The systems are operated in parallel, for example, when there is a call for ﬁrst stage heat, both induced draft motors operate, both gas valves are energized and both IGC boards initiate spark.

All of the gas heating control is performed through the IGC boards. The base module board serves only to initiate and terminate heating operation.

The base module board is powered by 24 vac. When the thermostat or room sensor calls for heating, power is sent from the base module board to W on each of the IGC boards. A light-emitting diode (LED) on the IGC board will be on during normal operation. Acheck is made to ensure that the rollout switches and limit switches are closed and the induced draft motors are not running. The induced-draft motors are then energized and when speed is proven with the hall effect sensor on the motor,theignitionactivationperiodbegins.The burners will ignite within 5 seconds.

When ignition occurs the IGC board will continue to monitor the condition of the rollout and limit switches, the hall effect sensor as well as the ﬂame sensor. If the unit is controlled through a room thermostat set for fan auto., 45 seconds after ignition occurs, the indoor-fan motor will be energized and the outdoor-air dampers will open to their minimum position. If for some reason the overtemperature limit opens prior to the start of the indoor fan blower, on the next attempt, the 45-second delay will be shortened to 5 seconds less than the time from initiation of heat to when the limit tripped. Gas will not be interrupted to the burners and heating will continue. Once modiﬁed, the fan on delay will not change back to 45 seconds unless power is reset to the control.

When additional heatisrequired,W2closes and initiates power to the second stage of the main gas valves. When the thermostat is satisﬁed, W1 and W2 open and the gas valves close interrupting the ﬂow of gas to the main burners. If the call for W1 lasted less than 1 minute, the heating cycle will not terminate until 1 minute after W1 became active. If the unit is controlled through a room thermostat set for fan auto., the indoor-fan motor will continue to operate for an additional 45 seconds then stop and the outdoor-air dampers will close. If the over-temperature limit opens after the indoor motor is stopped within 10 minutes of W1 becoming inactive, on the next cycle the time will be extended by 15 seconds. The maximum delay is 3 minutes. Once modiﬁed, the fan off delay will not change back to 45 seconds unless power is reset to the control.

C. Power Exhaust Operation

The optional power exhaust packages are factory- or ﬁeldinstalled with vertical units and optionally installed in the return air ductwork for horizontal applications. The standard and the modulating power exhaust (used with nonmodulatng to modulating conversion package) are the two packages offered. The modulating power exhaust package is equipped with a ﬁeld-adjustable static pressure controller to stage up to 4 power exhaust stages which will maintain a building static pressure. The blue controller located in the control box below the control board can be adjusted, by removing the covers and adjusting the set point dial to the desired building pressure. The blue controller monitors the 4 individual sequencers which activate the 4 individual power exhaust motors. The standard power exhaust package

—22—

controls up to 2 stages of power exhaust to maintain building pressure. The power exhaust package can be conﬁgured to deliver positive or negative building pressure. These power exhaust stages are staged according to a percentage of the economizer dampers position. Default values are 25% for Stage 1 and 75% for Stage 2.

D. Smoke Control Modes

The 580G,H units with an optional expansion board perform ﬁre and smoke control modes. The expansion board provides 4 modes which can be used to control smoke within the conditioned area. The modes of operation are ﬁre shutdown, pressurization, evacuation, and smoke purge. See Table 7.

E. Smoke Detector

A smoke detector can be used to initiate ﬁre shutdown. This can be accomplished by a set of normally closed pilot relay contacts which will interrupt power from the 24-v transformer, secondary ‘‘B’’ terminal to the control circuit breaker (CB4). See Fig. 33. The wire that connects these two points is white and labeled ‘‘W78.’’

NOTE: On standard gas models, the indoor fan will continue to run 45 seconds after the call for heat has been terminated. If ﬁre shutdown is initiated the fan will stop immediately. No 45-second delay will occur.

The smoke detector may be mounted in the return air duct or the supply duct.

F. Indoor Air Quality Control

The accessory expansion board and accessory IAQ sensor are required for IAQ control. The IAQ sensors operate with a 4 to 20 mA signal. The 4 to 20 mA signal is connected to T11 (+) and T12 (−) on the expansion board for the IAQ sensor, and T13 (+) and T14 (−) on the expansion board for the OAQ (Outdoor Air Quality) sensor. The sensor is ﬁeldmounted and wired to the expansion board installed in the unit main control box. The IAQ sensor must be powered by a ﬁeld-supplied 24-v power supply (ungrounded). Do not use the unit 24-v power supply to power the sensor.

Once installed, the sensor must be enabled. The sensor is conﬁgured with default values which may be changed through network access software. To work properly, the IAQ sensor high and low reference points for the sensor that is used must match the conﬁgured values. The expansion board reacts toa4to20mAsignal from the IAQ sensor. The low reference (4 mA output) must be conﬁgured to the minimum IAQ sensor reading. The high reference (20 mA output) must be conﬁgured to the maximum IAQ sensor reading.

The IAQ sensor can be conﬁgured to either low or high priority. The priority value can be changed by the user. The default is low.

Low Priority When the priority is set to low, the initial control is to the

IAQ set point, but the outside air damper position will change to its minimum position when the spacetemperatureisgreater than the occupied cooling set point plus 2° F or when the space temperature is less than the occupied heating set point minus 2° F. The damper will also change to minimum position when the outdoor air quality is greater than the outdoor air quality set point (ppm).

High Priority When the priority is set to high, the IAQ set point controls

the outside air damper exclusively,with no regard to comfort conditioning.

G. Time GuardT Circuit

The Time Guard function (built into the rooftop control board) maintains a minimum off time of 5 minutes, a minimum on time of 10 seconds, and a 10-second delay between compressor starts.

H. Crankcase Heater

Unit main power supply must remain on to provide crankcase heater operation. The crankcase heater in each compressor keeps oil free of refrigerant while compressor is off.

Table 7 — Smoke Control Modes

DEVICE PRESSURIZATION SMOKE PURGE EVACUATION FIRE SHUTDOWN

Economizer 100% 100% 100% 0% Indoor Fan ON ON OFF OFF Power Exhaust (all outputs) OFF ON ON OFF Heat Stages OFF OFF OFF OFF

Fig. 33 — Field-Supplied Smoke Detector Wiring

—23—

I. Head Pressure Control

Each unit has a fan cycling, outdoor thermostat to shut off the outdoor-fan motor(s) at 55 F. The head pressure control permits unit to operate with correct condensing temperatures down to 35 F outdoor-air temperature.

J. MotormasterT III Control

The Motormaster III Solid-State Head Pressure Control is a ﬁeld-installed accessory fan speed control device actuated by a temperature sensor. It is speciﬁcally designed for use on Bryant equipment and controls the condenser-fan motor speed in response to the saturated condensing temperature. For outdoor temperatures down to −20 F, it maintains condensing temperature at 100 F. Refer to the accessory Motormaster installation instructions for more information.

III. FIELD TEST OPERATION

The ﬁeld test program is initiated by moving up DIP switch no. 4 to the ‘‘On’’ position. The outdoor-air damper will close. The control allows 90 seconds for the damper to close in case it was in the full open position. Next, the indoor-fan contactor will be energized, and the outside-air damper will begin to open to its default value of 20% and stay at that position for a short period of time. The outdoor-air damper will then open to its full open position and stay at that position for a short period of time. The outdoor-air damper will then close.

If the unit is equipped with power exhaust, stage 1 will be energized for 5 seconds. If the unit is conﬁgured for stage 2 of power exhaust, stage 2 will be energized for 5 seconds after the ﬁrst stage is deenergized.

The ﬁrst stage of heat will be energized for 30 seconds, after which the second stage heat will be energized for an additional 30 seconds. Heat is then deenergized.

The last step is the Cooling mode. Outdoor-fan contactor no. 1 is energized. This is followed by each stage of cooling energized with a 10-second delay between stages. After this is complete, outdoor-fan contactor no. 2 is energized for 10 seconds.

The compressors will now deenergize, followed by the outdoorfan contactors and indoor-fancontactors.Iftheunit is equipped with the Integrated Gas Control (IGC) board the indoor fan will operate for an additional 30 seconds after deenergizing the circuit.

Setting of the outdoor-air damper position is performed in conjunction with a shortened version of the ﬁeld test. Open DIP switch no. 4 and then no. 6.

The outdoor-air damper will close. The control allows 90 seconds for the damper to close in case it is in the full open position. Next, the indoor-fan contactor will energize. The outdoor-air damper will remain at 0% for 30 seconds. It will then move to the 10% position for another 30 seconds. This will be repeated at every 10% increment for 30 seconds until the damper reaches 100% open. Close DIP switch no. 4 during the 30 seconds immediately after the desired outdoorair minimum damper position. The 30-second time period is to allow time where DIP switch no. 4 can be closed. The default value of the minimum outdoor-air damper position is 20%. If the desired minimum positionis30%,allowthedamper position to go to 10% for 30 seconds, then 20% for 30 seconds, and when it reaches 30% close DIP switch no. 4 during the 30-second period following the 30% position.

The minimum outdoor-air damper position is now set. Close DIP switch no. 6.

IV. INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS

CAUTION:

airﬂow is 300 to 450 cfm per each 12,000 Btuh of rated cooling capacity. For heating operation, the airﬂow must produce a temperature rise that falls within the range stamped on the unit rating plate.

A. Evaporator Fan Performance Adjustment

Be sure evaporator fans rotate in the proper direction. See Tables 8 and 9 for Fan Performance data. See Table 10 for Motor Limitation data. See Table 11 for air quantity limits.

IMPORTANT: Check to ensure that the unit drive matches the duct static pressure using Table 8.

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

To align fan and motor pulleys (Fig. 34):

1. Shut off unit power supply.

2. Loosen fan shaft pulley bushing.

3. Slide fan pulley along fan shaft.

4. Make angular alignment by loosening motor from mounting plate.

5. Retighten pulley.

Fig. 34 — Evaporator-Fan Pulley Alignment and

B. Belt Tension Adjustment

To adjust belt tension:

1. Remove power to unit.

2. Remove motor mount nuts and bolts.

3. Loosen fan motor nuts. See Fig. 35.

For cooling operation, the recommended

Adjustment

—24—

Fig. 35 — Belt Tension Adjustment

4. Turn motor jacking bolts to move motor mounting plate left or right for proper belt tension. Refer to Table 2 for proper belt tension.

5. Tighten nuts.

6. Adjust bolts and nut on mounting plate to secure motor in ﬁxed position. Recheck belt tension after 24 hours of operation. Adjust as necessary.

C. Condenser-Fan Adjustment

1. Shut off unit power supply.

2. Remove fan guard.

3. Loosen fan hub setscrews.

4. Adjust fan height on shaft using a straightedge placed across venturi and measure per Fig. 36.

5. Tighten setscrews and replace fan guard.

6. Turn on unit power.

To adjust regulator:

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

2. Turn ﬁeld-supplied main gas valve to OFF position.

3. Remove

⁄8-in. pipe plug from manifold. Install a water

manometer pressure-measuring device.

4. Set main gas valve to ON position.

5. Set thermostat at setting to call for heat.

6. Remove screw cap covering regulator adjustment screw (See Fig. 37).

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

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

pressure-measuring device and replace

⁄8-in. pipe plug

and screw cap.

Fig. 36 — Condenser-Fan Adjustment

V. 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 3 and 4, the pilot valve opens to the preset position. When power is supplied to terminals 1 and 2, the main valve opens to its preset position.

The regular factory setting is stamped on the valve body (3.5 in. wg).

Fig. 37 — Gas Valve

—25—

Table 8 — Fan Performance, 580G240-360 — Vertical Discharge Units

For 580H units, reduce net available external static pressure by 0.3 in. wg.

AIRFLOW

(Cfm)

4,000 340 0.83 416 1.17 480 1.52 537 1.90 588 2.29 635 2.69 679 3.11 720 3.53 5,000 384 1.25 453 1.61 513 1.99 566 2.39 615 2.79 660 3.21 703 3.64 742 4.08 6,000 432 1.79 495 2.19 550 2.59 600 3.01 647 3.43 690 3.87 730 4.31 769 4.77 7,000 483 2.48 540 2.91 591 3.33 638 3.77 682 4.22 723 4.67 762 5.14 799 5.61 8,000 536 3.33 588 3.78 635 4.23 679 4.69 720 5.16 759 5.64 797 6.12 832 6.61 8,250 549 3.57 600 4.02 646 4.48 690 4.95 730 5.42 769 5.90 806 6.39 841 6.88

9,000 590 4.34 637 4.82 681 5.30 722 5.78 762 6.27 799 6.77 834 7.27 868 7.77 10,000 645 5.54 689 6.04 729 6.54 768 7.04 805 7.56 840 8.07 874 8.59 906 9.12 11,000 701 6.92 741 7.44 779 7.96 816 8.49 850 9.03 884 9.56 916 10.10 947 10.65 12,000 757 8.49 795 9.04 830 9.59 865 10.14 898 10.69 929 11.25 960 11.81 990 12.37 12,500 786 9.36 822 9.92 856 10.47 890 11.03 922 11.60 953 12.16 983 12.73 1012 13.31 13,000 814 10.28 849 10.84 883 11.41 915 11.98 946 12.56 976 13.13 1006 13.71 1034 14.30 13,750 857 11.75 890 12.34 922 12.92 953 13.51 983 14.10 1012 14.69 1041 15.28 1068 15.88 14,000 871 12.27 904 12.86 936 13.45 966 14.05 996 14.64 1025 15.23 1053 15.83 1080 16.43 15,000 929 14.50 960 15.10 990 15.71 1019 16.33 1047 16.94 1074 17.55 1101 18.17 1127 18.79

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

AIRFLOW

(Cfm)

4,000 759 3.97 796 4.42 831 4.87 865 5.34 897 5.81 929 6.30 959 6.79 988 7.28

5,000 780 4.53 816 4.99 851 5.45 884 5.93 916 6.41 946 6.90 976 7.40 1005 7.91

6,000 805 5.23 840 5.70 874 6.18 906 6.67 937 7.16 968 7.66 997 8.17 1025 8.69

7,000 834 6.09 868 6.57 901 7.07 932 7.56 962 8.07 992 8.58 1020 9.10 1048 9.63

8,000 866 7.10 899 7.60 930 8.11 961 8.62 990 9.14 1019 9.67 1047 10.20 1074 10.74

8,250 874 7.38 907 7.89 938 8.40 968 8.92 998 9.44 1026 9.97 1054 10.50 1081 11.04

9,000 901 8.29 932 8.80 963 9.33 992 9.86 1021 10.39 1049 10.93 1076 11.48 1102 12.03 10,000 938 9.65 968 10.18 997 10.72 1026 11.27 1054 11.82 1081 12.37 1107 12.93 1133 13.49 11,000 977 11.19 1006 11.75 1035 12.30 1062 12.87 1089 13.43 1115 14.00 1141 14.57 1166 15.15 12,000 1019 12.94 1047 13.51 1074 14.08 1100 14.66 1126 15.24 1152 15.83 1177 16.42 1201 17.01 12,500 1040 13.88 1067 14.46 1094 15.05 1120 15.63 1146 16.22 1171 16.82 1195 17.41 — — 13,000 1062 14.88 1089 15.47 1115 16.06 1140 16.66 1166 17.25 1190 17.86 ———— 13,750 1095 16.48 1121 17.08 1147 17.68 1172 18.29 1196 18.90 —————— 14,000 1106 17.04 1132 17.64 1157 18.25 1182 18.86 ———————— 15,000 1152 19.41 1177 20.04 1200 20.66 ——————————

AIRFLOW

(Cfm)

4,000 1017 7.79 1045 8.30 1072 8.82 5,000 1033 8.42 1061 8.94 1087 9.46 6,000 1053 9.21 1080 9.73 1106 10.27 7,000 1075 10.16 1102 10.69 1127 11.24 8,000 1100 11.28 1126 11.83 1151 12.38 8,250 1107 11.59 1133 12.14 1158 12.69

9,000 1128 12.58 1153 13.14 1178 13.70 10,000 1158 14.06 1183 14.63 — — 11,000 1190 15.74 — — — — 12,000 —————— 12,500 —————— 13,000 —————— 13,750 —————— 14,000 —————— 15,000 ——————

1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2

Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp Rpm Bhp

AVAILABLE EXTERNAL STATIC PRESSURE

3.4 3.6 3.8

Rpm Bhp Rpm Bhp Rpm Bhp

(in. wg)

AVAILABLE EXTERNAL STATIC PRESSURE (in. wg)

LEGEND

Bhp — Brake Horsepower NOTES:

1. Fan performance is based on wet coils, economizer, roof curb, cabinet losses, and clean 2-in. ﬁlters.

2. Conversion — Bhp to watts: Watts =

Bhp x 746

Motor efficiency

—26—

Table 9 — Fan Performance — Power Exhaust

580G,H240-360 Airﬂow

(Cfm)

6,500 0.32 2.82 3160 0.70 2.98 3340 — — — — — — — — — — — — 6,700 0.23 2.87 3220 0.63 3.03 3400 0.60 3.01 3380 0.82 3.23 3620 — — — — — — 6,900 0.17 2.92 3270 0.59 3.09 3460 0.55 3.07 3440 0.78 3.28 3680 — — — — — — 7,100 0.13 2.93 3290 0.56 3.11 3490 0.49 3.12 3500 0.73 3.34 3740 — — — — — — 7,300 0.09 2.97 3330 0.53 3.15 3530 0.43 3.18 3560 0.68 3.39 3800 — — — — — — 7,500 — — — 0.51 3.19 3580 0.39 3.24 3630 0.64 3.44 3860 — — — — — — 7,700 — — — 0.48 3.23 3620 0.33 3.27 3670 0.59 3.48 3900 0.60 3.69 4140 0.73 3.98 4460 7,900 — — — 0.45 3.27 3670 0.27 3.32 3720 0.54 3.52 3950 0.56 3.74 4190 0.69 4.02 4510 8,100 — — — 0.40 3.33 3730 0.22 3.36 3770 0.49 3.57 4000 0.51 3.78 4240 0.65 4.07 4560 8,500 — — — — — — 0.17 3.47 3890 0.40 3.67 4120 0.41 3.83 4290 0.56 4.12 4620 8,900 — — — — — — 0.00 3.58 4010 0.30 3.77 4230 0.31 3.93 4410 0.47 4.23 4740 9,300 — — — — — — — — — 0.22 3.87 4340 0.20 4.07 4560 0.37 4.37 4900

9,700 — — — — — — — — — 0.16 3.95 4430 0.11 4.17 4670 0.30 4.47 5010 10,100 — — — — — — — — — 0.12 4.03 4520 0.04 4.25 4770 0.23 4.56 5110 10,500 — — — — — — — — — — — — — — — 0.17 4.66 5220 10,900 — — — — — — — — — — — — — — — 0.12 4.75 5330

11,300 — — — — — — — — — — — — — — — 0.07 4.80 5380 11,700 — — — — — — — — — — — — — — — 0.04 4.83 5420

Bhp — Brake Horsepower ESP — External Static Pressure (in. wg) Watts — Input Watts to Motor

ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts ESP Bhp Watts

LEGEND

Low Speed Medium Speed High Speed

208 v 230, 460, 575 v 208 v 230, 460, 575 v 208 v 230, 460, 575 v

Table 10 — Motor Limitations

STANDARD EFFICIENCY MOTORS

Nominal

7.5

Maximum

Bhp

5.9 14.6 — — 5,030 87.5

5.9 — 7.9 6.0 5,030 87.5

8.7 22.0 — — 7,334 88.5

9.5 — 12.0 10.0 8,008 88.5

10.2 28.0 — — 8,502 89.5

11.8 — 14.6 12.0 9,836 89.5

15.3 43.8 — — 12,543 91.0

18.0 — 21.9 19.0 14,756 91.0

22.4 62.0 — — 18,363 91.0

23.4 — 28.7 23.0 19,183 91.0

230 460 575

Maximum Amps

Maximum

Watts

Motor

Efficiency

HIGH EFFICIENCY MOTORS

Nominal

7.5

BHP — Brake Horsepower NOTE: Extensive motor and electrical testingon the these units has en-

sured that the full horsepower range of the motor can be utilized with

LEGEND

Maximum

Bhp

5.9 15.8 — 4,918 89.5

5.9 — 7.9 4,918 89.5

8.7 22.0 — 7,078 91.7

9.5 — 12.0 7,728 91.7

10.2 28.0 — 8,298 91.7

11.8 — 15.0 9,600 91.7

15.3 43.8 — 12,273 93.0

18.0 — 21.9 14,439 93.0

22.4 58.2 — 17,853 93.6

23.4 — 28.7 18,650 93.6

Maximum Amps

230 460

Table 11 — Air Quantity Limits

UNIT 580G,H

240 6,000 6,000 10,000 300 7,500 7,500 12,500 324 8,250 8,250 13,750 360 9,000 9,000 15,000

MINIMUM HEATING

CFM

Maximum

Watts

conﬁdence. Using your fan motors up to the horsepower ratings shown on the Motor Limitations table will not result in nuisance tripping or premature motor failure. Unit warranty will not be affected.

MINIMUM COOLING

CFM

Motor

Efficiency

MAXIMUM

CFM

—27—

VI. MAIN BURNERS

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

A. Main Burner Removal (Fig. 38)

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

2. Shut off power to unit.

3. Remove heating access panel.

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 4 screws that hold the burner support plate ﬂange to the vestibule plate.

10. Lift burner assembly out of unit.

IX. LOW AMBIENT KIT

Low Ambient Kit is a fan speed control device actuated by a temperature sensor.The ﬁeld-installed accessory is speciﬁcally designed for use on this equipment and controls the condenser-fan motor speed in response to the saturated condensing temperature. For outdoor temperatures down to

−20 F, it maintains condensing temperature at 100 F.

CARE AND MAINTENANCE

To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This combination heating/cooling unit should be inspected at least once each year by a qualiﬁed service person.

NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract.

WARNING:

nance on this equipment requires certain expertise, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in theUser’sManual.FAILURE TO HEED THIS WARNING COULD RESULTINSERIOUSPERSONAL INJURYAND POSSIBLE DAMAGE TO THIS EQUIPMENT.

The ability to properly perform mainte-

Fig. 38 — Main Burner Removal

VII. POWER EXHAUST OPERATION

The power exhaust packages are factory- or ﬁeld-installed with vertical units and optionally installed in the return air ductwork for horizontal applications. The standard and the modulating power exhaust are the two packages offered. The modulating power exhaust package is equipped with a ﬁeldadjustable static pressure controller to stage up to 4 power exhausts stages which will maintain a building static pressure. The blue sequencer located in the control box below the control board can be adjusted, by removing the covers and adjusting the set point dial to the desired building pressure. The standard power exhaust package controls up to 2 stages of power exhaust to maintain building pressure. These power exhaust stages are staged according to a percentage of the economizer dampers position.

VIII. HEAD PRESSURE CONTROL

Each unit has a fan cycling, outdoor thermostat to shut off the outdoor-fan motor at 55 F.Thehead pressure control permits unit to operate with correct condensing temperatures down to 35 F outdoor-air temperature.

The minimum maintenance requirements for this equipment are as follows:

1. Inspect air ﬁlters each month. Clean or replace when necessary.

2. Inspect cooling coil, drain pan, and condensate drain each cooling season for cleanliness. Clean when necessary.

3. Inspect blower motor and wheel each heating and cooling season. Clean and lubricate (if required) when necessary.

4. Lubricate bearings every 6 months if fan runs continuously or annually if fan runs intermittently.

5. Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service when necessary.

6. Check and inspect heating section before each heating season.

7. Check and clean vent screen if needed.

WARNING:

sult in serious personal injury:

1. Turn off electrical power to the unit before performing any maintenance or service on the unit.

2. Use extreme caution when removing panelsandparts. As with any mechanical equipment, personal injury can result from sharp edges, etc.

3. Never place anything combustible either on, or in contact with, the unit.

4. Should overheating occur, shut off the electrical supply.

Failure to follow these warnings could re-

—28—

SERVICE

WARNING:

Before beginning any maintenance, be sure to turn off power at the main disconnect switch. TAG THE SWITCH WITH A SUITABLE WARNING LABEL.

All unit components can be reached through clearly labelled hinged access doors. These doors are not equipped with tiebacks, so if heavy duty servicing is needed, either remove them or prop them open to prevent accidental closure.

Each door is held closed with 3 latches. The latches are se-

cured to the unit with a single

⁄4-in.-20x1⁄2-in. long bolt.

See Fig. 39.

To open, loosen the latch bolt using a

⁄16-in. wrench. Pivot the latch so it is not in contact with the door. Open the door. To shut, reverse the above procedure.

NOTE: Disassembly of the top cover may be required under special service circumstances. It is very important that the orientation and position of the top cover be marked on the unit prior to disassembly. This will allow proper replacement of the top cover onto the unit and prevent rainwater from leaking into the unit.

IMPORTANT: After servicing is completed, make sure door is closed and relatched properly, and that the latches are tight. Failure to do so can result in water leakage into the evaporator section of the unit.

NOTE: The unit requires industrial grade throwaway ﬁlters capable of withstanding face velocities up to 625 fpm.

To replace ﬁlters, open ﬁlter access door (marked with label). Remove inner access panel. Remove plastic ﬁlter retainer in between ﬁlter tracks by sliding and pulling outward. Remove ﬁrst ﬁlter by sliding out opening in ﬁlter track. Locate ﬁlter removal tool, which is shipped next to the return air dampers. Use the ﬁlter removal tool to remove the rest of the ﬁlters.

E. Main Burners

At the beginning of each heating season, inspect for deterioration or blockage due to corrosion or other causes. Observe the main burner ﬂames and adjust if necessary.Refer to Main Burners sections on page 28. Check spark gap. See Fig. 40.

F. Flue Gas Passageways

The ﬂue collector box and heat exchanger cells may be inspected by removing gas section access panel (Fig. 2 and

3), ﬂue box cover, collector box, and main burner assembly (Fig. 41 and 42). Refer to Main Burners section on page 28 for burner removal sequence. If cleaning is required, clean all parts with a wire brush. Reassemble using new cerafelt high-temperature insulation for sealing.

G. Combustion-Air Blower

Clean periodically to assure proper airﬂow and heating efficiency. Inspect blower wheel every fall and periodically during heating season. For the ﬁrst heating season, inspectblower wheel bi-monthly to determine proper cleaning frequency.

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 (Fig. 41 and 42). The motor,scroll, and wheel assembly can be removed from the unit. Remove scroll from plate. Remove the blower wheel from the motor shaft and clean with a detergent or solvent. Replace motor and wheel assembly.

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.

Fig. 39 — Door Latch

I. CLEANING

Inspect unit interior at beginning of each heating and cooling season and as operating conditions require. Remove unit top panel and/or side panels for access to unit interior.

A. Evaporator Coil

Clean as required with a commercial coil cleaner.

B. Condenser Coil

Clean condenser coil annually and as required by location and outdoor-air conditions. Inspect coil monthly — clean as required.

C. Condensate Drain

Check and clean each year at start of cooling season. In winter, keep drains and traps dry.

D. 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.

II. LUBRICATION A. Compressors

Each compressor is charged with the correct amount of oil at the factory. The correct oil charge is shown in Table 1. If oil is visible in the compressor sight glass, check unit for operating readiness as describedinStart-Upsection,thenstart the unit. Observe oil level and add oil, if required, to bring oil level in compressor crankcase up to between

⁄4and1⁄3of sight

glass during steady operation.

If oil charge is above

⁄3sight glass, do not remove any oil until the compressor crankcase heater has been energized for at least 24 hours with compressor off.

When additional oil or a complete charge is required, use only approved compressor oils:

Petroleum Specialties, Inc. ...................Cryol 150

Texaco, Inc. ...........................Capella WF-32

Witco Chemical Corp. .....................Suniso 3GS

IMPORTANT: Do not use reclaimed oil or oil that has been exposed to the atmosphere. Refer to Standard Service Techniques Manual, Chapter 1, Refrigerants section, for procedures to add or remove oil.

—29—

Fig. 40 — Spark Gap Adjustment

NOTES:

1. Torque setscrews on blower wheel to 70 in. lbs ± 2 in. lbs.

2. Torque setscrew on propeller fan to 15 in. lbs ± 2 in. lbs.

3. Dimensions are in inches.

Fig. 41 — Typical Gas Heating Section

Fig. 42 — Gas Heat Section Details

—30—

B. Fan Shaft Bearings

Lubricate the bearings at least twice annually with suitable bearing grease.Donotover grease. Typical lubricantsareshown below:

MANUFACTURER LUBRICANT

Texaco Regal AFB-2*

Mobil Mobilplex EP No. 1

Sunoco Prestige 42

Texaco Multifak 2

*Preferred lubricant because it contains rust and oxidation inhibitors.

C. Condenser and Evaporator-Fan Motor Bearings

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

III. EVAPORATOR FAN SERVICE AND REPLACEMENT

1. Turn off unit power.

2. Remove supply-air section panels.

3. Remove belt and blower pulley.

4. Loosen setscrews in blower wheels.

5. Remove locking collars from bearings.

6. Remove shaft.

7. Remove venturi on opposite side of bearing.

8. Lift out wheel.

9. Reverse above procedure to reinstall fan.

10. Check and adjust belt tension as necessary.

Unit panels must be in place when unit is operating during charging procedure.

A. No Charge

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

B. Low Charge Cooling

Using appropriate cooling charging chart (see Fig. 43), add or remove refrigerant until conditions of the appropriate chart are met. Note that charging chart is different from those normally used. An accurate pressure gage and temperature sensing device are required. Measure liquid line pressure at the liquid line service valve using pressure gage. Connect temperature sensing device to liquid line near the liquid line service valve and insulate it so that outdoor ambient temperature does not affectreading.Indoor-aircfm must be within normal operating range of unit. Take outdoor ambient temperature and read the suction pressure gage. Refer to appropriate chart to determine correct suction temperature. If intersection point on chart is above the curve, add refrigerant. If intersection point on chart is below curve, carefully recover some of the charge. Recheck suction pressure ascharge is adjusted.

IV. EVAPORATOR-FAN MOTOR REPLACEMENT

1. Shut off unit power supply.

2. Remove upper outside panel and open hinged door to gain access to motor.

3. Fully retract motor plate adjusting bolts.

4. Loosen the 2 rear (nearest the evaporator coil) motor plate nuts.

5. Remove the 2 front motor plate nuts and carriage bolts.

6. Slide motor plate to the rear (toward the coil) and remove fan belt(s).

7. Slide motor plate to the front and hand tighten one of the rear motor plate nuts (tight enough to prevent the motor plate from sliding back but loose enough to allow the plate to pivot upward).

8. Pivot the front of the motor plate upward enough to allow access to the motor mounting hex bolts and secure in place by inserting a prop.

9. Remove the nuts from the motor mounting hex bolts and remove motor.

10. Reverse above steps to install new motor.

V. POWER FAILURE

Dampers have a springreturn.Ineventofpower failure, dampers will return to fully closed position until power is restored.

VI. 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.

Fig. 43 — Cooling Charging Chart,

580G,H240-360

—31—

VII. FILTER DRIER

Replace whenever refrigerant system is exposed to atmosphere.

VIII. THERMOSTATIC EXPANSION VALVE (TXV)

Each circuit has one. It is nonadjustable and is factory set to maintain 10 to 13° F superheat leaving the evaporator coil. Controls ﬂow of liquid refrigerant to the evaporator coils.

IX. PROTECTIVE DEVICES A. Compressor Protection

Overcurrent Each compressor has one manual reset, calibrated trip, mag-

netic circuit breaker. Do not bypass connections or increase the size of the circuit breaker to correct trouble. Determine the cause and correct it before resetting the breaker.

Overtemperature Each 06D type compressor has an internal protector to pro-

tect it against excessively high discharge gas temperatures. Crankcase Heater Each compressor has a crankcase heater to prevent absorp-

tion of liquid refrigerant by oil in the crankcase when the compressor is idle. Since power for the crankcase heaters is drawn from the unit incoming power, main unit power must be on for the heaters to be energized.

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

B. Evaporator-Fan Motor Protection

A manual reset, calibrated trip, magnetic circuit breaker protects against overcurrent. Do not bypass connections or increase the size of the breaker to correct trouble. Determine the cause and correct it before resetting the breaker. If the evaporator-fan motor is replaced with a different horsepower motor, resizing of the circuit breaker is required. Contact Application Engineering.

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. To reset, manually move the thermostat setting.

E. Freeze Protection Thermostat (FPT)

Freeze protection thermostats are located on the evaporator coil for each circuit. One is located at the top and bottom of each circuit. They detect frost build-up and turn off the compressor, allowing the coil to clear. Once the frost has melted, the compressor can be reenergized.

X. RELIEF DEVICES

All units have relief devices to protect against damage from excessive pressures (i.e., ﬁre). These devices are installed on the suction line, liquid line, and on the compressor.

XI. CONTROL CIRCUITS A. 24-V Circuit

This control circuit is protected against overcurrent by a

3.2-amp circuit breaker (CB4). Breaker can be reset. If it trips, determine cause of trouble before resetting.

B. 115-V Circuit

This control circuit is protected against overcurrent by a

5.0-amp circuit breaker (CB3). Breaker can be reset. If it trips, determine cause of trouble before resetting.

XII. COMPRESSOR LOCKOUT LOGIC

If any of the safeties trip, the circuit will automatically reset (providing the safety has reset) and restart the compressor in 15 minutes. If any of the safeties trip 3 times within a 90-minute period, then the circuit will be locked out and will require manual resetting by turning off either the unit disconnect or the control circuit breaker.

XIII. REPLACEMENT PARTS

A complete list of replacement parts may be obtained from any distributor upon request.

—32—

TROUBLESHOOTING

Typical refrigerant circuiting diagram is shown in Fig. 44.

LEGEND

FPS — Freeze Protection Switch HPS — High-Pressure Switch LPS — Low-Pressure Switch

Fig. 44 — Typical Refrigerant Circuiting

I. DIAGNOSTIC LEDs (Light-Emitting Diodes)

There are 3 LEDs (red, yellow, and green) on the lower right hand side of the control board. The red light is used to check unit operation and alarms. A constant pulse is normal unit

operation. A series of quick blinks indicates an alarm. Refer to Table 12 for a description of alarms. The yellow and green LEDs have no signiﬁcance on 580G,H units.

—33—

Table 12 — Control Board LED Alarms

LED

BLINKS

1 Normal Operation The control board ﬂashes the red LED in one-second intervals

2 HF-13 Compressor 1 Safety The high or low pressure safety switch for compressor no. 1 has

3 HF-14 Compressor 2 Safety The high or low pressure safety switch for compressor no. 2 has

4 HF-15 Thermostat Failure The thermostat is calling for both heating and cooling at the same

5 HF-05 SAT Thermistor Failure The supply-air temperature (SAT) sensor has failed. First check for 6 HF-06 OAT Thermistor Failure The outside-air temperature (OAT) sensor has failed. First check 7 HF-03 DIP Switch 2 is Open Close DIP switch 2.

8 HF-12 DIP Switch 1 is Open Close DIP switch 1. 9 SE-05 Loss of Communications

10 HF-16 Control Board Failure Generated when hardware has failed on control board. Replace 11 HF-17 Expansion Board Failure Generated when hardware has failed on the expansion board.

LEGEND

DIP — Dual In-Line Package LED — Light-Emitting Diode

ERROR

CODE

DESCRIPTION

with Expansion Board

TROUBLESHOOTING

COMMENTS

when the board is operating properly. Make sure DIP switch 3 is closed.

opened for 3 seconds. The error will be cleared and compressor no. 1 will be allowed to turn on in 15 minutes. If the safeties have been tripped 3 times in 90 minutes, compressor no. 1 will be locked out until the control board has been manually reset.

opened for 3 seconds. The error will be cleared and compressor no. 2 will be allowed to turn on in 15 minutes. If the safeties have been tripped 3 times in 90 minutes, compressor no. 2 will be locked out until the control board has been manually reset.

time. The unit will operate on a ﬁrst call basis and will automatically reset.

wiring errors, then replace sensor. for wiring errors, then replace sensor.

Communications between the expansion board and the control board have been interrupted. Ensure that an expansion board is installed and wired using the wire harness supplied with the expansion module. If an expansion board is not used, ensure that DIP switch position 3 is in the closed position and reset power.

the control board. Replace the expansion board.

II. ERROR CODE SUMMARY

A summary of the error codes is listed in Table 13. If more than one error code exists, they will be displayed on the LED of the IGC board in sequence. Fault history is deleted when power is turned off.

Table 13 — IGC Board Error Code Summary

INDICATION ERROR MODE ON NORMAL OPERATION OFF HARDWARE FAILURE 1 FLASH FAN ON/OFF DELAY MODIFIED 2 FLASHES LIMIT SWITCH FAULT 3 FLASHES FLAME SENSE FAULT 4 FLASHES 4 CONSECUTIVE LIMIT SWITCH FAULTS 5 FLASHES IGNITION LOCKOUT FAULT 6 FLASHES INDUCED DRAFT MOTOR FAULT 7 FLASHES ROLLOUT SWITCH FAULT 8 FLASHES INTERNAL CONTROL FAULT

III. INPUT AND OUTPUT CHANNEL DESIGNATIONS

Table 14 shows the input and output channel designations. The Integrated Gas Controls for heating and cooling areshown

in Fig. 45.

—34—

Table 14 — I/O Channel Designations Base Module

TERMINAL

NO.

T1-2 — T3-4 — T5-6 OAT — 5KV Thermistor T7-8 SAT — 5KV Thermistor

T9-10 — T11-12 — T13-14 — T15-16 — T17-25 Y1 — DI (24 vac) T18-25 Y2 — DI (24 vac) T19-25 W1 — DI (24 vac) T20-25 W2 — DI (24 vac) T21-25 G — DI (24 vac) T22-25 Compressor 1 Safety — DI (24 vac) T23-25 Compressor 2 Safety — DI (24 vac) T24-25 Outside Air Enthalpy — DI (24 vac) T26-27 Economizer Pos. — AO (4-20 mA) T28-29 Heat 1 Relay — DO (24 vac) T30-29 Heat 2 Relay — DO (24 vac) T31-32 CV Power Exhaust 1/Modulating Pwr Exht — DO (115 vac) T33-32 CV Power Exhaust2—DO(115vac) T34-35 Condenser Fan — DO (115 vac) T36-35 OFC2 — DO (115 vac) T37-38 — T39-38 —

K1 Indoor Fan Relay — DO (HV) K2 Compr.1—DO(HV) K3 Compr.2—DO(HV)

LEGEND

AO — Analog Output CV — Constant Volume DI — Direct Input DO — Direct Output HV — High Voltage KV — Kilo Ohms OAT — Outdoor Air Thermistor OFC — Outdoor (Condenser) Fan Contactor SAT — Supply Air Thermistor T—Terminal

NOTE: For 4 to 20 mA signals, all even numbered terminals are negative (−) polarity and all odd

numbered terminals are positive (+) polarity.

ASSIGNMENT

—35—

LEGEND

IDM — Induced-Draft Motor IGC — Integrated Gas Controller

NOTE: Thermostat Fan Switch in the ‘‘AUTO’’ position.

Fig. 45 — IGC Control (Heating and Cooling)

—36—

LEGEND FOR FIG. 46-50

AHA — Adjustable Heat Anticipator BP — Building Pressure BR — Burner Relay C—Contactor, Compressor CAP — Capacitor CB — Circuit Breaker CC — Cooling Compensator CCB — Compressor Circuit Breaker CCH — Crankcase Heater COM — Common COMP — Compressor Motor CR — Control Relay CV — Constant Volume DM — Damper Motor EC — Enthalpy Control EQUIP — Equipment FLA — Full Load Amps FPT — Freeze Protection Thermostat FU — Fuse GND,GRD — Ground GVR — Gas Valve Relay HPS — High-Pressure Switch HR — Heat Relay HS — Hall Effect Sensor HV — Heat Valve

I—Ignitor IDM — Induced-Draft Motor IFC — Indoor Fan Contactor IFCB — Indoor Fan Circuit Breaker IFM — Indoor-Fan Motor IFR — Indoor-Fan Relay IGC — Integrated Gas Unit Controller IP — Internal Protector L—Light LPS — Low-Pressure Switch LS — Limit Switch MGV — Main Gas Valve NC — Normally Closed NEC — National Electrical Code NO — Normally Open OAT — Outdoor-Air Thermostat OD — Outside Diameter OFC — Outdoor-Fan Contactor OFM — Outdoor-Fan Motor PEC — Power Exhaust Contactor PEM — Power Exhaust Motor PES — Power Exhaust Sequencer PESC — Power Exhaust Sequencer

PL — Plug Assembly

Controller

RS — Rollout Switch SAT — Supply-Air Thermistor SW — Switch TB — Terminal Block TC — Thermostat Cooling TH — Thermostat Heating TRAN — Transformer

Terminal (Marked) Terminal (Unmarked)

Terminal Block Splice

Factory Wiring Field Wiring To Indicate Common Potential Only,

Not To Represent Wiring

Fig. 46 — 115 V Control Circuit Schematic; 580G,H240-360

—37—

NOTES:

1. Connect TRAN1 to H4 for 460 v units. Connect to H3 for 230 v. If 208/230 v units are run with a 208 v power supply connect to H2.

2. Connect TRAN2 to black lead for 460 v units. Connect to orange lead for 230 v units. If 208/230 v units are run with a 208 v power supply connect to red lead.

3. Circuit breaker must trip amps are equal to or less than 156% FLA for CB1 and CB2. All others are 140%.

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

5. Compressors and/or fan motors are thermally protected.

6. Three-phase motors are protected against primary single phasing conditions.

Fig. 47 — Power Schematic; 580G,H240-360 — 208/230-3-60 and 460-3-60

—38—

TABLE A

The Following Compressors Have Two

Parallel Wires Run From TB1 to the

Compressor

Model

06D-537 208-230-3-60 2

The Following Fan Motors Have Two

Parallel Wires Run From TB1 to the Fan

Indoor

Motor 20 HP 208-230-3-60 2

Compressors

Voltage

TABLE B

Motors

Voltage

Wire

Quantity

Wire

Quantity

NOTES:

1. Connect TRAN1 to H4 for 575V units.

2. Connect TRAN2 to black lead for 575V units.

3. Circuit breaker must trip amps are equal to or less than 156% FLA for CB1 and CB2. All others are 140%.

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

5. Compressors and/or fan motors are thermally protected.

6. Three-phase motors are protected against primary single phasing conditions.

Fig. 48 — Power Schematic; 580G,H240-360 — 575-3-60

—39—

—40—

NOTE: Red wire and violet wire are spliced together at the factory. The brown wire has a wire nut added at the factory.

Fig. 49 — 24 V Control Schematic; 580G,H240-360

Fig. 50 — Component Arrangement; 580G,H240-360

—41—

PACKAGED SERVICE TRAINING

Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual. Product programs cover:

• Unit Familiarization

• Installation Overview

• Maintenance

• Operating Sequence

A large selection of product, theory, and skills programs is available. All programs include a video cassette and/or slides and a companion booklet. Use these for self teaching or to conduct full training sessions.

For a free Service Training Material Catalog (STM), call 1-800-962-9212. Ordering instructions are included.

START-UP CHECKLIST

MODEL NO.: SOFTWARE VERSION (SEE FIG. 11) DATE:

PRE-START-UP:

M VERIFY THAT DIP SWITCH SETTINGS ARE CORRECT M VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT M REMOVE ALL SHIPPING HOLDDOWN BOLTS AND BRACKETS PER INSTRUCTIONS M VERIFY INSTALLATION OF ECONOMIZER HOOD M VERIFY INSTALLATION OF ALL OPTIONS AND ACCESSORIES M VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTRUCTIONS M VERIFY THAT ALL ELECTRICAL CONNECTIONS AND TERMINALS ARE TIGHT M CHECK GAS PIPING FOR LEAKS M CHECK THAT INDOOR-AIR FILTERS ARE CLEAN AND IN PLACE M VERIFY THAT UNIT IS LEVEL WITHIN TOLERANCES M CHECK FAN WHEELS AND PROPELLERS FOR LOCATION IN HOUSING/ORIFICE, AND VERIFY SETSCREW

IS TIGHT

SERIAL NO.: TECHNICIAN:

M VERIFY THAT FAN SHEAVESARE ALIGNED AND BELTS ARE PROPERLY TENSIONED M VERIFY THAT SUCTION, DISCHARGE, AND LIQUID SERVICE VALVES ON EACH CIRCUIT ARE OPEN

START-UP: ELECTRICAL

SUPPLY VOLTAGE L1-L2

COMPRESSOR AMPS — COMPRESSOR NO. 1 L1 L2 L3

— COMPRESSOR NO. 2 L1 L2 L3

SUPPLY FAN AMPS EXHAUST FAN AMPS

TEMPERATURES

OUTDOOR-AIR TEMPERATURE F DB (Dry Bulb) RETURN-AIR TEMPERATURE COOLING SUPPLYAIR GAS HEAT SUPPLY AIR

PRESSURES

GAS INLET PRESSURE GAS MANIFOLD PRESSURE STAGE NO. 1

L2-L3 L3-L1

FDB F WB (Wet Bulb) F

IN. WG

IN. WG STAGE NO. 2 IN. WG REFRIGERANT SUCTION CIRCUIT NO. 1 REFRIGERANT DISCHARGE CIRCUIT NO. 1

M VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS ON PAGE 31

PSIG CIRCUIT NO. 2 PSIG

CL-1

GENERAL

M SET ECONOMIZER MINIMUM VENT POSITION TO JOB REQUIREMENTS M ENSURE DRIVES OPERATE WITHIN LIMITS OF FAN PERFORMANCE TABLES.

HIGH-PRESSURE SWITCH SETTING PSIG LOW-PRESSURE SWITCH SETTING PSIG MOTOR PULLEY PART NUMBER FAN PULLEY PART NUMBER BELT PART NUMBER BELT SIZE in. FILTER QUANTITY FILTER SIZES in.

ADDITIONAL NOTES:

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

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Bryant 580G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual