Bryant 580J08-14D User Manual

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580J*08--14D,F (2--COMPRESSOR) NOMINAL 7.5 to 12.5 TONS WITH PURONR (R--410A) REFRIGERANT

Service and Maintenance Instructions

TABLE OF CONTENTS

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

UNIT ARRANGEMENT AND ACCESS 2...........

SUPPLY FAN (BLOWER) SECTION 4..............

COOLING 6....................................

PURONR (R--410A) REFRIGERANT 8..............

COOLING CHARGING CHARTS 10................

CONVENIENCE OUTLETS 16....................

SMOKE DETECTORS 17.........................

PROTECTIVE DEVICES 24.......................

GAS HEA TING SYSTEM 25......................

CONDENSER COIL SER VICE 35..................

RTU--MP CONTROL SYSTEM 35..................

ECONOMI$ER SYSTEMS 50......................

WIRING DIAGRAMS 59.........................

PRE--STAR T--UP 62..............................

START--UP, GENERAL 62........................

START--UP, RTU--MP CONTROL 64................

OPERATING SEQUENCES 67.....................

FASTENER TORQUE VALUES 71.................

APPENDIX I. MODEL NUMBER SIGNIFICANCE 72.

APPENDIX II. PHYSICAL DATA 73................

APPENDIX III. FAN PERFORMANCE 75...........

APPENDIX IV. WIRING DIAGRAM LIST 82........

APPENDIX V. MOTORMASTER SENSOR

LOCATIONS 83.................................

UNIT START-UP CHECKLIST 85..................

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualifie d service personnel should install, repair, or service air-conditioning equipment. Untrained personnel can perform the basic maintenance functions of replacing filters. Trained service personnel should perform all other operations.

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.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and National Electrical Code (NEC) for special requirements.

Recognize safety information. This is the safety--alert symbol

instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

. When you see this symbol on the unit and in

WARNING

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FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Refer to the User’s Information Manual provided with this unit for more details.

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:

DO NOT try to light any appliance. DO NOT touch any electrical switch, or use any phone in your buildi ng. IMMEDIATELY call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department.

WARNING

ELECTRICAL OPERATION HAZARD

Failure to foll ow this warning could result in personal injury or death.

Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrica l shock and rotating equipment could cause injury.

FIRE, EXPLOSION HAZARD

Failure to foll ow this warning could result in personal injury or death.

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

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing air conditioning units.

UNIT ARRANGEMENT AND ACCESS

General

WARNING

ELECTRICAL OPERATION HAZARD

Failure to foll ow this warning could result in personal injury or death.

Units with convenience outlet circuits may use multiple disconnects. Check convenience outlet for power status before opening unit for service. Locate its disconnect switch, if appropriate, and open it. Tag--out this switch, if necessary.

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal injury, death and/or equipment damage.

PuronR (R--410A) refrigerant systems operate at higher pressures than standard R--22 systems. Do not use R--22 service equipment or components on Puron refrigerant equipment.

Fig. 1 and Fig. 2 show general unit arrangement and access locations.

FILTER ACCESS PANEL

INDOOR COIL ACCESS PANEL

C06023

Fig. 1 -- Typical Access Panel Locations (Back)

BLOWER ACCESS PAN EL

COMPRESSORS

CONTROL BOX

Fig. 2 -- Typical Access Panel Location (Front)

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Heating

S Heat exchanger flue passageways cleanliness S Gas burner condition S Gas manifold pressure S Heating temperature rise

Economizer or Outside Air

Damper

S Inlet filters condition S Check damper travel (economizer) S Check gear and dampers for debris and dirt

Air Filters and Scr

eens

Each unit is equipped with return air filters. If the unit has an economizer, it will also have an outside air screen. If a manual outside air damper is added, a n inlet air screen will also be present.

Routine Maintenance

These items should be part of a routine maintenance program, to be c hecked every month or two, until a specific schedule for each can be identified for this installation:

Quarterly Inspection (and 30 days after initial

start)

S Return air filter replacement S Outdoor hood inlet filters cleaned S Belt tension checked S Belt condition checked S Pulley alignment checked S Fan shaft bearing locking collar tightness checked S Condenser coil cleanliness checked S Condensate drain checked

Seasonal Maintenance

These items should be checked at the beginning of each season (or more often if local conditions and usage patterns dictate):

Conditioning

Air

S Condenser fan motor mounting bolts tightness S Compressor mounting bolts S Condenser fan blade positioning S Control box cleanliness and wiring condition S Wire terminal tightness S Refrigerant charge level S Evaporator coil cleaning S Evaporator blower motor amperage

Each of these filters and screens will need to be periodically replaced or cleaned.

Return Air

Filters

Return air filters are disposable fiberglass media type. Access to t he filters is through the small lift--out panel located on the rear side of the unit, above the evaporator/return air access panel. (See Fig. 1.)

To remove the filters:

1. Grasp the bottom flange of the upper panel.

2. Lift up and swing the bottom out until the panel disengages and pulls out.

3. Reach inside and extract the filters from the filter rack.

4. Replace these filters as required with similar replacement filters of same size.

To re--install the access panel:

1. Slide the top of the panel up under the unit top panel.

2. Slide the bottom into the side channels.

3. Push the bottom flange down until it contacts the top of the lower panel (or economizer top).

IMPORTANT: DO NOT OPERATE THE UNIT WITHOUT THESE FILTERS!

Outside Air

Hood

Outside air hood inlet screens are permanent aluminum--mesh type filters. Check these for cleanliness. Remove the screens when cleaning is required. Clean by washing with hot low--pressure water and soft detergent and replace all screens before restarting the unit. Observe the flow direction arrows on the side of each filter frame.

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Economizer Inlet Air Screen

This air screen is retained by spring clips under the top edge of the hood. (See Fig. 3.)

22 3/8 (569 mm)

DIVIDER

OUTSIDE AIR

HOOD

CLEANABLE ALUMINUM FILTER

BAROMETRIC RELIEF

FILTER

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Fig. 3 -- Filter Installation

To remove the filter, open the spring clips. Re--install the filter by placing the frame in its track, then closing the spring clips.

FILTER CAP

C08634

SUPPLY FAN (BLOWER) SECTION

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause personal injury or death.

Before performing service or maintenance operations on the fan system, shut off all unit power and tag--out the unit disconnect switch. Do not reach into the fan section with power still applied to unit.

Supply Fan (Belt-- Drive)

The supply fan system consists of a forward--curved centrifugal blower wheel on a solid shaft with two concentric type bearings, one on each side of the blower housing. A fixed--pitch driven pulley is attac hed to the fan shaft and an adjustable--pitch driver pulley is on the motor. The pulleys are connected using a “V” type belt. (See Fig. 5.)

Manual Outside Air Hood Screen

This inlet screen is secured by a retainer angle across the top edge of the hood. (See Fig. 4.)

C07156

Fig. 4 -- Screens Installed on Outdoor--Air Hood

(Sizes 7-1/2 to 12-1/2 Tons Shown)

To remove the screen, loosen the screws in the top retainer and slip the retainer up until the filter can be removed. Re-install by placing the frame in its track, rotating the retainer back down and tighten all screws.

C07087

Fig. 5 -- Belt Drive Motor Mounting

Belt

Check the belt condition and tension quarterly. Inspect the belt for signs of cracking, fraying or glazing along the inside surfaces. Check belt tension by using a spring-force tool (such as Browning’s Part Number “Belt Tension Checker” or equivalent tool). Tension should be 6-lbs at a 5/8-in. (16 mm) deflection when measured at the centerline of the belt span. This point is at the center of the belt when measuring the distance between the motor shaft and the blower shaft.

NOTE: Without the spring--tension tool, place a straight edge ac ross the belt surface at the pulleys, then deflect the belt at mid--span using one finger to a 1/2-in. (13 m m) deflection.

Adjust belt tension by loosening the motor mounting plate front bolts and rear bolt and sliding the plate toward the fan (to reduce tension) or away from fan (to increase tension). Ensure the blower shaft and the motor shaft are parallel to each other (pulleys aligned). Tighten all bolts when finished.

To replace the belt:

1. Use a belt with same section type or similar size. Do not substitute a “FHP” type belt. When installing the new belt, do not use a tool (screwdriver or pry--bar) to force the belt over the pulley flanges, this will stress the belt and cause a reduction in belt life.

2. Loosen the motor mounting plate front bolts and rear bolts.

3. Push the motor and its mounting plate towards the blower housing as close as possible to reduce the center distance between fan shaft and motor shaft.

4. Remove the belt by gently lifting the old belt over one of the pulleys.

5. Install the new belt by gently sli ding the belt over both pulleys and then sliding the motor and plate away from the fan housing until proper tension is achieved.

6. Check the alignment of the pulleys, adjust if necessary.

7. Tighten all bolts.

8. Check the tension after a few hours of runtime and re--adjust as required.

Adjustable--Pitch Pulley on

Motor

The motor pulley is an adjustable--pitch type that allows a servicer to implement changes in the fan wheel speed to match as-- installed ductwork systems. The pulley consists of a fixed flange side that faces the motor (secured to the motor shaft) and a movable flange side that can be rotated around the fixed flange side that increases or reduces the pitch diameter of this driver pulley. (See Fig. 6.)

As the pitch diameter is changed by adjusting the position of the movable flange, the centerline on this pulley shifts laterally (along the motor shaft). This creates a requirement for a realignment of the pulleys afte r any adjustment of the movable flange. Also reset the belt tension after each realignment.

To align fan and motor pulleys:

1. Loosen fan pulley setscrews.

2. Slide fan pulley along fan shaft. Make angular alignment by loosening motor from mounting.

3. Tighten fan pulley setscrews and motor mounting bolts to torque specifications.

4. Recheck belt tension.

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C07075

Fig. 6 -- Supply--Fan Pulley Adjustment

Bearings

This fan system uses bearings featuring concentric split locking collars. The collars are tightened through a cap screw bridging the split portion of the collar. The cap screw has a Torx T25 socket head. To tighten the locking collar: Hold the locking collar tightly against the inner race of the bearing and torque the cap screw to 65--70 in-lb (7.4--7.9 Nm). (See Fig. 7.)

Check the condition of the motor pulley for signs of wear. Glazing of the belt contact surfaces and erosion on these surfaces are signs of improper belt tension and/or belt slippage. Pulley replacement may be necessary.

To change fan speed:

1. Shut off unit power supply.

2. Loosen belt by loosening fan motor mounting nuts. (See Fig. 5.)

3. Loosen movable pulley flange setscrew. (See Fig. 6.)

4. Screw movable flange toward fixe d flange to increase speed and away from fixed flange to decrease speed. Increasing fan speed increases load on motor. Do not exceed maximum speed specified.

5. Set movable flange at nearest keyway of pulley hub and tighten setscrew to torque specifications.

C08121

Fig. 7 -- Tightening Locking Collar

Motor

When replacing the motor, also replace the external--tooth lock washer (star washer) under the motor mounting base; this is part of the motor grounding system. Ensure the teeth on the lock washer are in contact with the motor’s painted base. Tighten motor mounting bolts to 120 +/-- 12 in--lbs. (13.5 +/-- 1.3 Nm).

Changing the Fan Wheel Speed by Changing Pulleys

TUBES

The horsepower rating of the belt is primarily dictated by the pitch diameter of the smaller pulley in the drive system (typically the motor pulley in these units). Do not install a replacement motor pulley with a smaller pitch diameter than provided on the original factory pulley. Change fan wheel speed by changing the fan pulley (larger pitch diameter to reduce wheel speed, smaller pitch diameter to increase wheel speed) or select a new system (both pulleys and matching belt(s).)

Before changing pulleys to increase fan wheel speed, check the fan performance at the target speed and airflow rate to determine new motor loading (bhp). Use the fan performance tables or use the Packaged Rooftop Builder software program. Confirm that the mot or in this unit is capable of operating at the new operating condition. Fan shaft loading increases dramatically as wheel speed is

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increased.

To reduce vibration, replace the motor’s adjustable pitch pulley with a fixed pitch pulley (after the final airflow balance adjustment). T his will reduce the amount of vibration generated by the motor/belt--drive system.

COOLING

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal injury, death and/or equipment damage.

This system uses PuronR refrigerant which has higher pressures tha n R--22 and other refrigerants. No other refrigerant may be used in this system. Gauge set, hoses, and recovery system must be de signed to handle Puron refrigerant. If unsure about equipment, consult the equi pment manufacturer.

Condenser Coil

The condenser coil is new NOVATION Heat Exchanger Technology. This i s an all--aluminum construction with louvered fins over single--depth crosstubes. The crosstubes have multiple small passages through which the refrigerant passes from header to header on each end. Tubes and fins are both aluminum construction. Connection tube joints are copper. The coil may be one--row or two--row. Two--row coils are spaced apart to assist in cleaning. (See Fig. 8.)

FINS

MANIFOLD

MICROCHANNELS

C07273

Fig. 8 -- NOVATION Heat Exchanger Coils

Evaporator Coil

The evaporator coil is traditional round--tube, plate--fin technology. Tube and fin c onstruction is of various optional materials and coatings (see Model Number Format). Coils are multiple--row.

Coil Maintenance and Cleaning Recommendation

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

Remove Surface Loaded

Surface loaded fibers or dirt should be rem oved with a vacuum cleaner. If a vacuum cleaner is not available, a soft non--metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges can be easily bent over and damage to the coating of a protecte d coil) if the tool is applied across the fins.

NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse.

Periodic Clean Water

A periodic clean water rinse is very beneficial for coils that are applied in coastal or industrial environments. However, it is very important that the water rinse is made with very low velocity water stream to avoid damaging the fin edges. Monthly cleaning as described below is recommended.

Fibers

Rinse

Routine Cleaning of NOVATION Condenser Coil Surfaces

To clean the NOVATION condenser coil, chemicals are NOT to be used; only water is approved as the cleaning solution. Only clean potable water is authorized for cleaning NOVATION condensers. Carefully remove any foreign objects or debris attached to the coil face or trapped within the mounting frame and brackets. Using a high pressure water sprayer, purge any soap or industrial cleaners from hose and/or dilution tank prior to wetting the coil.

Clean condenser face by spraying the coil core steadily and uniformly from top to bottom, directing the spray straight into or toward the coil face. Do not exceed 900 psig or a 45 degree angle ; nozzle must be at lea st 12 in. (30 cm) from the coil face. Reduce pressure and use caution to prevent damage to air centers (fins). Do not fracture the braze between air centers and refrigerant tubes. Allow water to drain from the coil core and check for refrigerant leaks prior to start--up.

NOTE: Please see the NOVATION Condenser Service section for specific information on the coil.

CAUTION

PERSONAL INJURY HAZARD

Failure to follow this caution may result in personal injury or equipment damage.

Chemical clea ning should NOT be used on the aluminum NOVATION condenser. Damage to the coil may occur. Only approved cleaning is recommended.

Routine Cleaning of Evaporator Coil Surfaces

Monthly cleaning with Totaline® environmentally sound coil cleaner is essential to extend the life of coils. This cleaner is available from Bryant Replacement parts division as part number P902--0301 for one gallon container, and part number P902--0305 for a 5 gallon container. It is recommended that all round tube coil cleaner as described below. Coil cleaning should be part of the unit’s regularly scheduled maintenanc e procedures to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment.

Avoid t he use of

S coil brighteners S acid cleaning prior to painting S high pressure washers S poor quality water for cleaning

Totaline environmenta lly sound coil cleaner is non--flammable, hypoallergenic, non--bacterial, and a USDA accepted biodegradable agent that will not harm coil or surrounding components such as electrical wiring, painted metal surfaces, or insulation. Use of non--recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.

Totaline Environmentally Sound Coil Cleaner Application Equipment

S 2-1/2 gallon garden sprayer S water rinse with low velocity spray nozzle

CAUTION

PERSONAL INJURY HAZARD

Failure to follow this caution may result in corrosion and damage to the unit.

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

CAUTION

PERSONAL INJURY HAZARD

Failure to follow this caution may result in reduced unit performance.

High velocity water from a pressure washer, garden hose, or compressed air should never be used to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pre ssure drop.

Totaline Environmentally Sound Coil Cleaner application Instructions

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

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

3. Thoroughly wet finned surfaces with clean water and a low velocity garden hose, being careful not to bend fins.

4. Mix Totaline environmentally sound coil cleaner in a 2 1/2 gallon garden spryer according to the instructions included with the cleaner. The optimum solution temperature is 100°F(38°C).

NOTE: Do NOT USE water in excess of 130°F(54°C), as the enzymatic activity will be destroyed.

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

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

7. Ensure cleaner thoroughly penetrates deep into finned areas.

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

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

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

11. T horoughly rinse all surfaces with low velocity clean water using downward rinsing m otion of water spray nozzle. Protect fins from damage from the spray nozzle.

Evaporator Coil Metering Devices

The metering devices are multiple fixed--bore devices (Acutrolt) swaged into the horizontal outlet tubes from the liquid header, located at the entrance to each evaporator coil circuit path. These are non--adjustable. Service requires replacing the entire liquid header assembly.

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To check for possible bloc kage of one or more of these metering devices, disconnect the supply fan contactor (IFC) coil, then start the compressor and observe the frosting pattern on the face of the evaporator coil. A frost pattern should develop uniformly across the face of the coil starting at each horizontal liquid tube. Failure to develop frost at an outlet tube can indicate a plugged or a missing orifice.

Refrigerant System Pressure Access Ports

There are two access ports in each compressor--circuit system -- on the suction tube near the compre ssor and on the discharge tube near the compressor. These are brass fittings with black plastic caps. The hose connection fittings are standard 1/4 SAE male flare couplings.

The brass fittings are two--piece High Flow valves, with a receptacle base brazed to the tubing and an integral spring-closed check valve core screwed into the base. (See Fig. 9.) This check valve is permane ntly assembled into the core body and cannot be serviced separately. Replace the entire core body if necessary. Service tools are available from RCD that allow the replacement of the check valve core without having to recover the entire system refrigerant charge. Apply compressor refrigerant oil to the check valve core’s bottom O-ring. Install the fitting body with 96 +/-- 10 in-lbs (Nm) of torque; do not overtighten.

PURONR (R--410A) REFRIGERANT

This unit is designed for use with Puron (R--410A) refrigerant. Do not use any other refrigerant in this system.

Puron (R--410A) refrigerant is provided in pink (rose) colored cylinders. These cylinde rs are available with and without dip tubes; cylinders with dip tubes will have a label indicating this feature. For a cylinder with a dip tube, place the cylinder in the upright position (access valve at the top) when removing liquid refrigerant for charging. For a cylinder without a dip tube, invert the cylinder (access valve on the bottom) when removing liquid refrigerant.

Because Puron (R--410A) refrigerant is a blend, it is strongly recommended that refrigerant always be removed from the cylinder as a liquid. Admit liquid refrigerant into the system in the discharge line. If adding refrigerant into the suction line, use a commercial metering/expansion device at the gauge manifold; remove liquid from the cylinder, pass it through the metering device at the gauge set and then pass it into the suction line as a vapor. Do not remove Puron (R--410A) refrigerant from the cylinder as a vapor.

Refrigerant Charge

Amount of refrigerant charge is listed on the unit’s nameplate. Refer to GTAC2--5 Charging, Recovery, Recycling and Reclamation training manual and the following procedures.

Unit panels must be in place when unit is operating during the charging procedure. To prepare the unit for charge adjustment.

Charge

Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant.

Low--Charge

Using Cooling Charging Charts (Fig. 10, 11, 12, and 13), vary refrigerant until the c onditions of the appropriate chart are met. Note the charging charts are different from the type normally used. Charts are based on charging the units to the correct superheat for the various operating conditions. Accurate pressure gauge and temperature sensing device are required. Connect the pressure gauge to the service port on t he suction line. Mount the temperature sensing device on the suction line and insulate it so that outdoor ambi ent temperature doe s not affect the reading. Indoor--air cfm must be within the normal operating range of the unit.

To Use Cooling Charging

Select the appropriate unit charging chart from Fig. 10, 11, 12, and 13.

S Sizes 08D,F and 12D,F each have one cooling charging

chart

S Size 14D,F has two cooling charging charts: Circuit A

and Circuit B

Take the outdoor ambient temperature and read the suction pressure gauge. Refer to chart to determine what suction temperature should be. If suction temperature is high, add refrigerant. If suction temperature is low, carefully recover some of the charge. Recheck the suction pressure as charge is adjusted.

For 14D,F size, perform this procedure once for Circuit A (using the Circuit A chart) and once for Circuit B (using the Circuit B chart).

Cooling

Charts

SEAT

CORE

(Part No. EC39EZ067)

1/2-20 UNF RH

5/8” HEX

.47

Fig. 9 -- CoreMax Access Port Assembly

EXAMPLE:

Model 580J*14D

Circuit 1:

Outdoor Temperature 85_F(29_ C)..................

Suction Pressure 125 psig (860 kPa).................

Suction Temperature should be 58_F(14_C)..........

Circuit 2:

Outdoor Temperature 85_F(29_ C)..................

Suction Pressure 120 psig (830 kPa).................

Suction Temperature should be 60_F(16_C)..........

0.596

WASHER

O-RING

This surface provides a metal to metal seal when torqued into the seat. Appropriate handling is required to not scratch or dent the surface.

1/2" HEX

DEPRESSOR PER ARI 720 +.01/-.035 FROM FACE OF BODY

7/16-20 UNF RH

C08453

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COOLING CHARGING CHARTS

Fig. 10 -- Cooling Charging Charts (08D,F -- Both Circuits)

C09221

COOLING CHARGING CHARTS

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Fig. 11 -- Cooling Charging Charts (12D,F -- Both Circuits)

C09222

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COOLING CHARGING CHARTS

12.5 TON CIRCUIT 1

Fig. 12 -- Cooling Charging Charts (14D,F -- Circuit 1)

C09240

COOLING CHARGING CHARTS

12.5 TON CIRCUIT 2

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Fig. 13 -- Cooling Charging Charts (14D,F -- Circuit 2)

C09241

Table 1 – Cooling Service Analysis

PROBLEM CAUSE REMEDY

Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker.

Compressor and Condenser Fan Will Not Start.

Compressor Will Not Start But Condenser Fan Runs.

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Compressor Cycles (other than normally satisfying thermostat).

Compressor Operates Continuously.

Excessive Head Pressure.

Head Pressure Too Low.

Excessive Suction Pressure.

Suction Pressure Too Low.

Evaporator Fan Will Not Shut Off.

Compressor Makes Excessive Noise.

Defective thermostat, contactor, transformer, or control relay.

Insufficient line voltage. Determine cause and correct. Incorrect or faulty wiring. Check wiring diagram and rewire correctly. Thermostat setting too high. Lower thermostat setting below room temperature. Faulty wiring or loose connections in

compressor circuit.

Compressor motor burned out, seized, or internal overload open.

Defective run/start capacitor, overload, start relay.

Onelegofthree---phasepowerdead.

Refrigerant overcharge or undercharge.

Defective compressor. Replace and determine cause. Insufficient line voltage. Determine cause and correct. Blocked condenser. Determine cause and correct. Defective run/start capacitor, overload, or start

relay.

Defective thermostat. Replace thermostat. Faulty condenser--- fan motor or capacitor. Replace. Restriction in refrigerant system. Locate restriction and remove. Dirty air filter. Replace filter. Unit undersized for load. Decrease load or increase unit size. Thermostat set too low. Reset thermostat. Low refrigerant charg e. Locate leak; repair and recharge. Leaking valves in compressor. Replace compressor. Air in system. Recover refrigerant, evacuate system, and recharge. Condenser coil dirty or restricted. Clean coil or remove restriction. Dirty air filter. Replace filter. Dirty condenser coil. Clean coil. Refrigerant overcharged. Recover excess refrigerant. Air in system. Recover refrigerant, evacuate system, and recharge. Condenser air restricted or air short --- cycling. Determine cause and correct. Low refrigerant charg e. Check for leaks; repair and recharge. Compressor valves leaking. Replace compressor. Restrictioninliquidtube. Remove restriction. High head load. Check for source and eliminate. Compressor valves leaking. Replace compressor. Refrigerant overcharged. Recover excess refrigerant. Dirty air filter. Replace filter. Low refrigerant charg e. Check for leaks; repair and recharge. Metering device or low side restricted. Remove source of restriction.

Insufficient evaporator airflow.

Temperature too low in conditioned area. Reset thermostat. Outdoor ambient below 25° F. Install low--- ambient kit.

Time off delay not finished. W a it f o r 3 0 --- s e c o n d o f f d e l a y .

Compressor rotating in wrong direction. Reversethe3---phasepowerleads.

Replace component.

Check wiring and repair or replace.

Determine cause. Replace compressor.

Determine cause and replace.

Replace fuse or reset circuit breaker. Determine cause.

Recover refrigerant, evacuate system, and recharge to nameplate.

Determine cause and replace.

Increase air quantity. Check filter and replace if necessary.

Compressors

Lubrication

Compressors are charged with the correct amount of oil at the factory.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to components.

The compressor is in a PuronR re frigerant system and uses a polyolester (POE) oil. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Avoid exposure of the oil to the atmosphere.

WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to foll ow this warning could result in personal injury or death.

Relieve pressure and recover all refrigerant before system repair or fi nal unit disposal.

Wear safety glasses and gloves when handling refrigerants.

Keep torches and other ignition sources away from refrigerants and oils.

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

NOTE: When the compressor is rotating in the wrong direction, the unit makes an elevated level of noise and does not provide cooling.

Filter Drier

Replace whenever refrigerant system is exposed to atmosphere. Only use factory specified liquid--line filter driers with working pressures no less than 650 psig. Do not install a suction-- line filter drier in liquid line. A liquid--line filter drier designed for use with Puron refrigerant is required on every unit.

Condenser--Fan Adjustment (08D--12D,F size)

1. Shut off unit power supply. Install lockout tag.

2. Remove condenser-fan assembly (grille, motor, a nd fan).

3. Loosen fan hub setscrews.

4. Adjust fan height as shown in Fig. 14.

5. Tighten setscrews to 84 in-lbs (9.5 N-m).

6. Replace condenser-fan assembly.

CONDUIT

0.14 in +0.0/-0.03

C08448

Fig. 14 -- Condenser Fan Adjustment (08D--12D,F)

580J

Replacing Compressor

The compressor used with Puron refrigerant contains a POE oil. This oil has a high affinity for moisture. Do not remove the compressor’s t ube plugs until ready to insert the unit suction and discharge tube ends.

Compressor mounting bolt torque is 65--75 in-lbs (7.3--8.5 N-m).

Compressor

1. Connect service gauges to suction and discharge pressure fittings.

2. Energize the compressor.

3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start--up.

NOTE: If the suction pressure does not drop and the discharge pressure does not rise to normal levels:

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

2. Turn off power to the unit.

3. Reverse any two of the unit power leads.

4. Reapply power to the compressor.

Rotation

Condenser--Fan Adjustment (14D,F size)

1. Shut off unit power supply. Install lockout tag.

2. Remove condenser fan grille.

3. Loosen fan hub setscrews.

4. Adjust fan height as shown in Fig. 15.

5. Tighten setscrews to 84 in-lbs (9.5 N-m).

6. Replace fan grille.

C09094

Fig. 15 -- Condenser Fan Adjustment (14D,F)

Troubleshooting Cooling System

Refer to Table 1 for additional troubleshooting topics.

CONVENIENCE OUTLETS

WARNING

ELECTRICAL OPERATION HAZARD

Failure to foll ow this warning could result in personal injury or death.

Two types of convenience outlets are offered on 580J models: Non--powered and unit--powered. Both types provide a 125-volt GFCI (ground--fault circuit--interrupter) duplex receptacle rated at 15-A behind a hinged

580J

waterproof access cover, located on the end panel of the unit. (See Fig. 16.)

Pwd-CO Transformer

Conv Outlet GFCI

Pwd-CO Fuse Switch

COVER - WHILE-IN-USE WEATHERPROOF

BASE PLATE FOR GFCI RECEPTACLE

C09244

Fig. 17 -- Weatherproof Cover Installation

5. Remove two slot fillers in the bottom of the cover to permit service tool cords to exit the cover. Check for full closing and latching.

Non--Powered T ype

This type requires the field installation of a general--purpose 125--volt 15--A circuit powered from a source elsewhere in the building. Observe national and local codes when selecting wire size, fuse or breaker requirements and disconnect switch size and location. Route 125--v power supply conductors into the bottom of the utility box containing the duplex receptacle.

C08128

Fig. 16 -- Convenience Outlet Location

Installing Weatherproof Cover

A weatherproof while--in--use cover for the factory--installed convenience outlets is now required by UL standards. This cover cannot be factory--mounted due to its depth. It must be installed at unit installation. For shipment, the convenience outlet is covered with a blank cover plate.

The weat herproof cover kit is shipped in the unit’s control box. The kit includes the hinged cover, a backing plate and gasket.

IMPORTANT: Disconnect all power to uni t and convenience outlet.

1. Remove the blank cover plate at the convenience outlet; discard the blank cover.

2. Loosen the two screws at the GFCI duplex outlet, until approximately 1/2--in (13 mm) under screw heads are exposed.

3. Press the gasket over the screw heads. Slip the backing plate over the screw heads at the keyhole slots and align with the gasket. Tighten the two screws until snug (do not over--tighten).

4. Mount the weatherproof cover to the backing plate as shown in Fig. 17.

Unit--Powered Type

A unit--mounted transformer is factory--installe d to stepdown the main power supply voltage to the unit to 115--v at the duplex receptacle. This option also includes a manual switch with fuse, located in a utility box and mounted on a bracket behind the convenience outlet; access is through the unit’s control box access panel. (See Fig. 16.)

The primary leads to the convenience outlet transformer are not factory--connected. Selection of primary power source is a customer--option. If local codes permit, the transformer primary leads can be connected at the line--side terminals on a unit--mounted non--fused disconnect or circuit--breaker switch; this will provide service power to the unit when the unit disconnect switch or circuit--breaker is open. Other connection methods will result in the convenience outlet circuit being de--energized when the unit disconnect or circuit--breaker is open. (See Fig. 18.)

C08283

UNIT

VOLTAGE

208,

230

460 480

575 600

CONNECT

240

PRIMARY

CONNECTIONS

L1: RED +YEL L2: BLU + GRA

L1: RED Splice BLU + YEL L2: GRA

L1: RED L2: GRA

TRANSFORMER

TERMINALS

H1 + H3 H2 + H4

H2 + H3

H1 H2

Fig. 18 -- Powered Convenience Outlet Wiring

Cycle

Duty

The unit--powered convenience outlet has a duty cycle limitation. The transformer is intended to provide power on an intermittent basis for service tools, lamps, etc; it is not intended to provide 15--amps loading for continuous duty loads (such as electric heaters for overnight use). Observe a 50% limit on circuit loading above 8--amps (i.e., limit loads exceeding 8--amps to 30 minutes of operation every hour).

Maintenance

Using Unit-- Mounted Convenience Outlets

Units with unit--mounted convenienc e outle t circuits will often require that two disconnects be opened to de--energize all power to the unit. Treat all units as electrica lly energized until the convenience outle t power is also checked and de--energization is confirmed. Observe National Electrical Code Article 210, Branch Circuits, for use of convenience outlets.

SMOKE DETECTORS

Smoke detectors are a vailable as factory--installed options on 580J models. Smoke detectors may be specified for Supply Air only or for Return Air without or with economizer or in combina tion of Supply Air and Return Air. Return Air smoke detectors are arranged for vertical return configurations only. All components necessary for operation are factory--provided and mounted. The unit is factory--configured for immediate smoke detector shutdown operation; additional wiring or modifications to unit terminal board may be necessary to complete the unit and smoke detector configuration to meet project requirements.

System

The smoke detector system consists of a four--wire controller and one or two sensors. Its primary function is to shut down the rooftop unit in order to prevent smoke from circulating throughout the building. It is not to be used as a life saving device.

Controller

The controller includes a controller housing, a printed circuit board, and a clear plastic c over. (See Fig. 19.) The controller can be connected to one or two compatible duct smoke sensors. The clear plastic cover is secured to the housing with a single captive screw for easy access to the wiring terminals. The controller has three LEDs (for Power, Trouble and Alarm) and a manual test/reset button (on the cover face).

580J

Periodically test the GFCI receptacle by pressing the TEST button on the face of the receptacle. This should cause the internal circuit of the receptacle to trip and open the receptacle. Check for proper grounding wires and power line phasing if the GFCI receptacle does not trip as required. Press the RESET button to clear the tripped condition.

Fuse On Powered Type

The factory fuse is a Bussman “Fusetron” T--15, non--renewable screw--in (Edison base) type plug fuse.

Duct smoke sensor

controller

Conduit nuts

(supplied by installer)

Conduit sup port plate

Controller housing

and electronics

Conduit cou plings

(supplied by installer)

Fastener

(2X)

Terminal block cover

Cover gasket

(ordering option)

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Alarm

Troub le

Power

Tes t / r e s e t switch

Fig. 19 -- Controller Assembly

Sensor

The sensor includes a plastic housing, a printed circuit board, a cl ear plastic cover, a sampling tube inlet and an exhaust tube. (See Fig. 20.) The sampling tube (when used) and exhaust tube are attached during installation. The sampling tube varies in length depending on the size of the rooftop unit. The clear plastic cover permits visual inspections without having to disassemble t he sensor. The cover attaches to the sensor housing using four captive screws and forms an airtight chamber around the sensing electronics. Each sensor includes a harness with an RJ45 terminal for connecting to the controller. Each sensor has four LEDs (Power, Trouble, Alarm and Dirty) and a manual test/reset button (on the left--side of the housing).

Air is introduced to the duct smoke detector sensor’s sensing chamber through a sampling tube that extends into the HVAC duct and is directed back into the ventilation system through a (shorter) exhaust tube. The difference in air pressure between the two tubes pulls the sampled air through the sensing chamber. When a sufficient amount of smoke is detected in the sensing chamber, the sensor signals an alarm state and the controller automatically takes the appropriate action to shut down fans and blowers, change over air handling systems, notify the fire alarm control panel, etc.

Controll er cover

C08208

Duct smoke s ensor

Exhaust tube

Exhaust gasket

Sensor housing and electro nics

See

Detail A

Intake

Plug

Detail A

gasket

TSD-CO2

(ordering option)

Sampling tube

(ordered separately)

Magnetic test/reset

switch

Coupling

Alarm

Troub le

Power Dirty

Cover gasket

(ordering option)

Sensor cover

C08209

Fig. 20 -- Smoke Detector Sensor

For installations using two sensors, the duct smoke detector does not differentiate which sensor signals an alarm or t rouble condition.

Smoke Detector Locations

Supply Air

The Supply Air smoke detector sensor is located to the left of the unit’s indoor (supply) fan. (See Fig. 21.) Access is through the fan access panel. There is no sampling tube used at this location. The sampling tube inlet extends through the side plate of the fan housing (into a high pressure area). The controller is located on a bracket to the right of the return filter, accessed through the lift--off filter panel.

The sensor uses a process called differential sensing to prevent gradual environmental changes from triggering false alarms. A rapid change in environmental conditions, such as smoke from a fire, ca uses the sensor to signal an alarm state but dust and debris accumulated over time does not.

Smoke Detector Sensor

C08245

Fig. 21 -- Typical Supply Air Smoke Detector

Sensor Location

Return Air Without Economizer

The sampling t ube is located across the return air opening on the unit basepan. (See Fig. 22.) The holes in the sampling tube face downward, into the return air stream. The sampling t ube is connected via tubing to the return ai r sensor that is mounted on a bracket high on the partition between return filter and controller location. (This sensor is shipped in a flat--mounting location. Installation requires that this sensor be relocated to its operating location and the tubing to the sampling tube be connected. See installation steps.)

Return Air Detector module (shipping position shown)*

Controller module

Return Air Detector Sampling Tube

*RA detector must be moved from shipping position to operating position by installer

C07307

Fig. 22 -- Typical Return Air Detector Location

Return Air With

Economizer

The sampling tube is inserted through the side plates of the economizer housing, placing it across the return air opening on the unit basepan. (See Fig. 23.) The holes in the sampling tube face downward, into the return air stream. The sampling tube is connected via tubing to the return air sensor that is mounted on a bracket high on the partition between return filter and controller location. (This sensor is shipped in a flat--mounting location. Installation requires that this sensor be relocated to its operating location and the tubing to the sampling tube be connected. See installation steps.)

Completing Installation of Return Air Smoke Sensor

1. Unscrew t he two screws holding the Return Air Sensor detector plate. (See Fig. 24.) Save the screws.

2. Remove the Return Air Sensor and its detector plate.

3. Rotate the detector plate so the sensor is facing outwards and the sampling tube connection is on the bottom. (See Fig. 25.)

SCREWS

EXHAUST TUBE

FLEXIBLE EXTENSION TUBE

SAMPLING

Fig. 24 -- Return Air Detector Shipping Position

4. Screw the sensor and detector plate into its operating position using screws from Step 1. Make sure the sampling tube c onnection is on the bottom and the exhaust tube is on the top. (See Fig. 24.)

5. Connect the flexible tube on the sampling inlet to the sampling tube on the basepan.

6. For units with an economizer, the sampling tube is integrated into the economizer housing but the connection of the flexible tubing to the sampling tube is the same.

580J

C08126

Return Air Sampling Tube

Fig. 23 -- Return Air Sampling Tube Location

C08129

C08127

Fig. 25 -- Return Air Sensor Operating Position

FIOP Smoke Detector Wiring and Response

All Units

FIOP smoke detector is configured to automatically shut down all unit operations when smoke condition is detected. See Fig. 26, Smoke Detector Wiring.

Highlight

JMP 3 is factory--cut, transferri ng unit control to smoke detector.

580J

Fig. 26 -- Typical Smoke Detector System Wiring

Highlight

Smoke detector NC contact set will open on smoke alarm condition, de--energizing the ORN conductor.

Highlight

24--v power signal via ORN lead is removed at Smoke Detector input on LCTB; all unit operations cease immediately.

RTU--MP Contr

Unit operating functions (fan, cooling and heating) are terminated as described a bove. In addition:

Highlight

On smoke alarm condition, the smoke detector NO Alarm contact will close, supplying 24--v power to GRA conductor.

Highlight

GRA lead at Smoke Alarm input on LCTB provides 24--v signal to FIOP DDC control.

TU--MP

ols

C08246

Additional Application Data — Refer to Catalog No. HKRNKA--1XA for discussions on additional control features of these smoke detectors including multiple unit coordination. (See Fig. 26.)

Sensor and Controller Tests

Sensor Alarm Test

The sensor alarm test checks a sensor’s ability to signal an alarm state. This test requires t hat you use a field provided SD--MAG test magnet.

CAUTION

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

This test places the duct detector into the alarm state. Unless part of the test, disconnect all auxiliary equipment from the controller before performing the test. If the duct detector is connected to a fire alarm system, notify the proper authorities before performing the test.

The 24--v signal is conveyed to RTU--MP’s J1--10 input terminal. This signal initiates the FSD sequence by the RTU--MP control. FSD status is reported to connected BAS network.

Using Remote

Five conductors are provided for field use (see Highlight F) for additional annunciation functions.

Logic

Sensor Alarm Test Procedure

1. Hold the test magnet where indicated on the side of the sensor housing for seven seconds.

2. Verify that the sensor’s Alarm LED turns on.

3. Reset the sensor by holding the test magnet against the sensor housing for two seconds.

4. Verify that the sensor’s Alarm LED turns off.

Controller Alarm Test

The controller alarm test checks the controller’s ability to initiate and indicate an alarm state.

CAUTION

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

This test places the duct detector into the alarm state. Disconnect all auxiliary equipment from the controller before performing the test. If the duct detector is connected to a fire alarm system, notify the prope r authorities before performing the test.

Tabl e 2 – D i rty L E D Te st

FLASHES DESCRIPTION

1 0--- 25% dirty. (Typical of a newly installed detector)

2 25--- 50% dirty

3 51--- 75% dirty

4 76--- 99% dirty

Dirty Sensor Test Procedure

1. Hold the test magnet where indicated on the side of the sensor housing for two seconds.

2. Verify that the sensor’s Dirty LED flashes.

CAUTION

Controller Alarm Test Procedure

1. Press the controller’s test/reset switch for seven seconds.

2. Verify that the controller’s Alarm LED turns on.

3. Reset the sensor by pressing the test/reset switch for two seconds.

4. Verify that the controller’s Alarm LED turns off.

Dirty Controller T

The dirty controller test checks the controller’s ability to initiate a dirty sensor test and indicate its results.

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

Pressing the controller’s test/reset switch for longer than seven seconds will put the duct detector into the alarm state and activate all automatic alarm responses.

Dirty Controller Test Procedure

S Press the controller’s test/reset switch for two seconds. S Verify that the controller’s Trouble LED flashes.

Dirty Sensor T

The dirty sensor test provides an indication of the sensor’s ability to compensate for gradual environmental changes. A sensor that can no longer compensate for environmental changes is considered 100% dirty and requires cleaning or replacing. You must use a field provided SD--MAG test magnet to initiate a sensor dirty test. The sensor’s Dirty LED indicates the results of the dirty test as shown in Table 2.

est

CAUTION

est

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

Changing the dirty sensor test operation will put the detector into the alarm state and activate all automatic alarm responses. Before changing dirty sensor test operation, disconnect all auxiliary equipment from the controller and notify the proper authorities if connected to a fire alarm system.

Changing the Dirty Sensor Test

By default, sensor dirty test results are indicated by:

S The sensor’s Dirty LED flashing. S The controller ’s Trouble LED flashing. S The controller’s supervision relay contacts toggle.

The operation of a sensor’s dirty test can be changed so that the controller’s supervision relay is not used to indicate test results. When two detectors are connected to a controller, sensor dirty te st operation on both sensors must be configured to operate in the same manner.

To Configure the Dirty Sensor Test Operation

1. Hold the test magnet where indicated on the side of the sensor housing until the sensor’s Alarm LED turns on and its Dirty LED flashes twice (approximately 60 seconds).

2. Reset the sensor by removing the test magnet then holding it against the sensor housing again until the sensor’s Alarm LED turns off (approximately 2 seconds).

Remote Station T

The remote station alarm test checks a test/reset station’s ability to initiate and indicate an alarm state.

est

CAUTION

580J

CAUTION

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

Holding the test magnet against the sensor housing for more than seven seconds will put the duct detector into the alarm state and activate all automatic alarm responses.

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

SD--TRK4 Remote Alarm Test Procedure

1. Turn the key switch to the RESET/TEST position for seven seconds.

2. Verify that the test/reset station’s Alarm LED turns on.

3. Reset the sensor by turning the key switch to the RESET/TEST position for two seconds.

4. Verify that the test/reset station’s Alarm LED turns off.

Remote Test/Reset Station Dirty Sensor T

est

The test/reset station dirty sensor test checks the test/reset station’s ability to initiate a sensor dirty test and indicate the results. It must be wired to the controller as shown in Fig. 27 and configured to operate the controller’s supervision relay. For more information, see “Changing the Dirty Sensor Test.”

580J

TB3

Smoke Detector Controller

−

Auxiliary

equipment

Dirty Sensor Test Using an SD--TRK4

1. Turn the key switch to the RESET/TEST position for two seconds.

2. Verify that the test/r eset station’s Trouble LED flashes.

Detector Cleaning

Cleaning the Smoke Detector

Clean the duct smoke sensor when the Dirty LED is flashing continuously or sooner if conditions warrant.

CAUTION

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

If the smoke detector is connected to a fire alarm system, first notify the proper authorities that the detector is undergoing maintenance then disable the relevant circuit to avoid generating a false alarm.

1. Disconnect power from the duct detector then remove the sensor’s cover. (See Fig. 28.)

S contacts [3]

Wire m

ust be

added by installer

upe

ision relay

SD-TRK4

18 Vdc ( )

−

Trouble

ower

Alarm

Reset/Test

C08247

Fig. 27 -- Remote Test/Reset Station Connections

CAUTION

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

If the test/reset station’s key switch is left in the RESET/TEST position for longer than seven seconds, the detector will automatically go into the alarm state and activate all automatic alarm responses.

CAUTION

OPERATIONAL TEST HAZARD

Failure to follow this caut ion may result in personnel and authority concern.

Holding the test magnet to the target area for longer than seven seconds will put the detector into the alarm state and activate all automatic alarm responses.

Sampling

tube

Airow

HVAC duct

Sensor housing

Optic plate

Retainer clip

Optic housing

C07305

Fig. 28 -- Sensor Cleaning Diagram

2. Using a vacuum cleaner, clean compressed air, or a soft bristle brush, remove loose dirt and debris from inside the sensor housing and cover. Use isopropyl alcohol and a li nt--free cloth to remove dirt and other contaminants from the gasket on the sensor’s cover.

3. Squeeze the retainer clips on both sides of the optic housing then l ift the housing away from the printed circuit board.

4. Gently remove dirt and debris from around the optic plate and inside the optic housing.

5. Replace the optic housing and sensor cover.

6. Connect power to the duct detector then perform a sensor alarm test.

INDICAT ORS

Normal State

The smoke detector operates i n the normal state in the absence of any trouble conditions and when its sensing chamber is free of smoke. In the normal state, the Power LED on both the sensor and the controller are on and all other LEDs are off.

Alarm

The smoke detector enters the alarm state when the amount of smoke particulate in the sensor’s sensing chamber exceeds the alarm threshold value. (See Table 3.) Upon entering the alarm state:

The SuperDuct duct smoke dete ctor enters the trouble state under the following conditions:

An internal sensor fault is detected upon entering the trouble state:

State

S The sensor’s Alarm LED and the controller’s Alarm LED

turn on.

S The contacts on the controller’s two auxiliary relays

switch positions.

S The contacts on the controller’s alarm initiation relay

close.

S The controller’s remote alarm LED output is activated

(turned on).

S The controller’s high impedance multiple fan shutdown

control line is pulled to ground Trouble state.

S A sensor’s cover is removed and 20 minutes pass before

it is properly secured.

S A sensor’s environmental compensation limit is reached

(100% dirty).

S A wiring fault between a sensor and the controller is

detected.

S The contacts on the controller’s supervisory relay switch

positions. (See Fig. 29.)

S If a sensor trouble , the sensor ’s Trouble LED the

controller’s Trouble LED turn on.

S If 100% dirty, the sensor’s Dirty LED turns on and the

controller’s Trouble LED flashes continuously.

S If a wiring fault between a sensor and the controller, the

controller’s Trouble LED turns on but not the sensor’s.

Tro uble

Alarm

Power

NOTE: All troubles are latched by the duct smoke detector. The trouble condition must be cleared and then the duct smoke detector must be reset in order to restore it to the normal state.

Resetting Alarm and Trouble Condition T

rips

Manual reset is required to restore smoke detector systems to Normal operation. For installations using two sensors, the duct smoke detector does not differentiate which sensor signals an alarm or trouble condition. Check each sensor for Alarm or Trouble status (indicated by LED). Clear the condition that has generated the trip at this sensor. Then reset the sensor by pressing and holding the reset button (on the side) for 2 seconds. Verify that the sensor’s Alarm and Trouble LEDs are now off. At the controller, clear its Alarm or Trouble state by pressing and holding the manual reset button (on the front cover) for 2 seconds. Verify that the controller’s Alarm and Trouble LEDs are now off. Replace all panels.

Troubleshooting

Controller’s Tr ouble LED is On

1. Check the Trouble LED on each sensor connected to the controller. If a sensor’s Trouble LED is on, determine the cause and make the necessary repairs.

2. Check the wiring between the sensor and the controller. If wiring is loose or missing, repair or replace as required.

Controller’s Tr ouble LED is

1. One or both of the sensors is 100% dirty.

2. Determine which Dirty LED is flashing then clean that sensor assembly as described in the detector cleaning section.

Sensor’s Trouble LED is

1. Check the sensor’s Dirty LED. If it is flashing, the sensor is dirty and must be c leaned.

2. Check the sensor’s cover. If it is loose or missing, secure the cover to the sensor housing.

3. Replace sensor assembly.

Sensor’s Power LED is

1. Check the controller’s Power LED. If it is off, determine why the controller does not have power and make the necessary repairs.

2. Check the wiring between the sensor and the controller. If wiring is loose or missing, repair or replace as required.

Flashing

Off

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Fig. 29 -- Controller Assembly

Test/reset switch

C07298

Table 3 – Detector Indicators

CONTROL OR INDICATOR DESCRIPTION

Magnetic test/reset switch

Alarm LED Indicates the sensor is in the alarm state.

Troub le LED Indicates the sensor is in the trouble state.

Dirty LED

Power LED Indicates the sensor is energized.

Resets the sensor when it is in the alarm or trouble state. Activates or tests the sensor when it is in the normal state.

Indicates the amount of environmental compensation used by the sensor (flashing continuously = 100%)

Controller’s Power LED is Off

1. Make sure the circuit supplying power to the controller is operational . If not, make sure JP2 and JP3 are set correctly on the controlle r before applying power.

2. Verify that power is applied to the controller’s supply

580J

input terminals. If power is not present, replace or repair wiring as required.

Remote Test/Reset Station’s Trouble LED Does Flash When Performing a Dirty Test, but Controller’s Tr ouble LED

Does

the

1. Verify that the remote test/station is wired as shown in Fig. 27. Repair or replac e loose or missing wiring.

2. Configure the sensor dirty test to activate the controller’s supervision relay. See “Changing Sensor Dirty Test Operation.”

Sensor’s Trouble LED is On, But the Controller’ Tr ouble LED is

OFF

Remove JP1 on the controller.

PROTECTIVE DEVICES

Compressor Protection

Overcurrent

Each compressor has internal linebreak motor protection. Reset is automatic after compressor motor ha s cooled.

Overtemperatur

Each compressor has an internal protector to protect it against excessively high discharge gas temperatures. Reset is automatic.

High Pressure

Each system is provided with a high pressure switch mounted on the discharge line. The switch is stem--mounted and brazed into the discharge tube. Trip setting is 630 psig +/-- 10 psig (4344 +/-- 69 kPa) when hot. Reset is automatic at 505 psig (3482 kPa).

Low Pressure

Switch

Not

Supply (Indoor) Fan Motor Pr

otection

Disconnect and lockout power when servicing fan motor. The supply fan motor is equipped with an overcurrent protection device. The type of device depends on the motor size. (See Table 4.)

Table 4 – Supply Fan Motor Protection Devices

Motor Size

(bhp)

1.7 Internal Linebreak Automatic

2.4 Internal Linebreak Automatic

2.9 Thermik Automatic

3.7 Thermik Automatic

5.2

Overload Device Reset

External

(Circuit Breaker)

Manual

The Internal Linebreak type is an imbedded switch that senses both motor current and internal motor temperature. When this switch reaches its trip setpoint, the switch opens the power supply to the motor and the motor stops. Reset is automatic when the motor windings cool down.

The Thermik device is a snap--action overtemperature protection device that is imbedded i n the motor windings. It is a pilot-- circuit device that is wired into the unit’s 24--v control circuit. When this switch reaches its trip setpoint, it opens the 24--v control circuit and causes all unit operation to cease. This device resets automatically when the motor windings cool. Do not bypass this switch to correct trouble. Determine the cause and correct it.

The External motor overload device is a specially--calibrated circuit breaker that is UL recognized as a motor overload controller. It is an overcurrent device. When the motor current exceeds the circuit breaker setpoint, the device opens all motor power leads and the motor shuts down. Reset requires a manual reset at the overload switch. This device (designated IFCB) is located on the side of the supply fan housing, behind the fan access panel.

Each system is protected against a loss of charge and low evaporator coil loading condition by a low pressure switch located on the suction line near the compressor. The switch is stem--mounted. Trip setting is 54 psig +/ -- 5 psig (372 +/-- 34 kPa). Reset is automatic at 117 +/-- 5 psig (807 +/-- 34 kPa).

Tr oubleshooting Supply Fan Motor Overload Trips

The supply fan used in 580J units is a forward--curved centrifugal wheel. At a constant wheel speed, this wheel has a characteristic that causes the fan shaft load to DECREASE when the static pressure in the unit--duct system increases and to INCREASE when the static pressure in the unit--duct system decreases (and fan airflow rate increases). Motor overload conditions typically develop when the unit is operated with an access panel removed, with unfinished duct work, in an economizer--open mode, or a leak develops in the duct system that allows a bypass back to unit return opening.

Condenser Fan Motor Pr

otection

The condenser fan motor is internally protected against overtemperature.

Control Circuit, 24--V

The control circuit is protected against overcurrent conditions by a circuit breaker mounted on control transformer TRAN. Reset is manual.

GAS HEATING SYSTEM

General

The heat exchanger system consists of a gas valve feeding multiple inshot burners off a manifold. The burners fire into matching primary tubes. The primary tubes discharge into combustion plenum where gas flow converges into secondary tubes. The secondary tube s exit into the induced draft fan wheel inlet. The induced fan wheel discharges into a flue passage and flue gases exit out a flue hood on t he side of the unit. The induced draft fan motor inc ludes a Hall Effect sensor circuit that confirms adequate wheel speed via the Integrated Gas Control (IGC) board. Safety switches include a Rollout Switch (at the top of the burner compartment) and a limit switch (mounted through the fan deck, over the tubes). (See Fig. 30 and 31.)

Limit Switch and Shield

C08284

Fig. 31 -- Limit Switch Location

Fuel Types and Pressures

Natural Gas

The 580J unit is factory--equipped for use with Natural Gas fuel at elevation under 2000 ft (610 m). See section Orifice Replacement for information in modifying this unit for installation at eleva tions above 2000 ft (610 m).

Gas line pressure entering the unit’s main gas valve must be within specified ranges. (See Table 5.) Adjust unit gas regulator valve as required or consult local gas utility.

Table 5 – Natural Gas Supply Line Pressure Ranges

UNIT MODEL UNIT SIZE MIN MAX

580J All

4.0 in. wg (996 Pa)

Manifold pressure is factory--adjusted for NG fuel use. (See Table 6.) Adjust as required to obtain best flame characteristic.

Table 6 – Natural Gas Manifold Pressure Ranges

UNIT

MODEL

580J All

UNIT SIZE

HIGH

FIRE

3.5 in. wg (872 Pa)

LOW FIRE

1.7 in. wg (423 Pa)

13.0 in. wg (3240 Pa)

RANGE

2.0--- 5.0 in. wg (Hi) (498--- 1245 Pa)

580J

INDUCED-

DRAFT

MOTOR

MOUNTING

PLATE

BURNER

SECTION

INDUCED-

DRAFT MOTOR

MANIFOLD

PRESSURE

TAP

GAS VALVE

Fig. 30 -- Burner Section Details

ROLLOUT SWITCH

FLUE EXHAUST

VESTIBULE PLATE

BLOWER HOUSING

Liquid Propane

Accessory packages are available for field--installation that will convert the 580J unit to operate with Liquid Propane (LP) fuels. These kits include new orifice spuds, new springs for gas valves and a supply line low pressure switch. See section on Orifice Replacement for details on orifice size selections.

Fuel line pressure entering unit gas valve must remain within specified range. (See Table 7.)

C09153

Table 7 – Liquid Propane Supply Line Pressure Ranges

UNIT MODEL UNIT SIZE MIN MAX

580J All

11.0 in. wg (2740 Pa)

Manifold pressure for LP fuel use must be adjusted to specified range. (See Table 8.) Follow instructions in the accessory kit to make initial readjustment.

Table 8 – Liquid Propane Manifold Pressure Ranges

UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE

580J All

10.0 in. wg (2490 Pa)

Supply Pressure Switch

The LP conversion kit includes a supply low pressure switch. The switch contacts (from terminal C to terminal NO) will open the gas valve power whenever the supply

580J

line pressure drops be low the setpoint. (See Fig. 32 and

33.) If t he low pressure remains open for 15 minutes during a call for heat, the IGC circuit will initiate a Ignition Fault (5 flashes) lockout. Reset of the low pressure switch is automatic on rise in supply line pressure. Re set of the IGC requires a recycle of unit power after the low pressure switch has closed.

13.0 in. wg (3240 Pa)

5.0 in. wg (1245 Pa)

PNK

LP LPS

GRA

BRN

MGV

C08285

IGC

BRN

J2-11

IGC

J2-12

TSTAT

Fig. 33 -- LP Supply Line Low Pressure Switch Wiring

This switch also prevents operation when the propane tank level is low which can result in gas with a high concentration of impurities, additives, and residues that have settled to t he bottom of the tank. Operation under these conditions can cause harm to the heat exchanger system. Contact your fuel supplier if this condition is suspected.

Flue Gas Passageways

To inspect the flue collector box and upper areas of the heat exchanger:

1. Remove t he combustion blower wheel and motor assembly according to directions in Combustion--Air Blower section. (See Fig. 34.)

2. Remove the flue cover to inspect the heat exchanger.

3. Clean all surfaces as required using a wire brush.

Combustion--Air Blower

580JD08 only

C08238

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

To access burner section, slide the sliding burner partition out of the unit.

To inspect blower wheel, shine a flashlight into draft hood opening. If cleaning is required, remove motor and wheel as follows:

1. Slide burner access panel out.

2. Remove the 7 screws that attach induce d--draft motor housing to vestibule plate. (See Fig. 34.)

3. The blower wheel can be cleaned at this point. If additional cleaning is required, continue with Steps 4 and 5.

4. To remove blower from the motor shaft, remove 2 setscrews.

5. To remove motor, remove the 4 screws that hold the motor to mounting plate. Remove the motor cooling fan by removing one setscrew. Then remove nuts that hold motor to mounting plate.

6. To reinstall, reverse the procedure outlined above.

C08239

All 580J*D except DD08

Fig. 32 -- LP Low Pressure Switch (Installed)

WIND CAP

ASSEMBLY

(SHOWN

INVERTED,

AS SHIPPED)

HEATER TUBE

ASSEMBLY

SEAL STRIPS,

SPONGE RUBBER

REGULATOR

GASKET

REGULATOR

RETAINER

580J

SUPPORT INSULATION ASSEMBLY

INDUCER FAN-MOTOR ASSEMBLY

BURNER ASSEMBLY

C08227

Fig. 34 -- Heat Exchanger Assembly

Burners and Igniters

CAUTION

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage.

When working on gas train, do not hit or plug orifice spuds.

Main Burners

To access burners, remove burner access panel and slide out burner partition. 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.

Orifice Projection

Refer to Fig. 35 for maximum projection dimension for orifice face to manifold tube.

ORIFICE

1.00-in

(25.4 mm)

ANIFOLD

PIPE

C08211

Fig. 35 -- Orifice Projection

Removal and Replacement of Gas Train

See Fig. 30, 34, and 36.

1. Shut off manual gas valve.

2. Shut off power to unit.

3. Slide out burner partition.

4. Disconnect gas piping at unit gas valve.

5. Remove wires connected to gas valve. Mark each wire.

MANIFOLD PRESSURE TAP

GAS

VALVE

BURNERS

Fig. 36 -- Burner Tray Details

6. Remove igniter wires and sensor wires at the Integrated Gas Unit Controller (IGC). (See Fig. 37.)

7. Remove the 2 screws that attach the burner rack to

580J

the vestibule plate. (See Fig. 34.)

8. Slide the burner tray out of the unit . (See Fig. 36.)

9. To reinstall, reverse the procedure outlined above.

Cleaning and Adjustment

1. Remove burner rack from unit as described in Removal and Replacement of Gas Train section.

2. Inspect burners; if dirty, remove burners from rack. (Mark each burner to identify its position before removing from the rack.)

3. Use a soft brush to clean burners and cross--over port as required.

4. Adjust spark gap. (See Fig. 38.)

5. If factory orifice has been removed, check that each orifice is tight at its threads into the manifold pipe and that orifice projection does not exceed maximum valve. (See Fig. 35).

6. Reinstall burners on rack in the same locations as factory--installed. (The outside crossover flame regions of the outermost burners are pinched off to prevent excessive gas flow from the side of the burner assembly. If the pinched crossovers are installed between two burners, the flame will not ignite properly.)

RACEWAY

INTEGRATED GAS UNIT CONTROLLER (IGC)

C09154

7. Reinstall burner rack as described in Removal and Replacement of Gas Train section, above.

Gas Valve — All unit sizes are equipped with 2--stage gas valves. See Fig. 39 for locations of adjustment screws and features on the gas valves.

To adjust gas valve pressure settings:

IMPORTANT: Leak check all gas connections including the main service connection, gas val ve, gas spuds, and manifold pipe plug. All leaks must be repaired before firing unit.

Check Unit Operation and Make Necessary Adjustments

NOTE: Gas supply pressure at gas valve inlet must be

within specified ranges for fuel type and unit size. (See Table 5, 6, 7, and 8.)

1. Remove manifold pressure tap plug from manifold and connect pressure gauge or manometer. (See Fig.

36.)

2. Turn on electrical supply.

3. Turn on unit main gas valve.

4. Set room thermostat to call for heat. Verify high-stage heat operation before attempting to adjust manifold pressure.

5. When main burners ignite, check all fittings, manifold, and orifices for leaks.

6. Adjust high--stage pressure to specified setting by turning the plastic adjustment screw clockwise to increase pressure, counter--clockwise to decrease pressure.

7. Set room thermostat to call for low--stage heat. Adjust low--stage pressure to specified setting.

8. Replace regulator cover screw(s) when finished.

9. With burner access panel removed, observe unit heating operation in both high stage and low stage operation. Observe burner flames to see if they are blue in appearance, and that the flames are approximately the same for each burner.

10. Turn off unit, remove pressure manometer and replace the 1/8 in. pipe fitting on the gas manifold. (See Fig. 36.)

Limit Switch

HOLE IN END PANEL (HIDDEN)

Fig. 37 -- Unit Control Box/IGC Location

Remove blower access panel. Limit switch is located on the fan deck. (See Fig. 31.)

C08454

125,000/90,000 BTUH INPUT

180,000/120,000 BTUH INPUT

240,000/180,000 BTUH INPUT 250,000/200,000 BTUH INPUT

Fig. 38 -- Spark Adjustment (08--14)

580J

C08447

Burner Ignition

Unit is equipped with a direct spark ignition 100% lockout system. Integrated Gas Unit Controller (IGC) is located in the control box. (See Fig. 37.) The IGC contains a self--diagnostic LED (light--emitting diode). A single LED on the IGC provides a visual display of operational or sequential probl ems when the power supply is uninterrupted. (See Fig. 40.) When a break in power occurs, the IGC will be reset (resulting in a loss of fault history) and the indoor (evaporator) fan ON/OFF times will be reset. The LED error code can be observed through the viewport. During servicing refer to the label on the control box cover or Table 9 for an explanation of LED error code descriptions.

If lockout occurs, unit may be reset by interrupting power supply to unit for at least 5 seconds.

Table 9 – LED Error Code Description*

LED INDICATION

ON Normal Operation

OFF Hardware Failure

2Flashes Limit Switch Fault

3Flashes Flame Sense Fault

4Flashes 4 Consecutive Limit Switch Faults

5Flashes Ignition Lockout Fault

6Flashes Induced ---Draft Motor Fault

7Flashes Rollout Switch Fault

8Flashes Internal Control Fault

9Flashes Software Lockout

LEGEND LED --- L i g h t E m i t t i n g D io d e

* A 3 – second pause exists between LED error code flashes. If

more than one error code exists, all applicable codes will be displayed in numerical sequence.

ERROR CODE DESCRIPTION

IMPORTANT: Refer to Troubleshooting Table 13 and 14 for additional information.

580J

580J08(D,F)150 only

C08240

Fig. 39 -- Gas Valve

All 580J*D,F except 150

C08241

Orifice Replacement

This unit uses orifice type LH32RFnnn (where nnn indicates orifice reference size). W hen replacing unit orifices, order the necessary parts via Bryant RCD. See Table 11 for available orifice sizes. See Table 12 for orifice sizes for Natural Gas and LP fuel usage at various elevations above sea level.

Check that each replacement orifice is tight at its threads into the manifold pipe and that orifice projection does not exceed maximum value. (See Fig. 35.)

Red LED-Status

580J

Fig. 40 -- Integrated Gas Control (IGC) Board

Table 10 – IGC Connections

TERMINAL LABEL POINT DESCRIPTION SENSOR LOCATION TYPE OF I/O

INPUTS

RT, C Input power from TRAN 1 control box 24 VAC —

SS Speed sensor gas section analog input J1, 1-3

FS, T1 Flame sensor gas section switch input —

W Heat stage 1 LCTB 24 VAC J2, 2

RS Rollout switch gas section switch input J2, 5-6

LS Limit switch fan section switch input J2, 7-8

CS Centrifugal switch (not used) — switch input J2, 9 -10

OUTPUTS

L1, CM Induced draft combustion motor gas section line VAC

IFO Indoor fan control box relay J2, 1

GV Gas valve (heat stage 1) gas section relay J2, 11-12

C08452

CONNECTION

PIN NUMBER

Table 11 – Orifice Sizes

580J

ORIFICE

DRILL SIZE

BRYANT

PART NUMBER

#30 LH32RF129 0.1285

1/8 LH32RF125 0.1250 #31 LH32RF120 0.1200 #32 LH32RF116 0.1160 #33 LH32RF113 0.1130 #34 LH32RF111 0.1110 #35 LH32RF110 0.1100 #36 LH32RF105 0.1065 #37 LH32RF104 0.1040 #38 LH32RF102 0.1015 #39 LH32RF103 0.0995 #40 LH32RF098 0.0980 #41 LH32RF096 0.0960 #42 LH32RF094 0.0935 #43 LH32RF089 0.0890 #44 LH32RF086 0.0860 #45 LH32RF082 0.0820 #46 LH32RF080 0.0810 #47 LH32RF079 0.0785 #48 LH32RF076 0.0760 #49 LH32RF073 0.0730 #50 LH32RF070 0.0700 #51 LH32RF067 0.0670 #52 LH32RF065 0.0635 #53 LH32RF060 0.0595 #54 LH32RF055 0.0550 #55 LH32RF052 0.0520 #56 LH32RF047 0.0465 #57 LH32RF043 0.0430 #58 LH32RF042 0.0420

DRILL

DIA. (in.)

Table 12 -- Altitude Compensation* (08--14)

125,000

ELEVATION

ft (m)

0 --- 2000 (610) 31

2000 (610) 32

3000 (914) 32 4000 (1219) 33 5000 (1524) 33 6000 (1829) 34 7000 (2134) 35 8000 (2438) 36 9000 (2743) 37

10000 (3048) 38 11000 (3353) 39 12000 (3658) †41 53 13000 (3962) †42 54 14000 (4267) †43 54

LEGEND NG = Natural Gas LP = Liquid Propane * As the height above sea level increases, there is less oxygen

per cubic ft. of air. Therefore, heat input rate should be reduced at higher altitudes.

{ Not included in kit. May be purchased separately through

dealer.

BTUH Nominal

NG Orifice

Size

LP Orifice

Size

250,000

BTUH Nominal

NG Orifice

Size

†30 46 †30 47

38 †40 53

1 = CRLPELEV001A00 2 = CRLPELEV002A00 3 = CRLPELEV003A00 4 = CRLPELEV004A00

LP Orifice

Size

180,000, 224,000

BTUH Nominal

NG Orifice

Size

39 †41 53 †42 53 †43 54

LP Orifice

Size

Minimum Heating Entering Air Temperature

When operating on first stage heating, the minimum

Thermostat

TH1

temperature of air entering the dimpled heat exchanger is 50_F c ontinuous and 45_F intermittent for standard heat exchangers and 40_F continuous and 35_F intermittent for

TH2

stainless steel heat exchangers. To operate at lower mixed--air temperatures, a field--supplied outdoor--air thermostat must be used to initiate both stages of heat when the temperature is below the minimum required temperature to ensure full fire operat ion. Wire the outdoor--air thermostat OALT (part no. HH22AG106) in series with the second stage gas valve. (See Fig. 41.) Set the outdoor--air thermostat at 35_F for stainless steel heat exchangers or 45_F for standard heat exchangers. This

Troubleshooting Heating System

Refer to Table 13 and 14 for additional troubleshooting topics.

temperature setting will bring on the second stage of heat whenever the ambient temperature is below the thermostat setpoint. Indoor comfort may be compromised when heating is initiated using low entering air temperatures with insufficient heating temperature rise.

Table 13 – Heating Service Analysis

PROBLEM CAUSE REMEDY

Check flame ignition and sensor electrode positioning. Adjust as needed.

Check gas line for air, purge as necessary. After purging gas line of air, allow gas to dissipate for at least 5 minutes before attempting to relight unit.

Check gas valve.

Check transformer. Transformers with internal overcurrent protection require a cool down period before resetting.

Replace thermostat.

Check gas pressure at manifold. Clock gas meter for input. If too low, increase manifold pressure, or replace with correct orifices.

Use high speed tap, increase fan speed, or install optional blower, as suitable for individual units.

Check rotation of blower, thermostat heat anticipator settings, and temperature rise of unit. Adjust as needed.

Adjust minimum position. Check economizer operation. Check all screws around flue outlets and burner

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

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

or reset power to unit.

Burners Will Not Ignite.

Inadequate Heating.

Poor Flame Characteristics.

Burners Will Not Turn Off.

Misaligned spark electrodes.

No gas at main burners.

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

circuit. Miswired or loose connections. Check all wiring and wire nut connections. Burned ---out heat anticipator in

thermostat. Broken thermostat wires. Run continuity check. Replace wires, if necessary. Dirty air filter. Clean or replace filter as necessary.

Gas input to unit too low.

Unit undersized for application. Replace with proper unit or add additional unit. Restricted airflow. Clean filter, replace filter, or remove any restrictions.

Blower speed too low.

Limitswitchcyclesmainburners.

Too much outdoor air.

Incomplete combustion (lack of combustion air) results in: Aldehyde odors, CO, sooting flame, or floating flame.

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

OALT

Fig. 41 -- OATL Connections

LCTB

C08442

580J

Table 14 – IGC Board LED Alarm Codes

LED

FLASH

DESCRIPTION

CODE

On Normal Operation — — —

Off Hardware Failure No gas heating. —

Flashes

580J

Flashes

LEGEND IGC --- Integrated Gas Unit Control LED --- L i g h t --- E m i t ti n g D i od e NOTES:

Limit Switch Fault

Flame Sense Fault

Four Consecutive Limit Switch Fault

Ignition Fault No gas heating.

Induced Draft Motor Fault

Rollout Switch Lockout

Internal Control Lockout No gas heating. Power reset.

Temporary Software Lockout

1. There is a 3 --- second pause between alarm code displays.

2. If more than one alarm code exists, all applicable alarm codes will be displayed in numerical sequence.

3. Alarm codes on the IGC will be lost if power to the unit is interrupted.

ACTION TAKEN BY

CONTROL

Gas valve and igniter Off. Indoor fan and inducer On.

Indoor fan and inducer On.

No gas heating.

If heat off: no gas heating. If heat on: gas valve Off and inducer On.

Gas valve and igniter Off. Indoor fan and inducer On.

No gas heating.

RESET METHOD PROBABLE CAUSE

Loss of power to the IGC. Check 5 amp fuse on IGC, power to unit, 24V circuit breaker, t r a n s f o r m e r, and wiring t o the IGC.

High temperature limit switch is open. Check the operation of the indoor

Limit switch closed, or heat call (W) Off.

(evaporator) fan motor. Ensure that the supply-air temperature rise is within the range on the unit nameplate. Check wiring and limit switch operation.

Flame sense normal. Power reset for LED reset.

Heat call (W) Off. Power reset for LED reset.

The IGC sensed a flame when the gas valve should be closed. Check wiring, flame sensor, and gas valve operation.

4 consecutive limit switch faults within a single call for heat. See Limit Switch Fault.

Unit unsuccessfully attempted ignition for

Heat call (W) Off. Power reset for LED reset.

15 minutes. Check igniter and flame sensor electrode spacing, gaps, etc. Check flame sense and igniter wiring. Check gas valve operation and gas supply.

Inducer sense On when heat call Off, or Inducer sense normal, or heat call (W) Off.

inducer sense Off when heat call On.

Check wiring, voltage, and operation of

IGC motor. Check speed sensor wiring to

IGC.

Rollout switch has opened. Check gas

Power reset.

valve operation. Check induced-draft

blower wheel is properly secured to motor

shaft.

IGC has sensed internal hardware or

software error . If fault is not cleared by

resetting 24 v power, replace the IGC.

Check gas valve connections to IGC

terminals. BRN lead must be on Pin 11.

1 hour auto reset, or power reset.

Electrical interference is disrupting the

IGC software.

CONDENSER COIL SERVICE

RTU--MP CONTROL SYSTEM

Condenser Coil

The condenser coil is new NOVATION Heat Exchanger Technology. Thi s is an all--aluminum construction with louvered fins over single--depth crosstubes. The c rosstubes have multiple small passages through which the refrigerant passes from header to header on each end. Tubes and fins are both aluminum construction. Connection tube joints are copper. The coil may be one--row or two--row. Two--row coils are spaced apart to assist in cleaning.

Repairing NOVATION Condenser Tube Leaks

RCD offers service repair kit Part Number 50TJ660007 for repairing tube leaks in the NOVATION coil crosstubes. This kit includes approved braze materials (aluminum flux core braze rods), a heat shield, a stainless steel brush, replacement fin segments, adhesive for replacing fin segments, and instructions specific to the NOVATION aluminum coil. See EPIC for instruction sheet 99TA526379.

The repair procedure requires the use of MAPP gas and torch (must be supplied by servicer) instead of conventional oxyacetylene fuel and torch. While the flame temperature for MAPP is lower than that of oxyacetylene (and thus provides more flexibility when working on aluminum), the flame temperature is still higher than the melting temperature of aluminum, so user caution is required. Follow instructions carefully. Use the heat shield.

The RTU--MP controller provides expanded stand--alone operation of the HVAC system plus connection and control through communication with several Building Automation Systems (BAS) through popular third--party network systems. (See Fig. 42.) The available network systems are BACnet MP/TP, Modbus and Johnson J2. Communication with LonWorks is also possible by adding an accessory interface card to the RTU--MP. Selection of the communication protocol and baud rate are made at on--board DIP switches.

Bryant’s diagnostic display tools BACviewer6 Handheld and Virtual BACview (loaded on a portable PC) must be used with the RTU--MP controller. Connection to the RTU--MP board is at the J12 access port. (See Fig. 42.)

The RTU--MP control is factory--mounted in the 48TC unit’s main control box, to the left of the LCTB. (See Fig.

43.) Factory wiring is completed through harnesses connected to the LCTB. Field connections for RTU--MP sensors will be made at the Phoenix connectors on the RTU--MP board. The fa ctory--installed RTU--MP c ontrol includes the supply--air temperature (SAT) sensor. The outdoor air temperature (OAT) sensor is included in t he FIOP/accessory EconoMi$er 2 package.

Refer to Table 15, RTU--MP Controller Inputs and Outputs, for locations of all connections to the RTU--MP board.

580J

Replacing NOVATION Condenser Coil

The service replacement coil is preformed and is equipped with transition joints with copper stub tubes. When brazing the connection joints to the unit t ubing, use a wet cloth around the aluminum tube at the transition joint. Avoid applying torch flame directly onto the aluminum tubing.

580J

C07129

Fig. 42 -- RTU--MP Multi--Protocol Control Board

C09163

580J

Fig. 43 -- Typical RTU--MP System Control Wiring Diagram

Table 15 – RTU--MP Controller Inputs and Outputs

POINT NAME

Space Temperature Sensor sptsens AI (10K Thermistor) J 2 0 --- 1 , 2 Supply Air Temperature sat AI (10K Thermistor) J 2 --- 1 , 2 Local Outside Air Temperature Sensor oatsens AI (10K Thermistor) J 2 --- 3 , 4 Space Temperature Offset Pot sptopot AI (100K Potentiometer) J 2 0 --- 3 Indoor Air Quality iaq A I ( 4 --- 2 0 m a ) J 4 --- 2 , 3 Outdoor Air Quality oaq AI ( 4 --- 2 0 m a) J 4 --- 5 , 6 Safety Chain Feedback safety DI (24 VAC) J 1 --- 9 Compressor Safety compstat DI (24 VAC) J 1 --- 2 Fire Shutdown firedown DI (24 VAC) J 1 --- 1 0 Enthalpy Switch enthalpy DI (24 VAC) J 2 --- 6 , 7 Humidistat Input Status humstat DI (24 VAC) J 5 --- 7 , 8

Space Relative Humidity sprh A I ( 4 --- 2 0 m a )

580J

Outside Air Relative Humidity oarh A I ( 4 --- 2 0 m a) Supply Fan Status fanstat DI (24 VAC) Filter Status filtstat DI (24 VAC) Remote Occupancy Input remocc DI (24 VAC)

Economizer Commanded Position econocmd 4 --- 2 0m a J 2 --- 5 SupplyFanRelayState sf DO Relay (24VAC , 1A) J 1 --- 4 Compressor 1 Relay State comp_1 DO Relay (24VAC , 1A) J 1 --- 8 Compressor 2 Relay State comp_2 DO Relay (24VAC , 1A) J 1 --- 7 Heat Stage 1 Relay State heat_1 DO Relay (24VAC , 1A) J 1 --- 6 Heat Stage 2 Relay State heat_2 DO Relay (24VAC , 1A) J 1 --- 5 Power Exhaust Relay State aux_2 DO Relay (24VAC , 1A) J 1 1 --- 3 Dehumidification Relay State humizer DO Relay (24VAC, 1A) J 1 1 --- 7 , 8

LEGEND AI --- A n a l o g In pu t AO --- A n a l o g O u t p u t DI --- D is c r e t e I n p ut DO --- Discrete Output

* These inputs (if installed) take the place of the default input on the specific channel according to schematic. P a r a ll e l p i n s J 5 --- 1 = J 2 --- 6 , J 5 --- 3 = J 1 --- 1 0 , J 5 --- 5 = J 1 --- 2 a re u s e d f o r f i e ld --- i n s t a ll a t i o n . Refer to the input configuration and accessory sections for more detail.

BACnet OBJECT

NAME

INPUTS

CONFIGURABLE INPUTS*

OUTPUTS

TYPE OF I/O

CONNECTION PIN

NUMBERS

J4--- 2,3 or J4---5,6

J 5 --- 1 , 2 o r J 5 --- 3 ,4 o r

J5 5,6 or J5 ---7,8

NOTE: Refer to RTU--MP Controls, Start-Up, Operation, and Troubleshooting Instructions (Form 48--50H--T--2T) for complete configuration of RTU--MP, operating sequences and troubleshooting information. Refer to RTU--MP 3rd Party Integration Guide for details on configuration and troubleshooting of connected networks. Have a copy of these manuals available at unit start--up.

The RTU--MP controller require s the use of a Bryant space sensor. A standard thermostat cannot be used with the RTU--MP system.

Supply Air Temperature (SAT) Sensor

On FIOP--equipped 580J unit, the unit i s supplied with a supply--air temperature (SAT) sensor (33ZCSENSAT). This sensor is a tubular probe type, approx 6--inches (12.7 mm) in length. It is a nominal 10--k ohm thermistor. See Table 16 for temperature--resistance characteristic.

The SAT is factory--wired. The SAT probe is wire--tied to the supply--air opening (on the horizontal opening end) in its shipping position. Remove the sensor for installation. Re--position the sensor in the flange of the supply --air opening or in the supply air duct (as required by local codes). Drill or punch a 1/2--in. hole in the flange or duct. Use two field--supplied, self--drilling screws to secure the sensor probe in a horizontal orientation. (See Fig. 43.)

Outdoor Air Temperature (OAT) Sensor

The OAT is factory--mounted in the EconoMi$er 2 (FIOP or accessory). It is a nominal 10k ohm thermistor attached to an eyelet mounting ring. See Table 16 for temperature--resistance characteristic.

Table 16 – Thermistor Resistance vs Temperature Values for Space Temperature Sensor, Supply Air

Temperature Sensor, and Outdoor Air Temperature

Sensor

TEMP

(C)

--- 4 0 --- 4 0 335,651

--- 3 5 --- 3 1 242,195

--- 3 0 --- 2 2 176,683

--- 2 5 --- 1 3 130,243

--- 2 0 --- 4 96,974

--- 1 5 5 72,895

--- 1 0 14 55,298

--- 5 23 42,315 0 32 32,651 5 41 25,395

10 50 19,903 15 59 15,714 20 68 12,494 25 77 10,000 30 86 8,056 35 95 6,530 40 104 5,325 45 113 4,367 50 122 3,601 55 131 2,985 60 140 2,487 65 149 2,082 70 158 1,752

TEMP

(F)

RESISTANCE

(Ohms)

S Enthalpy control (outdoor air or differential sensors) S Space CO S Outdoor air CO

sensor

Field Connections -- Field connections for accessory sensors and input devices are made the RTU--MP, at plugs J1, J2, J4, J5, J11 and J20. All field control wiring that connects to the RTU--MP must be routed through the raceway built into the corner post as shown in Fig. 37. The raceway provides the UL required clearance between high-- and low--voltage wiring. Pass the control wires through the hole provided in the corner post, then feed the wires thorough the raceway to the RTU-- MP. Connect to the wires to the removable Phoenix connectors and then reconnect the connectors to the board.

Space Temperature (SPT) Sensors

A field--supplied Bryant space temperature sensor is required with the RTU--MP to monitor space temperature. There are 3 sensors available for this application:

S 33ZCT55SPT, space temperature sensor with override

button

S 33ZCT56SPT, space temperature sensor with override

button and setpoint adjustment

S 33ZCT59SPT, space tempe rature sensor wit h LCD

(liquid c rystal display) screen, override button, and setpoint adjustment

Use 20 gauge wire to connect the sensor to the controller. The wire is suitable for distances of up to 500 ft. Use a three--conductor shielded cable for the sensor and setpoint adjustment connections. If the setpoint adjustment (slidebar) is not required, then an unshielded, 18 or 20 gauge, two--conductor, twisted pair cable may be used.

580J

SUPPLY AIR TEMPERATURE SENSOR

SUPPLY AIR

RETURN AIR

ROOF CURB

C08200

Fig. 44 -- Typical Mounting Location for Supply Air

Temperature (SAT) Sensor on Small Rooftop Units

EconoMi$er 2

The RTU--MP control is used with EconoMi$er2 (option or accessory) for outdoor air management. The damper position is controlled directly by the RTU--MP control; EconoMi$er 2 has no internal logic device.

Outdoor air management functions can be enhanced with field--installation of these accessory control devices:

Connect

T--55

See Fig. 45 for typical T--55 internal connections. Connect the T--55 SEN terminals to RTU--MP J20--1 and J20--2. (See Fig. 46.)

SW1

SEN

RED(+)

WHT(GND)

BLK(-)

BRN (GND)

BLU (SPT)

CCN COM

SENSOR WIRING

C08201

Fig. 45 -- T--55 Space Temperature Sensor Wiring

SEN

J20-1

J20-2

Fig. 46 -- RTU--MP T--55 Sensor Connections

C08460

OR SET SEN

BRN (COM)

BLK (STO)

BLU (SPT)

SENSOR WIRING

Connect

T--56

See Fig. 47 for T--56 internal connections. Install a jumper between SEN and SET terminals as illustrated. Connect T--56 terminals to RTU--MP J20--1, J20--2 and J20--3 pe r Fig. 48.

580J

SW1

Cool Warm

SEN

RED(+)

WHT(GND)

BLK(-)

SET

BRN (GND) BLU (SPT)

BLK (T56)

CCN COM

SENSOR WIRING

JUMPER TERMINALS AS SHOWN

Fig. 47 -- T--56 Internal Connections

SEN J20-1

SEN

Jumper

J20-2

SET

J20-3

Fig. 48 -- RTU--MP T--56 Sensor Connections

C08202

C08461

OPB C OM- PWR+

POWER

24 VAC

NOTE: Must use a separate isolated transformer.

WIRING

C07132

Fig. 49 -- Space Temperature Sensor Typical Wiring

(33ZCT59SPT)

Economizer Controls

Outdoor Air Enthalpy Control (PNO HH57AC077)

The enthalpy control (HH57AC077) is available as a field--installed accessory to be used with the E conoMi$er2 damper system. The outdoor air enthalpy sensor is part of the enthalpy control. (The separate field--installed accessory return air enthalpy sensor (HH57AC078) is required for differential enthalpy control.)

Locate the enthalpy control in the economizer hood. Locate two GRA leads in the factory harness and connect these leads to enthalpy control sensors 2 and 3. (See Fig.

50.) Connect the enthalpy control power input termina ls to economizer actuator power leads RED (connect to TR) and BLK (connect to TR1).

Enthalpy Switch

GRA

LCTB ECON

Connect

T--59

The T--59 space sensor requires a separate, isolated power supply of 24 VAC. See Fig. 49 for internal connections at the T--59. Connect the SEN terminal (BLU) to RTU--MP J20--1. Connect the COM terminal (BRN) to J20--2. Connect the SET terminal (STO or BLK) to J20--3.

GRA

Factory Wiring Harness

C08218

Fig. 50 -- Enthalpy Switch (HH57AC077) Connections

The outdoor enthalpy changeover setpoint is set at the enthalpy controller.

The enthalpy control receives the outdoor air enthalpy from the outdoor air enthalpy sensor and provides a dry contact switch input to the RTU--MP controller. A closed contact indicates that outside air is preferred to the return air. An open contact indicates that the economizer should remain at minimum position.

Differential Enthalpy Contr

Differential entha lpy control is provided by sensing and comparing the outside air and return air enthalpy conditions. Install the outdoor air enthalpy control as described above. Add and install a return air enthalpy sensor.

Return Air Enthalpy

Sensor

Mount the return--air enthalpy sensor (HH57AC078) in the return--air duct. The ret urn air sensor is wired to the enthalpy controller (HH57AC077). (See Fig. 51.)

Indoor Air Quality (CO

Sensor)

The indoor air quality sensor accessory monitors space carbon dioxide (CO

) levels. This information is used to

monitor IAQ levels. Several types of sensors are available, for wall mounting in the space or in return duct, with and without LCD display, a nd in combination with space temperature sensors. Sensors use infrared technology to measure the levels of CO

The CO

sensors are all factory set for a range of 0 to

present in the space air.

2000 ppm and a linear mA output of 4 to 20. Refer to the instructions supplied with the CO

sensor for electrical

requirements and terminal locations. See Fig. 52 for typical CO

sensor wiring schematic.

580J

ENTHALPY CONTROLLER

TR TR1

LED

NOTES:

1. Remove factory-installed jumper across SR and + before connecting wires from return air sensor.

2. Switches shown in high outdoor air enthalpy state. Terminals 2 and 3 close on low outdoor air enthalpy relative to indoor air enthalpy.

3. Remove sensor mounted on back of control and locate in outside airstream.

RED BRN

BLK

RED

GRAY/ORN

GRAY/RED

WIRE HARNESS IN UNIT

(OUTDOOR

AIR

ENTHALPY

SENSOR)

(RETURN AIR

ENTHALPY

SENSOR)

C06019

Fig. 51 -- Outside and Return Air Enthalpy

Sensor Wiring

To wire the return air enthalpy sensor, perform the following:

1. Use a 2 --conductor, 18 or 20 AWG, twisted pair cable to connect the return air enthalpy sensor to the enthalpy controller.

2. At the enthalpy control remove the factory--installed resistor from the (SR) and (+) terminals.

3. Connect the field--supplied RED wire to (+) spade connector on the return air enthalpy sensor and the (SR+) terminal on the enthalpy controller. Connect the BLK wire to (S) spade connector on the return air enthalpy sensor and the (SR) terminal on the enthalpy controller.

NOTE: The enthalpy control must be set to the “D” setting for differential enthalpy control to work properly.

The enthalpy control receives the indoor and return enthalpy from the outdoor and return air enthalpy sensors and provides a dry contact switch input to the RTU--MP controller. A closed contact indicates that outside air is preferred to the return air. An open contact indicates that the economizer should remain at minimum position.

C07134

Fig. 52 -- Indoor/Outdoor Air Quality (CO2)Sensor

(33ZCSENCO2) -- Typical Wiring Diagram

To accurately monitor the quality of the air in the conditioned air space, locate the sensor near a return--air grille (if present) so it senses the concentration of CO leaving the space. The sensor should be mounted in a location to avoid direct breath contact.

Do not mount the IAQ sensor in drafty areas such as near supply ducts, open windows, fans, or over heat sources. Allow at least 3 ft (0.9 m) between the sensor and any corner. Avoid mounting the sensor where it is influenced by the supply air; the sensor gives inaccurate readings if the supply air is blown directly onto the sensor or if the supply air does not have a chance to mix with the room air before it is drawn into the return airstream .

Wiring the Indoor Air Quality Sensor

For each sensor, use two 2--conductor 18 AWG (American Wire Gauge) twisted--pair cables (unshielded) to connect the separate isolated 24 vac power source to the sensor and to connect the sensor to the control board terminals.

To connect the sensor to the control, identify the positive (4 to 20 mA) and ground (SIG COM) terminals on t he sensor. (See Fig. 52.) Connect the 4--20 mA terminal to RTU--MP J4--2 and connect the SIG COM terminal to RTU--MP J4--3. (See Fig. 53.)

IAQ Sensor

SEN

COM

24 VAC

Fig. 53 -- RTU--MP / Indoor CO2Sensor

(33ZCSENCO2) Connections

Outdoor Air Quality Sensor (PNO 33ZCSENCO2 plus Weatherproof Enclosure)

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The outdoor air CO dioxide (CO

) levels in the outside ventilation air and

sensor is designed to monitor carbon

interface with the ventilation damper in an HVAC system. The OAQ sensor is packaged with an outdoor cover. (See Fig. 54.) The outdoor air CO

sensor must be located in

the economizer outside air hood.

J4-2

J4-3

C08462

OAQ Sensor/RH Sensor

SEN

COM

24 VAC

J4-5

J4-6

C08463

Fig. 55 -- RTU--MP / Outdoor CO2Sensor

(33ZCSENCO2) Connections

On 580J units equipped with factory--installed Smoke Detector(s), the smoke detector controller implements the unit shutdown through its NC contact set connect ed to the unit’s LCTB input. T he FSD function is initiated via the smoke detector’s Alarm NO contact set. The RTU--MP controller communicates the smoke detector’s tripped status to the BAS building control. See Fig. 26 for unit smoke detector wiring.

The Fire Shutdown Switch configuration,

→

Config→Inputs→input 5, identifies the

normally open status of this input when there is no fire alarm.

COVER REMOVED SIDE VIEW

C07135

Fig. 54 -- Outdoor Air Quality Sensor Cover

Wiring the Outdoor Air CO

Sensor

A dedicated power supply is required for this sensor. A two--wire cable is required to wire the dedicated power supply for the sensor. The two wires should be connected to the power supply and terminals 1 and 2.

Alarm state is reset when the smoke detector alarm condition is cleared and reset at the smoke detector in the unit.

Connecting Discrete Inputs

Filter Status

The filter status accessory is a field--installed accessory. This accessory detects plugged filters. When installing this accessory, the unit must be configured for filter status

→

by setting MENU to Filter Status and normally open (N/O) or normally closed (N/C). Input 8 or 9 is recommended for easy of installation. Refer to Fig. 42 and 43 for wire terminations at J5.

Status

Fan

The fan status accessory is a field--installed accessory. This accessory detects when the indoor fan is blowing air. When installing this accessory, the unit must be configured for fan status by setting

→

Config→Inputs→input3,5,8,or9to Fan

Status and normally open (N/O) or normally closed (N/C). Input 8 or 9 is recommended for easy of installation. Refer to Fig. 42 and 43 for wire terminations at J5.

Config→Inputs→input3,5,8,or9

To connect the sensor to the control, identify the positive (4 to 20 mA) and ground (SIG COM) terminals on t he OAQ sensor. (See Fig. 52.) Connect the 4 to 20 mA terminal to RTU--MP J4--5. Connect the SIG COM terminal to RTU--MP J4--6. (See Fig. 55.)

Remote Occupancy

The remote occupancy accessory is a field --installed accessory. This accessory overrides the unoccupied mode and puts the unit in occupied mode. When installing this accessory, the unit must be configured for remote

→

occupancy by setting MENU 5, 8, or 9 to Remote Occupancy and normally open (N/O)

or normally closed (N/C).

→

Also set MENU on/off. Input 8 or 9 is recommended for easy of installation. Refer to Fig. 42 and Table 15 for wire terminations at J5.

Schedules→occupancy source to DI

Config→Inputs→input 3,

Power Exhaust (output)

Connect the accessory Power Exhaust contactor coil(s) per Fig. 56.

Power Exhaust

PEC

TAN

J11-3

LCTB

THERMOSTAT

GRA

Fig. 56 -- RTU--MP Power Exhaust Connections

Space Relative Humidity

Space Relative Humidity Sensor -- The RH sensor is not used with 580J models at this time.

Sensor

C08464

Communication Wiring -- Protocols

General

Protocols are the communication languages spoken by control devices. The main purpose of a protocol is to communicate information in the most efficient method possible. Different protocols exist to provide different kinds of information for different applications. In the BAS application, many different protocols are used, depending on manufacturer. Protocols do not change the function of a controller; just make the front end user different.

The RTU--MP can be set to communicate on four different protocols: BACnet, Modbus, N2, and LonWorks. Switch 3 (SW3) on the board is used to set protocol and baud rate. Switches 1 and 2 (SW1 and SW2) are used to set the board’s network address. See Fig 57 for the switch setting per protocol. The 3rd party connection to the RTU--MP is through plug J19. Refer to t he RTU--MP 3rd Party Integration Guide for more detailed information on protocols, 3rd party wiring, and networking.

NOTE: Power must be cycled after changing the SW1--3 switch settings.

BACnet

BACnet Master Slave/Token Passing (MS/TP) is used for communicating BACnet over a sub--network of BACnet--only controllers. This is the default Bryant communications protocol. Each RTU--MP module acts as an MS/TP Master. The speed of an MS/TP network can range from 9600 to 76.8K baud. Physical Addresses can be set from 01 to 99.

Modbus

The RTU--MP module can speak the Modicon Modbus RTU Protocol as described in the Modicon Modbus Protocol Reference Guide, PI--MBUS--300 Rev. J. The speed of a Modbus network can range from 9600 to 76.8K baud. Physical Addresses can be set from 01 to 99.

Johnson

N2 is not a standard protocol, but one that was created by Johnson Controls, Inc. that has been made open and available to the public. The speed of N2 network is limited to only 9600 baud. Physical Addresses can be set from 01 to 99.

LonW

LonWorks is an open protocol that requires the use of Echelon’s Neuron microproc essor to encode and decode the LonWorks packets. In order to reduce the cost of adding that hardware on e very module, a separate LonWorks Option Card (LON--OC) was designed to connect to the RTU-- MP.

This accessory card is needed for LonWorks and has to be ordered and connected using the ribbon cable to plug J15. The RTU--MP’s baud rate must be set to 38.4k t o communicate with the LON--OC. The address switches (SW1 & SW2) are not used with LonWorks.

Local

BACview6Handheld

The BACview6is a keypad/display interface used to connect to the RTU-- MP to access the control information, read sensor values, and test the RTU. (See Fig. 58.) This is an accessory interface that does not come with the MP controller and can only be used at the unit. Connect the BACview are 2 password protected levels in the display (User and Admin). The user password defaults to 0000 but can be changed. The Admin password is 1111 and cannot be changed. There is a 10 minute auto logout if a screen is left idle. See RTU--MP Controls, Start--Up, Operation, and Troubleshooting Instructions (Form 48--50H--T--2T), Appendix A for navigation and screen content.

MS/TP

orks

Access

to the RTU-- MP’s J12 local access port. There

580J

SW3 Protocol Selection

PROTOCOL DS8 DS7 DS6 DS5 DS4 DS3 DS2 DS1 BACnet MS/TP

(Master) Modbus

(Slave) N2

(Slave) LonWorks Unused ON ON OFF ON OFF OFF OFF

NOTE: DS = Dip Switch BACnet MS/TP SW3 example shown

Unused OFF OFF OFF ON OFF Select Baud Select Baud

Unused OFF OFF ON ON OFF Select Baud Select Baud

Unused OFF OFF OFF ON ON OFF OFF

Baud Rate Selections

BAUD RATE DS2 DS1

9600 OFF OFF 19,200 ON OFF 38,400 OFF ON 76,800 ON ON

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Fig. 57 -- RTU--MP SW3 Dip Switch Settings

C07166

Virtual BACview

Virtual BACview is a freeware computer program that

functions as the BACview

Handheld. The USB Link interface (USB--L) is required to connect a computer to the RTU--MP board. T he link cable connects a USB port to the J12 local access port. This program functions and operates identical to the handheld.

RTU--MP Troubleshooting

Communication LEDs

The LEDs indicate if the controller is speaking to the devices on the network. The LEDs should reflect communication traffic based on the baud rate set. The higher the baud rate the more solid the LEDs will appear.

Fig. 58 -- BACview6Handheld Connections

C07170

Table 17 – LEDs

The LEDs on the RTU--MP show the status of certain functions

If this LED is on... Status is... Power The RTU MP has power Rx The RTU MP is receiving data from the network segment

Tx The RTU MP is transmitting data over the network segment DO# The digital output is active

The Run and Error LEDs indicate control module and network status

If Run LED shows...

2 flashes per second Off Normal

2 flashes per second

2 flashes per second On

5 flashes per second On Exec start--- up aborted, Boot is running

5 flashes per second Off

7 flashes per second

14 flashes per second

On On

And Error LED shows... Status is...

2flashes, alternating with Run LED 3flashes, then off 4flashes, then pause

7 flashes per second, alternating with Run LED 14 flashes per second, alternating with Run LED

Five minute auto --- restart delay after system error Control module has just been formatted Two or more devices on this network havethesameARC156networkaddress Exec halted after frequent system errors or control programs halted

Firmware transfer in progress, Boot is running Ten second recovery period after brownout

Brownout

Failure. Try the following solutions:

S Turn the RTU --- MP off, then on. S Fo r m a t t he R T U --- M P. S Download memory to the RTU---MP. S Replace the RTU ---MP.

580J

Table 18 – Troubleshooting Alarms

BACnet

POINT NAME

Safety Chain Alarm safety_chain

Fire Shutdown Alarm fire_alarm

Space Temp Sensor Failure

SAT Sensor Alarm sat_alarm

High Space Temp Alarm spt_hi Alarm Generated Automatic

Low Space Temp Alarm spt_lo Alarm Generated Automatic

High Supply Air Temp sat_hi Alarm Generated Automatic

580J

Low Supply Air Temp sat_lo Alarm Generated Automatic

Supply Fan Failed to Start

Supply Fan in Hand sf_hand

Compressor Safety Alarm

Setpoint Slider Alarm slide_alarm

Dirty Filter Alarm filter Alarm Generated

Switch Configuration Alarm

Misconfigured Analog Input

OAT Sensor Alarm oat_alarm

Space RH Sensor Alarm sprh_alarm

Outdoor RH Sensor Alarm

High Space Humidity sprh_hi Alarm Generated Automatic

Low Space Humidity sprh_lo Alarm Generated Automatic IRH is less then 35% for more then 10 minutes.

IAQ Sensor Alarm iaq_alarm

OAQ Sensor Alarm oaq_alarm

High Carbon Dioxide Level Supply Fan Runtime Alarm Compressor 1 Runtime Alarm Compressor 2 Runtime Alarm

OBJECT

NAME

spt_alarm

sf_fail

dx_compstat Alarm Generated Automatic Compressor would not start.

sw_cfg_alarm

an_cfg_alarm

oarh_alarm Alarm Generated Automatic

co2_hi Alarm Generated Automatic CO2 reading is above 1200ppm.

sf_rntm Alarm Generated

dx1_rntm Alarm Generated

dx2_rntm Alarm Generated

ACTION TAKEN BY

CONTROL

Alarm Generated Immediate Shutdown Alarm Generated Immediate Shutdown Alarm Generated Immediate Shutdown Alarm Generated Immediate Shutdown

Alarm Generated Immediately disable Operation Alarm Generated Ramp down Operations

Alarm Generated Offset set to zero

Alarm Generated Disable misconfigured switch functions Alarm Generated Disable 4 selectable analog inputs Alarm Generated Economizer and Low ambient DX cooling lockout disabled. Alarm Generated Dehumidification disabled

Alarm Generated Disables IAQ Operation Economizer moves to minimum position Alarm Generated Set OAQ to 400

RESET

METHOD

Automatic Over load Indoor Fan or Electric Heater overheat.

Automatic

Automatic Bad Fan Status Switch, Configuration incorrect.

Automatic

Automatic/re set timer when configured with or without switch

Configure correctly

Automatic

clear the timer clear the timer clear the timer

Smoke detected by smoke detector or configuration incorrect

Faulty, shorted, or open thermistor caused by wiring error or loose connection.

Thespacetemperaturehasrisenabovethecool setpoint by more than the desired amount. The space temperature has dropped below the heat setpoint by more than the desired amount. SAT is greater then 160 degrees for more than 5 minutes. Thesupplyairtemperatureisbelow35_Ffor more than 5 minutes. Tripped Circuit Breaker, Broken belt, Bad indoor fan motor, Configuration incorrect, Bad fan status switch.

STOsensorisopenorshortedformorethen5 seconds.

Dirty Filter, supply fan run time exceeded, filter switch configuration wrong.

More than one binary input is configured for the same purpose. More then one discrete input is configured to provide the same function.

More then one analog input is configured to provide the same function.

Faulty, shorted, or open thermistor caused by wiring error or loose connection.

Sensor reading is out of range. Bad sensor, bad wiring, or sensor configured incorrectly.

Sensor reading is out of range. Bad sensor, bad wiring, or sensor configured incorrectly. IRH is greater then 70% for more then 10 minutes.

Sensor reading is out of range. Bad sensor, bad wiring, or sensor configured incorrectly.

Supply fan run time exceeded user defined limit.

Compressor run time limit is exceeded.

PROBABLE CAUSE

Alarms

Alarms can be checked through the network and/or the local access. All the alarms are listed in Table 18 with name, object name, action taken by control, reset method, and probable cause. There are help screens for each alarm on the local access display and listed in RTU--MP Controls, Start--Up, Operation, and Troubleshooting Instructions (Form 48--50H--T--2T), Appendix A: Help Screens. Some alarms are explained in detail below.

Safety Chain

This alarm occurs immediately if the supply--fan internal overload trips or if an electric--heat limit switch trips. The Unit Status will be Shutdown and the System Mode will be Disable. When this happens LCTB (R terminal) will not have 24 VAC, but the RTU--MP board will still be powered. All unit operations stop immediately and will not restart until the alarm automatically clears. There are no configurations for this alarm; it is all based on internal wiring. This alarm will never occur if Fire Shutdown Alarm is active.

Fire Shutdown

This alarm occurs immediately when the smoke detector senses smoke. The Unit Status will be Shutdown and the System Mode will be Disable . All unit operations stop immediately and will not restart until the alarm automatically clears. If there is not a smoke detector installed or the smoke detector did not trip, check input configurations.

Space Temp Sensor Failur

This alarm occurs if the space sensor wired to the RTU--MP is disconnected or shorted for m ore then 10 seconds. When this occurs the Unit Status will be Shutdown and the System Mode will be Run. Sensor, sensor connections, wiring, board connection, and configurations should be checked for faults or errors. Alarm will reset automatically when cause is fixed.

SA T Sensor

This alarm occurs immediately when the supply air temperature sensor wired to the RTU-- MP is disconnected or shorted. When this occurs the Unit Status will be Shutdown and the System Mode will be Run. Sensor, sensor connections, wiring, board connection, and configurations should be checked for faults or errors. Alarm will reset automatically when cause is fixed.

Switch Configuration

This occurs if more than one binary input (inputs 3, 5, 8, and 9) is configured for t he same function. When this happens the two inputs (or more) c onfigured wrong will be disabled as an inputs. This alarm will automatically be cleared when configuration is corrected.

An example of this would be: Input 3 = Compressor Safety, input 5 = Fan Status, input 8 = Fan Status, and input 9 = Humidistat; the alarm would be active, unit would run, compressor safety and humidistat would function norm ally, and Fan Status (inputs 5 & 8) will be interpreted as “No Function.”

Alarm

Misconfigured Analog

Input

This occurs if more t han one analog input (inputs 1 & 2) is configured for the same sensor. When this happens the two inputs will be disabled as inputs. This alarm will automatically be cleared when configuration is corrected.

An example of this would be: Input 1 = IAQ Sensor, input 2 = IAQ Sensor; the alarm would be active, unit would run, but the IAQ Sensor (inputs 1 & 2) will be interpreted as “No Function.”

Third Party

Networking

Third party communication and networking troubleshooting should be done by or wit h assistance from the front end 3rd party te chnician. A Module Status

Report (Modstat) can be run from the BACview

,see Table 19 to perform. This lists information about the board status and networking state. For basic troubleshooting, see Table 20. Refer to the RTU--MP 3rd Party Integration Guide for additional information.

BACnet MS/TP

1. Verify that the BAS and controller are both set to speak the BACnet MS/TP protocol. The protocol of the controller is set via SW3 (switches 3, 4, 5, and 6). The protocol can also be verified by getting a Modstat of the controller through the BACview. Hit the “FN” key and the ’.’ key at the same time to pull up a Modstat. Scroll to the bottom of the page and there is a section entitled “Network Communications.” The active protocol and baud rate will be shown in this section.

2. Verify that the BAS and controller are set for the same baud rate. The baud rate of the controller is set via SW3 (switches 1 and 2). The baud rate can also be verified via the BACview by obtai ning a Modstat. (See Fig. 59.)

3. Verify that the BAS is configured to speak 2--wire EIA--485 to the controller. The BAS may have to configure jumper or DIP switches on their end.

4. Verify that the BAS and the controller have the same communication settings (8 data bits, No Parity, and 1 stop bit).

5. Verify that the controller has a unique MAC address on the MS/TP bus. The controller’s MS/TP MAC address is set by its rotary address switches.

6. Verify proper wiring between the BAS and the controller.

7. Verify that the BAS is reading or writing to the proper BACnet objects in the controller. Download the latest points list for the controller to verify.

8. Verify that the BAS is sending his requests to the proper MS/TP MAC address of our controller.

9. Present the BAS company with a copy of our controller’s BACnet PICS so that they know which BACnet commands are supported.

580J

Device Instance: 0160001

1 PRGs loaded. 1 PRGs running.

Module status: Firmware sections validated in flash memory ============================================ Boot16-H - v2.06:001 Jun 19 2007 RTU-MP DRIVER - v2.09:050 Jun 26 2007

Reset counters: 11 Power failures 0 Brownouts 18 Commanded warm boots 22 Commanded cold boots 0 System errors 0 Watchdog timeouts

580J

System error message history: Type Specific Warning message history: Information message history: POWERUP: BACnet reinitialize warmstart 06/29/07 10:49:40 Menu file not found. 06/29/07 10:48:35

ARC156 reconfigurations during the last hour (cleared upon reset):

Total ....................... 0

Initiated by this node ...... 0

Core board hardware: Type=147, board=34, manufactured on 05/14/2007, S/N 21A740188N RAM: 1024 kBytes; FLASH: 1024 kBytes, type = 3 Base board hardware: Type=147, board=71, manufactured on 05/14/2007, S/N RMP750037N

Largest free heap space = 65536.

Database size = 742082 , used = 352162, free = 389920.

Raw physical switches: 0x01280000

Module Communications: Network Protocol=BACnet MSTP Master Network Baud Rate=9600 bps

C07195

Fig. 59 -- Module Status Report (Modstat) Example

10. In certain situations, it may be necessary to tweak the MS/TP Protocol timing settings through the

BACview

. There are two settings that may be

tweaked:

S Max Masters: Defines the highest MS/TP Master

MAC address on this MS/TP network. For exa mple, if there are 3 master nodes on an MS/TP network, and their MAC addresses are 1, 8, and 16, then Max Masters would be set to 16 (since this is the highest MS/TP MAC address on the network). This propert y optimizes MS/TP network communications by preventing token passes and “poll for master” requests to non -- existent Master nodes (i.e., in the above example, MAC address 16 would know to pa ss the token back to MAC address 1 instead of counting up to MAC address 127). Each MS/TP master node on the network must have their Max Masters set to this same value. The default is

127.

S MaxInfo Frames: This property defines the maximum

number of responses tha t will be sent when our controller get s the token. A vali d number is any positive integer. The default i s 10 and should be ideal for the majority of applications. In cases where the controller is the target of many requests, this number could be increased as high as 100 or 200.

NOTE: MS/TP networks can be comprised of both Master and Slave nodes. Valid MAC addresses for Master nodes are 0 -- 127 and valid addresses for Slave nodes are 0 -- 254.

NOTE: See RTU--MP 3rd Party Integration Guide (or alternatively RTU--MP Controls, Start--Up, Operation, and Troubleshooting Instructions (Form 48--50H--T--2T) Appendix) for Protocol Maps.

Table 19 – Manufacture Date

When troubleshooting, you may need to know a control module’s manufacture date

Obtain the manufacture date from a...

Module status report (modstat) To obtain a modstat with BACview6:

Sticker on the back of the main control module board ”Serial No: RMPYMxxxxN” (Bar Coded & Typed Number)

Notes

1. Press Function (FN) key and hold.

2. Then press period (.)

3. Release both buttons. ThereportshowsthedateunderMain board hardware.

The serial numbers are unique and contain embedded information:

“RMP” -- - These first three digits are unique to RTU - --MP and are used as an identifier.

“YM” --- These two digits identify the last digit of the year and month (in hex, A=10/Oct)

of manufacture. ”74” would represent a date of manufacture of ”April 2007”.

“xxxx” --- These four digits represent the sequential number of units produced for a given

product for the mentioned manufacturing time period.

“N” --- This final digit represents the decade and toggles between ”N” and ”M” every

ten years.

Table 20 – Basic Protocol Troubleshooting

Problem Possible cause Corrective action

No communication with 3rd party vendor

Incorrect settings on SW1, SW2 and SW3 Verify and correct switch settings. Cycle

RS485 Port has no voltage output Verify RTU --- MP has correct power supply

(check with RTU--- MP disconnected from RS485 communication bus)

Bacnet @ 9600/19.2K --- .01 to .045vdc Check RS485 bus for external before

Bacnet @ 38.4K --- .06 to .09vdc Voltage, shorts or grounding

Bacnet @ 76.8K --- .1vdc before reconnecting to the bus

Modbus @ 9600 --- 76.8K - -- .124vdc

N2 @ 9600 --- .124vdc

Verify devices are daisy chained and repeaters and bias terminators are correctly installed

powertoRTU---MPafterchangingswitch settings.

Possible bad driver on board.

reconnecting to the bus

Check 3rd party vendor RS485 communication wiring guidelines and troubleshooting procedures

580J

Table 21 – Modbus Exception Codes that May be

Returned From This Controller

CODE NAME ME ANING

The Modbus function code used

01 Illegal Function

02 Illegal Data Address

04 SlaveDeviceFailure

in the query is not supported by the controller.

The register address used in the query is not supported by the controller.

The Modbus Master has attempted to write to a non--- existent register or a read--- only register in the controller.

Modbus

1. Verify that the BAS and controller are both set to speak the Modbus RTU protocol. The protocol of the controller is set via SW3 (switches 3, 4, 5, and 6). The protocol can also be verified by getting a Modstat of the controller through the BACview. Hit the ”FN” key and the ’.’ key at the same time to pull up a Modstat. Scroll to the bottom of the page and there is a section entitled “Network Communications.” The active protocol and baud rate will be shown in this section.

3. Verify that the BAS is configured to speak 2--wire EIA--485 to the controller. The BAS may have to configure jumper or DIP switches on their end.

4. Verify that the BAS and the controller have the same communication settings (8 data bits, No Parity, and 1 stop bit).

5. Verify that the controller has a unique Modbus slave address. The controller’s Modbus slave address is set by its rotary address switches.

6. Verify that the BAS is using the proper Modbus function codes to access data from our controller. Supported function codes are shown above.

7. Verify proper wiring between the BAS and the controller.

8. Verify that the BAS is reading or writing to the proper Modbus register numbers on the controller. Download the latest points list for the controller to verify.

9. Verify that the BAS is sending his requests to the proper slave address of our controller.

NOTE: See RTU--MP 3rd Party Integration Guide (or alternatively RTU--MP 3rd Party Integration Guide (or alternatively RTU--MP Controls, Start--Up, Operation, and Troubleshooting Instructions (Form 48--50H--T--2T), Appendix) for Modbus Protocol Conformance Statement.

1. Verify that the BAS and controller are both set to speak the N2 protocol. The protocol of the controller is set via SW3 (switches 3, 4, 5, and 6). The protocol can also be verified by getting a Modstat of the controller through the BACview. Hit the “FN” key and the ’.’ key at the same time to pull up a Modstat. Scroll to the bottom of the page and there is a section entitled ”Network Communications.” The active protocol and baud rate will be shown in this section.

2. Verify that the BAS and controller are set for 9600

580J

baud. The baud rate of the controller is set via SW3 (switches 1 and 2). The baud rate can also be verified via the BACview by obtaining a Modstat. (See Fig.

59.)

3. Verify that the BAS is configured to speak 2--wire EIA--485 to the controller. The BAS may have to configure jumper or DIP switches on their end.

4. Verify that the BAS and the controller have the same communication settings (8 data bits, No Parity, and 1 stop bit).

5. Verify that the controller has a unique N2 slave address on the N2 bus. The controller’s N2 slave address is set by its rotary address switches.

6. Verify proper wiring between the BAS and the controller.

7. Verify that the BAS is reading or writing to the proper network point addresses on the c ontroller. Download the latest points list for the controller to verify.

8. Verify that the BAS is sending his requests to the proper slave address of our controller.

ECONOMI$ER SYSTEMS

The 580J units may be equipped with a factory--installed or accessory (field --installed) economizer system. Two types are available: with a logic control system (EconoMi$er IV) and without a control system (EconoMi$er2, for use with external control systems). See Fig. 60 and Fig. 61 for component locations on each type. See Fig. 62 and Fig. 63 for economizer section wiring diagrams.

Both EconoMi$ers use direct--drive damper actuators.

ECONOMI$ER IV CONTROLLER

WIRING

HARNESS

ACTUATOR

(HIDDEN)

LOW TEMPERATURE

COMPRESSOR

LOCKOUT SWITCH

TEMPERATURE SENSOR

(OPERATING LOCATION)

OUTSIDE AIR

Fig. 60 -- EconoMi$er IV Component Locations

OUTDOOR AIR HOOD

ECONOMI$ER2 PLUG

BAROMETRIC RELIEF DAMPER

HOOD SHIPPING BRACKET

GEAR DRIVEN DAMPER

Fig. 61 -- EconoMi$er2 Component Locations

C07367

C06022

Fig. 62 -- EconoMi$er IV Wiring

500 OHM RESISTOR

NOTE 1

RUN

NOTE 3

50HJ540573

ACTUATOR ASSEMBLY

DIRECT DRIVE

ACTUATOR

NOTES:

1. Switch on actuator must be in run position for economizer to operate.

50HJ540573 actuator consists of the 50HJ540567 actuator and a harness with 500-ohm resistor.

OAT SENSOR

4-20mA SIGNAL

VIOLET

PINK

BLACK

BLUE

RED

YELLOW

WHITE

ECONOMISER2 PLUG

TRANSFORMER GROUND

24 VAC

580J

C09023

Fig. 63 -- EconoMi$er2 with 4 to 20 mA Control Wiring

C09223

Table 22 – EconoMi$er IV Input/Output Logic

INPUTS OUTPUTS

Demand Control

Ventilation (DCV)

(Free Cooling LED

Below set

(DCV LED Off)

(Free Cooling LED

Above set

(DCV LED On)

580J

* For single enthalpy control, the module compares outdoor enthalpy to the ABCD setpoint. † Power at N terminal determines Occupied/Unoccupied setting: 24 vac (Occupied), no power (Unoccupied). ** Modulation is based on the supply-air sensor signal. †† Modulation is based on the DCV signal. *** Modulation is based on the greater of DCV and supply-air sensor signals, between minimum position and either maximum position (DCV)

or fully open (supply-air signal).

††† Modulation is based on the greater of DCV and supply-air sensor signals, between closed and either maximum position (DCV) or fully

open (supply-air signal).

(Free Cooling LED

Enthalpy*

Outdoor Return

High

Low

Off)

Low

High

On)

High

Low

Off)

Low

High

On)

Y1 Y2

On On On On

Off Off Off Off

On On On Off

On Off Off Off

Off Off Off Off Minimum position Closed On On On On

On Off On Off

Off Off Off Off On On On Off

Off Off Off Off

Compressor NTerminal†

Stage1Stage

Occupied Unoccupied

Damper

Minimum position ClosedOn Off On Off

Modulating** (between

min. position and

full-open)

Modulating†† (between

min. position and DCV

maximum)

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

(between closed and

Modulating**

full-open)

Modulating††

maximum)

DCV

Fig. 64 -- EconoMi$er IV Functional View

EconoMi$er IV

Table 22 provides a summary of E conoMi$er IV. Troubleshooting instructions are enclosed.

A functional view of the EconoMi$er is shown in Fig. 64. Typical settings, sensor ranges, and jumper positions are also shown. An EconoMi$er IV simulator program is available from Bryant to help with EconoMi$er IV training and troubleshooting.

C06053

EconoMi$er IV Standard

Sensors

Outdoor Air Temperature (OAT) Sensor

The outdoor air temperature sensor (HH57AC074) is a 10 to 20 mA device used to measure the outdoor-air temperature. The outdoor-air t emperature is used to determine when the EconoMi$er IV can be used for free cooling. The sensor is factory-installed on the EconoMi$er IV in the outdoor airstream. (See Fig. 60.) The operating range of temperature measurement is 40_ to 100_F(4_ to 38_C). (See Fig. 67.)

Supply Air Temperature (SAT) Sensor

The supply air temperature sensor is a 3 K thermistor located at the inlet of the indoor fan. (See Fig. 65.) This sensor is factory install ed. The operating range of temperature measurement is 0° to 158_F(--18_ to 70_C). See Table 16 for sensor temperature/resistance values.

SUPPLY AIR TEMPERATURE SENSOR MOUNTING LOCATION

SUPPLY AIR TEMPERATURE SENSOR

C06033

Fig. 65 -- Supply Air Sensor Location

C06034

Fig. 66 -- EconoMi$er IV Controller Potentiometer

and LED Locations

580J

The temperature sensor looks l ike an e yelet terminal with wires running to it. The sensor is located in the “crimp end” and is sealed from moisture.

Outdoor Air Lockout Sensor

The EconoMi$er IV is equipped with an ambient temperature lockout switch located in the outdoor airstream which is used to lock out the compressors below a42_F(6_C) ambient temperature. (See Fig. 60.)

EconoMi$er IV Control

Modes

IMPORTANT: The optional EconoMi$er2 does not

include a controller. The EconoMi$er2 is operated by a 4 to 20 mA signal from an existing field-supplied controller. See Fig. 63 for wiring information.

Determine the EconoMi$er IV control mode before set up of the control. Some modes of operation may require different sensors. (See Table 22.) The EconoMi$er IV is supplied from the factory with a supply-air temperature sensor and an outdoor-air temperature sensor. This allows for operation of the EconoMi$er IV with outdoor air dry bulb changeover control. Additional accessories can be added to allow for different types of changeover control and operation of the EconoMi$er IV and unit.

Outdoor Dry Bulb Changeover

The standard controller is shipped from the factory configured for outdoor dry bulb changeover control. The outdoor air and supply air temperature sensors are included as standard. For this control mode, the outdoor temperature is compared to an adjustable setpoint selected on the control. If the outdoor-air temperature is above the setpoint, the EconoMi$er IV will adjust the outside air dampers to minimum position. If the outdoor-air temperature is below the setpoint, the position of the outside air dampers will be controlled to provided free cooling using outdoor air. When in this mode, the LED next to the free cooling setpoint potentiometer will be on. The changeover temperature setpoint is controlled by the free cooling setpoint potentiometer located on the control. (See Fig. 66.)

The scale on the potentiometer is A, B, C, and D. See Fig. 63 for the corresponding temperature changeover values.

LED ON

LED OFF

DEGREES FAHRENHEIT

LED ON

LED OFF

LED ON

LED OFF

LED ON

LED OFF

100

Fig. 67 -- Outside Air Temperature Changeover

Setpoints

0.13 0.20 0.22 0.25 0. 30 0. 35 0.40 0.45 0.50

FLOW IN CUBIC FEET PER MINUTE (cfm)

STATIC PRESSURE (in. wg)

Fig. 68 -- Outdoor--Air Damper Leakage

C06035

C06031

Differential Dry Bulb Control

For differential dry bulb control the standard outdoor dry bulb sensor is used in conjunction with an additional accessory dry bulb sensor (part number CRTEMPSN002A00). The accessory sensor must be mounted i n the return airstream. (See Fig. 69.) Wiring is provided in the EconoMi$er IV wiring harness. (See Fig.

62.)

ECONOMI$ERIV CONTROLLER

ECONOMI$ERIV

580J

RETURN AIR SENSOR

GROMMET

In this mode of operation, the outdoor-air temperature is compared to the return-air temperature and the lower temperature airstream is used for cooling. When using this mode of changeover control, turn the entha lpy setpoint potentiometer fully clockwise to the D setting. (See Fig.

66.)

Outdoor Enthalpy Changeover

For enthalpy control, accessory enthalpy sensor (part number HH57AC078) is required. Replace the sta ndard outdoor dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. (See Fig.

69.) When the outdoor air enthalpy rises a bove the outdoor enthalpy changeover setpoint, the outdoor-air damper moves to its minimum position. The outdoor enthalpy changeover setpoint is set with the outdoor enthalpy setpoint potentiometer on the EconoMi$er IV controller. The setpoints are A, B, C, and D. (See Fig. 70.) The factory-installed 620-ohm jumper must be in place across terminals S

and SR+ on the E conoMi$er IV

controller.

RETURN DUCT (FIELD-PROVIDED)

C07085

Fig. 69 -- Return Air Temperature or Enthalpy Sensor

Mounting Location

CONTROL

CONTROL POINT

deg. F (deg. C)

APPROX.

AT 50% RH

73 (23) 70 (21) 67 (19) 63 (17)

ENTHALPY BTU PER POUND DRY AIR

(13)

(10)

(7) 40 (4)

35 (2)

(18)

(16)

CURVE

A B C D

(21)

(29)90(32)95(35)

(27)

(24)

100 (38)

RELATIVE HUMIDITY (%)

(41)

105

110

(43)

(2)

APPROXIMATE DRY BULB TEMPERATURE--degrees F (degrees C)

(4)

(10)

(13)

(7)

(16)

(18)

(21)

(24)

(27)

(29)90(32)95(35)

Fig. 70 -- Enthalpy Changeover Setpoints

(38)

HIGH LIMIT

110 (43)

CURVE

105

100

(41)

C06037

2V 10V

EXH

Open

2V 10V

DCV

2V 10V

Free Cool

EXH

Set

Min Pos

DCV

Max

DCV

Set

AQ1

SO+

SR+

Fig. 71 -- EconoMi$er IV Control

TR1

24 Vac

Va c

COM

HOT

EF1

C06038

Adjust the DCV potentiometers to correspond to the DCV voltage output of the indoor air quality sensor at the user-determined set point. (See Fig. 72.)

CO SENSOR MAX RANGE SETTING

6000

5000

4000

3000

2000

1000

RANGE CONFIGURATION (ppm)

2345678

DAMPER VOLTAGE FOR MAX VENTILATION RATE

800 ppm 900 ppm 1000 ppm 1100 ppm

C06039

Fig. 72 -- CO2Sensor Maximum Range Settings

580J

Differential Enthalpy Control

For differential enthalpy control, the EconoMi$er IV controller uses two enthalpy sensors (HH57AC078 and CRENTDIF004A00), one in the outside air and one in the return air duct. The EconoMi$er IV controller compares the outdoor air enthalpy to the return air enthalpy to determine EconoMi$er IV use. The control ler selec ts the lower enthalpy air (return or outdoor) for cooling. For example, when the outdoor air has a lower e nthalpy than the return air, the EconoMi$er IV opens to bring in outdoor air for free cooling.

Replace the standard outside air dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. (See Fig. 60.) Mount the return air enthalpy sensor in the return air duct. (See Fig. 69.) Wiring is provided in the EconoMi$er IV wiring harness. (See Fig. 62.) T he outdoor enthalpy changeover setpoint is set with the outdoor enthalpy setpoint potentiometer on the EconoMi$er IV controller. When using this mode of changeover control, turn the enthalpy setpoint potentiometer fully clockwise to the D setting.

Indoor Air Quality (IAQ) Sensor Input

The IAQ input can be used for demand control ventilation control based on the level of CO

measured in the space

or return air duct. There is both a factory-installed (FIOP) CO2option

(sensor 8001B with no display, which is mounted on the side of the EconoMi$er) and a field-installed CO

option

(sensor 8002 with display, which is mounted on the return air duct). While performing the same function, they differ in their ability to be configured. The FIOP version is preset and requires no changes in most appli cations. If a configuration change is required, service kit #UIP2072 (software CD, cables, and instructions) and a laptop PC are required. The field-installed version with display can be configured stand-alone. (See section “CO

Sensor

Configuration”). Mount the accessory IAQ sensor according to

manufacturer specifications. The IAQ sensor should be wired to the AQ and AQ1 terminals of the controller.

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

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

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

Exhaust Setpoint Adjustment

The exhaust setpoint will determine when the exhaust fan runs based on damper position (if accessory power exhaust is installed). The setpoint is modified with the Exhaust Fan Setpoint (EXH SET) potentiometer. (See Fig.

66.) The setpoint represents the damper position above which the exhaust fans will be turned on. When there is a call for exhaust, the EconoMi$er IV controller provides a 45 ± 15 second delay before exhaust fan activation to allow the dampers to open. This delay allows the damper to reach the appropriate position to avoid unnecessary fan overload.

Minimum Position Control

There is a minimum damper position potentiometer on the EconoMi$er IV controller. (See Fig. 66.) The minimum damper position maintains the minimum airflow into the building during the occupied period.

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

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

To determine the minimum position setting, perform the following procedure:

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

100 100

+(TR

)

)=T

TO= Outdoor-Air Temperature OA = Percent of Outdoor Air

= Return-Air Temperature

RA = Percent of Return Air

580J

= Mixed-Air Temperature

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

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

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

3. Ensure that the factory-installed jumper is in place across terminals P and P1. If remote damper positioning is being used, make sure that the terminals are wired according to Fig. 62 and that the minimum position potentiometer is turned fully clockwise.

4. Connect 24 vac across terminals TR and TR1.

5. Carefully adjust the minimum position potentiometer until the measured mixed air temperature matches the calculated value.

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

Remote control of the EconoMi$er IV damper is desirable when requiring additional temporary ventilation. If a field-supplied remote potentiometer (Honeywell part number S963B1128) is wired to the EconoMi$er IV controller, the minimum position of the damper can be controlled from a remote location.

To control the minimum damper position remotely, remove the factory-installed jumper on the P and P1 terminals on the EconoMi$e r IV controller. Wire the field-supplied potentiometer to the P and P1 terminals on the EconoMi$er IV controller. (See Fig. 62.)

Damper Movement

Damper movement from full open to full closed (or vice

versa) takes 2-

/2minutes.

Thermostats

The EconoMi$er IV control works with conventi onal thermostats that have a Y1 (cool stage 1), Y2 (cool stage

2), W1 (heat stage 1), W2 (heat stage 2), and G (fan). The EconoMi$er IV control does not support space temperature sensors. Connections are made at the thermostat terminal connection board located in the main control box.

Demand Control Ventilation (DCV)

When using the EconoMi$er IV for demand controlled ventilation, there are some equipment selection criteria which should be considered. When selecting the heat capacity and cool capacity of the equipment, the maximum ventilation rate must be evaluated for design conditions. The maximum damper position must be calculated to provide the desired fresh air.

Typically the maximum ventilation rate will be about 5 to 10% more than the typical cfm required pe r person, using normal outside air design criteri a.

A proportional anticipatory strategy should be taken with the following conditions: a zone with a large area, varied occupancy, and equipment that cannot exceed the required ventilation rate at design conditions. Exceeding the required ventilation rate means the equipment can condition air at a maximum ventilation rate that is greater than the required ventilation rate for maximum occupancy. A proportional-anticipatory strategy will cause the fresh air supplied to increase as the room CO increases even though the CO reached. By the time the CO

setpoint has not been

level reaches the setpoint,

level

the damper will be at maximum ventilation and should maintain the setpoint.

In orde r to have the CO

sensor control the economizer

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

100 100

+(TR

)

)=T

TO= Outdoor-Air Temperature OA = Percent of Outdoor Air T

= Return-Air Temperature

RA = Percent of Return Air T

= Mixed-Air Temperature

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

The same equation can be used to determine the occupied or maximum ventilation rate to the building. For example, an output of 3.6 volts to the actuator provides a base ventilation rate of 5% and an output of 6.7 volts provides the maximum ventilation rate of 20% (or base plus 15 cfm per person). Use Fig. 72 to determine the maximum setting of the CO

sensor. For example, an 1100 ppm

setpoint relates to a 15 cfm per person design. Use the 1100 ppm curve on Fig. 72 to find the point when the CO sensor output will be 6.7 volts. Line up the point on the graph with the left side of the chart to determine that the range configuration for the CO

sensor should be 1800

ppm. The EconoMi$er IV controller will output the 6.7 volts from the CO

sensor to the actuator when the CO

concentration in the space is at 1100 ppm. The DCV setpoint may be left at 2 volts since the CO

sensor voltage will be ignored by the EconoMi$er IV controller until it rises above the 3.6 volt setting of the minimum position potentiometer.

Once the fully occupied damper position has been determined, set the maximum damper demand control ventilation potentiometer to this position. Do not set to the maximum position as this can result in over-ventilation to the space and potential high humidity levels.

Sensor Configuration

The CO2sensor has preset standard voltage settings that can be selected anytime after the sensor is powered up.

(See Table 23.) Use setting 1 or 2 for Bryant equipment. (See Table 23.)

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

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

580J

Table23–CO

SETTING EQUIPMENT OUTPUT

2 Proportional Any

3 Exponential Any

5 Proportional 20

6 Exponential 15

7 Exponential 20

8 Health & Safety Proportional —

Interface w/Standard

Building Control System

Economizer

Parking/Air Intakes/

Loading Docks

Proportional Any

Proportional 15

Proportional —

Sensor Standard Settings

VENTILATION

RATE

(cfm/Person)

ANALOG OUTPUT

0 --- 1 0 V

4 --- 2 0 m A

2 --- 1 0 V

7 --- 2 0 m A

0 --- 1 0 V

4 --- 2 0 m A

0 --- 1 0 V

4 --- 2 0 m A

0 --- 1 0 V

4 --- 2 0 m A

0 --- 1 0 V

4 --- 2 0 m A

0 --- 1 0 V

4 --- 2 0 m A

0 --- 1 0 V

4 --- 2 0 m A

0 --- 1 0 V

4 --- 2 0 m A

CONTROL

RANGE

(ppm)

0--- 2000 1000 50

0--- 2000 1100 50

0--- 1100 1100 50

0 --- 9 0 0 900 50

0--- 1100 1100 50

0 --- 9 0 0 900 50

0--- 9999 5000 500

0--- 2000 700 50

OPTIONAL

RELAY SETPOINT

(ppm)

RELAY

HYSTERESIS

(ppm)

Table 24 – EconoMi$er IV Sensor Usage

ECONOMI$ER IV WITH OUTDOOR AIR DRY

APPLICATION

Outdoor Air

Dry Bulb

Differential

Dry Bulb

Single Enthalpy HH57AC078

Differential

Enthalpy

CO2for DCV

Control using a

Wall-Mounted

Sensor

CO2for DCV

Control using a

Duct-Mounted

Sensor

* CRENTDIF004A00 and CRTEMPSN002A00 accessories are

580J

used on many different base units. As such, these kits may

contain parts that will not be needed for installation. † 33ZCSENCO2 is an accessory CO ** 33ZCASPCO2 is an accessory aspirator box required for

duct-mounted applications. †† CRCBDIOX005A00 is an accessory that contains both

33ZCSENCO2 and 33ZCASPCO2 accessories.

None. The outdoor air dry bulb sensor is

HH57AC078 and CRENTDIF004A00*

33ZCSENCO2† and

33ZCASPCO2**OR

BULB SENSOR

Accessories Required

factory installed.

CRTEMPSN002A00*

33ZCSENCO2

CRCBDIOX005A00††

sensor.

3. Use the Up/Down button to select the preset number. (See Table 23.)

4. Press Enter to lock in the selection.

5. Press Mode to exit and resume normal operati on.

The custom settings of the CO

sensor can be changed

anytime after the sensor is energized. Follow the steps below to change the non-standard settings:

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

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

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

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

5. Press Mode to move through the variables.

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

Dehumidification of Fresh Air with DCV (Demand Controlled Ventilation) Control

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

EconoMi$er IV Pr

eparation

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

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

IMPORTANT: Be sure to record the positions of all potentiometers before starting troubleshooting.

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

2. Disconnect device at P and P1.

3. Jumper P to P1.

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

5. Jumper TR to 1.

6. Jumper TR to N.

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

8. Put 620--ohm resistor across terminals SR and +.

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

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

11. Set enthalpy potentiometer to D.

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

Differential

Enthalpy

To check differential enthalpy:

1. Make sure EconoMi$er IV preparation procedure has been performed.

2. Place 620--ohm resistor across SO and +.

3. Place 1.2 kilo--ohm resistor across SR and +. The Free Cool LED should be lit.

4. Remove 620--ohm resistor across SO and +. The Free Cool LED should turn off.

5. Return EconoMi$er IV settings and wiring to normal after c ompleting troubleshooting.

Enthalpy

Single

To check single enthalpy:

1. Make sure EconoMi$er IV preparation procedure has been performed.

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

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

4. Return EconoMi$er IV settings and wiring to normal after c ompleting troubleshooting.

DCV (Demand Controlled Ventilation) and

Power

Exhaust

To check DCV and Power Exhaust:

1. Make sure EconoMi$er IV preparation procedure has been performed.

2. Ensure terminals AQ and AQ1 are open. The LED for both DCV and Exhaust should be off. The actuator should be fully closed.

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

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

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

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

7. Return EconoMi$er IV settings and wiring to normal after c ompleting troubleshooting.

DCV Minimum and Maximum

To check the DCV minimum and maximum position:

1. Make sure EconoMi$er IV preparation procedure has been performed.

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

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

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

5. Turn the Minimum Position potentiometer to midpoint. The actuator should drive to between 20 and 80% open.

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

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

8. Return EconoMi$er IV settings and wiring to normal after c ompleting troubleshooting.

Supply--Air Sensor

Input

Position

EconoMi$er IV Troubleshooting

This procedure is used to return the EconoMi$er IV to operation. No troubleshooting or testing is done by performing the following procedure.

1. Disconnect power at TR and TR1.

2. Set enthalpy potentiometer to previous setting.

3. Set DCV maximum position potentiometer to previous setting.

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

5. Remove 620--ohm resistor from terminals SR and +.

6. Remove 1.2 kilo--ohm checkout resistor from terminals SO and +. If used, reconnect sensor from terminals SO and +.

7. Remove jumper from TR to N.

8. Remove jumper from TR to 1.

9. Remove 5. 6 kilo--ohm resistor from T and T1. Reconnect wires at T and T1.

10. Remove jumper from P to P1. Reconnect device at P and P1.

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

Completion

WIRING DIAGRAMS

See Fig. 73 and 74 for typical wiring diagrams.

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To check supply--air sensor input:

1. Make sure EconoMi$er IV preparation procedure has been performed.

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

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

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

5. Return EconoMi$er IV settings and wiring to normal after c ompleting troubleshooting.

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Fig. 73 -- 580J Typical Unit Wiring Diagram -- Power (08D,F, 208/230--3--60)

C09156

C09157

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Fig. 74 -- 580J Typical Unit Wiring Diagram -- Control (08--12D,F, 208/230--3--60)

PRE--START-- UP

WARNING

PERSONAL INJURY HAZARD

Failure to foll ow this warning could result in personal injury or death.

1. Follow recognized safety prac tices 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 are disconnected.

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4. Relieve all pressure 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 and then gas to unit.

b. Recover refrigerant to relieve all pressure from

system using both high--pressure and low pressure ports.

c. Cut component connection tubing with tubing

cutter and remove component from unit.

d. Carefully unsweat remaining tubing stubs

when necessary. Oil can ignite when exposed to torch flame.

WARNING

ELECTRICAL OPERATION HAZARD

Failure to foll ow this warning could result in personal injury or death.

The unit must be electrically grounded in accordance with local codes and NEC ANSI/NFP A 70 (American National Standards Institute/National Fire Protection Association).

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, and INFORMATION labels attached to, or shipped with, unit.

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to foll ow this warning could result in personal injury or death.

Relieve pressure and recover all refrigerant before system repair or fi nal unit disposal.

Wear safety glasses and gloves when handling refrigerants.

Keep torches and other ignition sources away from refrigerants and oils.

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

as broken lines, loose parts, or 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 using electronic leak detector, halide torch, or liquid--soap solution.

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

connections. Be sure that connections are completed and tight. Be sure that wires are not in contact with refrigerant t ubing or sharp edges.

d. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fi n comb.

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

positioned in fan orifice. See Condenser--Fan

Adjustment section for more details. b. Make sure that air filter(s) is in place. c. Make sure that condensate drain trap is filled

with water to ensure proper drainage. d. Make sure that all tools and miscellaneous loose

parts have been removed.

START--UP, GENERAL

Unit Preparation

Make sure that unit has been installed in accordance with installation instructions and applicable codes.

Gas Piping

Check gas piping for leaks.

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to foll ow this warning could result in personal injury or death.

Disconnect gas piping from unit when leak testing at pressure greater than 1/2 psig. Pressures greater than 1/2 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than 1/2 psig, it must be replaced before use. When pressure testing field --supplied gas piping at pressures of 1/2 psig or less, a unit connected to such pi ping must be isolated by manually closing the gas valve.

Return--Air Filters

Make sure correct filters are installed in unit (see Appendix II -- Physical Data). Do not operate unit without return--air filters.

Outdoor--Air Inlet Screens

Outdoor--air inlet screen must be in place before operating unit.

NOTE: When the compressor is rotating in the wrong direction, the unit will make an elevated le vel of noise and will not provide cooling.

Cooling

Set space thermostat to OFF position. To start unit, turn on main power supply. Set system selector switch at COOL position and fan switch at AUTO. position. Adjust thermostat to a setting approximately 5_F(3_C) below room temperature. Both compressors start on closure of contactors.

Check unit charge. Refer to Refrigerant Charge section.

Reset thermostat at a position above room temperature. Both compressors will shut off. Evaporator fan will shut off immediately.

To shut off unit, set system selector switch at OFF position. Resetting thermostat at a position above room temperature shuts unit off temporarily until space temperature exceeds thermostat setting.

Main Burners

Main burners are factory set and should re quire no adjustment.

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Compressor Mounting

Compressors are internally spring mounted. Do not loosen or remove compressor hold down bolts.

Internal Wiring

Check all factory and field electrical connections for tightness. Tighten as re quired.

Refrigerant Service Ports

Each unit system has two 1/4” SAE flare (with check valves) service ports: one on the suction line, and one on the compressor discharge line. Be sure that caps on the ports are tight.

Compressor Rotation

On 3--phase units with scroll compressors, it is important to be certain com pressor is rotating i n the proper direction. To determine whether or not compressor is rotating in the proper directi on:

1. Connect service gauges to suction and discharge pressure fittings.

2. Energize the compressor.

3. The suction pressure should drop and the discharge pressure should rise, as is normal on any start--up.

If the suction pressure does not drop and the discharge pressure does not rise to normal levels:

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

2. Turn off power to the unit and install lockout tag.

3. Reverse any two of the unit power leads.

4. Re--energize to the compressor. Check pressures.

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

To check ignition of main burners and heating controls, move thermostat setpoint above room temperature and verify that the burners light and evaporator fan is energized. Check heating effect, then lower the thermostat setting below the room temperature and verify that the burners and evaporator fan turn off.

Refer to Table 11 for the correct orifice to use at high altitudes.

Heating

1. Purge gas supply line of air by opening union ahead of the gas valve. If gas odor is detected, tighten union and wait 5 minutes before proceeding.

2. Turn on electrical supply and manual gas valve.

3. Set system switch selector at HEAT position and fan switch at AUTO. or ON position. Set heating temperature lever above room te mperature.

4. The induced--draft m otor will start.

5. After a call for heating, the main burners should light within 5 seconds. If the burner does not light, then there is a 22--second delay before another 5--second try. If the burner still does not light, the time delay is repeated. If the burner does not light within 15 minutes, there is a lockout. To reset the c ontrol, break the 24 v power to W1.

6. The evaporator--fan motor will turn on 45 seconds after burne r ignition.

7. The evaporator--fan motor will turn off in 45 seconds after the thermostat temperature is satisfied.

8. Adjust airflow to obtain a temperature rise within the range specified on the unit nameplate.

NOTE: The default value for the evaporator--fan motor on/off delay is 45 seconds. The Integrated Gas Unit Controller (IGC) modifies this value when abnormal limit switch cycles occur. Based upon unit operating conditions, the on delay can be reduced to 0 seconds and the off delay can be extended to 180 seconds.

If the limit switch trips at the start of the heating cycle during the evaporator on delay, the time period of the on delay for the next cycle will be 5 seconds less than the time at which the switch tripped. (Example: If the limit switch trips at 30 seconds, the evaporator--fan on delay for the next cycle will occur at 25 seconds.) To prevent short--cycling, a 5 --second reduction will only occur if a minimum of 10 minutes has elapsed since the last call for heating.

The evaporator--fan off delay can also be modified. Once the call for heating has ended, there is a 10--minute period

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during which the modification can occur. If the limit switch trips during this period, the evaporator--fan off delay will increase by 15 seconds. A maximum of 9 trips can occur, extending the evaporator-fan off delay to 180 seconds.

To restore the original default value, reset the power to the unit.

To shut off unit, set system selector switch at OFF position. Resetting heating selector lever below room temperature will temporarily shut unit off until space temperature falls below thermostat setting.

Ventilation (Continuous Fan)

Set fan and system selector switches at ON and OFF positions, respectively. Evaporator fan operates continuously to provide constant air circul ation. When the evaporator-fan selector switch is turned to the OFF position, there is a 30--second delay before the fan turns off.

START --UP, RTU--MP CONTROL

Field Service Test, explained below, will assist in proper start--up. Configuration of unit parameters, scheduling options, and operation are also discussed in t his section.

Field Service Test

The Field Service Test function can be used to verify proper operation of compressors, heating stages, indoor fan, power exhaust fans, economi zer, and dehumidification. Use of Field Service Test is recommended at initial system start up and during troubleshooting. See RTU--MP Controls, Start--Up, Operation, and Troubleshooting Instructions (Form 48--50H--T--2T), Appendix A for Field Service Test Mode table.

Field Service Test mode has t he following cha nges from normal operation:

S Outdoor air temperature limits for cooling circuits,

economizer, and heating are ignored.

S Normal compressor time guards and other staging delays

are ignored.

S The status of Alarms (except Fire and Safety chain) is

ignored but all alerts and alarms are still broadcasted on the network.

Field Service Test can be turned ON/OFF at the unit display or from the network. Once turned ON, othe r entries may be made with the display or through the network. To turn Field Service Test on, change the value of Test Mode to ON, to turn Field Service Test off, change the value of Test Mode to OFF.

NOTE: Service Test mode is password protected when accessing from the display. Depending on the unit model, factory--installed options, and field--installed accessories, some of the Field Service Test functions may not apply.

The independent outputs (IndpOutputs) submenu is used to change output status for the supply fan, economizer, and Power Exhaust. These independent outputs can operate simultaneously with other Field Service Test modes. All outputs return to normal operation when Field Service Test is turned off.

The Cooling submenu is used to change out put status for the individual compressors and the dehumidification relay. Compressor starts are not staggered. The fans and heating service test outputs are reset to OFF for the cooling service test. Indoor fans and outdoor fans are controlled normally to maintain proper unit operat ion. All normal cooling alarms and alerts are functional.

NOTE: Circuit A is always operated with Circuit B due to outdoor fan control on Circuit A. Always test Circuit A first, and leave it on to test other Circuits.

The Heating submenu is used to change output status for the individual heat stages, gas or electric. The fans and cooling service test outputs a re reset to OFF for the heating service test. All normal heating alarms and alerts are funct ional.

Configuration

The RTU--MP controller configuration points affect the unit operation and/or control. Review and understand the meaning and purpose of each configuration point before changing it from the factory default value. The submenus containing configuration points are as follows: Unit, Cooling, Heating, Inputs, Economizer, IAQ, Clock--Set, and User Password (USERPW). Each configuration point is described below under its according submenu. See RTU--MP Controls, Start--Up, Operation, and Troubleshooting Instructions (Form 48--50H--T--2T), Appendix for display tables.

Unit

Start Delay

This refers to the time delay the unit will wait after power up before it pursues any specific operation.

Factory Default = 5 sec Range = 0--600 sec

Filter Service Hours

This refers to the timer set for the Dirty Filter Alarm. After the number of runtime hours set on this point is exceeded the corresponding alarm will be generated, and must be manually cleared on the alarm reset screen after the maintenance has been completed. The timer will then begin counting its runtime again for the next maintenance interval.

Factory Default = 600 hr

NOTE: Setting this configuration timer to 0, disables the alarm.

Supply Fan Service Hours

This refers to the timer set for the Supply Fan Runtime Alarm. After the number of runtime hours set on this point is exceeded the corresponding alarm will be generated, and must be manually cleared on the alarm reset screen after the maintenance has been completed. The timer will then begin counting its runtime again for the next maintenance interval.

Factory Default = 0 hr

NOTE: Setting this configuration timer to 0, disables the alarm.

Compressor1 Service Hours

This refers to the timer set for the Compressor 1 Runtime Alarm. After the number of runtime hours set on this point is exceeded the corresponding alarm will be generated, and must be manually cleared on the alarm reset screen after the maintenance has been completed. The timer will then begin counting its runtime again for the next maintenance interval.

Factory Default = 0 hr

NOTE: Setting this configuration timer to 0, disables the alarm.

Compressor2 Service Hours

This refers to the timer set for the Compressor 2 Runtime Alarm. After the number of hours set on this point is exceeded the corresponding alarm will be generated, and must be manually cleared on the alarm rest screen after the maintenance has been completed. The timer will then begin counting its runtime again for the next maintenance interval

Factory Default = 0 hr

NOTE: Setting this configuration timer to 0, disables the alarm.

Cooling

Number of Compressor Stages

This refers to the number of mechanical cooling stages available on a specific unit. Set this point to “One Stage” if there is one compressor in the specific unit, set to “Two Stage” if there are two compressors in the unit, and set to “None” if economizer cooling ONLY is desired.

Factory Default = One Stage for 1 compressor units Two Stage for 2 compressor units

Cooling/Econ SAT Low Setpt

The supply air temperature must remain above thi s value to allow cooling with the economizer and/or compressors. There is 5_F plus and minus deadband to this point. If the SAT falls below this value during cooling, all compressors will be staged off. The economizer will start to ramp down to minimum position when the SAT = this configuration +5_F.

Factory Default = 50_F Range = 45--75_F

Cooling Lockout Temp

This defines the minimum outdoor air temperature that cooling mode can be enabled and run. If the OAT falls below this threshold during cooli ng, then compressor cooling will not be allowed.

Factory Default = 45_F Range = 0--65_F

Heating

Heating SAT High Setpt

The supply air temperature must remain bel ow this value to allow heating. There is 5_F plus and minus deadband to this point. If the SAT rises above this value during heating the heat stages will begin to decrease until the SAT has dropped below this value.

Factory Default = 120_F Range = 95--150_F

Heating Lockout Temp

This defines the maximum outdoor air temperature that heating mode can be enabled and run. If the OAT rises above this threshold during heating, then heating will not be allowed.

Factory Default = 65_F Range = 49--95_F

Inputs

NOTE: For installation of inputs and field installed

accessories, refer to the appropriate sections.

Input 3

This input is a discrete input and can be configured to be one of five different inputs: No Function, Compressor Safety, Fan Status, Filter Status, or Remote Occupancy. This input can also be configured to be either Normally Open (N/O) or Normally Closed (N/C). Input 3 is factory wired to pin J1--2. Field accessories get wired to its parallel pin J5--5. Do not connect inputs to both locations, one function per input.

Factory Default = Compressor Safety and N/O

NOTE: Compressor Safety input comes from the CLO board. J1--2 is always factory wired to TB1--8 (X) terminal on the unit. If the unit has a CLO board, do not configure input 3 for anything but Compressor Safe ty.

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Input 5

This input is a discrete input and can be configured to be one of five different inputs: No Function, Fire Shutdown, Fan Status, Filter Status, or Remote Occupancy. This input can also be configured to be either Normally Open (N/O) or Normally Closed (N/C). Input 5 is factory wired to pin J1--10. Field accessories get wired to its parallel pin J5--3. Do not connect inputs to both locations, one function per input.

Factory Defaul t = Fire Shutdown and N/C

NOTE: Fire Shutdown input comes from TB4--7. J1--10 is always factory wired to TB4--7. Only change input 5s function if absolutely needed.

Input 8

This input is a discrete input and can be configured to be one of five different inputs: No Function, Enthalpy Switch, Fan Status, Filter Status, or Remote Occupancy.

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This input can also be configured to be either Normally Open (N/O) or Normally Closed (N/C). Input 8 is factory wired to pin J2--6. Field accessories get wired to its parallel pin J5--1. Do not connect inputs to both locations, one function per input.

Factory Defaul t = No Function and N/O

Input 9

This input is a discrete input and can be configured to be one of five different inputs: No Function, Humidistat, Fan Status, Filter Status, or Remote Occupancy. This input can also be configured to be either Normally Open (N/O) or Normally Closed (N/C). Input 9 is factory and field wired to pin J5--7. Do not connect inputs to both locations, one function per input.

Factory Default = Humidistat and N/O

Space Sensor Type

This tells the controller what type of space sensor is installed to run the unit. The three types that can be used are the T55 space sensor, the T56 space sensor, or the RS space sensor.

Factory Default = T55 Type

Input 1 Function

This input is an analog input and can be configured to be one of five different inputs: No Sensor, IAQ Sensor, OAQ Sensor, Space RH Sensor, or Outdoor RH Sensor. Input 1 iswiredtopinJ4--5.

Factory Default = No Sensor

Input 2 Function

This input is an analog input and can be configured to be one of five different inputs: No Sensor, IAQ Sensor, OAQ Sensor, Space RH Sensor, or Outdoor RH Sensor. Input 2 iswiredtopinJ4--2.

Factory Default = No Sensor

Setpoint Slider Range

This sets the slider range of the space sensor (with this built in function). The slider is used to offset the current control setpoint.

Factory Default = 5 n_F Range = 0--15 n_F

T55/56 Override Duration

This sets the occupancy override duration when the override button is pushed on the space sensor.

Factory Default = 1 hr Range = 0--24 hr

IAQ Low Reference @ 4mA

This is used when an IAQ sensor is installed on Input 1 or

2. This value is displayed and used when 4mA is seen at the input.

Factory Default = 0 PPM Range = 0--400 PPM

IAQ High Reference @ 20mA

This is used when an IAQ sensor is installed on Input 1 or

2. This value is displayed and used when 20mA is seen at the input.

Factory Default = 2000 PPM Range = 0--5000 PPM

NOTE: IAQ low Reference @ 4mA and IAQ High Reference @ 20mA are used to set the linear curve of mA vs. PPM.

OAQ Low Reference @ 4mA

This is used when an OAQ sensor is installed on Input 1 or 2. This value is displayed and used when 4mA is seen at the input.

Factory Default = 0 PPM Range = 0--400 PPM

OAQ High Reference @ 20mA

This is used when an OAQ sensor is installed on Input 1 or 2. This value is displayed and used when 20mA is seen at the input.

Factory Default = 2000 PPM Range = 0--5000 PPM

NOTE: OAQ low Reference @ 4mA and OAQ High Reference @ 20mA are used to set the linear curve of mA vs. PPM.

Economizer

Economizer Exists

This point tells the controller if there is an economizer installed on the unit.

Factory Default = NO if no economizer YES if there is an economizer installed

Economizer Minimum P osition

This defines the lowest economizer position when the indoor fan is running and the building is occupied.

Factory Default = 20% Range = 0--100 %

Economizer High OAT Lockout

If the out door air temperature rises above this value, economizer cooling will be disabled and dampers will return and stay at minimum position.

Factory Default = 75_F Range = 55--80_F

Power Exhaust Setpt

When the economizer damper position opens above this point the power exhaust operation will begin. When the damper position falls 10% below the setpoint, the power exhaust will shutdown.

Factory Default = 50% Range = 20--90 %

NOTE: This point is only used when Continuous Occ Exhaust = NO

Continuous Occ Exhaust

This point tells the controller when to run the power exhaust if equipped on the unit. If set to YES, the power exhaust will be on all the time when in occupied mode and will be off when in unoccupied mode. If set to NO the power exhaust will be controlled by the Power Exhaust Setpoint.

Factory Default = NO

IAQ

Max Differential CO

If the difference between indoor an outdoor air quality becomes greater then this value the damper position will stay at the IAQ Greatest Min Dmpr Pos. configuration point

Factory Default = 650 PPM Range = 300--950 PPM

IAQ Greatest Min Dmpr Pos.

This is the greatest minimum position the economizer will open to while trying to control the indoor air quality, CO differential.

Factory Defaul t = 50% open Range = 10--60% open

Clockset

This submenu screen allows you to set the date and time manually. The Daylight Savings Time (DST) can also be changed here. The date and time is automatically set when ever software is downloaded. The clock is a 24 hour clock and not am/pm. The time should be verified (and maybe changed) according to unit location and time zone.

Factory Default = Eastern Standard Time

USERPW

This submenu screen allows you to change the user password to a four number password of choice. The User password change screen is only accessible with the Administrator Password (1111). The ADMIN password will always override the user password.

Setpt

OPERATING SEQUENCES

Base Unit Controls

Cooling, Units Without Economizer

When thermostat calls for Stage 1 cooling, terminals G and Y1 are energized. The indoor--fan contactor (IFC), outdoor fan contactor (OFC) and Compressor 1 contactor (C1) are energized and indoor-fan motor, outdoor fan and Compressor 1 start. The outdoor fan motor runs continuously whil e unit is in Stage 1 or Stage 2 cooling. (08D,F and 12D,F units have two outdoor fans; both run while unit is in Stage 1 or Stage 2 cooling.)

If Stage 1 cooling does not satisfy the space load, the space temperature will rise until thermostat calls for Stage 2 cooling (Y2 closes). Compressor 2 contactor (C2) is energized; Compressor 2 starts and runs.

Heating, Units Without Economizer

When the thermostat calls for heating, terminal W1 is energized. To prevent thermostat short-cycling, the unit is locked into the Heating mode for at least 1 minute when W1 is energized. The induced-draft motor is energized and the burner i gnition sequence begins. The indoor (evaporator) fan motor (IFM) is energized 45 seconds after a flame is ignited.

If Stage 1 heating does not satisfy the space load, the space temperature will fall until thermostat calls for Stage 2 heating (W2 closes). Terminal W2 is energized and the

high-fire solenoid on the main gas valve (MGV) is energized. Firing rate increases to high-fire. When space load is partially satisfied, terminal W2 is de--energized; the high-fire solenoid is de--energized and heating operation continues on low--fire.

When the space heating load is fully satisfied, thermostat terminal W1 is also deenergized. All heating operations cease. The IFM stops after a 45-second time off delay.

Cooling, Unit With EconoMi$er IV

For Occupied mode operation of EconoMi$er IV, there must be a 24-v signal at terminals TR and N (provided through PL6-3 from the unit’s IFC coil). Removing the signal at N places the EconoMi$er IV control in Unoccupied mode.

During Occupied mode operation, indoor fan operation will be accompanied by economizer dampers moving to Minimum Position setpoint fo r ventilation. If indoor fan is off, dampe rs will close. During Unoccupied mode operation, dampers will remain closed unless a Cooling (by free cooling) or DCV demand is received.

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When free cooling using outside air is not available, the unit cooling sequence will be controlled directly by the space thermostat as described above as Cool ing, Unit Without Economizer. Outside air damper position will be closed or Minimum Position as determined by occupancy mode and fan signal.

When free cooling is available as determined by the appropriate changeover command (dry bulb, outdoor enthalpy, differential dry bulb or differential enthalpy), a call for cooling (Y1 closes at the thermostat) will cause the economizer control to modulate the dampers open and closed to maintain the unit supply air temperature at 50 to 55_F. Compressor will not run.

During free cooling operation, a supply air temperature (SAT) above 50_F will cause the dampers to modulate between Minimum Position setpoint and 100% open. With SAT from 50_Fto45_F, the dampers will maintain at the Minimum Position setting. With SAT below 45_F, th e outside air dampers will be closed. When SAT rises to 48_F, the dampers will re-open to Minimum Position setting.

Should 100% outside air not be capable of satisfying the space temperature, space temperature will rise until Y2 is

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closed. The economizer control will call for compressor operation. Dampers will modulate to maintain SAT at 50 to 55_F concurrent with Compressor 1 operation. The Low Ambient Lockout Thermostat will block compressor operation with economizer operation below 42_F outside air temperature.

When space temperature demand is satisfied (thermostat Y1 opens), the dampers will return to Minimum Damper position if indoor fan i s running or fully closed if fan i s off.

If accessory power exhaust is installed, the power exhaust fan motors will be energized by the economizer control as the dampers open above the PE-On setpoint and will be de--energized as the dampers close below the PE-On setpoint.

Damper movement from full closed to full open (or vice versa) will take between 1-1/2 and 2-1/2 minutes.

Heating With EconoMi$er IV

When the room temperature calls for heat (W1 closes), the heating controls are energized as described in Heating, Unit Without Economizer above.

DCV operation is available in Occupied and Unoccupied periods with EconoMi$er IV. However, a control modification will be required on the 580J unit to implement the Unoccupied period function.

Supplemental Controls

Compressor Lockout Relay (CLO) -- The CLO is available as a factory-installed option or as a field--installed accessory. Each compressor has a CLO. The CLO compares the demand for compressor operation (via a 24-v input from Y at CLO terminal 2) to operation of the compressor (determined via compressor current signal input at the CLO’s current transformer loop); if the compressor current signal is lost while the demand input still exists, the CLO will trip open and prevent the compressor from restarting until the CLO has been manually reset. In the lockout condition, 24-v will be available at terminal X. Reset is accomplished by removing the input signal at terminal 2; open the thermostat briefly or cycle the main power to the unit.

Phase Monitor Relay (PMR) -- The PMR protects the unit in the event of a loss of a phase or a reversal of power line phase in the three--phase unit power supply. In normal operation, the relay K1 is energized (contact set closed) and red LED indicator is on steady. If the PMR detects a loss of a phase or a phase sequenc e reversal, the relay K1 is energized, its conta ct set is opened and unit operation is stopped; red LED indicator will blink during lockout condition. Reset of the PMR is automatic when all phases are restored and phase sequence is correct. If no 24--v control power is available to the PMR, the red LED will be off. Smoke Detectors -- Factory--installed smoke detectors are discussed in detail starting on page 17.

RTU--MP Sequence of Operation

The RTU--MP will control the compressor, economizer and heating outputs based on its own space temperature input and setpoints. An optional CO in the space can influence the economizer minimum position. The RTU--MP has its own hardware clock that is set automatically when the software is installed on the board. The RTU--MP’s def ault is to control to occupied setpoints all the time, until a type of occupancy control is set. Occupancy types are described in the scheduling section. The following sections describe the operation for the functions of the RTU--MP. All point objects that are referred to in this sequence will be in refe rence to the objects as viewed in BACview

IAQ sensor mounted

Handheld.

Demand Controlled Ventilation

If a field-installed CO2sensor is connected to the Economize IV control, a Demand Controlled Ventilation strategy will operate automatically. As the CO2 level in the space increases above the setpoint (on the EconoMi$er IV controller), the minimum position of the dampers will be inc reased proportionally, until the Maximum Ventilation setting is reached. As the space CO decreases because of the increase in fresh air, the outdoor-damper will follow the higher demand condition from the DCV mode or from the free-cooling mode.

level

Scheduling

Scheduling is used to start heating or cooling (become occupied) based upon a day of week and a time period and control to the occupied heating or cooling setpoints. Scheduling functions are located under occupancy determination and the schedule menu accessed by the Menu softkey (see Appendix -- for menu structure). Your local time and date should be set for these functions to operate properly. Five scheduling functions are available by changing the Occupancy Source to one of the following selections:

Always Occupied (Default Occupancy)

The unit will run continuously. RTU--MP ships from the factory with this setting.

Local Schedule

The unit will operate according to the schedule configured and stored in the unit. The local schedule is made up of three hierarchy levels that consist of two Override schedules, twelve Holiday and four Daily schedules, and are only accessible by the BACview screen (handheld or virtual).

The Daily schedule is the lowest schedule in the hierarchy and is overridden by both the Holiday and Override schedule. It consists of a start time, a stop time (both in 24 hour mode) and the seven days of the week, starting with Monday and ending in Sunday. To select a daily schedule scroll to the Schedules menu off of the Menu selecti on. Enter the User password and change the Occupancy Source to Local Schedule. Scroll down and over to the Daily menu and press enter. Choose one of the four Daily schedules by pressing the Next softkey and change the Use? point from NO to YES by selecting the point and pressing the INCR or DECR softkey. Press the OK softkey and scroll to the start and stop times. Edit these times following the same steps as the Use? point. Finally scroll down to the Days: section and highlight the days required for the Daily schedule by INCR or DECR softkeys and press OK softkey.

The Holiday schedule is created to override the Daily schedule a nd identify a specific day and month of the year to start and stop the unit and change control to the unoccupied heating and cooling setpoints. Follow the same steps to turn on one of the twelve Holiday schedules and start and stop times. Next, select one out of the twelve months and one out of the thirty--one days of that month. The RTU--MP will now ignore the Daily schedule for the specific day and time you selected and follow the Holiday Schedule for this period.

The Override schedules primary purpose is to provide a temporary change in the occupied heating and cooling setpoints and force the unit to control to the unoccupied heating and cooling setpoints. This would occur on a set day in a particular month and last during the start and stop time configured. The Override schedule is enabled by following the same steps to create the Holiday schedule.

NOTE: Push button override is only available when running a local or BACnet Schedule.

BACnet Schedule

For use with a Building Automation System that supports native BACnet scheduling is scheduling the unit. With the Occupancy Source set to BACnet schedule the BAS will control t he unit through network communication and it’s own scheduling function.

BAS On/Off

The Building Automation System is scheduling the unit via an On/Off command to the BAS ON/OFF software point. The Building Automation System can be speaking BACnet, Modbus, or N2 and is writing t o the BAS On/Off point in the open protocol point map.

NOTE: If the BAS supports NATIVE BACnet scheduling, then set t he Occupancy Source to BACnet schedule. If the BAS is BACnet but does NOT support NATIVE BACnet scheduling, then set the Occupancy Source to BAS On/Off.

DI On/Off

A hard--wired input on the RTU--MP will command the unit to start/stop. Inputs 3, 5, 8, and 9 on plug J5 can be hard--wired to command the unit to start/stop.

NOTE: Scheduling can either be controlled via the unit or the BAS, but NOT both.

Indoor

Fan

The indoor fan will be turned on whenever any one of the following conditions is true:

S It is in the occupied mode. This will be determined by its

own internal occupancy schedule.

S Whenever there is a demand for cooling or heating in the

unoccupied mode.

S Whenever the remote occupancy switch is closed during

DI On/Off schedule type or if occupancy is forced occupied by the BAS during BAS On/Off schedule type.

When transitioning from unoccupied to occupied, there will be a configured time delay of 5 to 600 seconds before starting the fan. The fan will continue to run as long as compressors, heating stages, or the dehumidification relays are on when transiti oning from occupied to unoccupied with the exception of Shutdown mode. If Fire Shutdown, safety chain, SAT alarm or SPT alarm are active; the fan will be shutdown immediately regardless of the occupancy state or demand.

The RTU--MP has an optional Supply Fan Status input to provide proof of airflow. If thi s is enabled, the point will look for a contact closure whenever the Supply Fan Relay is on. If it is not enabled then it will always be the same state as the Supply Fan Relay. The cooling, economizer, heating, dehumidification, CO

and power exha ust

routines will use this input point for fan status.

580J

Cooling

The compressor outputs are controlled by the Cooling Control PID Loop and Cooling Stages Capacity algorithm. They will be used to calculate the desired number of stages needed to satisfy the space by comparing the Space Temperature (SPT) to the Occupied Cool Setpoint plus the T56 slider offset when occupied and the Unoccupied Cool Setpoint (UCSP) plus the T56 slider offset, i f unoccupied. The economizer, if available, will be used for cooling in addition to the compressors. The following conditions must be true in order for t his algorithm to run:

S Indoor Fan has been ON for at least 30 seconds. S Heat mode is not active and the time guard between

modes equals zero.

S If occupied and the SPT >(occupied cool setpoint plus

the T56 slider offset).

S Space Temperature reading is available.

580J

S If it is unoccupi ed and the SPT > (unoccupied cool

setpoint plus the T56 slider offset). The indoor fan will be turned on by the staging algorithm.

S If economizer is available and active and economizer

open > 85% and SAT > (SAT low limit + 5_F) and SPT > effective setpoint + 0.5_F.

Economizer i s available, but not active

Economizer i s not available

S OAT > DX Lockout temperature.

If all of the above conditions are met, the compressors will be energized as required, otherwise they will be de--energized.

There is a fixed 3--minute minimum on time and a 5--minute off time for each compressor output and a 3--minute minimum time delay between staging up or down.

Any time the compressors are running the RTU--MP will stage down the compressors if the SAT becomes less than the cooling low supply air setpoint.

After a compressor is staged off, it may be started again after a normal time--guard period and the supply air temperature has increased above the low supply air setpoint.

Economizer

The Economizer dampers are used to provide free cooling and Indoor Air Quality, if optional CO

sensor is installed,

when the outside conditions are suitable. The following conditions must be true for economizer

operation:

S Indoor Fan has been on for at least 30 seconds. S Enthalpy is Low if the Enthalpy input is enabled. S SAT reading is available. S OAT reading is available. S SPT reading is available. S OAT <= High OAT ec onomizer lockout configuration

(default = 75).

S OA T <= SPT

If any of the mentioned conditions are not true, the economizer will be set to its configured minimum position. The minimum damper position can be overridden by the IAQ routine described later in this section.

If the above conditions are true, the Economizer Control Master Loop will calculate a damper position value based on the following calculation: Damper Position = minimum position + PID (SPT -- econ setpoint). Econ setpoint is half way between the effective cool and heat setpoints. If the SAT drops below the cooling low supply air setpoint (+ 5_F), the economizer will ramp down to minimum position.

Power

Exhaust

If RTU--MP is also controlling an exhaust fan, it can be enabled based on damper position or by occupancy. If configured for continuous occupied operation, it will be energized whenever the controller is in the occupied mode and disabled when in t he unoccupied mode. If configured for damper position control, it will be energized whenever the economizer exceeds the power exhaust setpoint and disabled when the economizer drops below the setpoint by a fixed hysteresis of 10%.

Heating

The heating outputs are controlled by the Heating Control PID Loop and Heating Stages Capacity algorithm. They will be used to calculate the desired number of stages needed to satisfy the space by comparing the SPT to the Occupied Heat Setpoint plus the T56 slider offset when occupied and the Unoccupied Heat Setpoint plus the T56 slider offset if unoccupied. The following conditions must be true in order for this algorithm to run:

S Indoor Fan has been ON for at least 30 seconds. S Cool mode is not active and the time guard between

modes equals zero.

S If occupied and SPT <(occupied heat setpoint plus T56

slider offset)

S SPT reading is available S If it is unoccupi ed and t he SPT < (unoccupied heat

setpoint plus T56 slider offset). The indoor fan will be turned on by the staging algorithm.

S OA T < High OAT lockout t emperature.

If all of the above conditions are met, the heating outputs will be energized as required, otherwise they will be de--energized. If the SAT begins to exceed the high supply air setpoint, a ramping function will cause the Heat Stages Capacity algorithm to decrease the number of stages until the SAT has dropped below the setpoint.

There is a fixed one minute minimum on time and a one minute off time for each heat output. Heat staging has a 3 minute stage up and 30 second stage down delay.

Indoor Air Quality

If the optional indoor air quality sensor is installed, the RTU--MP will maintain indoor air quality within the space at the user configured differential setpoint. The setpoint is the difference between the indoor air quality and an optional outdoor air quality sensor. If the outdoor air quality is not present then a fixed value of 400ppm is used. The following conditions must be true in order for this algorithm to run:

S The mode is occupied. S Indoor Fan has been ON for at least 30 seconds. S Indoor Air Quality sensor has a valid reading

As air quality within the space changes, the minimum position of the economizer da mper will be changed thus allowing more or less outdoor air into the space depending on the relationship of the indoor air quality to the differential setpoint. If all the above conditions are true, the IAQ algorithm will run and calculates an IAQ minimum position value using a PID loop. The IAQ minimum damper position is then compared against the user configured economizer minimum position and the greatest value becomes the final minimum damper position of the economizer output.

If the calculated IAQ minimum position is greater than the IAQ maximum damper position configuration then it will be clamped to the configured value.

Demand

Limit

If the RTU--MP receives a level 1 (one degree offset), 2 (two degree offset), or a 3 (4 degree offset) to the BACnet demand limit variable, the controller will expand the heating and cooling setpoints by the configured demand limit setpoint value and remain in effect until the BACnet demand limit variable receives a 0 value.

FASTENER TORQUE VALUES

See Table 25 for torque values.

580J

Table 25 – Torque Values

Supply fan motor mounting

Supply fan motor adjustment plate

Motor pulley setscrew

Fan pulley setscrew

Blower wheel hub setscrew

Bearing locking collar setscrew 65 to 70 in ---lbs 7.3 to 7.9 Nm Compressor mounting bolts 65 to 75 in ---lbs 7.3 to 7.9 Nm

Condenser fan motor mounting bolts

Condenser fan hub setscrew

120 ¦ 12 in --- lbs 13.5 ¦ 1.4 Nm

72 ¦ 5 i n --- l b s 8.1 ¦ 0.6 Nm

20 ¦ 2 i n --- l b s 2.3 ¦ 0.2 Nm

84 ¦ 1 2 i n --- l b s 9.5 ¦ 1.4 Nm

Model Number Nomenclature

Unit Type Design Revision

580J = Cooling/Gas Heat RTU --- = First Revision

Voltage Packaging

E = 4 6 0 --- 3 --- 6 0 A=Standard

P = 208/230 ---3--- 60 B=LTL

T = 5 7 5 --- 3 --- 6 0

Cooling Tons 0A = None

08 = 7.5 Ton

580J

12 = 10 Ton Intake/Exhaust Options

14 = 12.5 Ton A=None

Refrig. System/Gas Heat Options E=Tempeconow/barorelief&CO

D = 2 --- S ta ge C om p r e s s o r /A l H X H = Enthalpy econo w/ baro relief

F = 2 --- S ta ge C om p r e s s o r /S S H X L = Enthalpy econo w/ baro relief & CO

Heat Level

125 = 125,000 Indoor Fan Options

150 = 150,000 1 = Standard static option

180 = 180,000 2 = Medium static option

224 = 224,000 3 = High static option

250 = 250,000

APPENDIX I. MODEL NUMBER SIGNIFICANCE

123456789101112131415161718

5 8 0 J E 0 8 D 1 2 5 A 1 A 0 A A --

____________ ______ ________ ______

Factory Installed Options

B=Tempeconow/barorelief

Q = Motorized 2 pos damper

2 --- S ta g e C o o l i n g C o i l O p t i o n s ( O u td o o r --- I n d o o r )

G = Al/Al --- Al/ Cu

T = A l /A l --- Al / C u --- L o uv er e d H a i l G u a r d s

Serial Number Format

POSITION NUMBER 1 2 3 4 5 6 7 8 9 10

TYPICAL 1 2 0 9 G 1 2 3 4 5

POSITION DESIGNATES

1--- 2 Week of manufacture (fiscal calendar) 3--- 4 Year of manufacture (“09” = 2009)

5 Manufacturing location (G = ETP, Texas, USA)

6--- 10 Sequential number

APPENDIX II. PHYSICAL DATA

Physical Data (Cooling) 7.5 -- 12.5TONS

580J*08D,F 580J*12D,F 580J*14D,F

Refrigeration System

#Circuits/#Comp./Type 2/2/Scroll 2/2/Scroll 2/2/Scroll

PuronR refrig. (R ---410A) charge per

High---press. Trip / Reset (psig) 630 / 505 630 / 505 630 / 505

Low--- press. Trip / Reset (psig) 54 / 117 54 / 117 54 / 117

Evaporator Coil

Condensate Drain Conn. Size 3/4” 3/4” 3/4”

Evaporator Fan and Motor

Motor Qty / Drive Type 1/Belt

3phase

Standard Static

Motor Frame Size 56 56 56

Fan Diameter (in) 15 x 15 15 x 15 15 x 15

c i r c u i t A / B ( l b s --- o z )

Oil A/B (oz) 42 / 42 42 / 42 56 / 56

Metering Device Accutrol Accutrol Accutrol

Material Cu / Al Cu / Al Cu / Al

Coil type 3/8” RTPF 3/8” RTPF 3/8” RTPF

Rows / FPI 3 / 15 4/15 4/15

Tot a l Fa ce Ar e a ( f t2)8.9 11.1 11.1

Max BHP 1.7

RPM Range 489 ---747 591---838 652 ---843

Fan Qty / Type 1/Centrifugal 1/Centrifugal 1/Centrifugal

4 --- 6 / 4 --- 6

6 --- 0 / 6 --- 0 7 --- 6 / 8 --- 0

1/Belt 1/Belt

2.4 2.9*

580J

Motor Qty / Drive Type 1/Belt 1/Belt 1/Belt

Max BHP 2.9* 3.7 3.7

RPM Range 733 ---949 838 ---1084 838---1084

3phase

Medium Static

3phase

High Static

Condenser Coil

Condenser fan / motor

Filters

AI / AI: Aluminum Tube / Aluminum Fin Cu / AI: Copper Tube / Aluminum Fin RTPF: Round Tube / Plate Fin *

575V motor utilizes 3.7 BHP

Motor Frame Size 56 56 56

Fan Qty / Type 1/Centrifugal 1/Centrifugal 1/Centrifugal

Fan Diameter (in) 15 x 15 15 x 15 15 x 15

Motor Qty / Drive Type 1/Belt 1/Belt 1/Belt

Max BHP 4.7 4.7 4.7

RPM Range 909-- -1102 1022 --- 1240 1022 ---1240

Motor Frame Size 145TY 145TY 145TY

Fan Qty / Type 1/Centrifugal 1/Centrifugal 1/Centrifugal

Fan Diameter (in) 15 x 15 15 x 15 15 x 15

Tot a l Fa ce Ar e a ( f t2) 20.5 25.1 25.1

Qty / Motor Drive Type 2/ Direct 2/Direct 1/ Direct

Motor HP / RPM 1/4 / 1100 1/4 / 1100 1 / 1175

Fan diameter (in) 22 22 30

RAFilter#/Size(in) 4/16x20x2 4/20x20x2 4/20x20x2

OA inlet screen # / Size (in) 1/20x24x1 1/20x24x1 1/20x24x1

Material Al / Al Al / Al Al / Al

Coil type NOVATION ™ NOVATION ™ NOVATION ™

Rows / FPI 1 / 20 1/20 2/20

APPENDIX II. PHYSICAL DATA (cont.)

Physical Data (Heating) 7.5 -- 12.5TONS

580J**08 580J**12 580J**14

Gas Connection

#ofGasValves 1 1 1

Nat. gas supply line press (in. w.g.)/(PSIG) 4 --- 1 3 / 0 . 1 8 --- 0 .4 7 4 --- 1 3 / 0 . 18 --- 0 . 4 7 4 --- 1 3 / 0 . 1 8 --- 0 . 4 7

LP supply line press (in. w.g.)/(PSIG) 11 ---13 / 0.40--- 0.47 11--- 13 / 0.40 --- 0.47 11 --- 13 / 0.40 ---0.47

Heat Anticipator Setting (Amps)

1st stage 0.14 0.14 0.14

2nd stage 0.14 0.14 0.14

Natural Gas Heat, Liquid Propane Heat

#ofstages/#ofburners(total) 1/3 2/4 2/4

Connection size 1/2” NPT 3/4” NPT 3/4” NPT

580J

LOW

MED

HIGH

Rollout switch opens / Closes 195 / 115 195 / 115 195 / 115

Temperature rise (min/max) 20 --- 50 25 --- 65 25 --- 65

#ofstages/#ofburners(total) 2/4 2/5 2/5

Connection size 3/4” NPT 3/4” NPT 3/4” NPT

Rollout switch opens / Closes 195 / 115 195 / 115 195 / 115

Temperature rise (min/max) 35 --- 65 30 --- 65 25 --- 65

#ofstages/#ofburners(total) 2/5 2/5 2/5

Connection Size 3/4” NPT 3/4” NPT 3/4” NPT

Rollout switch opens / Closes 195 / 115 195 / 115 195 / 115

Temperature rise (min/max) 45 --- 75 35 --- 70 35 --- 70

APPENDIX III. FAN PERFORMANCE

580J**08 3 PHASE 7.5 TON HORIZONTAL SUPPLY

AVAILABLEEXTERNALSTATICPRESSURE(in.wg)

CFM

2250 505 0.52 586 0.73 657 0.97 722 1.22 782 1.50 2438 533 0.62 610 0.85 679 1.09 742 1.36 800 1.65 2625 562 0.74 635 0.98 701 1.23 2813 591 0.88 661 1.13 725 1.39 783 1.68 839 1.98 3000 621 1.03 688 1.29 749 1.57 806 1.87 859 2.18 3188 652 1.21 715 1.48 774 1.77 829 2.07 881 2.40 3375 682 1.40 743 1.68 800 1.98 853 2.30 903 2.63 3563 713 1.61 772 1.91 826 2.22 878 2.55 927 2.89 3750 745 1.85 801 2.15 853 2.48 903 2.82 951 3.18

CFM

2250 838 1.81 891 2.12 941 2.46 988 2.82 1033 3.19 2438 854 1.96 906 2.28 955 2.63 1001 2.99 1046 3.37 2625 872 2.12 922 2.46 970 2.81 1016 3.17 1060 3.56 2813 890 2.31 940 2.65 986 3.01 1031 3.38 1074 3.77 3000 910 2.51 958 2.86 1004 3.23 1048 3.61 1090 4.01 3188 930 2.74 977 3.10 1022 3.47 1065 3.86 1107 4.26 3375 951 2.99 997 3.35 1041 3.74 1083 4.13 1124 4.54 3563 973 3.26 1018 3.63 1061 4.02 1103 4.43 -- -- 3750 996 3.55 1040 3.93 1082 4.34 -- -- -- --

0.2 0.4 0.6 0.8 1.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Standard Static Option Medium Static Option

762

AVAILABLEEXTERNALSTATICPRESSURE(in.wg)

1.2 1.4 1.6 1.8 2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Medium Static Option High Static Option

1.51 819 1.81

580J

NOTE: For more information, see General Fan Performance Notes. Boldface indicates field--supplied drive is required.

1. Recommend using field--supplied fan pulley (part no. KR11AZ002) and belt (part no. KR29AF054).

580J**08 3 PHASE 7.5 TON VERTICAL SUPPLY

AVAILABLEEXTERNALSTATICPRESSURE(in.wg)

CFM

2250 513 0.54 595 0.76 665 1.01 728 1.27 786 1.56 2438 541 0.65 620 0.89 688 1.14 750 1.42 806 1.71 2625 570 0.77 645 1.02 712 1.29 772 1.58 827 1.88 2813 600 0.91 672 1.18 736 1.46 794 1.76 848 2.07 3000 629 1.07 699 1.35 761 1.64 818 1.95 871 2.28 3188 660 1.25 726 1.54 787 1.85 842 2.17 894 2.51 3375 690 1.45 754 1.75 813 2.07 867 2.41 917 2.76 3563 721 1.67 783 1.98 840 2.32 892 2.67 941 3.03 3750 752 1.91 812 2.24 867 2.59 918 2.95 966 3.32

CFM

2250 839 1.86 889 2.18 935 2.52 980 2.87 1022 3.23 2438 858 2.02 907 2.35 953 2.70 997 3.06 1039 3.43 2625 878 2.20 926 2.54 972 2.89 1015 3.26 1056 3.64 2813 899 2.40 946 2.75 991 3.11 1033 3.49 1074 3.88 3000 920 2.62 966 2.98 1010 3.35 1052 3.74 1093 4.14 3188 942 2.86 987 3.23 1031 3.61 1072 4.01 1112 4.42 3375 964 3.12 1009 3.50 1052 3.89 1093 4.30 -- -3563 988 3.41 1032 3.80 1074 4.20 1114 4.61 -- -- 3750 1011 3.71 1054 4.11 1096 4.53 -- -- --- ---

0.2 0.4 0.6 0.8 1.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Standard Static Option Medium Static Option

AVAILABLEEXTERNALSTATICPRESSURE(in.wg)

1.2 1.4 1.6 1.8 2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Medium Static Option High Static Option

NOTE: For more information, see General Fan Performance Notes. Boldface indicates field--supplied drive is required.

1. Recommend using field--supplied fan pulley (part no. KR11AZ002) and belt (part no. KR29AF054).

FAN PERFORMANCE (cont.)

580J**12 3 PHASE 10 TON HORIZONTAL SUPPLY

AVAILABLEEXTERNALSTATICPRESSURE(in.wg)

0.2 0.4 0.6 0.8 1.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

1.2 1.4 1.6 1.8 2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

AVAILABLEEXTERNALSTATICPRESSURE(in.wg)

Medium Static Option High Static Option

Standard Static Option Medium Static Option

580J

CFM

F i e l d --- S u p p l i e d D r i v e

3000 579 0.70 660 0.89 732 1.09 799 1.29 860 1.50 3250 613 0.85 690 1.06 760 1.27 823 1.49 883 1.71 3500 648 1.03 721 1.25 788 1.48 850 1.71 907 1.95 3750 683 1.23 753 1.47 817 1.71 877 1.96 933 2.21 4000 719 1.45 786 1.71 848 1.97 905 2.23 959 2.50 4250 756 1.71 819 1.98 879 2.26 934 2.53 987 2.81 4500 792 1.99 853 2.28 910 2.57 964 2.87 1015 3.16 4750 830 2.31 888 2.62 943 2.92 995 3.23 1044 3.54 5000 867 2.66 923 2.98 976 3.30 1026 3.63 1074 3.95

CFM

3000 917 1.70 970 1.91 1021 2.13 1070 2.34 1117 2.56 3250 938 1.93 991 2.16 1041 2.38 1089 2.61 1134 2.85 3500 961 2.18 1013 2.42 1062 2.66 1108 2.91 1153 3.15 3750 985 2.46 1035 2.71 1083 2.97 1129 3.23 1173 3.49 4000 1011 2.76 1059 3.03 1106 3.30 1151 3.58 1194 3.85 4250 1037 3.09 1084 3.38 1130 3.66 1174 3.95 1216 4.24 4500 1064 3.46 1110 3.76 1155 4.06 1198 4.36 1239 4.66 4750 1091 3.85 1137 4.16 1180 4.48 -- -- -- -5000 1120 4.28 1164 4.61 -- -- --- --- --- ---

NOTE: For more information, see General Fan Performance Notes. Boldface indicates field--supplied drive is required.

1. Recommend using field--supplied fan pulley (part no. KR11AD912) and belt (part no. KR29AF051).

2. Recommend using field--supplied motor pulley (part no. KR11HY410).

580J**12 3 PHASE 10 TON VERTICAL SUPPLY

AVAILABLEEXTERNALSTATICPRESSURE(in.wg)

CFM

3000 616 0.79 689 0.97 757 1.16 821 1.36 882 1.57 3250 655 0.96 724 1.16 788 1.37 849 1.58 907 1.80 3500 695 1.17 760 1.38 821 1.60 879 1.83 934 2.06 3750 736 1.41 797 1.63 855 1.86 910 2.10 963 2.35 4000 777 1.68 834 1.91 889 2.16 942 2.41 993 2.67 4250 818 1.98 873 2.23 925 2.49 976 2.75 1025 3.02 4500 860 2.32 912 2.58 962 2.85 1010 3.13 1057 3.41 4750 902 2.69 951 2.97 999 3.26 1046 3.55 1091 3.84 5000 944 3.11 991 3.40 1037 3.70 1082 4.00 1125 4.31

CFM

3000 939 1.79 994 2.01 1047 2.24 1098 2.47 1147 2.71 3250 962 2.03 1015 2.26 1066 2.50 1115 2.75 1163 3.00 3500 987 2.30 1038 2.54 3750 1014 2.60 1063 2.86 1111 3.12 1157 3.39 1202 3.66 4000 1042 2.93 1090 3.20 1136 3.48 1180 3.76 1224 4.04 4250 1072 3.30 1118 3.58 1162 3.87 1205 4.16 -- -4500 1103 3.70 1147 4.00 1190 4.29 1232 4.60 -- -4750 1135 4.14 1177 4.45 -- -- -- -- --- --5000 1167 4.63 -- -- --- --- --- --- --- ---

0.2 0.4 0.6 0.8 1.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Standard Static Option Medium Static Option

AVAILABLEEXTERNALSTATICPRESSURE(in.wg)

1.2 1.4 1.6 1.8 2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Medium Static Option High Static Option

1088

2.80 1135 3.05 1181 3.32

NOTE: For more information, see General Fan Performance Notes. Boldface indicates field--supplied drive is required.

1. Recommend using field--supplied motor pulley (part no. KR11HY410).

580J**14 3 PHASE 12.5 TON HORIZONTAL SUPPLY

Available External Static Pressure (in. wg)

CFM

3438 639 0.98 713 1.20 781 1.43 843 1.65 901 1.88 3750 683 1.23 753 1.47 817 1.71 877 1.96 933 2.21 4063 728 1.52 794 1.78 855 2.04 912 2.31 966 2.57 4375 774 1.85 836 2.13 894 2.41 949 2.70 1001 2.98 4688 820 2.23 879 2.53 935 2.83 987 3.14 1037 3.44 5000 867 2.66 923 2.98 976 3.30 1026 3.63 1074 3.95 5313 914 3.15 967 3.49 1018 3.83 1066 4.17 1112 4.52 5625 962 3.69 1012 4.05 1061 4.42 -- -- -- -5938 1009 4.30 1058 4.68 -- -- -- -- -- -6250 -- -- -- -- -- -- -- -- -- --

CFM

3438 955 2.12 1007 2.35 1056 2.59 1103 2.83 1148 3.08 3750 985 2.46 1035 2.71 1083 2.97 1129 3.23 1173 3.49 4063 1017 2.84 1066 3.12

4375 1050 3.27 1097 3.56 1142 3.86 1186 4.15 1228 4.45 4688 1084 3.75 1130 4.06 1174 4.37 1216 4.68 1257 5.00 5000 1120 4.28 1164 4.61 -- -- 1248 5.27 1288 5.60 5313 -- -- -- -- -- -- -- -- -- -5625 -- -- -- -- -- -- -- -- -- -5938 -- -- -- -- -- -- -- -- -- -6250 -- -- -- -- -- -- -- -- -- --

0.2 0.4 0.6 0.8 1.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Standard Static Option Medium Static Option

Available External Static Pressure (in. wg)

1.2 1.4 1.6 1.8 2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Medium Static Option High Static Option

1112 3.39 1157 3.67 1200 3.95

580J

NOTE: For more information, see General Fan Performance Notes. Boldface indicates field--supplied drive is required.

580J**14 3 PHASE 12.5 TON VERTICAL SUPPLY

Available External Static Pressure (in. wg)

CFM

3438 685 1.12 751 1.32 813 1.54 871 1.76 927 1.99 3750 736 1.41 797 1.63 855 1.86 910 2.10 963 2.35 4063 787 1.75 844 1.99 898 2.24 951 2.49 1001 2.75 4375 839 2.14 892 2.40 943 2.67 993 2.94 1041 3.21 4688 891 2.60 941 2.87 990 3.15 1037 3.44 1082 3.73 5000 944 3.11 991 3.40 1037 3.70 1082 4.00 1125 4.31 5313 997 3.69 1042 4.00 1085 4.32 1128 4.64 -- -5625 1051 4.34 1093 4.67 -- -- -- -- -- -5938 -- -- -- -- -- -- -- -- -- -6250 -- -- -- -- -- -- -- -- -- --

CFM

580J

3438 981 2.23 1032 2.47 1082 2.72 1130 2.97 1177 3.23 3750 1014 2.60 1063 2.86 1111 3.12 1157 3.39 1202 3.66 4063 1049 3.02 1097 3.29 1142 3.57 1186 3.85 1230 4.14 4375 1087 3.49 1132 3.78 1176 4.08 1218 4.37 1260 4.68 4688 1126 4.03 1169 4.33 1211 4.64 -- -- -- -5000 1167 4.63 -- -- -- -- -- -- -- -5313 -- -- -- -- -- -- -- -- -- -5625 -- -- -- -- -- -- -- -- -- -5938 -- -- -- -- -- -- -- -- -- -6250 -- -- -- -- -- -- -- -- -- --

0.2 0.4 0.6 0.8 1.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Standard Static Option Medium Static Option

Available External Static Pressure (in. wg)

1.2 1.4 1.6 1.8 2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Medium Static Option High Static Option

NOTE: For more information, see General Fan Performance Notes. Boldface indicates field--supplied drive is required.

General fan performance notes:

1. Interpolation is permissible. Do not extrapolate.

2. External static pressure is the static pressure difference between the return duct and the supply duct plus the static pressure caused by any FIOPs or accessories.

3. Tabular data accounts for pressure loss due to clean filters, unit casing, and wet coils. Factory options and accessories may add static pressure losses. Selection software is available, through your salesperson, to help you select the best motor/drive combination for your applic ation.

4. The Fan Performance tables offer motor/drive recommendations. In cases when two motor/drive combinations would work, Bryant recommended the lower horsepower option.

5. For information on the electrical properties of Bryant motors, please see the Electrical information section of this book.

6. For more information on the performance limits of Bryant motors, see the application data section of this book.

Pulley Adjustment

UNIT

MOTOR/DRIVE

COMBO

Standard Static 747 721 695 670 644 618 592 566 541 515 489

Medium Static 949 927 906 884 863 841 819 798 776 755 733

3phase

High Static 1102 1083 1063 1044 1025 1006 986 967 948 928 909

Standard Static 838 813 789 764 739 715 690 665 640 616 591

Medium Static 1084 1059 1035 1010 986 961 936 912 887 863 838

High Static 1240 1218 1196 1175 1153 1131 1109 1087 1066 1044 1022

Standard Static 838 813 789 764 739 715 690 665 640 616 591

Medium Static 1084 1059 1035 1010 986 961 936 912 887 863 838

High Static 1240 1218 1196 1175 1153 1131 1109 1087 1066 1044 1022

APPENDIX III. FAN PERFORMANCE (cont.)

MOTOR PULLEY TURNS OPEN

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

NOTE: Do not adjust pulley further than 5 turns open.

-- Factory settings

580J

ELECTRICAL INFORMATION

580J*08D,F 2--- Stage Cooling 7.5 Tons

VOLTAGE

V --- P h --- H z

2 0 8 --- 3 --- 6 0 187 253 13.6 83 13.6 83 325 1.5

2 3 0 --- 3 --- 6 0 187 253 13.6 83 13.6 83 325 1.5

4 6 0 --- 3 --- 6 0 414 506 6.1 41 6.1 41 325 0.8

5 7 5 --- 3 --- 6 0 518 633 4.2 33 4.2 33 325 0.6

580J

RANGE

MIN MAX

580J*12D,F 2--- Stage Cooling 10 Tons

VOLTAGE

V --- P h --- H z

2 0 8 --- 3 --- 6 0 187 253 15.6 110 15.9 110 325 1.5

2 3 0 --- 3 --- 6 0 187 253 15.6 110 15.9 110 325 1.5

4 6 0 --- 3 --- 6 0 414 506 7.7 52 7.7 52 325 0.8

5 7 5 --- 3 --- 6 0 518 633 5.8 39 5.7 39 325 0.6

RANGE

MIN MAX

COMP (Cir 1) COMP (Cir 2) OFM (ea) IFM

RLA LRA RLA LRA WATTS FLA TYPE

STD 1448 5.5 80% 5.2

MED 2278 7.9 81% 7.5

HIGH 4400 15.0 81% 15.0

STD 1448 5.5 80% 5.2

MED 2278 7.9 81% 7.5

HIGH 4400 15.0 81% 15.0

STD 1448 2.7 80% 2.6

MED 2278 3.6 81% 3.4

HIGH 4400 7.4 81% 7.4

STD 1379 2.5 80% 2.4

MED 3775 2.9 81% 2.8

HIGH 4400 5.9 81% 5.6

COMP (Cir 1) COMP (Cir 2) OFM (ea) IFM

RLA LRA RLA LRA WATTS FLA TYPE

STD 2120 5.5 80% 5.2

MED 3775 10.5 81% 10.0

HIGH 4400 15.0 81% 15.0

STD 2120 5.5 80% 5.2

MED 3775 10.5 81% 10.0

HIGH 4400 15.0 81% 15.0

STD 2120 2.7 80% 2.6

MED 3775 4.6 81% 4.4

HIGH 4400 7.4 81% 7.4

STD 1390 2.1 80% 2.0

MED 3775 2.9 81% 2.8

HIGH 4400 5.9 81% 5.6

Max

WATTS

Max

WATTS

Max

AMP Draw

Max

AMP Draw

EFF at Full Load FLA

580J*14D,F 2--- Stag e Cooling 12.5 Tons

VOLTAGE

V --- P h --- H z

2 0 8 --- 3 --- 6 0 187 253 19.0 123 22.4 149 1288 6.2

2 3 0 --- 3 --- 6 0 187 253 19.0 123 22.4 149 1288 6.2

4 6 0 --- 3 --- 6 0 414 506 9.7 62 10.6 75 1288 3.1

5 7 5 --- 3 --- 6 0 518 633 7.4 50 7.7 54 1288 2.5

RANGE

MIN MAX

COMP (Cir 1) COMP (Cir 2) OFM (ea) IFM

RLA LRA RLA LRA WATTS FLA TYPE

STD 2615 7.9 81% 7.5

MED 3775 10.5 81% 10.0

HIGH 4400 15.0 81% 15.0

STD 2615 7.9 81% 7.5

MED 3775 10.5 81% 10.0

HIGH 4400 15.0 81% 15.0

STD 2615 3.6 81% 3.4

MED 3775 4.6 81% 4.4

HIGH 4400 7.4 81% 7.4

STD 3775 2.9 81% 2.8

MED 3775 2.9 81% 2.8

HIGH 4400 5.9 81% 5.6

Max

WATTS

Max

AMP Draw

EFF at Full Load FLA

MCA/MOCP DETERMINATION NO C.O. OR UNPWRD C.O.

IFM

COMBUSTION

FAN MOTOR

FLA

UNIT

NOM.

V --- P h --- H z

TYPE

STD

208/230--- 3 --- 60

MED 45.9 50 49 235 49.7 60 53 239

0.48 3.8

HIGH 53.8 60 58 261 57.6 70 62 265

STD

4 6 0 --- 3 --- 6 0

MED 20.9 25 22 116 22.7 25 24 118

0.25 1.8

HIGH 25.3 30 27 129 27.1 30 29 131

580J*08D,F

5 7 5 --- 3 --- 6 0

STD

MED 15.2 20 16 94 19.0 25 21 98

0.24 3.8

HIGH 18.3 20 19 108 22.1 25 24 112

STD

208/230--- 3 --- 60

MED 53.3 60 57 306 57.1 70 61 310

0.48 3.8

HIGH 58.3 70 62 315 62.1 70 67 319

STD

4 6 0 --- 3 --- 6 0

MED 25.5 30 27 147 27.3 30 29 149

0.25 1.8

HIGH 28.5 35 31 151 30.3 35 33 153

580J*12D,F

5 7 5 --- 3 --- 6 0

STD

MED 18.7 25 20 106 22.5 25 24 110

0.24 3.8

HIGH 21.5 25 23 120 25.3 30 27 124

208/230--- 3 --- 60

STD

MED 68.0 80 72 382 71.8 80 76 386

0.48 3.8

HIGH Model not available due to high amperage draw.

STD

4 6 0 --- 3 --- 6 0

MED 32.7 40 35 192 34.5 45 37 194

0.25 1.8

HIGH 35.7 45 38 196 37.5 45 40 198

580J*14D,F

5 7 5 --- 3 --- 6 0

STD

MED 24.0 30 25 144 27.8 30 30 148

0.24 3.8

HIGH 26.8 30 29 158 30.6 35 33 162

LEGEND:

CO --- Convenient outlet DISC --- Disconnect FLA - -- Full load amps IFM --- Indoor fan motor LRA --- Locked rotor amps MCA --- Minimum circuit amps MOCP --- Maximum over current protection P E --- P o w er e x h au st UNPWRD CO --- Unpowered convenient outlet NOTES:

1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and

440), the overcurrent protective device for the unit shall be fuse or HACR breaker. Canadian units may be fuse or circuit breaker.

2. Unbalanced 3-Phase Supply Voltage Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percentage of voltage imbalance.

% Voltage Imbalance = 100 x

max voltage deviation from average voltage

average voltage

POWER

EXHAUST

FLA

NO P.E. w/ P.E. (pwrd fr/ unit)

NO C.O. or UNPWRD C.O.

MCA MOCP

DISC. SIZE

FLA LRA FLA LRA

MCA MOCP

DISC. SIZE

43.6 50 46 198 47.4 60 51 202

20.1 25 21 97 21.9 25 23 99

14.8 20 16 79 18.6 20 20 83

48.5 60 51 263 52.3 60 56 267

23.7 30 25 125 25.5 30 27 127

17.9 20 19 95 21.7 25 23 99

65.5 80 69 365 69.3 80 73 369

31.7 40 33 183 33.5 40 35 185

24.0 30 25 144 27.8 30 30 148

Example: Supply voltage is 230-3-60

AB = 224 v BC = 231 v AC = 226 v

Average Voltage =

(224 + 231 + 226)

= 227

681

Determine maximum deviation from average voltage. (AB) 227 – 224 = 3 v (BC) 231 – 227 = 4 v (AC) 227 – 226 = 1 v Maximum deviation is 4 v. Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x

= 1.76%

227

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.

580J

APPENDIX IV. WIRING DIAGRAM LIST

Wiring Diagrams

580J

SIZE VOLTAGE CONTROL POWER

208/230--- 3 --- 60 48TM501325 48TM501326

08D,F

12D,F

14D,F

All RTU--- MP* 48TM500988

NOTE: Component arrangement on Control; Legend on Power Schematic

580J

* RTU--MP control labels overlay a portion of the base unit control label. The base unit label drawing and the control option drawing are required to

provide a complete unit control diagram.

460--- 3 --- 60 48TM501325 48TM501326 575--- 3 --- 60 48TM501325 48TM501327

208/230--- 3 --- 60 48TM501325 48TM501326

460--- 3 --- 60 48TM501325 48TM501326 575--- 3 --- 60 48TM501325 48TM501327

208/230--- 3 --- 60 48TM501379 48TM501380

460--- 3 --- 60 48TM501379 48TM501380 575--- 3 --- 60 48TM501379 48TM501381

APPENDIX V. MOTORMASTER SENSOR LOCATIONS

580/558J-D08

580/558J-D12

580J

C09226

Fig. 75 -- 580J*08--12D,F Outdoor Circuiting

NOTE: The low ambient kit for the 12.5 ton unit utilizes a pressure transducer, and therefore there is no Motormaster

temperature sensor location for this unit.

E2009 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231 Printed i n U.S.A. Edition Date: 5/09

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No.SM580J--- 02

Replaces: NEW

580J

UNIT START-UP CHECKLIST

I. PRELIMINARY INFORMATION:

MODEL NO.: DATE: ______________

II. PRE-START-UP (insert check mark in box as each item is completed):

j VERIFY THAT ALL PACKAGING MATERIALS HAVE BEEN REMOVED FROM UNIT j VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS j VERIFY THAT FLUE HOOD IS INSTALLED j CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS j CHECK TO ENSURE NO WIRES ARE TOUCHING REFRIGERANT TUBING OR SHARP EDGES j CHECK GAS PIPING FOR LEAKS j CHECK THAT RETURN--AIR F ILTER IS CLEAN AND IN PLACE j VERIFY THAT UNIT INSTALLATION IS LEVEL j CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND VERIFY SETSCREW IS TIGHT j VERIFY PULLEY ALIGNMENT AND BELT TENSION ARE CORRECT

III. START-UP

ELECTRICAL

SUPPLY VOLTAGE L1-L2 L2-L3 L3-L1

SERIAL NO: _____________________________________ TECHNICIAN: ___________________________________ BUILDING LOCATION:____________________________

580J

COMPRESSOR 1 L1

COMPRESSOR 2 L1 L2 L2

INDOOR FAN AMPS L1 L2 L2

L2 L2

TEMPERATURES

OUTDOOR-AIR TEMPERATURE DB WB

RETURN-AIR TEMPERATURE

COOLING SUPPLY AIR

GAS HEAT SUPPLY AIR

DB WB

PRESSURES

GAS INLET PRESSURE IN. WG

GAS MANIFOLD PRESSURE

REFRIGERANT SUCTION

REFRIGERANT DISCHARGE

j VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS j VERIFY THAT 3--PHASE SCROLL COMPRESSORS ARE ROTATING IN CORRECT DIRECTION

CIR 1

CIR 2

CIR 1

CIR 2

IN. WG (LOW FIRE) IN. WG (HI FIRE) PSIG TEMP _F

PSIG TEMP _F PSIG TEMP _F PSIG TEMP _F

Bryant 580J08-14D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual