Bryant 581J-04A, Preferred Series, 581J-06A, 581J-05A Installation Instructions Manual

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Preferred Series 581J 04-06 Single Package Rooftop Gas Heat/Electric Cooling Unit with

Puron

(R-410A) Refrigerant

Installation Instructions

CONTENTS

Page

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

Rated Indoor Airflow (cfm). . . . . . . . . . . . . . . . . . . . . . . . . 2

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 1 — Plan for Unit Location. . . . . . . . . . . . . . . . . . . . .6

Step 2 — Plan for Sequence of Unit Installation . . . . . . . .7

Step 3 — Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 4 — Provide Unit Support. . . . . . . . . . . . . . . . . . . . . . 7

Step 5 — Field Fabricate Ductwork . . . . . . . . . . . . . . . . . . 9

Step 6 — Rig and Place Unit. . . . . . . . . . . . . . . . . . . . . . . . 9

Step 7 — Convert to Horizontal and Connect

Ductwork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Step 8 — Install Outside Air Hood . . . . . . . . . . . . . . . . . . 11

Step 9 — Relocate Latch (Units with Hinged Panels

Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Step 10 — Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . . 12

Step 11 — Install Gas Piping . . . . . . . . . . . . . . . . . . . . . .12

Step 12 — Install External Condensate Trap and Line . . . 14

Step 13 — Make Electrical Connections. . . . . . . . . . . . . . 15

Perfect Humidity™ System Control Connections. . . . . . . 19

EconoMi$er

Low Ambient Control (Factory Option) . . . . . . . . . . . . . .34

RTU Open Controller System . . . . . . . . . . . . . . . . . . . . . .36

Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Communication Wiring — Protocols . . . . . . . . . . . . . . . . 43

Local Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Outdoor Air Enthalpy Control (P/N 33CSENTHSW) . . . 45

Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Step 14 — Adjust Factory Installed Options. . . . . . . . . . . 47

Step 15 — Install Accessories. . . . . . . . . . . . . . . . . . . . . .47

Step 16 — Check Belt Tension . . . . . . . . . . . . . . . . . . . . .47

Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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

X (Factory-Installed Option) . . . . . . . . . . . 21

GENERAL

See Fig. 1 for 581J model number nomenclature. See Fig. 2 for unit dimensional drawings. Figure 3 shows service clearance dimensions.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The

qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloths for brazing operations and have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and appropriate national electrical codes (in USA, ANSI/NFPA70, National Electrical Code (NEC); in Canada, CSA C22.1) for special requirements.

It is important to recognize safety information. This is the safety-alert symbol and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. 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 hazards 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

WARNING

CARBON-MONOXIDE POISONING HAZARD

Failure to follow instructions could result in severe personal injury or death due to carbon-monoxide poisoning, if combustion products infiltrate into the building.

Check that all openings in the outside wall around the vent (and air intake) pipe(s) are sealed to prevent infiltration of combustion products into the building.

Check that furnace vent (and air intake) terminal(s) are not obstructed in any way during all seasons.

WARNING

Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation and service. There may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work is completed.

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WARNING

MANIFOLD

GAS VALVE

MANIFOLD PRESSURE

TAP SET SCREW

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

Disconnect gas piping from unit when leak testing at pressure greater than 0.5 psig (3450 Pa). Pressures greater than

0.5 psig (3450 Pa) will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than 0.5 psig (3450 Pa), it must be replaced before use. When pressure testing field-supplied gas piping at pressures of 0.5 psig (3450 Pa) or less, a unit connected to such piping must be isolated by closing the manual gas valve.

WARNING

FIRE HAZARD

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

Inlet pressure tap set screw must be tightened and pipe plug must be installed to prevent gas leaks.

GAS VALVE

/8 in. NPT

WARNING

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

Puron

(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.

WARNING

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

Relieve pressure and recover all refrigerant before system repair or final unit disposal. Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

CAUTION

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 equipment.

INLET PRESSURE

TAP SET SCREW

WARNING

FIRE HAZARD

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

Manifold pressure tap set screw must be tightened and

/8 in. NPT pipe plug must be installed to prevent gas leaks.

Rated Indoor Airflow (cfm) — Table 1 lists the rated

indoor airflow used for the AHRI efficiency rating for the units covered in this document.

Table 1 — Rated Indoor Airflow

MODEL NUMBER FULL LOAD AIRFLOW (CFM)

581J*A/B/F04 1050 581J*A/B/F05 1400 581J*A/B/F06 1625

Pre-Installation — Complete the following checks before

installation.

1. Consult local building codes and the NEC (National Electrical Code) ANSI/NFPA 70 for special installation requirements.

2. Determine unit location (from project plans) or select unit location.

Check for possible overhead obstructions which may inter-

fere with unit lifting or rigging.

For model number nomenclature see Fig. 1. For unit dimen-

sions and service clearances see Fig. 2-4.

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Unit Type

High Efficiency Gas Heat RTU

Model

–

Puron Refrigerant Model

Voltage

E = 460-3-60 J = 208/230-1-60 P = 208/230-3-60 T = 575-3-60

1 2 3 4 5 6 7 8 9 1011121314151617

5 8 1 J E 0 6 A 0 7 2 A 0 B 0 A

Packaging and 2-Speed Indoor Fan Motor

A = Standard Packaging, electro mech. controls that require W7212 EconoMi$er IV B = LTL Packaging, electro mech. controls that require W7212 EconoMi$er IV C = Standard Packaging, electro mech. controls that require W7220 EconoMi$er X D = Standard Packaging and 2-Speed Indoor Fan Motor (VFD) Controller E = LTL Packaging, and 2-Speed Indoor Fan Motor (VFD) Controller F = LTL Packaging, electro mech. controls that

require W7220 EconoMi$er X

Cooling Tons 04 - 3 ton 05 - 4 ton 06 - 5 ton

Refrig. System/Gas Heat Options

A = Standard One Stage cooling models/Nat. Gas Heat B = Standard One Stage cooling models/Low NO C = Standard One Stage cooling models/SS HX Heat

Heat

G = Standard One Stage cooling models and Perfect Humidity™ H = Standard One Stage cooling/Low NOx Heat and Perfect Humidity J = Standard One Stage cooling/SS HX Heat and Perfect Humidity

Heat Level Input

Standard/Stainless Steel 072 = 72,000 (1 Phase = 65,000) 180 = 180,000 115 = 115,000 (1 Phase = 90,000) 224 = 224,000 125 = 125,000 240 = 240,000 150 = 150,000 (1 Phase = 130,000) 250 = 250,000

Low NOx 060 = 60,000 090 = 90,000 120 = 120,000

Note: On single phase (-J voltage code) models, the following are not available as a factory installed option:

- Perfect Humidity

- Coated Coils or Cu Fin Coils

- Louvered Hail Guards

- Economizer or 2 Position Damper

- Powered 115 Volt Convenience Outlet

Factory Installed Options

Outdoor Air Options

A = None B = Temp Econo, Baro Relief, Standard Leak (W7212 or W7220) H = Enthalpy Econo, Baro Relief, Standard Leak (W7212 or W7220) E = Temp Econo, Baro Relief, Standard Leak w/CO (W7212 or W7220) L = Enthalpy Econo, Baro Relief, Standard Leak w/CO (W7212 or W7220) Q = Motorized 2 Position Damper U = Temp Econo, Baro Relief, Ultra Low Leak, (W7220) W = Enthalpy Econo, Baro Relief, Ultra Low Leak, (W7220)

Indoor Fan Options 3,4,5 Ton Models Only

0 = Electric (Direct) Drive x13 Motor

–

2 = Medium Static Option 3 = High Static Option

Belt Drive

–

Belt Drive

See price page details for specific Perfect Humidity

Coil Options (outdoor-indoor-hail guard)

A = Al/Cu - Al/Cu B = Precoat Al/Cu - Al/Cu C = E-coat Al/Cu - Al/Cu D = E-coat Al/Cu - E-coat Al/Cu E = Cu/Cu - Al/Cu F = Cu/Cu - Cu/Cu M = Al/Cu - Al/Cu – Louvered Hail Guards N = Precoat Al/Cu - Al/Cu – Louvered Hail Guards P = E-coat Al/Cu - Al/Cu – Louvered Hail Guards Q = E-coat Al/Cu - E-coat Al/Cu – Louvered Hail Guards R = Cu/Cu - Al/Cu – Louvered Hail Guards S = Cu/Cu - Cu/Cu – Louvered Hail Guards

Fig. 1 — 581J 04-06 Model Number Nomenclature (Example)

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Vertical Connections / Economizer

Horizontal Connections / Economizer

Fig. 2 — Unit Dimensional Drawing

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Fig. 2 — Unit Dimensional Drawing (cont)

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Fig. 3 — Service Clearance Dimensional Drawing

LOCATION DIMENSION CONDITION

48 in. (1219 mm) Unit disconnect is mounted on panel 18 in. (457 mm) No disconnect, convenience outlet option 18 in. (457 mm) Recommended service clearance 12 in. (305 mm) Minimum clearance

40 in. (1067 mm) Surface behind servicer is grounded (e.g., metal, masonry wall) 36 in. (914 mm) Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass) Special Check sources of flue products within 10 ft (3 m) of unit fresh air intake hood

36 in. (914 mm) Side condensate drain is used 18 in. (457 mm) Minimum clearance

48 in. (1219 mm) No flue discharge accessory installed, surface is combustible material 42 in. (1067 mm) Surface behind servicer is grounded (e.g., metal, masonry wall) 36 in. (914 mm) Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass) Special Check for adjacent units or building fresh air intakes within 10 ft (3 m) of this unit’s flue outlet

INSTALLATION

Jobsite Survey —

installation.

1. Consult local building codes and the NEC (National Electrical Code) ANSI/NFPA 70 for special installation requirements.

2. Determine unit location (from project plans) or select unit location.

3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.

Complete the following checks before

Step 1 — Plan for Unit Location — Select a location

for the unit and its support system (curb or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 3.

NOTE: Consider also the effect of adjacent units.

block the combustion intake or flue outlet.

Class A, B, or C roof-covering material when roof curb is used.

Be sure that unit is installed such that snow will not

Unit may be installed directly on wood flooring or on

Do not install unit in an indoor location. Do not locate air inlets near exhaust vents or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section

5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute) and NFPA (National Fire Protection Association) 54 TIA–54–84–1. In Canada, installation must be in accordance with the CAN1–B149 installation codes for gas burning appliances.

Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit.

Locate mechanical draft system flue assembly at least 4 ft (1.2 m) from any opening through which combustion products could enter the building, and at least 4 ft (1.2 m) from any adjacent building (or per local code). Locate the flue assembly at least 10 ft (3.05 m) from an adjacent unit’s fresh air intake hood if within 3 ft (0.91 m) of same elevation (or per local code). When unit is located adjacent to public walkways, flue assembly must be at least 7 ft (2.1 m) above grade.

Select a unit mounting system that provides adequate height to allow installation of condensate trap per

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requirements. Refer to Step 12 — Install External Condensate Trap and Line on page 14 for required trap dimensions.

ROOF MOUNT — Check building codes for weight distribution requirements. Unit operating weights are shown in Table 2.

Table 2 — Operating Weights

581J--

Base Unit 505 (229) 590 (268) 600 (272) Economizer Vertical 50 (23) 50 (23) 50 (23) Horizontal 80 (36) 80 (36) 80 (36) Perfect Humidity Cu Fins 25 (11) 43 (20) 56 (25) Powered Outlet 32 (15) 32 (15) 32 (15) Curb 14 in. (356 mm) 110 (50) 110 (50) 110 (50) 24 in. (610 mm) 145 (66) 145 (66) 145 (66)

™

System 27 (10) 34 (13) 34 (13)

UNIT LB (KG)

04 05 06

Step 2 — Plan for Sequence of Unit Installation —

The support method used for this unit will dictate different sequences for the steps of unit installation. For example, on curb-mounted units, some accessories must be installed on the unit before the unit is placed on the curb. Review the following for recommended sequences for installation steps:

CURB-MOUNTED INSTALLATION

1. Install curb

2. Install field-fabricated ductwork inside curb

3. Install accessory thru-base service connection package (affects curb and unit) (refer to accessory installation instructions for details)

4. Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Step 12 — Install External Condensate Trap and Line on page 14 for details)

5. Rig and place unit

6. Install outdoor air hood

7. Install flue hood

8. Install gas piping

9. Install condensate line trap and piping

10. Make electrical connections

11. Install other accessories

PAD-MOUNTED INSTALLATION

1. Prepare pad and unit supports

2. Check and tighten the bottom condensate drain connection plug

3. Rig and place unit

4. Convert unit to side duct connection arrangement

5. Install field-fabricated ductwork at unit duct openings

6. Install outdoor air hood

7. Install flue hood

8. Install gas piping

9. Install condensate line trap and piping

10. Make electrical connections

11. Install other accessories

FRAME-MOUNTED INSTALLATION — Frame-mounted applications generally follow the sequence for a curb installation. Adapt the sequence as required to suit specific installation plan.

Step 3 — Inspect Unit — Inspect unit for transportation

damage. File any claim with transportation agency.

Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

On units with hinged panel option, check to be sure all latches are snug and in closed position.

Locate the carton containing the outside air hood parts. Do not remove carton until unit has been rigged and located in final position.

Step 4 — Provide Unit Support

ROOF CURB MOUNT — Accessory roof curb details and

dimensions are shown in Fig. 4. Assemble and install accessory roof curb in accordance with instructions shipped with the curb.

NOTE: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket supplied with the roof curb as shown in Fig. 4. Improperly applied gasket can also result in air leaks and poor unit performance.

Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are shown in Fig. 5. Refer to Accessory Roof Curb Installation Instructions for additional information as required.

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CONNECTOR

PKG. ACCY.

D ALT

DRAIN

HOLE

GAS POWER CONTROL

ACCESSORY

POWER

CRBTMPWR001A01

1’-9

/16”

[551]

/4”

[44.5]

1’-4”

[406]

/4” [19]

NPT

CRBTMPWR003A01

/4” [19]

NPT

/2” [12.7]

NPT

/2” [12.7]

NPT

/2” [12.7]

NPT

ROOFCURB

ACCESSORY

AUNIT SIZE

CRRFCURB002A01

CRRFCURB001A01

1’-2”

[356]

2’-0”

[610]

581J*04-06

NOTES:

1. Roof curb accessory is shipped disassembled.

2. Insulated panels.

3. Dimensions in [ ] are in millimeters.

4. Roof curb: galvanized steel.

5. Attach ductwork to curb (flanges of duct rest on curb).

6. Service clearance: 4 ft on each side.

7. Direction of airflow.

8. Connector package CRBTMPWR001A01 is for thru-the-curb type gas

. CRBTMPWR003A01 is for thru-the-base type gas connections.

Fig. 4 — Roof Curb Details

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Fabricate supply ductwork so that the cross sectional di-

MAXIMUM ALLOWABLE

DIFFERENCE IN. (MM)

A-B B-C A-C

0.5 (13) 1.0 (25) 1.0 (25)

mensions are equal to or greater than the unit supply duct opening dimensions for the first 18 in. (458 mm) of duct length from the unit basepan.

Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

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

If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.

A minimum clearance is not required around ductwork.

Step 6 — Rig and Place Unit

CAUTION

Fig. 5 — Unit Leveling Tolerances

Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and not to the unit. The accessory thru-the-base power and gas connection package must be installed before the unit is set on the roof curb. If field-installed thru-the-roof curb gas connections are desired, use factory-supplied

/2-in. pipe coupling and gas plate assembly to mount the thru-the-roof curb connection to the roof curb. Gas connections and power connections to the unit must be field-installed after the unit is installed on the roof curb.

If electric and control wiring is to be routed through the basepan, attach the accessory thru-the-base service connections to the basepan in accordance with the accessory installation instructions.

SLAB MOUNT (HORIZONTAL UNITS ONLY) —

Provide a level concrete slab that extends a minimum of 6 in. (150 mm) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.

NOTE: Horizontal units may be installed on a roof curb if required.

ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR SLAB MOUNT) — A non-combustible sleeper rail

can be used in the unit curb support area. If sleeper rails cannot be used, support the long sides of the unit with a minimum of 3 equally spaced 4-in. x 4-in. (102 mm x 102 mm) pads on each side.

Step 5 — Field Fabricate Ductwork — Cabinet re-

turn-air static pressure (a negative condition) shall not exceed 0.35 in. wg (87 Pa) with economizer or 0.45 in. wg (112 Pa) without economizer.

For vertical ducted applications, secure all ducts to roof curb and building structure. Do not connect ductwork to unit.

Failure to follow this caution may result in damage to roofing materials.

Membrane roofs can be cut by sharp sheet metal edges. Be careful when placing any sheet metal parts on such roof.

Keep unit upright and do not drop. Spreader bars are required. Rollers may be used to move unit across a roof. Rigging materials under unit (cardboard or wood) must be removed PRIOR to placing the unit on the roof curb. Level by using unit frame as a reference. See Table 2 and Fig. 6 for additional information.

Lifting holes are provided in base rails as shown in Fig. 6. Refer to rigging instructions on unit.

Rigging materials under unit (cardboard to prevent base pan damage) must be removed PRIOR to placing the unit on the roof curb

When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before setting the unit in place. The red drain plug an be tightened with a

/2-in. square socket drive extension. For further details, see “Step 12 — Install External Condensate Trap and Line” on page 14.

Before setting the unit onto the curb, recheck gasketing

on curb.

CAUTION

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

All panels must be in place when rigging. Unit is not designed for handling by fork truck when panels or packaging are removed.

If using top crate as spreader bar, once unit is set, carefully lower wooden crate off building roof top to ground. Ensure that no people or obstructions are below prior to lowering the crate.

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Fig. 6 — Rigging Details

DETAIL "A"

PLACE ALL SEAL STRIP IN PLACE BEFORE PLACING UNIT ON ROOF CURB.

DUCT END

SEE DETAIL "A"

"A"

(914-1371)

36"- 54"

"C"

"B"

SPREADER

BARS

REQUIRED

NOTES:

1. SPREADER BARS ARE REQUIRED. Top damage will occur if spreader bars are not used.

2. Dimensions in () are in millimeters.

3. Hook rigging shackles through holes in base rail, as shown in Detail A. Holes in base rails are centered around the unit center of gravity. Use wooden top to prevent rigging straps from damaging unit.

MAX WEIGHT

DIMENSIONS

UNIT ABC

LB KG in. MM in. MM in. MM 581J-04A 760 345 74.5 1890 38.0 965 33.5 850 581J-05A 895 407 74.5 1890 38.0 965 41.5 1055 581J-06A 930 423 74.5 1890 37.5 955 41.5 1055

POSITIONING ON CURB — Position unit on roof curb so that the following clearances are maintained:

/4 in. (6.4 mm) clearance between the roof curb and the base rail inside the front and rear, 0.0 in. clearance between the roof curb and the base rail inside on the duct end of the unit. This will result in the distance between the roof curb and the base rail inside on the condenser end of the unit being approxi-

mately

/4 in. (6.4 mm).

Although unit is weatherproof, guard against water from

higher level runoff and overhangs.

Step 7 — Convert to Horizontal and Connect Ductwork (When Required) — Unit is shipped in the

vertical duct configuration. Unit without factory-installed economizer or return air smoke detector option may be field-converted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers and remove covers. Using the same screws, install covers on vertical duct openings with the insulation-side down. Seals around duct openings must be tight. See Fig. 7.

CAUTION

Failure to follow this caution may result in equipment damage.

All panels must be in place when rigging. Unit is not designed for handling by fork truck when panels or packaging are removed.

Flue vent discharge must have a minimum horizontal clearance of 4 ft (1220 mm) from electric and gas meters, gas regulators, and gas relief equipment. Minimum distance between unit and other electrically live parts is 48 inches (1220 mm).

Flue gas can deteriorate building materials. Orient unit such that flue gas will not affect building materials. Locate mechanical draft system flue assembly at least 48 in. (1220 mm) from an adjacent building or combustible material.

NOTE: Installation of accessory flue discharge deflector kit will reduce the minimum clearance to combustible material to

18 in. (460 mm).

After unit is in position, remove rigging skids and shipping materials.

duct openings and all ductwork should be secured to the flanges. Insulate and weatherproof all external ductwork, joints, and roof or building openings with counter flashing and mastic in accordance with applicable codes.

tive data plate when insulating horizontal ductwork.

Fig. 7 — Horizontal Conversion Panels

Field-supplied flanges should be attached to horizontal

Do not cover or obscure visibility to the unit’s informa-

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Step 8 — Install Outside Air Hood

FILTER ACCESS PANEL

OUTDOOR-AIR OPENING AND INDOOR COIL ACCESS PANEL

COMPRESSOR ACCESS PANEL

Hood Parts

Plastic Tie Wrap Qty (2)

Screws for Metal Tray Qty (2)

TOP PAN EL

INDOOR COIL ACCESS PAN EL

INDOOR

COIL

ACCESS

PAN EL

CAULK HERE

TOP PAN EL

ECONOMIZER AND TWO POSITION DAMPER HOOD PACKAGE REMOVAL AND SETUP (FACTORY OPTION)

NOTE: Economizer and two position damper are not available as factory installed options for single phase (-3 voltage code) models.

The hood is shipped in knock-down form and must be field assembled. The indoor coil access panel is used as the hood top while the hood sides, divider and filter are packaged together, attached to a metal support tray using plastic stretch wrap, and shipped in the return air compartment behind the indoor coil access panel. The hood assembly’s metal tray is attached to the basepan and also attached to the damper using two plastic tie-wraps.

1. To gain access to the hood, remove the filter access

panel. See Fig. 8.

ECONOMIZER AND TWO-POSITION HOOD

NOTE: If the power exhaust accessory is to be installed on the unit, the hood shipped with the unit will not be used and must be discarded. Save the aluminum filter for use in the power exhaust hood assembly.

1. The indoor coil access panel will be used as the top of the hood. Remove the screws along the sides and bottom of the indoor coil access panel. See Fig. 10.

2. Locate the (2) screws holding the metal tray to the

Fig. 8 — Typical Access Panel Locations

basepan and remove. Locate and cut the (2) plastic tiewraps securing the assembly to the damper. See Fig. 9. Be careful to not damage any wiring or cut tie-wraps securing any wiring.

Fig. 9 — Economizer and Two-Position Damper Hood

3. Carefully lift the hood assembly (with metal tray)

Parts Location

through the filter access opening and assemble per the steps outlined in the Economizer Hood and Two-Position Hood section.

Fig. 10 — Indoor Coil Access Panel Relocation

2. Swing out indoor coil access panel and insert the hood sides under the panel (hood top). Use the screws provided to attach the hood sides to the hood top. Use screws provided to attach the hood sides to the unit. See Fig. 11.

TOP PAN EL

INDOOR COIL ACCESS PANEL

LEFT HOOD SIDE

19 1/16”

(483mm)

HOOD DIVIDER

SCREW

33 3/8”

(848mm)

Fig. 11 — Economizer Hood Construction

3. Remove the shipping tape holding the economizer barometric relief damper in place (economizer only).

4. Insert the hood divider between the hood sides. See Fig. 11 and 12. Secure hood divider with 2 screws on each hood side. The hood divider is also used as the bottom filter rack for the aluminum filter.

5. Open the filter clips which are located underneath the hood top. Insert the aluminum filter into the bottom filter rack (hood divider). Push the filter into position past the open filter clips. Close the filter clips to lock the filter into place. See Fig. 12.

6. Caulk the ends of the joint between the unit top panel and the hood top.

7. Replace the filter access panel.

Page 12

Fig. 12 — Economizer Filter Installation

DIVIDER

BAROMETRIC RELIEF

CLEANABLE ALUMINUM FILTER

FILTER

HOOD

FILTER CLIP

OUTSIDE AIR

BLOWER ACCESS PANEL

FLUE OPENING

BLOWER ACCESS PANEL

Step 9 — Relocate Latch (Units with Hinged Panels Only) —

compartment behind the hinged compressor door to location shown in Fig. 13 after unit installation.

If the unit does not have hinged panels, skip this step and

continue at Step 10 below.

Relocate latch shipped inside the compressor

Step 11 — Install Gas Piping — Installation of the gas

piping must be accordance with local building codes and with applicable national codes. In U.S.A., refer to NFPA 54/ ANSI Z223.1 National Fuel Gas Code (NFGC). In Canada, installation must be accordance with the CAN/CSA B149.1 and CAN/CSA B149.2 installation codes for gas burning appliances.

This unit is factory equipped for use with Natural Gas fuel at elevations up to 2000 ft (610 m) above sea level. Unit may be field converted for operation at elevations above 2000 ft (610 m) and/or for use with liquefied petroleum fuel. See accessory kit installation instructions regarding these accessories.

NOTE: Furnace gas input rate on rating plate is for installation up to 2000 ft (610 m) above sea level. In U.S.A. the input rating for altitudes above 2000 ft (610 m) must be derated by 4% for each 1000 ft (305 m) above sea level. In Canada the input rating must be derated by 10% for altitudes of 2000 ft (610 m) to 4500 ft (1372 m) above sea level.

For natural gas applications, gas pressure at unit gas connection must not be less than 4 in. wg (996 Pa) or greater than 13 in. wg (3240 Pa) while the unit is operating. On 581J*05-06 high-heat units, the gas pressure at unit gas connection must not be less than 5 in. wg (1245 Pa) or greater than 13 in. wg (3240 Pa) while the unit is operating. See Table 3. For liquefied petroleum applications, the gas pressure must not be less than 11 in. wg (2740 Pa) or greater than

13.6 in. wg (3390 Pa) at the unit connection.

Table 3 — Natural Gas Supply Line Pressure Ranges

Fig. 13 — Compressor Door Latch Location

Step 10 — Install Flue Hood — Flue hood is shipped

screwed to the basepan beside the burner compartment access panel. Remove from shipping location and using screws provided, install flue hood and screen in location shown in Fig. 14.

UNIT MODEL UNIT SIZE MIN. MAX.

581JD/E/L/M/S/R 04, 05, 06

581JF/N/T

(High Heat Units Only)

04, 05, 06

4.0 in. wg (996 Pa)

5.0 in. wg

(1245 Pa)

13.0 in. wg (3240 Pa)

The gas supply pipe enters the unit at the burner access panel on the front side of the unit, through the long slot at the bottom of the access panel. The gas connection to the unit is made to the

/2-in. FPT gas inlet port on the unit gas

valve.

Manifold pressure is factory-adjusted for natural gas fuel use. Adjust as required to obtain best flame characteristics. See Table 4.

Table 4 — Natural Gas Manifold Pressure Ranges

UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE

581JD/E/L/M/S/R 04, 05, 06

581JF/N/T

(High Heat Units Only)

04, 05, 06

3.5 in. wg (872 Pa)

1.7 in. wg (423 Pa)

CAUTION

Failure to follow this caution may result in equipment damage.

When connecting the gas line to the unit gas valve, the installer MUST use a backup wrench to prevent damage to the valve.

Fig. 14 — Flue Hood Details

Install a gas supply line that runs to the unit heating section. Refer to the NFPA 54/NFGC or equivalent code for gas pipe sizing data. Do not use a pipe size smaller than

/2-in. Size the gas supply line to allow for a maximum pressure drop of 0.5-in. wg (124 Pa) between gas regulator source and unit gas valve connection when unit is operating at high-fire flow rate.

Page 13

The gas supply line can approach the unit in three ways:

BASE UNIT

BASE RAIL

ROOF CURB

9” MINIMUM CLEARANCE FOR PANEL REMOVAL

MANUAL GAS SHUTOFF VALVE

GAS REGULATOR

48” MINIMUM

DRIP LEG PER NFGC

FIELD-FABRICATED SUPPORT

FROM GAS METER

LEGEND *Field supplied.

NOTE: Follow all local codes.

NFGC —

National Fuel Gas Code

STEEL PIPE NOMINAL

DIAMETERS (IN.)

SPACING OF SUPPORTS

X DIMENSION (FT.)

/4 or 1 8

/4 or larger 10

9” (229mm) min

Union

Shut Off

Valve

Drip Leg

Thru-Curb Adapter

Unit Base Rail

horizontally from outside the unit (across the roof), thrucurb/under unit basepan (accessory kit required), or through unit basepan (factory option or accessory kit required). Consult accessory kit installation instructions for details on these installation methods. Observe clearance to gas line components per Fig. 15.

tend it through the access panel at the gas support bracket. See Fig. 17.

Fig. 15 — Gas Piping Guide

(with Accessory Thru-the-Curb Service Connections)

FACTORY-OPTION THRU-BASE CONNECTIONS (GAS CONNECTIONS) — This service connection kit

consists of a electrical bulkhead connector and a

/2-in. NPT gas adapter fitting (brass), a 1/2-in.

/4-in. electrical bulkhead connector, all factory-installed in the embossed (raised) section of the unit basepan in the condenser section. See Fig. 16.

EMBOSSMENT

BRASS FITTING FOR 3-6 TON UNITS

SUPPORT BRACKET

Fig. 17 — Gas Line Piping for 3 to 5 Ton Units Only

Other hardware required to complete the installation of the gas supply line includes a manual shutoff valve, a sediment trap (drip leg) and a ground-joint union. A pressure regulator valve may also be required (to convert gas pressure from pounds to inches of pressure). The manual shutoff valve must be located within 6 ft (1.83 m) of the unit. The union, located in the final leg entering the unit, must be located at least 9 in. (230 mm) away from the access panel to permit the panel to be removed for service. If a regulator valve is installed, it must be located a minimum of 4 ft (1220 mm) away from the unit’s flue outlet. Some municipal codes require that the manual shutoff valve be located upstream of the sediment trap. See Fig. 18 and 19 for typical piping arrangements for gas piping that has been routed through the sidewall of the curb. See Fig. 20 for typical piping arrangement when thru-base is used. Ensure that all piping does not block access to the unit’s main control box or limit the required working space in front of the control box.

LOW VOLTAGE CONDUIT CONNECTOR

HIGH VOLTAGE CONDUIT

BRASS FITTING FOR 3 TO 6 TON UNITS.

Fig. 16 — Thru-Base Gas Connection Fittings

The thru-base gas connector has male and female

threads. The male threads protrude above the basepan of the unit; the female threads protrude below the basepan.

Check tightness of connector lock nuts before connecting

gas piping.

Install a ting. Attach a 16-in. (406 mm) (field-supplied) to the street elbow and ex-

/2-in. NPT street elbow on the thru-base gas fit-

/2-in. pipe nipple with minimum length of

CONNECTOR

Fig. 18 — Gas Piping, Typical Curb Sidewall Piping

(Example 1)

Page 14

Fig. 19 — Gas Piping, Typical Curb Sidewall Piping

Drip Leg

Shut Off

Valve

Union

Thru-Curb Adapter

Burner Access Panel

9” (229mm) min

Unit Base Rail

BURNER

ORIFICE

(Example 2)

disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig (3450 Pa). Pressure test the gas supply piping system at pressures equal to or less than 0.5 psig (3450 Pa). The unit heating section must be isolated from the gas piping system by closing the external main manual shutoff valve and slightly opening the groundjoint union.

Check for gas leaks at the field-installed and factory-installed gas lines after all piping connections have been completed. Use soap-and-water solution (or method specified by local codes and/or regulations).

WARNING

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

• Connect gas pipe to unit using a backup wrench to avoid damaging gas controls.

• Never purge a gas line into a combustion chamber.

• Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

• Use proper length of pipe to avoid stress on gas control manifold.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. See Fig. 21.

Fig. 20 — Gas Piping, Typical Thru-Base Connections

When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFPA 54/ ANSI Z223.1 NFGC latest edition (in Canada, CAN/CSA B149.1). In the absence of local building codes, adhere to the following pertinent recommendations:

• Avoid low spots in long runs of pipe. Grade all pipe

/4 in. per every 15 ft (7 mm per every 5 m) to prevent traps. Grade all horizontal runs downward to risers. Use risers to connect to heating section and to meter.

• Protect all segments of piping system against physical and thermal damage. Support all piping with appropriate straps, hangers, etc. Use a minimum of one hanger every 6 ft (1.8 m). For pipe sizes larger than ommendations of national codes.

• Apply joint compound (pipe dope) sparingly and only to

• Pressure-test all gas piping in accordance with local and

male threads of joint when making pipe connections. Use only pipe dope that is resistant to action of liquefied petroleum gases as specified by local and/or national codes. If using PTFE (Teflon is Double Density type and is labeled for use on gas lines. Apply tape per manufacturer’s instructions.

national plumbing and gas codes before connecting pip-

) tape, ensure the material

ing to unit.

NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be

1. Teflon is a registered trademark of DuPont.

/2 in., follow rec-

Fig. 21 — Orifice Hole

Step 12 — Install External Condensate Trap and Line

The unit has one 3/4-in. condensate drain connection on the end of the condensate pan and an alternate connection on the bottom. See Fig. 22. Unit airflow configuration does not determine which drain connection to use. Either drain connection can be used with vertical or horizontal applications.

When using the standard side drain connection, ensure the red plug in the alternate bottom connection is tight. Do this before setting the unit in place. The red drain pan can be tightened with a

To use the alternate bottom drain connection, remove the red drain plug from the bottom connection (use a square socket drive extension) and install it in the side drain connection.

/2-in. square socket drive extension.

/2-in.

Page 15

The piping for the condensate drain and external trap can

DRAIN (FACTORY-INSTALLED)

PLUG

CONDENSATE PAN (SIDE VIEW)

STANDARD SIDE DRAIN

ALTERNATE BOTTOM DRAIN

NOTE: Trap should be deep enough to offset maximum unit static difference. A 4 in. (102 mm) trap is recommended.

MINIMUM PITCH 1˝ (25 mm) PER 10´ (3 m) OF LINE

BASE RAIL

OPEN VENT

TO ROOF DRAIN

DRAIN PLUG

ROOF CURB

SEE NOTE

3˝ (76 mm)

MIN

be completed after the unit is in place. See Fig. 23.

Fig. 22 — Condensate Drain Pan (Side View)

the source leads to the line side of the unit-mounted disconnect. (Check with local codes to ensure this method is acceptable in your area.) If a de-energize via unit disconnect switch operation of the convenience outlet is desired, connect the source leads to the load side of the unit disconnect. On a unit without a unit-mounted disconnect, connect the source leads to compressor contactor C and indoor fan contactor IFC pressure lugs with unit field power leads.

See CONVENIENCE OUTLETS on page 16 for power

transformer connections.

Field power wires are connected to the unit at line-side pressure lugs on compressor contactor C and indoor fan contactor IFC (see wiring diagram label for control box component arrangement) or at factory-installed option nonfused disconnect switch or HACR. Maximum wire size is #2ga AWG (copper only) per pole on contactors and #2ga AWG (copper only) per pole on optional disconnect or HACR. See Fig. 24 and unit label diagram for field power wiring connections.

NOTE: Unit may be equipped with short test leads (pigtails) on the field line connection points on contactor C or optional disconnect switch. These leads are for factory-run test purposes only; remove and discard before connecting field power wires to unit connection points. Make field power connections directly to line connection pressure lugs only.

Units Without Disconnect or HACR Option

11 2 3

Equip

GR Lug

1-ph Belt Drive IFM

CIFC

13 13 23

Direct Drive IFM

Equip

GR Lug

Fig. 23 — Condensate Drain Pan Piping Details

All units must have an external trap for condensate drainage. Install a trap at least 4 in. (102 mm) deep and protect against freeze-up. If drain line is installed downstream from the external trap, pitch the line away from the unit at 1 in. per 10 ft (25 mm per 3 m) of run. Do not use a pipe size smaller than the unit connection (

Step 13 — Make Electrical Connections

WARNING

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

Do not use gas piping as an electrical ground. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code); ANSI/NFPA 70, latest edition (in Canada, Ca-

nadian Electrical Code CSA [Canadian Standards Association] C22.1), and local electrical codes.

NOTE: Field-supplied wiring shall conform with the limitations of minimum 63°F (33°C) rise.

FIELD POWER SUPPLY — If equipped with optional Powered Convenience Outlet, the power source leads to the convenience outlet’s transformer primary are not factory connected. Installer must connect these leads according to required operation of the convenience outlet. If an alwaysenergized convenience outlet operation is desired, connect

/4 in.).

Disconnect

per

NEC

208/230-1-60

Ground

(GR)

208/230-3-60

L2 L3

460-3-60 575-3-60

Disconnect

per

NEC

Ground

(GR)

Units With Disconnect or HACR Option

3 Phase Onl y 3 Phase Only

Ground

(GR)

Optional

Disconnect

Switch

Disconnect factory test leads; discard.

Equip GR Lug

Fig. 24 — Power Wiring Connections

UNITS WITH FACTORY-INSTALLED NON-FUSED DISCONNECT OR HACR — The factory-installed op-

tion non-fused disconnect (NFD) or HACR switch is located in a weatherproof enclosure located under the main control box. The manual switch handle and shaft are shipped in the disconnect or HACR enclosure. Assemble the shaft and handle to the switch at this point. Discard the factory test leads (see Fig. 24).

Factory Wiring

Page 16

Failure to follow this caution could result in fire, intermit-

COPPER

WIRE ONLY

ELECTRIC

DISCONNECT

SWITCH

ALUMINUM

WIRE

CONVENIENCE

OUTLET GFCI

PWD-CO FUSE SWITCH

PWD-CO TRANSFORMER

CONTROL BOX ACCESS PANEL

tent operation, or unsatisfactory performance.

switch and air conditioning unit. Use only copper wire. See Fig. 25.

UNITS WITHOUT FACTORY-INSTALLED NONFUSED DISCONNECT OR HACR — When installing

units, provide a disconnect switch per NEC (National Electrical Code) of adequate size. Disconnect sizing data is provided on the unit informative plate. Locate on unit cabinet or within sight of the unit per national or local codes. Do not cover unit informative plate if mounting the disconnect on the unit cabinet.

ALL UNITS — All field wiring must comply with NEC and all local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit informative plate. See Fig. 24 and the unit label diagram for power wiring connections to the unit power terminal blocks and equipment ground. Maximum wire size is #2ga AWG (copper only) per pole on contactors. See Fig. 24 and unit label diagram for field power wiring connections.

tection device (fuse or breaker) per NEC Article 440 (or local codes). Refer to unit informative data plate for MOCP (Maximum Over-Current Protection) device size.

NOTE: Units ordered with factory installed HACR do not need an additional ground fault and short circuit over-current protective device unless required by local codes.

quirements.

voltage shown on the nameplate. If the 208/230v unit is to

be connected to a 208v power supply, the control transformer must be rewired by moving the black wire with the female spade connector from the 230v connection and moving it to the 200v the transformer. Refer to unit label diagram for additional information. Field power wires will be connected at lineside pressure lugs on the power terminal block or at factoryinstalled option non-fused disconnect.

NOTE: Check all factory and field electrical connections for tightness.

CAUTION

Do not connect aluminum wire between disconnect

Fig. 25 — Disconnect Switch and Unit

Provide a ground fault and short circuit over-current pro-

All field wiring must comply with the NEC and local re-

All units except 208/230v units are factory wired for the

/4-in.

/4-in. male terminal on the primary side of

CONVENIENCE OUTLETS

WARNING

Failure to follow 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. Lock-out and tag-out this switch, if necessary.

Two types of convenience outlets are offered on 581J models: non-powered and unit-powered. Both types provide a 125-volt GFCI (ground-fault circuit interrupter) duplex receptacle rated at 15A behind a hinged waterproof access cover, located on the end panel of the unit. See Fig. 26.

NOTE: Unit powered convenience outlets are not available as factory installed options for single phase (-J voltage code) models.

Fig. 26 — Convenience Outlet Location

Installing Weatherproof Cover

— A weatherproof while-inuse cover for the factory-installed convenience outlets is now required by UL standards. This cover cannot be factorymounted due its depth; it must be installed at unit installation. For shipment, the convenience outlet is covered with a blank cover plate.

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

WARNING

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

Disconnect all power to unit and convenience outlet.

Lock-out and tag-out all power.

1. Remove the blank cover plate at the convenience out-

let; discard the blank cover.

2. Loosen the two screws at the GFCI duplex outlet, until

approximately

in. (13 mm) under screw heads is

exposed. Press the gasket over the screw heads.

Page 17

3. Slip the backing plate over the screw heads at the key-

T O P

TOP

OCA

ONS

W E T

L O C A T

I O

COVER - WHILE-IN-USE

WEATHERPROOF

BASEPLATE FOR

GFCI RECEPTACLE

GASKET

GFCI RECEPTACLE

NOT INCLUDED

UNIT

VOLTAGE

CONNECT ASPRIMARY

CONNECTIONS

TRANSFORMER

TERMINALS

208, 230 240

L1: RED + YEL L2: BLU + GRA

H1 + H3 H2 + H4

460 480

L1: RED

Splice BLU + YEL

L2: GRA

H2 + H3

575 600

L1: RED L2: GRA

H1 H2

4. Mount the weatherproof cover to the backing plate as

5. Remove two slot fillers in the bottom of the cover to

6. Check for full closing and latching.

Non-Powered Convenience Outlet field installation of a general-purpose 125v 15A 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 125v power supply conductors into the bottom of the utility box containing the duplex receptacle.

Unit-Powered Convenience Outlet transformer is factory-installed to step down the main power supply voltage to the unit to 115v 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. 26.

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 the unit-mounted non-fused disconnect or HACR breaker switch; this will provide service power to the unit when the unit disconnect switch or HACR switch is open. Other connection methods will result in the convenience outlet circuit being de-energized when the unit disconnect or HACR switch is open. See Fig. 28.

hole slots and align with the gasket; tighten the two screws until snug (do not over-tighten).

shown in Fig. 27.

permit service tool cords to exit the cover.

Fig. 27 — Weatherproof Cover Installation

— This type requires the

— A unit-mounted

The primary leads to the convenience outlet transformer

Fig. 28 — Powered Convenience Outlet Wiring

Using Unit-Mounted Convenience Outlets

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

Fuse On Power Type “Fusetron”

T-15, non-renewable screw-in (Edison base)

— The factory fuse is a Bussman

type plug fuse. Duty Cycle

— 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.

Convenience outlet usage rating:

• Continuous usage: 8 amps maximum

• Intermittent usage: Up to 15 amps maximum for up to 2

hours maximum

Test the GFCI receptacle by pressing the TEST button on the face 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.

1. Bussman and Fusetron are trademarks of Cooper Technologies Company.

Page 18

AB = 224 v

O/B/Y2

T H E R M O

T A T

(Note 1)

(Note 2)

Note 1: Typical multi-function marking. Follow manufacturer’s conguration Instructions to select Y2.

Note 2: Y2 to Y2 connection required on single-stage cooling units when integrated economizer function is desired.

Field Wiring

Central

Te r mi n al

Board

Typical

Thermostat

Connections

BC = 231 v AC = 226 v

Average Voltage =

224 + 231 + 226

681

= 227

Fig. 29 — Convenience Outlet Utilization

Notice Label

FACTORY-OPTION THRU-BASE CONNECTIONS (ELECTRICAL CONNECTIONS) — This service con-

nection kit consists of a (brass), a

/2-in. electrical bulkhead connector, and a 3/4-in.

/2-in. NPT gas adapter fitting

electrical bulkhead connector, all factory-installed in the embossed (raised) section of the unit basepan in the condenser section. The low-voltage control wires to pass through the basepan. The

/2-in. electrical bulkhead connector allows the high-voltage

/4-in. bulkhead connector enables the

power wires to pass through the basepan. See Fig. 16 on page 13.

Check tightness of connector lock nuts before connecting

electrical conduits.

Field-supplied and field-installed liquid tight conduit connectors and conduit may be attached to the connectors on the basepan. Pull correctly rated high voltage and low voltage through appropriate conduits. Connect the power conduit to the internal disconnect (if unit is so equipped) or to the external disconnect (through unit side panel). A hole must be field cut in the main control box bottom on the left side so the 24-v control connections can be made. Connect the control power conduit to the unit control box at this hole.

UNITS WITHOUT THRU-BASE CONNECTIONS (ELECTRICAL CONNECTIONS)

1. Install power wiring conduit through side panel open-

ings. Install conduit between disconnect and control box.

2. Install power lines to terminal connections as shown in

Fig. 24 on page 15.

Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. On 3phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in the example below to determine the percent of voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Bryant warranty.

Unbalanced 3-Phase Supply Voltage:

IMPORTANT: 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

Example: Supply voltage is 230-3-60.

max voltage deviation from

average voltage

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 = 100x

226

=1.76%

This amount of phase imbalance is satisfactory as it is be-

low the maximum allowable 2%.

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

NOTE: Check all factory and field electrical connections for tightness.

FIELD CONTROL WIRING — The 581J unit requires an external temperature control device. This device can be a thermostat emulation device provided as part of a third party Building Management System.

THERMOSTAT — Install a Bryant-approved accessory thermostat according to installation instructions included with the accessory. For complete economizer function, select a two-stage cooling thermostat. Locate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in accordance with the thermostat installation instructions. Typical low-voltage connections are shown in Fig. 30.

Fig. 30 — Low-Voltage Thermostat Connections

Page 19

If the thermostat contains a logic circuit requiring 24v power, use a thermostat cable or equivalent single leads of different colors with minimum of seven leads. If the thermostat does not require a 24v source (no “C” connection required), use a thermostat cable or equivalent with minimum of six leads. Check the thermostat installation instructions for additional features which might require additional conductors in the cable.

For wire runs up to 50 ft. (15 m), use no. 18 AWG (American Wire Gage) insulated wire [95°F (35°C) minimum]. For 50 to 75 ft. (15 to 23 m), use no. 16 AWG insulated wire [95°F (35°C) minimum]. For over 75 ft. (23 m), use no. 14 AWG insulated wire [95°F (35°C) minimum]. Wire sizes larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.

Thermostat Wiring, Units Without Thru-Base Connection Kit — Pass the thermostat control wires through the hole provided in the corner post; then feed the wires through the raceway built into the corner post to the control box. Pull the wires over to the terminal strip on the upper-left corner of the Controls Connection Board. See Fig. 31.

NOTE: If thru-the-bottom connections accessory is used, refer to the accessory installation instructions for information on routing power and control wiring.

RACEWAY

HOLE IN END PANEL (HIDDEN)

Fig. 31 — Field Control Wiring Raceway

HEAT ANTICIPATOR SETTINGS — Set heat anticipa-

tor settings at 0.14 amp for the first stage and 0.14 amp for second-stage heating, when available.

Perfect Humidity™ Control Connections

PERFECT HUMIDITY — SPACE RH CONTROLLER

Fig. 32 — Edge Programmable Thermostat

To connect a field- supplied humidistat:

1. Route the humidistat 2-conductor cable (field -supplied) through the hole provided in the unit corner post.

2. Feed wires through the raceway built into the corner post (see Fig. 31) to the 24-v barrier located on the left side of the control box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. Use wire nuts to connect humidistat cable to two PINK leads in the low–voltage wiring as shown in Fig. 33.

To connect the Edge Programmable Thermidistat (T6-

PRH01- A):

1. Route the Edge Programmable Thermostat multi-conductor cable (field-supplied) through the hole provided in the unit corner post.

2. Feed wires through the raceway build into the corner post (see Fig. 31) to the 24-v barrier located on the left side of the control box. The raceway provides the UL-required clearance between high-voltage and low-voltage wiring.

3. The Edge Programmable Thermostat has dry contacts at terminals D1 and D2 for dehumidification operation (see Fig. 33). The dry contacts must be wired between CTB terminal R and the PINK lead to the LTLO switch with field-supplied wire nuts (See Fig. 33). Refer to the installation instructions included with the Bryant Edge Programmable Thermidistat device for more information.

NOTE: Perfect Humidity is a factory installed option which is only available for units equipped with belt-drive motors. Perfect Humidity is not available for single phase (-J voltage code) models.

The Perfect Humidity dehumidification system requires a field-supplied and installed space relative humidity control device. This device may be a separate humidistat control (contact closes on rise in space RH above control setpoint) or a combination thermostat-humidistat control device such as Bryant’s

Edge

Pro Thermidistat with isolated contact set for dehumidi-

fication control (see Fig. 32).

Page 20

Fig. 33 — Typical Rooftop Unit with Perfect Humidity

O/W2/B

OAT

RRS

SRTN

HUM

D1 D2 V+ Vg

EDGE Pro THERMIDISTAT

Unit CTB

THERMOSTAT

*Connection not required.

Perfect Humidity™ FIOP

Adaptive Dehumidification System

and Edge

Pro Thermidistat Device

™

Fig. 34 — Typical Perfect Humidity Adaptive Dehumidification System Humidistat Wiring

Page 21

EconoMi$er® X (Factory-Installed Option)

PRODUCT DESCRIPTION

The EconoMi$er X system is an expandable economizer control system, which includes a W7220 economizer module (controller) with an LCD and keypad (See Fig. 35). The W7220 can be configured with optional sensors.

Fig. 35 — W7220 Economizer Module

The W7220 economizer module can be used as a standalone economizer module wired directly to a commercial setback space thermostat and sensors to provide outside air drybulb economizer control.

The W7220 economizer module can be connected to optional sensors for single or differential enthalpy control. The W7220 economizer module provides power and communications for the sensors.

The W7220 economizer module automatically detects sensors by polling to determine which sensors are present. If a sensor loses communications after it has been detected, the W7220 economizer controller indicates a device fail error on its LCD.

SYSTEM COMPONENTS — The EconoMi$er X system includes an economizer module, 20k mixed air sensor, damper actuator, and either a 20k outdoor air temperature sensor or SBus enthalpy sensors.

Economizer Module: EconoMi$er X system. The module is mounted in the unit’s control box, and includes the user interface for the system. The W7220 economizer module provides the basic inputs and outputs to provide simple economizer control. When used with the optional sensors, the economizer module provides more advanced economizer functionality.

S-Bus Enthalpy Control Sensors: tion temperature and humidity sensor which is powered by and communicates on the S-Bus. Up to three sensors may be configured with the W7220 economizer module.

Sensor (optional): The sensor can be added for Demand

Controlled Ventilation (DCV).

SPECIFICATIONS

W7220 Economizer Module: with 2 to 10 Vdc or bus communicating actuator. The module includes terminals for CO Outdoor Dry Bulb sensor. Enthalpy and other options are available with bus sensors.

User Interface: rameters, checkout tests, and alarm and error conditions with a 2-line 16 character LCD display and four button keypad.

Electrical

Rated Voltage — 20 to 30 Vac RMS, 50/60 Hz

The module is the core of the

The sensor is a combina-

The module is designed for use

sensor, Mixed Air sensor, and an

Provides status for normal operation, setup pa-

Transformer — 100 va maximum system input Nominal Power Consumption (at 24 Vac, 60 Hz) — 11.5

VA without sensors or actuators

Relay Digital Output Rating at 30 Vac (maximum power

from Class 2 input only) — 1.5A run:

3.5A inrush at 0.45PF (200,000 cycles) or

7.5A inrush at 0.45PF (100,000 cycles) External Sensors Power Output — 21 Vdc ± 5% at 48mA

IMPORTANT: All inputs and outputs must be Class 2 wiring.

INPUTS Sensors: NOTE: A Mixed Air (MA) analog sensor is required on all

W7220 units; either an Outdoor Air (OA) sensor for dry bulb change over or an OA bus sensor for outdoor enthalpy change over is required in addition to the MA sensor. An additional Return Air (RA) bus sensor can be added to the system for differential enthalpy or dry bulb changeover. For differential dry bulb changeover a 20k ohm sensor is required in the OA and a bus sensor in the RA. DIP switch on RA bus sensor must be set in the RA position.

Dry Bulb Temperature (optional) and Mixed Air (required), 20k NTC

2-wire (18 to 22 AWG); Temperature range -40 to 150°F (-40 to 65°C) Temperature accuracy -0°F/+2°F

Temperature and Humidity, C7400S1000 (optional)

S-Bus; 2-wire (18 to 22 AWG) Temperature: range -40 to 150°F (-40 to 65°C) Temperature accuracy -0°F/+2°F Humidity: range 0 to 100% RH with 5% accuracy.

NOTE: Up to three (3) S-Bus sensors may be connected to the W7220 economizer module. For outdoor air (OA), return air (RA) and discharge (supply) air (DA).

4 Binary Inputs

1-wire 24 Vac + common GND.

24 Vac power supply

20 to 30 Vac 50/60Hz; 100 VA Class 2 transformer.

OUTPUTS

Actuator Signal:

2-10 Vdc; minimum actuator impedance is

2k ohm; bus two-wire output for bus communicating actuators. Exhaust fan, Y1, Y2 and AUX1 O:

All Relay Outputs (at 30 Vac): Running: 1.5A maximum Inrush: 7.5A maximum

ENVIRONMENTAL

Operating Temperature:

-40 to 150°F (-40 to 65°C). Exception of display operation down to -4°F with full

recovery at -4°F from exposure to -40°F Storage Temperature:

-40 to 150°F (-40 to 65°C)

Shipping Temperature:

-40 to 150°F (- 40 to 65°C)

Relative Humidity:

5% to 95% RH non-condensing

Page 22

ECONOMIZER MODULE WIRING DETAILS —

AUX2-

OCC

E-GND

EXH1

AUX1-O

Y2-

Y1-

Y2-O

Y1-O

50048848-002

Rev. A

OCC

Y2I

Y2O

Y1I

Y1O

Cert Product

California Title 24, Part 6

HJW10

www.energy.ca.gov

MAT

OAT

S-BUS

IAQ 2-10

IAQ COM

IAQ 24V

ACT 2-10

ACT CO M

ACT 24V

MA MA

OA OA

SB SB

V C R

50040839-001

Rev. G

Use Fig. 36 and Tables 5 and 6 to locate the wiring terminals for the Economizer module.

NOTE: The four terminal blocks are removable. Slide out each terminal block, wire it, and then slide it back into place.

Table 6 — Economizer Module - Right Hand Terminal

Blocks

LABEL TYPE DESCRIPTION

Top Right Terminal Blocks

AUX2 I 24 vac IN The first terminal is not used.

Shut Down (SD) or HEAT (W)

OCC 24 vac IN

E-GND E-GND Occupied/Unoccupied Input

EXH1

AUX1 O

24 vac OUT

Bottom Right Terminal Blocks

Y2-I 24 vac IN

Y2-O

24 vac OUT

Y1-I 24 vac IN

Y1-O

24 vac OUT

C COM 24 vac Common

R 24 vac 24 vac Power (hot)

Conventional only and Heat Pump Changeover (O-B) in Heat Pump mode.

Exhaust Fan 1 Output

Programmable: Exhaust fan 2 output or ERV or System alarm output

Y2 in - Cooling Stage 2 Input from space thermostat

Y2 out - Cooling Stage 2 Output to stage 2 mechanical cooling

Y1 in - Cooling Stage 2 Input from space thermostat

Y1 out - Cooling Stage 2 Output to stage 2 mechanical cooling

Fig. 36 — W7220 Wiring Terminals

Table 5 — Economizer Module - Left Hand Terminal

Blocks

LABEL TYPE DESCRIPTION

Top Left Terminal Block

MAT MAT

OAT OAT

S-BUS S-BUS

IAQ 2-10 2-10 vdc

IAQ COM COM Air Quality Sensor Common

IAQ 24V 24 vac Air Quality Sensor 24 vac Source

ACT 2-10 2-10 vdc Damper Actuator Output (2-10 vdc)

ACT COM COM Damper Actuator Output Common

ACT 24v 24 vac Damper Actuator 24 vac Source

*Sylk is a trademark of Honeywell International Inc.

20k NTC and COM

S-BUS (Sylk* Bus)

Bottom Left Terminal Block

Mixed Air Temperature Sensor (Polarity Insensitive Connection)

Outdoor Air Temperature Sensor (Polarity Insensitive Connection)

Enthalpy Control Sensor (Polarity Insensitive Connection)

Air Quality Sensor Input (e.g. CO sensor)

S-BUS SENSOR WIRING — The labels on the sensors and controller are color coded for ease of installation. Orange labeled sensors can only be wired to orange terminals on the controller. Brown labeled sensors can only be wired to S-bus (brown) terminals. Use Fig. 37 and Table 10 to locate the wiring terminals for each S-Bus sensor.

Use Fig. 37 and Table 7 to locate the wiring terminals for

each enthalpy control sensor.

DIP SWITCH LABEL

DIP SWITCHES (3)

S-BUS TERMINALS (1 AND 2)

S-BUS 2 PIN SIDE CONNECTOR

Fig. 37 — S-Bus Sensor DIP Switches

Page 23

CO2 SENSOR

24V

ANALOG

OUT

L1 (HOT) L2

RED

BLACK

YELLOW

BROWN

ORANGE

GREEN

–

POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

Table 7 — HH57AC081 Sensor Wiring Terminations

TERMINAL

NUMBER LABEL

1 S-BUS S-BUS

2 S-BUS S-BUS

TYPE DESCRIPTION

Communications

(Enthalpy Control

Sensor Bus)

Communications

(Enthalpy Control

Sensor Bus)

Use Fig. 37 and Table 8 to set the DIP switches for the desired use of the sensor.

Table 8 — HH57AC081 Sensor DIP Switch

DIP SWITCH POSITIONS FOR SWITCHES 1, 2, AND 3

USE

DA OFF ON OFF

RA ON OFF OFF

OA OFF OFF OFF

123

NOTE: When a S-Bus sensor is connected to an existing network, it will take 60 minutes for the network to recognize and auto-configure itself to use the new sensor.

During the 60-minute setup period, no alarms for sensor failures (except SAT) will be issued and no economizing function will be available.

SENSOR WIRING — When using a CO2 sensor the

black and brown common wires are internally connected and only one is connected to “IAQ COM” on the W7220. Use the power from the W7220 to power the CO

sensor OR make sure

the ground for the power supplies are common. See Fig. 38 for CO

sensor wiring.

Fig. 38 — CO

Sensor Wiring

INTERFACE OVERVIEW — This section describes how

to use the Economizer’s user interface for:

• Keypad and menu navigation

• Settings and parameter changes

• Menu structure and selection

USER INTERFACE — The user interface consists of a 2line LCD display and a 4-button keypad on the front of the economizer controller.

KEYPAD — The four navigation buttons (see Fig. 39) are used to scroll through the menus and menu items, select menu items, and to change parameter and configuration settings.

To use the keypad when working with menus:

• Press the ▲ (Up arrow) button to move to the previous

menu.

• Press the ▼ (Down arrow) button to move to the next

menu.

S-BUS

• Press the (Enter) button to display the first item in the currently displayed menu.

Fig. 39 — W7220 Controller Navigation Buttons

Press the (Menu Up/Exit) button to exit a menu’s item and return to the list of menus. To use the keypad when working with Setpoints, System and Advanced Settings, Checkout tests and Alarms:

1. Navigate to the desired menu.

2. Press the (Enter) button to display the first item in the currently displayed menu.

3. Use the ▲ and ▼ buttons to scroll to the desired parameter.

4. Press the (Enter) button to display the value of the currently displayed item.

5. Press the ▲ button to increase (change) the displayed parameter value.

6. Press the ▼ button to decrease (change) the displayed parameter value.

NOTE: When values are displayed, pressing and holding the ▲ or ▼ button causes the display to automatically increment.

7. Press the (Enter) button to accept the displayed value and store it in nonvolatile RAM. “CHANGE STORED” displays.

8. Press the (Enter) button to return to the current menu parameter.

9. Press the (Menu Up/Exit) button to return to the previous menu.

MENU STRUCTURE — Table 9 illustrates the complete hierarchy of menus and parameters for the EconoMi$er

X sys-

tem.

The Menus in display order are:

•STATUS

• SETPOINTS

•SYSTEM SETUP

• ADVANCED SETUP

• CHECKOUT

•ALARMS

IMPORTANT: Table 9 illustrates the complete hierarchy. Menu parameters may be different depending on the configuration. For example, if there is no DCV (CO

) sensor, then none of the DCV parameters appear

and only MIN POS will display. If there is a CO

sen-

sor, the DCV MIN and DCV MAX will appear AND if there is a 2 speed fan DCV MIN (high and low speed) and DCV MAX (high and low speed will appear).

Page 24

NOTE: Some parameters in the menus use the letters MA or MAT, indicating a mixed air temperature sensor location before the cooling coil. This unit application has the control sensor located after the cooling coil, in the fan section, where it is designated as (Cooling) Supply Air Temperature or SAT sensor.

SETUP AND CONFIGURATION — Before being placed into service, the W7220 Economizer module must be setup and configured for the installed system.

IMPORTANT: During setup, the economizer module is live at all times.

The setup process uses a hierarchical menu structure that is easy to use. Press the ▲ and ▼ arrow buttons to move forward and backward through the menus and press the (Enter) button to select and confirm setup item changes.

TIME-OUT AND SCREENSAVER — When no buttons have been pressed for 10 minutes, the LCD displays a screen saver, which cycles through the Status items. Each Status items displays in turn and cycles to the next item after 5 seconds.

Page 25

MENU PARAMETER

ECONO AVAIL NO YES/NO

ECONOMIZING NO YES/NO

OCCUPIED NO YES/NO

HEAT PUMP N/A

COOL Y1—IN OFF ON/OFF

COOL Y1—OUT OFF ON/OFF

COOL Y2—IN OFF ON/OFF

COOL Y2—OUT OFF ON/OFF

STATUS

MA TEMP _ _ . _ F 0 to 140°F

DA TEMP _ _ . _ F 0 to 140°F

OA TEMP _ _ . _ F -40 to 140°F

OA HUM _ _ % 0 to 100%

RA TEMP _ _ . _ F 0 to 140°F

RA HUM _ _ % 0 to 100%

IN CO2 _ _ _ ppm 0 TO 2000 ppm

DCV STATUS N/A ON/OFF

DAMPER OUT 2.0v 2.0 TO 10.0v Displays voltage output to the damper actuator.

ACT POS N/A 0 to 100% Displays actual position of outdoor air damper actuator

Table 9 — Menu Structure

PARAMETER

DEFAULT

VALUE

PARAMETER

RANGE AND INCREMENT

COOL HEAT

NOTES

FIRST STAGE COOLING DEMAND (Y1–IN) YES = economizing available; the system can use outside air for free cooling when required

FIRST STAGE COOLING RELAY OUTPUT YES = outside air being used for 1 stage cooling

OCCUPIED YES = OCC signal received from space thermostat or unitary controller YES = 24 Vac on terminal OCC NO = 0 Vac on terminal OCC

HEAT PUMP MODE Displays COOL or HEAT when system is set to heat pump (Non-conventional)

FIRST STAGE COOLING DEMAND (Y1-IN) Y1–I signal from space thermostat or unitary controller for cooling stage

1. ON = 24 Vac on terminal Y1–I OFF = 0 Vac on terminal Y1–I

FIRST STAGE COOLING RELAY OUTPUT Cool stage 1 Relay Output to stage 1 mechanical cooling (Y1–OUT terminal)

SECOND STAGE COOLING DEMAND (Y2–IN) Y2–I signal from space thermostat our unitary controller for second stage cooling. ON = 24 Vac on terminal Y2–I OFF = 0 Vac on terminal Y2–I

SECOND STAGE COOLING RELAY OUTPUT Cool Stage 2 Relay Output to mechanical cooling (Y2–OUT terminal)

SUPPLY AIR TEMPERATURE, Cooling Mode Displays value of measured mixed air from MAT sensor. Displays _ _ . _ F if not connected, short or out-of-range.

DISCHARGE AIR TEMPERATURE, after Heating section Displays when Discharge Air sensor is connected and displays measured discharge temperature. Displays _ _ . _F if sensor sends invalid value, if not connected, short or out-of-range.

OUTSIDE AIR TEMP Displays measured value of outdoor air temperature. Displays _ _ . _F if sensor sends invalid value, short or out-of-range.

OUTSIDE AIR RELATIVE HUMIDITY Displays measured value of outdoor humidity from OA sensor. Displays _ _% if not connected short, or out-of-range.

RETURN AIR TEMPERATURE Displays measured value of return air temperature from RAT sensor. Displays _ _ . _ F if sensor sends invalid value, if not connected, short or out-of-range

RETURN AIR RELATIVE HUMIDITY Displays measured value of return air humidity from RA sensor. Displays _ _% if sensor sends invalid value, if not connected, short or out-of-range

SPACE/RETURN AIR CO Displays value of measured CO2 from CO2 sensor. Invalid if not connected, short or out-of-range

DEMAND CONTROLLED VENTILATION STATUS Displays ON if above setpoint and OFF if below setpoint, and ONLY if a

sensor is connected.

Page 26

MENU PARAMETER

ACT COUNT N/A 1 to 65535 Displays number of times actuator has cycled.

ACTUATOR N/A OK/Alarm (on

EXH1 OUT OFF ON/OFF EXHAUST STAGE 1 RELAY OUTPUT

STATUS

(CONT)

EXH2 OUT OFF ON/OFF EXHAUST STAGE 2 RELAY OUTPUT

MECH COOL ON

HEAT STAGES ON

FAN SPEED N/A LOW or HIGH SUPPLY FAN SPEED

W (HEAT ON) N/A ON/OFF HEAT DEMAND STATUS

MAT SET 53°F

LOW T LOCK 32°F

DRYBLB SET 63°F

ENTH CURVE ES3

DCV SET 1100ppm

MIN POS 2.8 V 2 to 10 Vdc

VENTMAX

With 2-speed fan units

VENTMAX L (low speed fan)

and VENTMAX H (high speed fan) settings are

required

SETPOINTS

VENTMIN

With 2-speed fan units VENTMIN L (low speed fan) and VENTMIN

H (high speed fan) set

ERV OAT SP 32°F

EXH1 SET With 2-speed fan units Exh1 L (low speed fan) and Exh1

H (high speed fan) settings

are required

EXH2 SET With 2-speed fan units Exh2 L (low speed fan) and Exh2

H (high speed fan) settings

are required

Table 9 — Menu Structure (cont)

PARAMETER

DEFAULT

VALUE

ERV OFF ON/OFF ENERGY RECOVERY VENTILATOR

0 0, 1, or 2 Displays stage of mechanical cooling that is active.

2.8 V

2.25 V

50%

75%

PARAMETER

RANGE AND

INCREMENT

Alarm menu)

38 to 65°F; incre-

ment by 1

-45 to 80°F;

increment by 1

48 to 80°F; incre-

ment by 1

ES1,ES2,ES3,ES

4, or ES5

500 to 2000ppm;

increment by 100

2 to 10 Vdc

100 to 9990 cfm; increment by 10

2 to 10 Vdc

2 to 10 Vdc or 100

to 9990 cfm incre-

ment by 10

100 to 9990 cfm; increment by 10

2 to 10 Vdc

0 to 50°F; incre-

ment by 1

0 to 100%;incre-

ment by 1

0 to 100%; incre-

ment by 1

NOTES

1 cycles equals 180 deg. of actuator movement in any direction.

Displays ERROR if voltage or torque is below actuator range.

Output of EXH1 terminal: ON = relay closed OFF = relay open

Output of AUX terminal; displays only if AUX = EXH2

Output of AUX terminal; displays only if AUX = ERV

Displays the stage of heat pump heating that is active.

Displays speed setting of fan on a 2-speed fan unit.

Displays status of heat demand on a 2-speed fan unit.

SUPPLY AIR SETPOINT Setpoint determines where the economizer will modulate the OA damper to maintain the mixed air temperature.

COMPRESSOR LOW TEMPERATURE LOCKOUT Setpoint determines outdoor temperature when the mechanical cooling cannot be turned on. Commonly referred to as the Compressor lockout.

OA DRY BULB TEMPERATURE CHANGEOVER SETPOINT Setpoint determines where the economizer will assume outdoor air temperature is good for free cooling; e.g.; at 63°F unit will economize at 62°F and below and not economize at 64°F and above. There is a 2°F deadband.

ENTHALPY CHANGEOVER CURVE Enthalpy boundary “curves” for economizing using single enthalpy.

DEMAND CONTROLLED VENTILATION Displays only if CO Ventilation of space. Above the setpoint, the OA dampers will modulate open to bring in additional OA to maintain a space ppm level below the setpoint.

VENTILATION MINIMUM POSITION Displays ONLY if a CO

DCV MAXIMUM DAMPER POSITION Displays only if a CO max cfm) setpoint. Displays 2 to 10 V if <3 sensors (RA,OA, and MA). In AUTO mode dampers controlled by CFM.

If OA, MA, RA, and CO is set to AUTO mode, the OA dampers are controlled by CFM and displays from 100 to 9990 CFM.

With 2-speed fan units VENT L (low speed fan) and MIN POS H (high speed fan) settings are required. Default for VENTMAX L is 3.2V and VENTMAX H is 2.8V

DCV MINIMUM DAMPER POSITION Displays only if a CO cfm) setpoint. Displays 2 to 10 V if <3 sensors (RA, OA, and MA). Va is only set if DCV is used. This is the ventilation for less than maximum occupancy of the space. In AUTO mode dampers controlled by CFM.

If OA, MA, RA, and CO is set to AUTO mode, the OA dampers are controlled by CFM and displays from 100 to 9990 CFM.

With 2-speed fan units VENTMIN L (low speed fan) and MIN POS H (high speed fan) settings are required. Default for VENTMIN L is 3.2V and VENTMIN H is 2.8V

ENERGY RECOVERY VENTILATOR UNIT OUTDOOR AIR TEMPERATURE SETPOINT Only when AUX1 O = ERV

EXHAUST FAN STAGE 1 SETPOINT Setpoint for OA damper position when exhaust fan 1 is powered by the economizer. With 2-speed fan units Exh1 L (low speed fan) and Exh1 H (high speed fan) settings are required. Default for Exh1 L is 65% and Exh1 H is 50%

EXHAUST FAN STAGE 2 SETPOINT Setpoint for OA damper position when exhaust fan 2 is powered by the economizer. Only used when AUX1 O is set to EHX2. With 2-speed fan units Exh2 L (low speed fan) and Exh2 H (high speed fan) settings are required. Default for Exh2 L is 80% and Exh2 H is 75%

sensor is connected. Setpoint for Demand Control

sensor is NOT connected.

sensor is connected. Used for Vbz (ventilation

sensors are connected and DCV CAL ENABLE

sensor is connected. Used for Ba (ventilation min

sensors are connected and DCV CAL ENABLE

Page 27

MENU PARAMETER

INSTALL 01/01/10 N/A Display order = MM/DD/YY

UNITS DEG F F or C Sets economizer controller in degrees Fahrenheit or Celsius

EQUIPMENT CONV Conventional or HPCONV = conventional;

AUX2 IN W SD/W or HP(O)/

FAN SPEED 2 speed 1 speed/2 speed Sets the economizer controller for operation of 1 speed or 2 speed sup-

SYSTEM

SETUP

FAN CFM 5000cfm 100 to 15000 cfm;

AUX1 OUT NONE NONE

FACTORY DEFAULT NO NO or YES Resets all set points to factory defaults when set to YES. LCD

MA LO SET 45°F 35 to 55°F;

FREEZE POS CLO CLO or MIN FREEZE PROTECTION DAMPER POSITION

CO2 ZERO 0ppm 0 to 500 ppm;

CO2 SPAN 2000ppm 1000 to 3000

STG3 DLY 2.0h 0 min, 5 min, 15

ADVANCED

SETUP

SD DMPR POS CLO CLO or OPN Indicates shutdown signal from space thermostat or unitary controller.

D A L O A L M 4 5 °F (7 ° C ) 3 5 t o 6 5° F ; ( 2 t o

DA HI ALM 80°F (27°C) 70 to 180°F; (21 to

DCVCAL ENA MAN MAN (manual)

Table 9 — Menu Structure (cont)

PARAMETER

DEFAULT

VALUE

OCC INPUT INPUT or

PARAMETER

RANGE AND INCREMENT

HP(B)

increment by 100

ERV

EXH2

SYS

ALWAYS

Incremented by 1

Increment by 10

ppm; Increment by

min, then 15 min

intervals. Up to 4

hrs or OFF

18°C) Incre-

mented by 5 deg.

82°C) Incre-

mented by 5 deg.

AUTO

NOTES

Setting order = DD, MM, then YY.

HP O/B = Enable Heat Pump mode. Use AUX2 I for Heat Pump input from thermostat or controller. See Menu Note 7.

In CONV mode: SD + Enables configuration of shutdown (default); W = Informs controller that system is in heating mode. NOTE: If using 2-speed fan mode, ONV mode must be programmed for W. Shutdown is not available in 2-speed fan mode. See Menu Note 7. In HP O/B mode: HP(O) = energize heat pump on Cool (default); HP(B) = energize heat pump on heat.

ply fan. NOTE: 2-speed fan option also needs Heat (W1) programmed in AUX 2 In. See Menu Note 7.

UNIT DESIGN AIRFLOW (CFM) Enter only if using DCVAL ENA = AUTO The value is on the nameplate label for the specific unit.

Select OUTPUT for AUX1 O relay

• NONE = not configured (output is not used)

• ERV = Energy Recovery Ventilator

• EXH2 = second damper position relay closure for second exhaust fan

• SYS = use output as an alarm signal

OCCUPIED MODE BY EXTERNAL SIGNAL When using a setback thermostat with occupancy out (24 vac), the 24 vac is input “INPUT” to the OCC terminal. If no occupancy output from the thermostat then change program to “ALWAYS” OR add a jumper from terminal R to OCC terminal.

flash YES and change to NO but all parameters will change to the factory default values. NOTE: RECHECK AUX2 IN and FANTYPE for required 2-speed values.

SUPPLY AIR TEMPERATURE LOW LIMIT

Temperature to achieve Freeze Protection (close damper and alarm if temperature falls below setup value).

Damper position when freeze protection is active (closed or MIN POS).

ppm level to match CO2 sensor start level.

ppm span to match CO2 sensor.

COOLING STAGE 3 DELAY Delay after stage 2 cool has been active. Turns on 2 when economizer is 1 Allows three stages of cooling, 1 economizer and 2 mechanical. OFF = no Stage 3 cooling

When controller receives 24 Vac input on the SD terminal in conventional mode, the OA damper will open if programmed for OPN and OA damper will close if programmed for CLO. All other controls, e.g., fans, etc. will shut off.

Used for alarm for when the DA air temperature is too low. Set lower range of alarm, below this temperature the alarm will show on the display.

Used for alarm for when the DA air temperature is too high. Set upper range of alarm, above this temperature the alarm will show on the display.

Turns on the DCV automatic control of the dampers. Resets ventilation based on the RA, OA, and MA sensor conditions. Requires all 3 RA, OA, and MA sensors.

stage and mechanical cooling is 2

will

stage of cooling

stage.

briefly

Page 28

MENU PARAMETER

MAT T CAL 0.0°F ±2.5°F SUPPLY AIR TEMPERATURE CALIBRATION

OAS T CAL 0.0°F ±2.5°F OUTSIDE AIR TEMPERATURE CALIBRATION

OA H CAL 0% RH ±10% RH OUTSIDE AIR HUMIDITY CALIBRATION

ADVANCED

SETUP (CONT)

CHECKOUT

ALARMS

RA T CAL 0.0°F ±2.5°F RETURN AIR TEMPERATURE CALIBRATION

RA H CAL 0% RH ±10% RH RETURN AIR HUMIDITY CALIBRATION

DA T CAL 0.0°F ±2.5°F DISCHARGE AIR TEMPERATURE CALIBRATION

2SP FAN DELAY 5 Minutes 0 to 20 minutes in

DAMPER MINIMUM POSI-

DAMPER OPEN N/A N/A Position damper to the full open position.

DAMPER CLOSE N/A N/A Positions damper to the fully closed position

CONNECT Y1–O N/A N/A Closes the Y1-O relay (Y1-O)

CONNECT Y2–O N/A N/A Closes the Y2-O relay (Y2-O)

CONNECT AUX1-O N/A N/A Energizes the AUX output. If Aux setting is:

CONNECT EXH1 N/A N/A Closes the power exhaust fan 2 relay (EXH1)

Alarms display only when they are active. The menu title “ALARMS(#)” includes the number of active alarms in parenthesis ( ). When using

SYLK bus sensors, “SYLK” will appear on the screen, and when using 20k OA temperature sensors, “SENS T” will appear on the screen

MA T SENS ERR N/A N/A SUPPLY AIR TEMPERATURE SENSOR ERROR

CO2 SENS ERR N/A N/A CO

OA SYLK T ERR N/A N/A OUTSIDE AIR S-BUS SENSOR ERROR

OA SYLK H ERR N/A N/A

RA SYLK T ERR N/A N/A RETURN AIR S-BUS SENSOR ERROR

RA SYLK H ERR N/A N/A

DA SYLK T ERR N/A N/A DISCHARGE AIR S-BUS SENSOR ERROR

OA SENS T ERR N/A N/A OUTSIDE AIR TEMPERATURE SENSOR ERROR

ACT ERROR N/A N/A ACTUATOR ERROR

FREEZE ALARM N/A N/A Check if outdoor temperature is below the LOW Temp Lockout on set-

TION

Table 9 — Menu Structure (cont)

PARAMETER

DEFAULT

VALUE

N/A N/A The checkout for the damper minimum position is based on the system.

PARAMETER

RANGE AND

INCREMENT

1 minute incre-

ments

NOTES

Allows for the operator to adjust for an out of calibration temperature sensor.

Allows for operator to adjust for an out of calibration humidity sensor.

Allows for the operator to adjust for an out of calibration temperature sensor.

Allows for operator to adjust for an out of calibration humidity sensor.

Allows for the operator to adjust for an out of calibration temperature sensor.

TIME DELAY ON 2nd STAGE ECONOMIZING When in economizing mode this is the delay for the high speed fan to try to satisfy the call for second stage cooling before the first stage mechanical cooling is enabled.

See Table 10.

Exhaust fan contacts enable during the DAMPER OPEN test. Make sure to pause in the mode to allow exhaust contacts to energize due to the delay in the system.

• NONE — not action taken

• ERV — 24 Vac out. Turns on or signals an ERV that the conditions are not good for economizing but are for ERV operation.

• SYS — 24 Vac out. Issues a system alarm

Mixed air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

SENSOR ERROR

sensor has failed, gone out of range or become disconnected -

check wiring then replace sensor if the alarm continues.

Outdoor air enthalpy sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

Return air enthalpy sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

Discharge air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues.

Outdoor air temperature sensor has failed or become disconnected check wiring then replace if the alarm continues.

Actuator has failed or become disconnected - check for stall, over voltage, under voltage and actuator count. Replace actuator if damper is movable and supply voltage is between 21.6 V and 26.4 V. Check actuator count on STATUS menu.

point menu. Check if Mixed air temperature on STATUS menu is below the Lo Setpoint on Advanced menu. When conditions are back in normal range then the alarm will go away.

Page 29

MENU PARAMETER

SHUTDOWN ACTIVE N/A N/A AUX2 IN is programmed for SHUTDOWN and 24 V has been applied to

DMP CAL RUNNING N/A N/A DAMPER CALIBRATION ROUTINE RUNNING

ALARMS

(CONT)

DA SENS ALM N/A N/A DISCHARGE AIR TEMPERATURE SENSOR ALARM

SYS ALARM N/A N/A When AUX1-0 is set to SYS and there is any alarm (e.g., failed sensors,

ACT UNDER V N/A N/A ACTUATOR VOLTAGE LOW

ACT OVER V N/A N/A ACTUATOR VOLTAGE HIGH

ACT STALLED N/A N/A ACTUATOR STALLED

Table 9 —Menu Structure (cont)

PARAMETER

DEFAULT

VALUE

PARAMETER RANGE AND

INCREMENT

NOTES

AUX2 IN terminal.

If DCV Auto enable has been programmed, when the W7220 is completing a calibration on the dampers, this alarm will display. Wait until the calibration is completed and the alarm and RA sensors for DCV calibration; set up in the Advanced setup menu.

Discharge air temperature is out of the range set in the ADVANCED SETUP Menu. Check the temperature of the discharge air.

etc.), the AUX1-0 terminal has 24 Vac out.

Voltage received by actuator is above expected range.

Voltage received by actuator is below expected range.

Actuator stopped before achieving commanded position.

will

go away. Must have OA, MA

LEGEND

CLO — Compressor Lockout ERV — Energy Recovery Ventilator LCD — Liquid Crystal Display MA — Mixed Air MAT — Mixed Air Temperature N/A — Not Applicable OA — Outdoor Air OAT — Outdoor Air Temperature OCC — Occupied RA — Return Air RAT — Return Air Temperature RTU — Rooftop Unit SYS — System

NOTES:

1. Table 9 illustrates the complete hierarchy. Menu parameters may be different depending on the configuration. For example if there is no DCV (CO ters appear.

2. When values are displayed, pressing and holding the or button causes the display to automatically increment.

3. ERV Operation: When in cooling mode AND the conditions are NOT OK for economizing - the ERV terminal will be energized. In the Heating mode, the ERV terminal will be energized when the OA is below the ERV OAT setpoint in the setpoint menu.

) sensor, then none of the DCV parame-

Table 10 — Damper Minimum Position Settings and Readings on Checkout Menu

DEMAND CONTROLLED

VENTILATION

(CO

SENSOR)

YES

FAN SPEED SETPOINTS CHECKOUT

4. STATUS —> OCCUPIED — The factory-standard Occupancy signal originates with a thermostat or other controller call for indoor fan operation at CTB terminal G. This signal passes through the Central Terminal Board’s OCCUPIED jumper JMP1 to the ECONO connector and to the W7220’s OCC input terminal. An external timeclock or relay is required to implement an Occupancy schedule on the economizer damper position.

5. STATUS —> MA TEMP, SETPOINTS —> MAT SET — The W7220 menu parameters and labels include designations MA, MAT and Mixed Air for the economizer cooling control sensor. On these rooftop units, the economizer control sensor is located downstream of the evaporator/indoor coil in the supply fan section where this sensor is designated as Supply Air Temperature (SAT) sensor.

6. SETPOINTS —> DRYBLB SET — This point is not displayed if a Return Air (differential) temperature sensor or an Outdoor Air enthalpy sensor is connected.

7. SYSTEM SETUP parameters must be configured as noted for 2-Speed unit operation:

EQUIPMENT = CONV AUX2 IN = W FAN SPEED = 2SPEED

For damper minimum position settings and checkout menu readings, see Table 10. For dry bulb operation with a 1 speed indoor fan, with or without DCV, see Tables 11 and 12. For enthalpy operation with a 1 speed indoor fan, with or without DCV, see Tables 13 and 14. For dry bulb operation with a 2 speed indoor fan, with or without DCV, see Tables 15 and 16. For enthalpy operation with a 2 speed indoor fan, with or without DCV, see Tables 17 and 18.

MIN POS VMAX–HS

N/A N/A

MIN POS H VMAX–HS

MIN POS L VMAX–LS VENT MIN VMAX–HS

VENT MAX VMAX–HS

VENT MIN H VMAX–HS

VENT MAX H VMAX–LS

VENT MIN L N/A VENT MAX L N/A

Page 30

Table 11 — Dry Bulb Operation No DCV (CO

DEMAND

CONTROLLED

VENTILATION (DCV)

NONE NO

NONE YES

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2-O after the delay if the call for Y1-I and Y2-I have not been satisfied.

OUTSIDE AIR

GOOD TO

ECONOMIZE

Y1-I Y2-I

OFF OFF HIGH 0v/Off 0v/Off MIN POS Closed

ON OFF HIGH 24v/On 0v/Off MIN POS Closed

ON ON HIGH 24v/On 24v/On MIN POS Closed

OFF OFF HIGH 0v/Off 0v/Off MIN POS Closed

ON OFF HIGH 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off*

FAN

SPEED

Sensor) — 1 Speed Fan

Y1-O Y2-O OCCUPIED UNOCCUPIED

MIN POS to Full

Open

MIN POS to Full

Open

Closed to Full-Open

Table 12 — Dry Bulb Operation With DCV (CO2 Sensor) — 1 Speed Fan

DEMAND

CONTROLLED

VENTILATION (DCV)

Below CO

Above CO

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2-O after the delay if the call for Y1-I and Y2-I have not been satisfied.

Set

OUTSIDE AIR

GOOD TO

ECONOMIZE

Yes

Y1-I Y2-I

OFF OFF HIGH 0v/Off 0v/Off VENTMIN Closed

ON OFF HIGH 24v/On 0v/Off VENTMIN Closed

ON ON HIGH 24v/On 24v/On VENTMIN Closed

OFF OFF HIGH 0v/Off 0v/Off VENTMIN Closed

ON OFF HIGH 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off

OFF OFF HIGH 0v/Off 0v/Off

ON OFF HIGH 24v/On 0v/Off

ON ON HIGH 24v/On 24v/On

OFF OFF HIGH 0v/Off 0v/Off

ON OFF HIGH 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off*

FAN

SPEED

Y1-O Y2-O OCCUPIED UNOCCUPIED

VENTMIN to

Full-Open

VENTMIN to

Full-Open

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

Full-Open

VENTMIN to

Full-Open

Closed to Full-Open

Closed

Closed to Full-Open

Table 13 — Enthalpy Operation No DCV (CO2 Sensor) — 1 Speed Fan

DEMAND

CONTROLLED

VENTILATION (DCV)

NONE NO

NONE YES

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2-O after the delay if the call for Y1-I and Y2-I have not been satisfied.

OUTSIDE AIR

GOOD TO

ECONOMIZE

Y1-I Y2-I

OFF OFF HIGH 0v/Off 0v/Off MIN POS Closed

ON OFF HIGH 24v/On 0v/Off MIN POS Closed

ON ON HIGH 24v/On 24v/On MIN POS Closed

OFF OFF HIGH 0v/Off 0v/Off MIN POS Closed

ON OFF HIGH 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off*

FAN

SPEED

Y1-O Y2-O OCCUPIED UNOCCUPIED

MIN POS to Full

Open

MIN POS to Full

Open

Closed to Full-Open

Page 31

Table 14 — Enthalpy Operation With DCV (CO

DEMAND

CONTROLLED

VENTILATION (DCV)

Below CO

Above CO

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2-O after the delay if the call for Y1-I and Y2-I have not been satisfied.

Set

OUTSIDE AIR

GOOD TO

ECONOMIZE

Yes

Y1-I Y2-I

OFF OFF HIGH 0v/Off 0v/Off VENTMIN Closed

ON OFF HIGH 24v/On 0v/Off VENTMIN Closed

ON ON HIGH 24v/On 24v/On VENTMIN Closed

OFF OFF HIGH 0v/Off 0v/Off VENTMIN Closed

ON OFF HIGH 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off

OFF OFF HIGH 0v/Off 0v/Off

ON OFF HIGH 24v/On 0v/Off

ON ON HIGH 24v/On 24v/On

OFF OFF HIGH 0v/Off 0v/Off

ON OFF HIGH 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off*

FAN

SPEED

Y1-O Y2-O OCCUPIED UNOCCUPIED

Sensor) — 1 Speed Fan

VENTMIN to

Full-Open

VENTMIN to

Full-Open

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

Full-Open

VENTMIN to

Full-Open

Closed to Full-Open

Closed

Closed to Full-Open

Table 15 — Dry Bulb Operation No DCV (CO2 Sensor) — 2 Speed Fan

DEMAND

CONTROLLED

VENTILATION (DCV)

NONE NO

NONE YES

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2-O after the delay if the call for Y1-I and Y2-I have not been satisfied.

OUTSIDE AIR

GOOD TO

ECONOMIZE

Y1-I Y2-I

OFF OFF LOW 0v/Off 0v/Off MIN POS Closed

ON OFF LOW 24v/On 0v/Off MIN POS Closed

ON ON HIGH 24v/On 24v/On MIN POS Closed

OFF OFF LOW 0v/Off 0v/Off MIN POS Closed

ON OFF LOW 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off*

FAN

SPEED

Y1-O Y2-O OCCUPIED UNOCCUPIED

MIN POS to Full

Open

MIN POS to Full

Open

Closed to Full-Open

Page 32

DEMAND

CONTROLLED

VENTILATION (DCV)

Table 16 — Dry Bulb Operation With DCV (CO

OUTSIDE AIR

GOOD TO

ECONOMIZE

Y1-I Y2-I

FAN

SPEED

Y1-O Y2-O OCCUPIED UNOCCUPIED

Sensor) — 2 Speed Fan

OFF OFF LOW 0v/Off 0v/Off VENTMIN Closed

ON OFF LOW 24v/On 0v/Off VENTMIN Closed

ON ON HIGH 24v/On 24v/On VENTMIN Closed

Below CO

Set

Yes

Above CO

Set

Yes

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2-O after the delay if the call for Y1-I and Y2-I have not been satisfied.

OFF OFF LOW 0v/Off 0v/Off VENTMIN Closed

ON OFF LOW 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off

OFF OFF LOW 0v/Off 0v/Off

ON OFF LOW 24v/On 0v/Off

ON ON HIGH 24v/On 24v/On

OFF OFF LOW 0v/Off 0v/Off

ON OFF LOW 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off*

VENTMIN to

Full-Open

VENTMIN to

Full-Open

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

Full-Open

VENTMIN to

Full-Open

Closed to Full-Open

Closed

Closed to Full-Open

Table 17 — Enthalpy Operation No DCV (CO2 Sensor) — 2 Speed Fan

DEMAND

CONTROLLED

VENTILATION (DCV)

NO CO

SENSOR

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2-O after the delay if the call for Y1-I and Y2-I have not been satisfied.

OUTSIDE AIR

GOOD TO

ECONOMIZE

YES

Y1-I Y2-I

FAN

SPEED

Y1-O Y2-O OCCUPIED UNOCCUPIED

OFF OFF LOW 0v/Off 0v/Off MIN POS Closed

ON OFF LOW 24v/On 0v/Off MIN POS Closed

ON ON HIGH 24v/On 24v/On MIN POS Closed

OFF OFF LOW 0v/Off 0v/Off MIN POS Closed

ON OFF LOW 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off*

MIN POS to Full

Open

MIN POS to Full

Open

Closed to Full-Open

Table 18 — Enthalpy Operation With DCV (CO2 Sensor) — 2 Speed Fan

DEMAND

CONTROLLED

VENTILATION (DCV)

Below CO

Above CO

Set

*With stage 3 delay (STG3 DLY) in Advanced setup menu can turn on second stage of mechanical cooling Y2-O after the delay if the call for Y1-I and Y2-I have not been satisfied.

OUTSIDE AIR

GOOD TO

ECONOMIZE

Yes

Y1-I Y2-I

FAN

SPEED

Y1-O Y2-O OCCUPIED UNOCCUPIED

OFF OFF LOW 0v/Off 0v/Off VENTMIN Closed

ON OFF LOW 24v/On 0v/Off VENTMIN Closed

ON ON HIGH 24v/On 24v/On VENTMIN Closed

OFF OFF LOW 0v/Off 0v/Off VENTMIN Closed

ON OFF LOW 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off

OFF OFF LOW 0v/Off 0v/Off

ON OFF LOW 24v/On 0v/Off

ON ON HIGH 24v/On 24v/On

OFF OFF LOW 0v/Off 0v/Off

ON OFF LOW 0v/Off 0v/Off

ON ON HIGH 24v/On 0v/Off*

VENTMIN to

Full-Open

VENTMIN to

Full-Open

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

VENTMAX

VENTMIN to

Full-Open

VENTMIN to

Full-Open

Closed to Full-Open

Closed

Closed to Full-Open

Page 33

Fig. 40 — Single Enthalpy Curve Boundaries

ECONOMIZING

AVAILABLE

NOT AVAILABLE

ENTHA

LPY

RA HUM (%RH)

RA TEMP

TEMPERATURE

ABSOLUTE HUMIDITY

ES5

ES4

ES3

ES2 ES1

P1 (T,RH)

P2 (T,RH)

SINGLE ENTHALPY

DUAL ENTHALPY

HIGH LIMIT

Table 19 — Single Enthalpy and Dual Enthalpy High Limit Curves

ENTHALPY

CURVE

ES1 80 60 28.0 80 36.8 66.3 80.1 ES2 75 57 26.0 75 39.6 63.3 80.0 ES3 70 54 24.0 70 42.3 59.7 81.4 ES4 65 51 22.0 65 44.8 55.7 84.2 ES5 60 48 20.0 60 46.9 51.3 88.5

HL 86 66 32.4 86 38.9 72.4 80.3

TEMP. DRY

BULB (F)

TEMP.

DEWPOINT (F)

ENTHALPY

(btu/lb/da)

TEMP. (F)

POINT P1 POINT P2

HUMIDITY

(%RH)

TEMP. (F)

HUMIDITY

(%RH)

ENTHALPY SETTINGS — When the OA temperature, enthalpy and dew point are below the respective setpoints, the Outdoor Air can be used for economizing. Fig. 40 shows the new single enthalpy boundaries in the W7220. There are 5 boundaries (setpoints ES1 through ES5), which are defined by dry bulb temperature, enthalpy and dew point.

Refer to Table 19 for ENTH CURVE setpoint values.

The W7220 calculates the enthalpy and dew point using the OA temperature and humidity input from the OA enthalpy sensor. When the OA temperature, OA humidity and OA dew point are all below the selected boundary, the economizer sets the economizing mode to YES, economizing is available.

When all of the OA conditions are above the selected boundary, the conditions are not good to economize and the mode is set to NO.

Fig. 40 shows the 5 current boundaries. There is also a high limit boundary for differential enthalpy. The high limit boundary is ES1 when there are no stages of mechanical cooling energized and HL (high limit) when a compressor stage is energized.

Table 19 provides the values for each boundary limit.

TWO-SPEED FAN OPERATION — The W7220 controller has the capability to work with a system using a 2-speed supply fan. The W7220 does not control the supply directly but uses the following input status to determine the speed of the supply fan and controls the OA damper to the required position, see Table 20.

Table 20 — Fan Speed

STATE FAN SPEED

OCC Low

Y1 Low Y2 High

W High

The W (heating mode) is not controlled by the W7220 but it requires the status to know where to position the OA damper for minimum position for the fan speed.

The 2 speed fan delay is available when the system is programmed for 2 speed fan (in the System Setup menu item). The 2 speed fan delay is defaulted to 5 minutes and can be changed in the Advanced Setup menu item. When the unit has a call for Y1 In and in the free cooling mode and there is a call for Y2 In, the 2-speed fan delay starts and the OA damper will modulate 100% open, the supply fan should be set to high speed by the unit controller.

After the delay one of two actions will happen:

• The Y2 In call will be satisfied with the damper 100%

open and fan on high speed and the call will turn off.

• If the call for additional cooling in the space has not been

satisfied then the first stage of mechanical cooling will

be enabled through Y1 Out or Y2 Out.

CHECKOUT — Inspect all wiring connections at the economizer module’s terminals, and verify compliance with the installation wiring diagrams.

For checkout, review the Status of each configured parameter and perform the Checkout tests.

NOTE: For information about menu navigation and use of the keypad see Interface Overview on page 23.

Page 34

WARNING

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

Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lock(s) and lockout tag(s). Unit may have more than one power switch. Ensure electrical service to rooftop unit agrees with voltage an amperage listed on the unit rating plate.

If any wiring changes are required, first be sure to remove power from the Economizer module before starting work. Pay particular attention to verifying the power connection (24 Vac).

Power Up apply power.

Initial Menu Display plays on the first line and economizer W7220 on the second line. After a brief pause, the revision of the software appears on the first line and the second line will be blank.

Power Loss (Outage or Brownout) vanced settings are restored after any power loss or interruption.

NOTE: All settings are stored in non-volatile flash memory. Status

rameter values for the various devices and sensors configured. NOTE: For information about menu navigation and use of the

keypad see Interface Overview on page 23. Checkout Tests

test the damper operation and any configured outputs. Only items that are configured are shown in the Checkout menu.

the keypad see Interface Overview on page 23.

1. Scroll to the desired test in the Checkout menu using

2. Press the button to select the item. RUN? appears.

3. Press the button to start the test. The unit pauses and

— After the W7220 module is mounted and wired,

— On initial start up, Honeywell dis-

— All setpoints and ad-

— Use the Status menu (see Table 9) to check the pa-

— Use the Checkout menu (on page 28) to

NOTE: For information about menu navigation and use of

To perform a Checkout test:

the ▲ and ▼ buttons.

then displays IN PROGRESS. When the test is complete, DONE appears.

4. When all desired parameters have been tested, press the (Menu Up) button to end the test.

The Checkout tests can all be performed at the time of installation or at any time during the operation of the system as a test that the system is operable.

TROUBLESHOOTING

Alarms

— The economizer module provides alarm messages

that display on the 2-line LCD. NOTE: Upon power up, the module waits 60 minutes before

checking for alarms. This allows time for all the configured devices (e.g. sensors, actuator) to become operational. The exception is the SAT sensor which will alarm immediately.

If one or more alarms are present and there has been no keypad activity for at least 5 minutes, the Alarms menu displays and cycles through the active alarms.

It is possible to navigate to the Alarms menu at any time. Clearing Alarms

the cause has been removed (e.g. replaced faulty sensor) the alarm can be cleared from the display.

To clear an alarm, perform the following:

1. Navigate to the desired alarm.

2. Press the button. ERASE? displays.

3. Press the button. ALARM ERASED displays.

4. Press the (Menu up/Exit) button to complete the action and return to the previous menu.

NOTE: If the alarm still exists after it is cleared, it is redisplayed within 5 seconds.

— Once the alarm has been identified and

CAUTION

Failure to follow this caution may result in damage to equipment. Be sure to allow enough time for compressor start-up and shutdown between checkout tests so the compressor does not short-cycle.

Low Ambient Control (Factory Option) — If the unit

comes with Electro-Mechanical (EM) control, then no adjustment is necessary.

If the unit comes with RTU Open controller option, then refer to its installation control manual for details on adjusting “Cooling Lock-Out” setting and configure for the specific job requirements.

Page 35

Fig. 41 — Typical Perfect Humidity™ Dehumidification System Humidistat Wiring

Page 36

RTU Open Controller System — The RTU Open con-

J2J1

J5 J5

J22

J17

J19

J14

J11

J22

J13

J12

J15

J20

Network Comm

Configurable - Input_8

24 VAC

Configurable - Input_5

24 VAC

Configurable - Input_3

24 VAC

Input_9 (Humidistat)

24 VAC

Input _8 (Enthalpy)

AO-1 (ECON)

Gnd

(OAT)

Gnd

(SAT)

Input_5 (SMK)

Input_4 (R)

BO-5 (Y1)

BO-4 (Y2)

BO-3

(W1)

BO-2

(W2)

BO-1 (G)

Gnd

Input_3 (X)

24 VAC IN

+24 VDC

Input_2 (CO2/RH)

Gnd

+24 VDC

Input_1 (CO2/RH)

Gnd

Board Power

(AO-1)

0-10VDC

4-20mA

BO-6 (H) Humidimizer

BO-7

(Reversing Valve/High Speed Fan/Y3)

BO-8 (Power Exhaust)

LonWorks Option Card Port

Example set for BACnet MS/TP and 76.8K baud (1, 2, and 4 ON) Recommended for all i-Vu Open installations

2N ro ,subdoM ,tenCAB)tupni pmet( TPSrotceleS locotorP

(LON connection J15)

SPT (common)

SPT (offset input)

*Remove both for 0-5V

AO-2

GND

(2-10V)

3-Volt Lithium Battery

BO-1 BO-2 BO-3 BO-4 BO-5

BO-6

BO-7

BO-8

VFD Output

troller is factory-mounted in the 581J unit’s main control box, to the left of the CTB (see Fig. 42). Factory wiring is completed through harnesses connected to the CTB. Field-connections for RTU Open controller sensors will be made at the Phoenix connectors on the RTU Open board. The factory-installed RTU Open controller includes the supply-air temperature (SAT) sensor. The outdoor air temperature (OAT) sensor is included in the FIOP/accessory EconoMi$er 2 package.

The RTU Open controller is an integrated component of the Bryant rooftop unit. Its internal application programming provides optimum performance and energy efficiency. RTU Open enables the unit to run in 100% stand-alone control mode or a Third Party Building Automation System (BAS). Onboard DIP switches allow to select your protocol (and baud

rate) of choice among the four most popular protocols in use today: BACnet

, Modbus2, Johnson N2 and LonWorks3. (See

Fig. 42.)

Refer to Table 21, RTU Open Controller Inputs and Outputs for locations of all connections to the RTU Open controller board. See Fig. 43 and 44 for wiring diagrams.

1. BACnet is a registered trademark of ASHRAE (American Society of Heating, Refrigerating and Air-Conditioning Engineers).

2. Modbus is a registered trademark of Schneider Electric.

3. LonWorks is a registered trademark of Echelon Corporation.

Fig. 42 — RTU Open Multi-Protocol Controller Board

Page 37

Fig. 43 — Typical RTU Open Controller Wiring Diagram

Page 38

Fig. 44 — Typical RTU Open Controller Wiring Diagram with Perfect Humidity™ System Option

Page 39

Table 21 — RTU Open Controller Inputs and Outputs

POINT NAME

BACNET OBJECT

NAME

TYPE OF I/O

DEDICATED INPUTS

Space Temp / Zone Temp

Supply Air Temperature

Outside Air Temperature

Space Temperature Offset Pot

Safety Chain Feedback

Compressor Safety Status

(1)

Fire Shutdown Status

Enthalpy Status

Humidistat Input Status

Zone Temperature

CONFIGURABLE INPUTS

Indoor Air CO

Outdoor Air CO

(4)

Space Relative Humidity

Supply Fan Status

Filter Status

Door Contact

Remote Occupancy input

IGC input

(2)

zone_temp AI (10K Thermistor) J20—1 & 2 Analog Input 10

sa_temp AI (10K Thermistor) J2—1 & 2 Analog Input 6

oa_temp AI (10K Thermistor) J2—3 & 4 Analog Input 7

stpt_adj_offset AI (100K Potentiometer) J20—3 & 4 Analog Input 11

safety_status BI (24 VAC) J1—9 Binary Input 4

comp_status BI (24 VAC) J1—2 Binary Input 3

firedown_status BI (24 VAC) J1—10 Binary Input 5

enthalpy_status BI (24 VAC) J2—6 & 7 Binary Input 8

humstat_status BI (24 VAC) J5—7 & 8 Binary Input 9

N/A N/A J13—1—4 Rnet

iaq AI (4-20 mA)

oaq AI (4-20 mA) Analog Input 1

space_rh AI (4-20 mA) Analog Input 10

sfan_status BI (24 VAC)

filter_status BI (24 VAC)

door_contact_sta-

tus

BI (24 VAC)

occ_contact_status BI (24 VAC)

igcovr_status BI (24 VAC)

OUTPUTS

Economizer Output

Supply Fan VFD

Supply Fan Relay

Cool 1 Relay State

Cool 2 Relay State

Cool 3 Relay State

Heat 1 Relay State

Heat 2 Relay State

Power Exhaust Relay State

Dehumidification Relay

econ_output AO (4-0mA) J2—5 Analog Output 1

vfd_output AO (2-10Vdc) J22—1 & 2 Analog Output 2

sfan BO Relay (24VAC, 1A) J1—4 Binary Output 1 (G)

comp_1 BO Relay (24VAC, 1A) J1—8 Binary Output 5 (Y1)

comp_2 BO Relay (24VAC, 1A) J1— 7 Binary Output 4 (Y2)

comp_3 BO Relay (24VAC, 1A) J11—5 & 6 Binary Output 7 (Y3)

heat_1 BO Relay (24VAC, 1A) J1—6 Binary Output 3 (W1)

heat_2 BO Relay (24VAC, 1A) J1—5 Binary Output 2 (W2)

pexh BO Relay (24VAC, 1A) J11—2 & 3 (N.O.) Binary Output 8 (PE)

dehum BO Relay (24VAC, 1A) J11—7 & 8 (N.O.) Binary Output 6

LEGEND

AI — Analog Input AO — Analog Output BI — Binary Input BO — Binary Output

1. Safety Chain Feedback: 24Vac required at this terminal to provide “Run Enable” status. See Input/Output section for additional instructions.

CONNECTION PIN

NUMBER(S)

CHANNEL DESIGNATION

Analog Input 2

J4—2 & 3 or J4—5 & 6

Binary Input 3, 5, 8, or 9, except where intrinsic input is used

J5—1 & 2 or J5—3 & 4,

J5—5 & 6 or J5—7 & 8

Binary Input 3, 5, 8, or 9,

(3)

except where intrinsic input is used

Binary Input 3, 5, 8, or 9, except where intrinsic input is used

Binary Input 9. Mandatory input on gas heat units.

2. These inputs are configurable. If installed, they take the place of the default input on the specific channel. See appropriate Input Configuration Section for wiring and setup instructions.

3. Parallel pins J5—1 = J2—6, J5—3 = J1—10, J5—5 = J1—2 are used for field installation.

4. Refer to the input configuration and accessory sections of the RTU Open Multi-Protocol Controller Controls, Start-Up, Operation and Troubleshooting manual for more detail.

Page 40

The RTU Open controller requires the use of a Bryant space

SW1

SEN

BRN (GND) BLU (SPT)

RED(+)

WHT(GND)

BLK(-)

CCN COM

SENSOR WIRING

sensor. A standard thermostat cannot be used with the RTU Open system.

SUPPLY AIR TEMPERATURE (SAT) SENSOR — On FIOP-equipped 581J unit, the unit is supplied with a supply-air temperature (SAT) sensor (33ZCSENSAT). This sensor is a tubular probe type, approx 6-inches (152 mm) in length. It is a nominal 10k ohm thermistor.

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

/2-in. hole in the flange or duct. Use two field-supplied, selfdrilling screws to secure the sensor probe in a horizontal orientation. See Fig. 45.

has a variety of options consisting of: timed override button, set point adjustment, a LCD screen, and communication tie in. Space temperature can be also be written to from a building network or zoning system. However, it is still recommended that return air duct sensor be installed to allow stand-alone operation for back-up. Refer to the configuration section for details on controller configurations associated with space sensors.

• 33ZCT55SPT, space temperature sensor with override button (T-55)

• 33ZCT56SPT, space temperature sensor with override button and setpoint adjustment (T-56)

• 33ZCT59SPT, space temperature sensor with LCD (liquid crystal display) screen, override button, and setpoint adjustment (T-59)

Use 20 gauge wire to connect the sensor to the controller.

The wire is suitable for distances of up to 500 ft. Use a threeconductor 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.

Connect T-55

— See Fig. 46 for typical T-55 internal connections. Connect the T-55 SEN terminals to the RTU Open controller at J20-1 and J20-2. See Fig. 47.

SUPPLY AIR TEMPERATURE SENSOR

SUPPLY AIR

RETURN AIR

Fig. 45 — Typical Mounting Location for Supply Air

Temperature (SAT) Sensor on Small Rooftop Units

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.

ECONOMI$ER 2 — The RTU Open controller is used with EconoMi$er 2 (factory-installed option or field-installed accessory) for outdoor air management. The damper position is controlled directly by the RTU Open controller; EconoMi$er 2 has no internal logic device.

Outdoor air management functions can be enhanced with

field-installation of these accessory control devices:

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

sensor

Field Connections — Field connections for accessory sen-

sors and input devices are made the RTU Open controller, at plugs J1, J2, J4, J5, J11 and J20. All field control wiring that connects to the RTU Open controller must be routed through the raceway built into the corner post as shown in Fig. 31. 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 through the raceway to the RTU Open controller. Connect to the wires to the removable Phoenix connectors and then reconnect the connectors to the board.

SPACE TEMPERATURE (SPT) SENSORS — There are two types of SPT sensors available from Bryant, resistive input non-communicating (T55, T56, and T59) and Rnet communicating (SPS, SPPL, SPP, and SPPF) sensors. Each type

ROOF CURB

Fig. 46 — T-55 Space Temperature Sensor Wiring

SEN

J20-1

J20-2

Fig. 47 — RTU Open Controller T-55 Sensor

Connections

Connect T-56

— See Fig. 50 for T-56 internal connections. Install a jumper between SEN and SET terminals as illustrated. Connect T-56 terminals to the RTU Open controller at J20 J20

—2 and J20—3 per Fig. 49.

—1,

Page 41

SEN J20-1

J20-2

SEN

SET

Jumper

J20-3

SET

OR SET SEN

OPB COM- PWR+

BLU (SPT)

BLK (STO)

24 VAC

SENSOR WIRING

POWER WIRING

BRN (COM)

NOTE: Must use a separate isolated transformer.

J20-3

J20-2

J20-1

To controller

24 Vac Line

Dedicated Transformer

24 Vac

or Vdc

8 7 6 5 4

2 1

SENSOR LEGEND

1 +24 Vac/Vdc 2 Gnd (-24 Vac/Vdc) 4 -Thermistor 5 +Thermistor 6 4-20 mA 7 SIG COM 8 0-5 Vdc

INDOOR AIR QUALITY (CO

) SENSOR — The in-

door air quality sensor accessory monitors space carbon dioxide (CO

) levels. This information is used to monitor IAQ lev-

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

SW1

SEN

RED(+)

WHT(GND)

BLK(-)

SET

BLK (T56)

BRN (GND)

BLU (SPT)

CCN COM

SENSOR WIRING

JUMPER TERMINALS AS SHOWN

space air.

The CO

sensors are all factory set for a range of 0 to 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. 51 for typical CO schematic.

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 The sensor should be mounted in a location to avoid direct breath contact.

present in the

sensor wiring

leaving the space.

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;

Cool Warm

the sensor gives inaccurate readings if the supply air is blown directly onto the sensor or if the supply air does not have a

Fig. 48 — T-56 Internal Connections

chance to mix with the room air before it is drawn into the return airstream.

Fig. 49 — RTU Open Controller T-56 Sensor

Connections

Connect T-59

— The T-59 space sensor requires a separate, isolated power supply of 24 VAC. See Fig. 50 for internal connections at the T-59. Connect the SEN terminal (BLU) to the RTU Open controller at J20 (BRN) to J20 J20—3.

Fig. 50 — Space Temperature Sensor Typical Wiring

—2. Connect the SET terminal (STO or BLK) to

—1. Connect the COM terminal

(33ZCT59SPT)

Fig. 51 — Indoor/Outdoor Air Quality (CO

) Sensor

(33ZCSPTCO2-01 or 33ZCSPTCO2LCD-01) Typical

Wiring Diagram

Wiring the Indoor Air Quality Sensor: For each sensor, use two 2-conductor 18 AWG (American Wire Gage) 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 the sensor. See Fig. 51. Connect the 4-20 mA terminal to the RTU Open controller at J4-2 and connect the SIG COM terminal to the RTU Open controller at J4-3. See Fig. 52.

Page 42

SEN

COM

J4-2

J4-3

IAQ Sensor

24 VAC

SEN

COM

J4-5

J4-6

OAQ Sensor

24 VAC

SPACE RELATIVE HUMIDITY SENSOR OR HUMIDISTAT

Fig. 52 — RTU Open Controller/Indoor CO2 Sensor

(33ZCSPTCO2-01 or 33ZCSPTCO2LCD-01)

Connections

OUTDOOR AIR QUALITY SENSOR (P/N 33ZCSPTCO2-01 OR 33ZCSPTCO2LCD-01 PLUS WEATHERPROOF ENCLOSURE) — The outdoor air CO

sensor is

designed to monitor carbon dioxide (CO2) levels in the outside ventilation air and interface with the ventilation damper in an HVAC system.

The OAQ sensor is packaged with an outdoor cover. See

Fig. 53. The outdoor air CO

sensor must be located in the

economizer outside air hood.

Perfect Humidity™ System Control Wiring

— In units equipped with the Perfect Humidity option there are two loose wires loose in the control box (one PNK and one PNK/BLK) used to control the dehumidification function of the unit. These wires are meant to be tied to a space humidistat or thermidistat on an electromechanical unit. On RTU Open controller equipped units these wires must be connected to J11

—7 and 8

to allow the Open board to operate the dehumidification function for the unit. Disconnect the J11 Phoenix style connector from the board and use the plug screws to secure the wires as follows: secure the PNK/BLK wires at pin 7 and the PNK wires at pin 8, and then reconnect the plug to the board at J11.

Relative Humidity Sensors (Space or Duct Mounted)

— The accessory space humidity sensor (33ZCSENSRH-01) or duct humidity sensor (33ZCSENDRH-01) is used to measure the relative humidity of air within the space or return air duct. The RH reading is used to control the Perfect Humidity option of the rooftop unit. For wiring distances up to 500 ft (152 m), use a 3-conductor, 18 or 20 AWG shielded cable. The shield must be removed from the sensor end of the cable and grounded at the unit end. The current loop power for sensor is provided by the RTU Open controller as 24vdc. Refer to the instructions supplied with the RH sensor for the electrical requirements and terminal locations. RTU Open controller configurations must be changed after adding an RH sensor. See Fig. 55 and 56 for typical RH sensor wiring.

•J4

—1 or J4—4 = 24vdc loop power

•J4

—2 or J4—5 = 4-20mA signal input

NOTE: The factory default for dehumidification control is normally open humidistat.

COVER REMOVED SIDE VIEW

Fig. 53 — 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.

To connect the sensor to the control, identify the positive (4 to 20 mA) and ground (SIG COM) terminals on the OAQ sensor. See Fig. 51. Connect the 4 to 20 mA terminal to the RTU Open controller at J4 the RTU Open controller at J4

—5. Connect the SIG COM terminal to

—6. See Fig. 54.

Fig. 54 — RTU Open Controller/Outdoor CO

Sensor

(33ZCSPTCO2-01 or 33ZCSPTCO2LCD-01)

Connections

MOUNTING HOLES

Gnd

Vin

SW2

123456

Vin - J4-1 or J4-4 24Vdc Io - J4-2 or J4-5 -20mA output

WIRING OPENING

Fig. 55 — Space Relative Humidity Sensor Typical

Wiring

Page 43

SPAN

ZERO

4-20mAVAC

VDC

GND 0-5V

0-10V

123456

J4-1 or J4-4 + 24 VDC

SUPPLY VOLTAGE

J4-2 or J4-5 (-)4 to 20 mA Current

LOOP OUTPUT TO RTU OPEN

RELATIVE HUMIDITY SENSOR (POLARIZED MALE CONNECTOR)

Fig. 56 — Duct Relative Humidity Sensor Typical

Wiring

Humidistat

— The accessory humidistat provides the RTU Open controller insight to the relative humidity in the space. The humidistat reads the RH level in the space and compares it to its setpoint to operate a dry contact. The humidistat is a dedicated input on the configurable input 9 and tells the RTU Open controller when the RH level is HIGH or LOW. The normal condition for humidity is LOW. A normally open humidistat is the factory default control for the Perfect Humidity system option.

To wire in the field:

•J5

—8 = 24 VAC source for dry contact

•J5

—7 = Signal input

SMOKE DETECTOR/FIRE SHUTDOWN (FSD) —

On 581J units equipped with factory-installed Smoke Detector(s), the smoke detector controller implements the unit shutdown through its NC contact set connected to the unit’s CTB input. The FSD function is initiated via the smoke detector’s Alarm NO contact set. The RTU Open controller communicates the smoke detector’s tripped status to the BAS building control. See Fig. 43 and 44, (RTU Open Controller wiring diagrams).

The Fire Shutdown Switch configuration, MENU

fig



Inputsinput 5, identifies the normally open status of



Con-

this input when there is no fire alarm.

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



ConfigInputsinput 3, 5, 8, or 9 to

Filter Status and normally open (N/O) or normally closed (N/C). Input 8 or 9 is recommended for ease of installation. Refer to Fig. 42 and Fig. 43 or 44 for wire terminations at J5.

Fan Status

— 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 MENU



ConfigInputsinput 3,

5, 8, or 9 to 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 Fig. 43 or 44 for wire terminations at J5.

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



ConfigInputsinput 3, 5, 8, or 9 to

Remote Occupancy and normally open (N/O) or normally closed (N/C).

Also set MENU



Schedulesoccupancy source to DI on/

off. Input 8 or 9 is recommended for ease of installation. Refer to Fig. 42 and Table 21 for wire terminations at J5.

Power Exhaust (output)

— The relay used by the RTU Open controller board to control power exhaust is a dry contact which means it does not have 24vac. This 24vac must be connected to the relay to allow it to operate the power exhaust relay in the PE accessory. A 24vac source must be provided to J11

—2 on the RTU Open controller board. This can be provid-

ed by the unit’s transformer from various sources. The “R” terminal on the unit’s central terminal board (CTB) is a logical source. Refer to Fig. 42 and Fig. 43 or 44 for wire terminations at J11.

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 Open controller 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 and 58 for protocol switch settings and address switches. The third party connection to the RTU Open controller is through plug J19. See Fig. 59 for wiring.

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

Refer to the RTU Open Controller Integration Guide for more detailed information on protocols, third party wiring, and networking.

—3

Page 44

SW3 Protocol Selection

UNUSED

(OFF)

(ON)

COMM

OPTION

PORT

SET TO MSTP

(MASTER)

SET TO

38.4k

BAUD

PROTOCOL SELECTOR DIP SWITCHES

PROTOCOL DS8 DS7 DS6 DS5 DS4 DS3 DS2 DS1

BACnet MS/TP (Master) Unused OFF OFF OFF ON OFF

Modbus (Slave) Unused OFF OFF ON ON OFF

N2 (Slave) Unused OFF OFF OFF ON ON OFF OFF LonWorks Unused ON ON OFF ON OFF OFF ON

LEGEND DS – Dip Switch

NOTE: BACnet MS/TP SW3 example shown

Select

Baud

Select

Baud

Select

Baud

Select

Baud

Baud Rate Selections

BAUD RATE DS2 DS1

9,600 OFF OFF 19,200 ON OFF 38,400 OFF ON 76,800 ON ON

Fig. 57 — RTU Open Controller SW3 Dip Switch Settings

FIELD ASSISTANT — Field Assistant is a computer pro-

gram included with the purchase of the Tech Tool Kit (USB-

MSB LSB

TKIT). This is a field Tech Tool to set-up, service, or download application software to the RTU Open controller and includes a

USB Link Cable. The link cable connects a USB port to the J12 local access port. See Fig. 60.

RTU OPEN CONTROLLER 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

SW1 SW2

higher the baud rate the more solid the LEDs will appear. See Table 22.

Fig. 58 — RTU Open Controller Address Switches

NOTE: Refer to the RTU Open Multi-Protocol Controller Controls, Start-Up, Operation and Troubleshooting manual for complete configuration of the RTU Open controller, operating sequences and troubleshooting information. Refer to the RTU Open v3 Integration Guide for details on configuration and troubleshooting of connected networks. Have a copy of these manuals available at unit start-up.

NET+

NET-

SHLD

J19

Fig. 59 — Network Wiring

Local Access

WALL MOUNTED EQUIPMENT TOUCH INTERFACE — The Equipment Touch™ interface is a wall mount-

ed interface used to connect to the RTU Open controller to access the control information, read sensor values, and maintenance. This is an accessory interface that does not come with the RTU Open controller. Wire the Equipment Touch interface to the RTU Open controller’s J13 local access port. There are 2 password protected levels in the display (User and Admin). See

the Equipment Touch Installation and Setup Guide for more information. See Appendix A for navigation and screen content.

Page 45

Connect to computer’s USB port

Connect to

the Local

Access port

USB Link Kit

RTU Open Controller

Access

Port

J12

P1 P1

P5 P5

LOCAL

ACCESS

PORT

GND

*Therm

UI-10

UI-11

SW3

COMM

OPTION

CR2032

SW1 SW2

MSB LSB

TXRX

+12 DVC RnetRnet+ GND

RNET

J12

J13

J15

J20

The LEDs on the RTU Open Controller show the status of certain functions

If this LED is on... Status is...

Power

BO#

The RTU Open controller has power

The RTU Open controller is receiving data from the network segment

The RTU Open controller is transmitting data over the network segment

The binary output is active

The Run and Error LEDs indicate control module and network status

If Run LED shows...

2 flashes per second

5 flashes per second

7 flashes per second

14 flashes per second

Off Normal

2 flashes, alternating with Run LED Five minute auto-restart delay after system error

3 flashes, then off Control module has just been formatted

4 flashes, then pause

On Exec start-up aborted, Boot is running

Off Firmware transfer in progress, Boot is running

7 flashes per second, alternating with Run LED Ten second recovery period after brownout

14 flashes per second, alternating with Run LED

Outdoor Air Enthalpy Control (P/N 33CSENTHSW) —

(33CSENTHSW) is available as a field-installed accessory to be used with the EconoMi$er air enthalpy sensor is part of the enthalpy control. (The separate field-installed accessory return air enthalpy sensor (33CSENTSEN) is required for differential enthalpy control. See Fig. 61.)

Locate the enthalpy control in the economizer next to the Actuator Motor. Locate two GRA leads in the factory harness and connect the gray lead labeled “ESL” to the terminal labeled “LOW.” See Fig. 61. Connect the enthalpy control power input terminals to economizer actuator power leads RED (connect to 24V) and BLK (connect to GND).

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

The enthalpy control

2 damper system. The outdoor

Fig. 60 — PC Running Field Assistant

Table 22 — LEDs

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

Two or more devices on this network have the same MSTP network address

Exec halted after frequent system errors or control programs halted

Brownout

Failure. Try the following solutions:

· Turn the RTU Open controller off, then on.

· Format the RTU Open controller.

· Download memory to the RTU Open controller.

· Replace the RTU Open controller.

Enthalpy Switch

Fig. 61 — Enthalpy Switch (33CSENTHSW)

24V

GND

LOW

RED

BLK

GRA

FACTORY WIRING HARNESS

Connections

PL6-1 (24-V)

PL6-4 (COM)

CTB ECON

(P’LINK: to J4-2) or (RTU Open: to J2-6)

Page 46

DIFFERENTIAL ENTHALPY CONTROL — Differen-

GRA

BLK

RED – 4-20 MAIN

+ VDC OUT

– 4-20 MAIN OUT

+ 24-36 VDC IN

LOW

GND

24V

PL6-1 (24-V)

PL6-4 (COM)

OUTSIDE AIR ENTHALPY SWITCH

RETURN AIR ENTHALPY SENSOR

CTB ECON (P’LINK: to J4-2) or (RTU Open: to J2-6)

RETURN AIR SMOKE DETECTOR (AS SHIPPED)

STEP 1 STEP 2 STEP 3

tial enthalpy 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 (33CSENTSEN) in the return-air section of the economizer. The return air sensor is wired to the enthalpy controller (33CSENTHSW). See Fig. 62.

Fig. 62 — Outside and Return Air Enthalpy Sensor

Wiring

To wire the return air enthalpy sensor, perform the follow-

ing:

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

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

–) terminal on the enthalpy controller.

Smoke Detectors — Smoke detectors are available as fac-

tory-installed options on 581J models. Smoke detectors may be specified for Supply Air only or for Return Air without or with economizer or in combination of Supply Air and Return Air. 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.

Units equipped with factory-optional Return Air smoke detectors require a relocation of the sensor module at unit installation. See Fig. 63 for the as shipped location.

Completing Installation of Return Air Smoke Sensor:

1. Unscrew the two screws holding the Return Air Smoke Detector assembly. See Fig. 64, Step 1. Save the screws.

2. Turn the assembly 90 and then rotate end to end. Make sure that the elbow fitting is pointing down. See Fig. 64, Step 2.

3. Screw the sensor and detector plate into its operating position using screws from Step 1. See Fig. 64, Step 3.

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

Fig. 63 — Return Air Smoke Detector, Shipping

Position

ADDITIONAL APPLICATION DATA — Refer to the

Application Data sheet titled Factory Installed Smoke Detectors for Small and Medium Rooftop Units 2 to 25 Tons for discussions on additional control features of these smoke detectors including multiple unit coordination.

Fig. 64 — Completing Installation of Return Air Smoke Sensor

Page 47

Economizer 2 Position Damper

Unit Without Economizer or 2 Position Damper

Fig. 65 — EconoMi$er

Step 14 — Adjust Factory-Installed Options

SMOKE DETECTORS — Smoke detector(s) will be con-

nected at the Controls Connections Board, at terminals marked “Smoke Shutdown.” Cut jumper JMP 3 when ready to energize unit.

ECONOMI$ER IV OCCUPANCY SWITCH — Refer to Fig. 65 for general EconoMi$er IV wiring. External occupancy control is managed through a connection on the Controls Connections Board.

If external occupancy control is desired, connect a time clock or remotely controlled switch (closed for Occupied, open for Unoccupied sequence) at terminals marked OCCUPANCY. Cut jumper JMP 2 to complete the installation.

Step 15 — Install Accessories — Available accessories

include:

•Roof Curb

• Thru-base connection kit (must be installed before unit is

set on curb)

• LP conversion kit

• Flue discharge deflector

• Manual outside air damper

• Two-Position motorized outside air damper

• EconoMi$er IV (with control)

• EconoMi$er2 (without control/for external signal)

• Power Exhaust

• Differential dry-bulb sensor (EconoMi$er IV)

• Outdoor enthalpy sensor

• Differential enthalpy sensor

•CO

sensor

• Louvered hail guard

• Motormaster

• Phase monitor control

• Energy Recovery Ventilator (ERV)

head pressure controls

IV Wiring

Refer to separate installation instructions for information on

installing these accessories.

Step 16 — Check Belt Tension — Measure the belt

span length as shown in Fig. 66. Calculate the required deflection by multiplying the belt span length by the belt span length is 32 inches: 32 x

BELT FORCE — DEFLECTION METHOD — Check the belt tension with a spring-force belt force deflection gauge (available from drive belt manufacturer).

1. Place a straightedge along the belt between the two pulleys. Measure the distance between the motor shaft and the blower shaft.

2. Set the tension gauge to the desired tension (see Table 1 in Fig. 66). Place the large O-ring at that point.

3. Press the tension checker downward on the belt until the large O-ring is at the bottom of the straightedge.

4. Adjust the belt tension as needed.

Adjust belt tension by loosing the motor mounting plate front bolts and rear bolt (see Fig. 67) and slide the plate towards the fan (to reduce tension) or away from the fan (to increase tension). Ensure the blower shaft and motor shaft are parallel to each other (pulleys aligned). Tighten all bolts securely when finished.

/64. For example, if

/64 = 1/2 inch deflection.

Page 48

BELT TENSION METHOD — Requires belt tension

Table 1

Table 2

BELT

CROSS

SECTION

SMALLEST

SHEAVE

DIAMETER

BELT DEFLECTION FORCE (LBS)

UNNOTCHED

BELTS

NOTCHED BELTS

USED NEW USED NEW

A, AX

3.0-3.6 3.7 5.5 4.1 6.1

3.8-4.8 4.5 6.8 5.0 7.4

5.0-7.0 5.4 8.0 5.7 8.4

B, BX

3.4-4.2 — — 4.9 7.2

4.4-5.6 5.3 7.9 7.1 10.5

5.8-8.6 6.3 9.4 8.5 12.6

BELT CONDITION TENSION FORCE IN BELT (LBS)

New 100

Used 80

gauge that measures tension in belt in units of lbs force.

BLOWER PULLEY

V-B ELT

MOTOR PULLEY

MOTOR

Fig. 66 — V-Belt Force Label

MOUNTING

BOLTS (4)

MOTOR MOUNTING

PLATE

Fig. 67 — Belt Drive Motor Mounting

Pre-Start and Start-Up — This completes the mechani-

cal installation of the unit. Refer to the unit’s Service Manual for detailed Pre-Start and Start-Up instructions. Download the latest versions from HVAC Partners (www.hvacpartners.com).

Page 49

Page 50

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: II581J-13

Page 51

START-UP CHECKLIST FOR 581J 04-06 SINGLE PACKAGE ROOFTOP

GAS HEATING/ELECTRIC COOLING UNIT

(REMOVE AND USE FOR JOB FILE)

NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Installation Instruction document.

I. PRELIMINARY INFORMATION

MODEL NO__________________________________________________

JOB NAME __________________________________________________

SERIAL NO __________________________________________________

ADDRESS ___________________________________________________

START-UP DATE______________________________________________

TECHNICIAN NAME__________________________________________

ADDITIONAL ACCESSORIES

___________________________________________________________________________________________________________________

II. PRE-START-UP

Verify that all packaging materials have been removed from unit (Y/N) _____ Verify installation of outdoor air hood (Y/N) _____ Verify installation of flue exhaust and inlet hood (Y/N) _____ Verify that condensate connection is installed per instructions (Y/N) _____ Verify that all electrical connections and terminals are tight (Y/N) _____ Verify gas pressure to unit gas valve is within specified range (Y/N) _____ Check gas piping for leaks (Y/N) _____ Check that indoor-air filters are clean and in place (Y/N) _____ Check that outdoor air inlet screens are in place (Y/N) _____ Verify that unit is level (Y/N) _____ Check fan wheels and propeller for location in housing/orifice and verify setscrew is tight (Y/N) _____ Verify that fan sheaves are aligned and belts are properly tensioned (Y/N) _____ Verify that scroll compressors are rotating in the correct direction (Y/N) _____ Verify installation of thermostat (Y/N) _____ Verify that crankcase heaters have been energized for at least 24 hours (Y/N) _____

III. START-UP

ELECTRICAL

Supply Voltage L1-L2_____________ L2-L3_____________ L3-L1_____________ Compressor Amps 1 L1 _____________ L2 _____________ L3 _____________ Compressor Amps 2 L1 _____________ L2 _____________ L3 _____________ Supply Fan Amps L1 _____________ L2 _____________ L3 _____________

TEMPERATURES

Outdoor-air Temperature _____________ °F DB (Dry Bulb) Return-air Temperature _____________ °F DB _____________ °F WB (Wet Bulb) Cooling Supply Air Temperature _____________ °F Gas Heat Supply Air _____________ °F

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. CL-1 Replaces: II581J-13

Catalog No: II581J-4-6-01

Page 52

PRESSURES

Gas Inlet Pressure _____________ in. wg Gas Manifold Pressure STAGE 1 _____________ in. wg

STAGE 2 _____________ in. wg

Refrigerant Suction CIRCUIT A _____________ PSIG

CIRCUIT B _____________ PSIG

Refrigerant Discharge CIRCUIT A _____________ PSIG

CIRCUIT B _____________ PSIG

Verify Refrigerant Charge using Charging Charts (Y/N) _____

GENERAL

Economizer minimum vent and changeover settings to job requirements (if equipped) (Y/N) _____ Verify smoke detector unit shutdown by utilizing magnet test (Y/N) _____

IV. PERFECT HUMIDITY® START-UP

STEPS

1. Check CTB for jumper 5, 6, 7 (Jumper 5, 6, 7 must be cut and open) (Y/N) _____

2. Open humidistat contacts (Y/N) _____

3. Start unit In cooling (Close Y1) (Y/N) _____

OBSERVE AND RECORD

A. Suction pressure _______________ PSIG B. Discharge pressure _______________ PSIG C. Entering air temperature _______________ °F D. Liquid line temperature at outlet or reheat coil _______________ °F E. Confirm correct rotation for compressor (Y/N) _____ F. Check for correct ramp-up of outdoor fan motor as condenser coil warms (Y/N) _____

4. Check unit charge per charging chart (Y/N) _____ (Jumper 32L Motormaster

5. Switch unit to high-latent mode (sub-cooler) by closing humidistat with Y1 closed (Y/N) _____

OBSERVE

A. Reduction in suction pressure (5 to 7 psi expected) (Y/N) _____ B. Discharge pressure unchanged (Y/N) _____ C. Liquid temperature drops to 50 to 55°F range (Y/N) _____ D. LSV solenoid energized (valve closes) (Y/N) _____

6. Switch unit to dehumid (reheat) by opening Y1 (Y/N) _____

OBSERVE

A. Suction pressure increases to normal cooling level B. Discharge pressure decreases (35 to 50 psi) (Limited by Motormaster control) C. Liquid temperature returns to normal cooling level D. LSV solenoid energized (valve closes) E. DSV solenoid energized, valve opens

7. With unit in dehumid mode close W1 compressor and outdoor fan stop; LSV and DSV solenoids de-energized

(Y/N) _____

8. Open W1 restore unit to dehumid mode (Y/N) _____

9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____

10. Restore set-points for thermostat and humidistat (Y/N) _____

temperature sensor during this check. Remove jumper when complete.)

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. CL-2 Replaces: II581J-13

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