Bryant Legacy Series, 582J 04-06 Installation Instructions Manual
Legacy Series
582J 04-06
Single Package Rooftop Gas Heat/Electric Cooling Unit with
®
Puron
(R-410A) Refrigerant
Installation Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1
MODEL NUMBER NOMENCLATURE AND
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Jobsite Survey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 1 — Plan for Unit Location . . . . . . . . . . . . . . . . . . . 6
Step 2 — Plan for Sequence of Unit Installation . . . . . . 7
Step 3 — Inspect Usonit. . . . . . . . . . . . . . . . . . . . . . . . . . 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 (When Required) . . . . . . . . . . . . . . . . . . 10
Step 8 — Install Outside Air Hood . . . . . . . . . . . . . . . . .11
Step 9 — 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 13 — Make Electrical Connections . . . . . . . . . . . 15
EconoMi$er X
Outdoor Air Enthalpy Control
(P/N 33CSENTHSW). . . . . . . . . . . . . . . . . . . . . . . . 38
Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RTU Open Controller (Factory-Installed Option) . . . 39
Step 14 — Adjust Factory-Installed Options. . . . . . . . 39
Step 15 — Install Accessories . . . . . . . . . . . . . . . . . . . . 39
Step 16 — Check Belt Tension . . . . . . . . . . . . . . . . . . . 40
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . CL-1
®
(Factory-Installed Option). . . . . . . . . 26
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 safetyalert symbol . When you see this symbol on the unit 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.
CAUTION
Ensure clearances are in accordance with local installation
codes, the requirements of the gas supplier and the manufacturer's installation Instructions.
ATTENTION
Assurez-vous que les dégagements sont conformes aux codes
d'installation locaux, aux exigences du fournisseur de gaz et
aux instructions d'installation du fabricant.
WARNING
ELECTRICAL OPERATION HAZARD
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.
WARNING
GAS VALVE
INLET PRESSURE
TAP SET SCREW
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in serious personal
injury, death, and/or property damage.
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(s).
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal injury,
death and/or equipment damage.
This system uses Puron
sures than R-22 and other refrigerants. No other refrigerant
may be used in this system. Gage set, hoses, and recovery
system must be designed to handle Puron refrigerant. If unsure about equipment, consult the equipment manufacturer.
®
refrigerant, which has higher pres-
AVERTISSEMENT
RISQUE D’INTOXICATION AU MONOXYDE DE
CARBONE
Si ces directives ne sont pas suivies, cela peut entraîner des
blessures graves ou une intoxication au monoxyde de carbone
pouvant causer la mort, si des produits de combustion
s’infiltrent dans le bâtiment.
Vérifier que toutes les ouvertures pratiquées dans le mur
extérieur autour du ou des tuyaux d’évent (et de la prise d’air)
sont scellées de manière à empêcher l’infiltration de produits
de combustion dans le bâtiment.
Veiller à ce que la ou les sorties de l’évent de l’appareil de
chauffage (et la prise d’air) ne soient, en aucune façon,
obstruées, quelle que soit la saison.
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.
1
/8-in. NPT
WARNING
PERSONAL INJURY AND ENVIRONMENTAL HAZARD
Failure to follow this warning could cause personal injury or
death.
Relieve pressure and recover all refrigerant before system re-
pair or final unit disposal.
Wear safety glasses and gloves when handling refrigerants.
Keep torches and other ignition sources away from refrigerants and oils.
CAUTION
PROPERTY DAMAGE HAZARD
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.
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
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
NPT pipe plug must be installed to prevent gas leaks.
MANIFOLD PRESSURE
TAP SET SCREW
MANIFOLD
GAS VALVE
1
/8-in.
2
MODEL NUMBER NOMENCLATURE AND
Model
J - Puron
®
(R-410A) Refrigerant
Unit Type
582 - Gas Heat RTU, Legacy Series
Packaging and Control
A = Standard Packaging, electro-mechanical
controls that require W7212 EconoMi$er® IV
B = LTL Packaging
, electro-mechanical
controls that require W7212 EconoMi$er IV
C = Standard Packaging, electro-mechanical
controls that require W7220 EconoMi$er X
F = LTL Packaging, electro-mechanical
controls that require W7220 EconoMi$er X
Cooling Tons
04 - 3 tons
05 - 4 tons
06 - 5 tons
Heat Level Input
Standard / Stainless Steel
072 = 72,000
115 = 115,000
150 = 150,000
Low NOx
060 = 60,000
090 = 90,000
120 = 120,000
Indoor Fan Options
0 = Direct Drive ECM
2 = Medium Static Option
3 = High Static Option
Refrig. System/Gas Heat Options
A = Standard One Stage cooling models/Nat. Gas Heat
B = Standard One Stage cooling models/Low NO
x
Heat
C = Standard One Stage cooling models/SS HX Heat
G = One-Stage cooling models/Alum Heat Exchanger
with Perfect Humidity™
H = One-Stage cooling models/Low NO
x
Heat
with Perfect Humidity
J = One-Stage cooling models/Stainless Steel Exchanger
with Perfect Humidity
Coil Options (RTPF) (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 Guard
N = Precoat Al/Cu - Al/Cu — Louvered Hail Guard
P = E-coat Al/Cu - Al/Cu — Louvered Hail Guard
Q = E-coat Al/Cu - E-coat Al/Cu — Louvered Hail Guard
R = Cu/Cu - Al/Cu — Louvered Hail Guard
S = Cu/Cu - Cu/Cu — Louvered Hail Guard
Voltage
E = 460-3-60
J = 208/230-1-60
P = 208/230-3-60
T = 575-3-60
Outdoor Air Options
A = None
B = Temperature Economizer, Barometric Relief,
Standard Leak (W7212 or W7220)
E = Temperature Economizer, Barometric Relief,
Standard Leak w/CO
2
(W7212 or W7220)
H =
Enthalpy
Economizer, Barometric Relief,
Standard Leak (W7212 or W7220)
L =
Enthalpy
Economizer, Barometric Relief,
Standard Leak w/CO
2
(W7212 or W7220)
Q = Motorized 2 Position Damper
U = Temperature
Economizer,
Barometric
Relief,
Ultra Low Leak (W7220)
W =
Enthalpy Economizer,
Barometric
Relief, Ultra Low Leak
(W7220)
Example:
Position:
582JE06A072A0B0AA
1234567891011 12 13 14 15 16 17
Factory Installed Options
0A = None
NOTE: See the 582J 3 to 5 ton Price Pages
for a complete list of factory installed
options.
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
DIMENSIONS
See Fig. 1 for 582J model number nomenclature. See Fig. 2 for
unit dimensional drawings. Figure 3 shows service clearance
dimensions.
Rated Indoor Airflow
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)
582J*04 1050
582J*05 1400
582J*06 1750
Fig. 1 — 582J 04-06 Model Number Nomenclature (Example)
3
Fig. 2 — Unit Dimensional Drawing
4
Fig. 2 — Unit Dimensional Drawing (cont)
5
Fig. 3 — Service Clearance Dimensional Drawing
C
B
A
D
LOCATION DIMENSION CONDITION
A
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
B
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
C
36 in. (914 mm) Side condensate drain is used
18 in. (457 mm) Minimum clearance
D
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
Be sure that unit is installed such that snow will not block the
combustion intake or flue outlet.
Installation of this furnace at altitudes above 2000 ft (610 m) shall
be made in accordance with the Listed High Altitude Conversion
Kit available with this furnace.
L'installation de ce générateur de chaleur à des altitudes
supérieures à 2000 pi (610 m) doit être effectuée conformément
aux instructions accompagnant la trousse de conversion pour
haute altitude fournie avec cet appareil.
Jobsite Survey
Complete the following checks before installation.
1. Consult local building codes and the NEC (National Elec-
trical 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.
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.
Unit may be installed directly on wood flooring or on Class A, B,
or C roof-covering material when roof curb is used.
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 (Ameri-
can National Standards Institute) and NFPA (National Fire Protec-
tion 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 adja-
cent 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 al-
low installation of condensate trap per requirements. Refer to In-
stall External Condensate Trap and Line on page 15 for required
trap dimensions.
6
ROOF MOUNT
Check building codes for weight distribution requirements. Unit
operating weights are shown in Table 2.
Table 2 — Operating Weights
582J
Base Unit 490 (222) 544 (246) 597 (270)
Economizer
Vertical 50 (23) 50 (23) 50 (23)
Horizontal 80 (36) 80 (36) 80 (36)
Perfect Humidity
System
Cu Fins 25 (11) 43 (20) 56 (25)
Powered Outlet 35 (16) 35 (16) 35 (16)
Curb
14-in. (356 mm) 115 (52) 115 (52) 115 (52)
24-in. (610 mm) 197 (89) 197 (89) 197 (89)
™
50 (23) 50 (23) 50 (23)
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 curbmounted 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 Install External
Condensate Trap and Line on page 15 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.
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-sup-
1
plied
/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.
7
E
E
7/16"
[11]
4 9/16"
[115.5]
1/4"
[7.0]
5' 7-3/8"
[1711.3]
1' 4-13/16"
[427] INSIDE
1-3/4"
[44.4]
2-3/8"
[61]
1-3/4"
[44.5]
1.00"
[25.4]
"A"
1-3/4"
[44.4]
21.74"
[552.2]
5.42"
[137.7]
11.96"
[303.8]
4.96"
[126.0]
70.87"
[1800.2]
40.69"
[1033.5]
21.84"
[554.7]
16.03"
[407.2]
1.75"
[44.5]
20.41"
[518.3]
3.00"
[76.2]
13.78"
[350.0]
14.00"
[355.6]
3.00"
[76.2]
15.19"
[385.8]
32.19"
[817.6]
3'-1 3/16"
[944.6]
"A"
1-3/4"
[44.5]
CRBTMPWR001A01 3/4" [19] NPT
3/4" [19] NPT
1/2" [12.7] NPT
CRRFCURB002A01
CONNECTOR PKG. ACC. GAS CONNECTION TYPE GAS FITTING
POWER WIRING
FITTING
CONTROL WIRING
FITTING
ACCESSORY CONVENIENCE
OUTLET WIRING CONNECTOR
THRU THE CURB
1/2" [12.7] NPT 1/2" [12.7] NPT
CRBTMPWR003A01 THRU THE BOTTOM
ROOF CURB
ACCESSORY #
A
CRRFCURB001A01
14"
[356]
24"
[610]
NOTES:
1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED.
2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY.
3. DIMENSIONS IN [ ] ARE IN MILLIMETERS.
4. ROOFCURB: 18 GAGE STEEL.
5. ATTACH DUCTWORK TO CURB. (FLANGES OF DUCT REST ON CURB).
6. SERVICE CLEARANCE 4 FEET ON EACH SIDE.
7. DIRECTION OF AIR FLOW.
8. CONNECTOR PACKAGE CRBTMPWR001A01 IS FOR THRU-THE-CURB GAS TYPE
PACKAGE CRBTMPWR003A01 IS FOR THRU-THE-BOTTOM TYPE GAS CONNECTIONS.
TYPICAL (4) SIDES
SUPPLY AIR RETURN AIR
ROOFING MATERIAL
(FIELD SUPPLIED)
CANT STRIP
(FIELD SUPPLIED)
ROOFING FELT
(FIELD SUPPLIED)
COUNTER FLASHING
(FIELD SUPPLIED)
UNIT
GASKET
(SUPPLIED WITH CURB)
RIGID INSULATION
(FIELD SUPPLIED)
DUCT
(FIELD SUPPLIED)
NAIL (FIELD SUPPLIED)
VIEW "B"
CORNER DETAIL
SEE VIEW "B"
RETURN AIR
SUPPLY AIR
SUPPLY AIR
OPENING
RETURN AIR
OPENING
GAS SERVICE PLATE
THRU THE CURB
DRILL HOLE
2" [50.8] @
ASSEMBLY (IF
REQUIRED)
(SEE NOTE #8)
SEE NOTE #2
11 3/4"[298.5] WIDE
INSULATED DECK PANELS
8 9/16"[217.5] WIDE
INSULATED DECK PANEL
1/3/4"[44.5]
SCALE 0.250
E-ESECTION
48TC400427
Fig. 4 — Roof Curb Details
8
Fig. 5 — Unit Leveling Tolerances
A
B
C
MAXIMUM ALLOWABLE
DIFFERENCE IN. (MM)
A-B B-C A-C
0.5 (13) 1.0 (25) 1.0 (25)
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
UNIT
MAX WEIGHT
DIMENSIONS
ABC
LB KG IN. MM IN. MM IN. MM
582J*A04 795 361 74.5 1890 39 990 33.5 850
582J*A05 890 405 74.5 1890 39 990 33.5 850
582J*A06 1020 464 74.5 1890 39 990 41.5 1055
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.
Step 5 — Field Fabricate Ductwork
Cabinet return-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.
Fabricate supply ductwork so that the cross sectional dimensions
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
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 or wood 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
1
/2in. square socket drive extension. For further details, see “Install
External Condensate Trap and Line” on page 15.
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.
Fig. 6 — Rigging Details
9
POSITIONING ON CURB
REMOVABLE HORIZONTAL
SUPPLY DUCT OPENING COVER
REMOVABLE HORIZONTAL
RETURN DUCT OPENING COVER
SCREWS
DUCT COVERS
SHEET METAL
FACE UP
BASEPAN
Position unit on roof curb so that the following clearances are
maintained:
1
/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 approximately
1
/4 in.
(6.4 mm).
Although unit is weatherproof, guard against water from higher
level runoff and overhangs.
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.
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 (see Fig. 7) and remove covers. Use the screws to install
the covers on vertical duct openings with the insulation-side
down. The panels must be inserted into the notches on the basepan
to properly seal. The notches are covered by the tape used to secure the insulation to the basepan and are not easily seen. See Fig.
8 for position of the notches in the basepan. Seals around duct
openings must be tight. Secure with screws as shown in Fig. 9.
Cover seams with foil duct tape.
Field-supplied flanges should be attached to horizontal 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.
Do not cover or obscure visibility to the unit’s informative data
plate when insulating horizontal ductwork.
Fig. 7 — Horizontal Conversion Panels
NOTCHES
BASEPAN
NOTCHES
Fig. 8 — Location of Notches
Fig. 9 — Horizontal Duct Panels In Place
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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 (-J 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. 10.
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. 12.
2. Locate the (2) screws holding the metal tray to the basepan
and remove. Locate and cut the (2) plastic tie-wraps securing the assembly to the damper. See Fig. 11. Be careful to
not damage any wiring or cut tie-wraps securing any wiring.
3. Carefully lift the hood assembly (with metal tray) through
the filter access opening and assemble per the steps outlined in the Economizer Hood and Two-Position Hood
section.
Fig. 11 — Economizer and Two-Position Damper Hood
Fig. 10 — Typical Access Panel Locations
Parts Location
Fig. 12 — 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. 13.
TOP
PAN EL
INDOOR COIL
ACCESS PANEL
LEFT
HOOD
SIDE
19 1/16”
B
(483mm)
SCREW
HOOD DIVIDER
33 3/8”
(848mm)
Fig. 13 — 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. 13 and 14. 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. 14.
6. Caulk the ends of the joint between the unit top panel and
the hood top.
7. Replace the filter access panel.
11
Fig. 14 — Economizer Filter Installation
DIVIDER
BAROMETRIC
RELIEF
CLEANABLE
ALUMINUM
FILTER
FILTER
HOOD
FILTER
CLIP
OUTSIDE
AIR
COMPRESSOR DOOR
OUTDOOR COIL
LATCH
Step 9 — Units with Hinged Panels Only
Relocate latch shipped inside the compressor compartment behind
the hinged compressor door to location shown in Fig. 15 after unit
installation.
If the unit does not have hinged panels, skip this step and continue
at Step 10.
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. The input rating for altitudes
above 2000 ft (610 m) must be derated by 4% for each 1000 ft
(305 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 582JF*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 liquified petroleum applications,
the gas pressure must not be less than 11 in. wg (2740 Pa) or greater than 13.0 in. wg (3240 Pa) at the unit connection, see Table 4.
Table 3 — Natural Gas Supply Line Pressure Ranges
UNIT MODEL UNIT SIZE MIN. MAX.
582JD/E/L/M/S/R 04, 05, 06
582JF/N/T
(High Heat Units Only)
05, 06
4.0 in. wg
(996 Pa)
5.0 in. wg
(1245 Pa)
13.0 in. wg
(3240 Pa)
13.0 in. wg
(3240 Pa)
Fig. 15 — 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. 16.
BLOWER
ACCESS
PANEL
FLUE OPENING
Fig. 16 — Flue Hood Details
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
Table 4 — Liquid Propane Supply Line Pressure Ranges
UNIT MODEL UNIT SIZE MIN. MAX.
582JD/E/S/R 04, 05, 06
582JF/T
(High Heat Units Only)
05, 06
11.0 in. wg
(2740 Pa)
11.0 in. wg
(2740 Pa)
13.0 in. wg
(3240 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
1
/2-in.
FPT gas inlet port on the unit gas valve.
Manifold pressure is factory-adjusted for natural gas fuel use. Ad-
just as required to obtain best flame characteristics. See Table 5.
Table 5 — Natural Gas Manifold Pressure Ranges
UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE
582JD/E/L/M/S/R 04, 05, 06
582JF/N/T
(High Heat Units Only)
NOTE: LOW FIRE, 1.7 in. wg (423 Pa), applies to the following three
phase voltage units only: 582JE04 and 582JF05/06.
05, 06
3.5 in. wg
(872 Pa)
3.5 in. wg
(872 Pa)
SEE NOTE
BELOW
SEE NOTE
BELOW
Manifold pressure for LP fuel use must be adjusted to specified
range. Follow instructions in the accessory kit to make initial readjustment, see Table 6.
Table 6 — Liquid Propane Manifold Pressure Ranges
unit model UNIT SIZE high fire low fire
582JD/E/S/R 04, 05, 06
582JF/T
(High Heat Units Only)
NOTE: LOW FIRE, 5.0 in. wg (1245 Pa), applies to the following three
phase voltage units only: 582JE04 and 582JF05/06.
05, 06
10 in. wg
(2490 Pa)
10 in. wg
(2490 Pa)
SEE NOTE
BELOW
SEE NOTE
BELOW
12
CAUTION
LEGEND *Field supplied.
NOTE: Follow all local codes.
NFGC —
National Fuel Gas
Code
STEEL PIPE NOMINAL
DIAMETERS (IN.)
SPACING OF SUPPORTS
X DIMENSION (FT.)
1
/
2
6
3
/4 or 1 8
1-
1
/4 or Larger 10
Failure to follow this caution may result in equipment damage.
When connecting the gas line to the unit gas valve, the in-
staller MUST use a backup wrench to prevent damage to
the valve.
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
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.
The gas supply line can approach the unit in three ways: horizontally from outside the unit (across the roof), thru-curb/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. 17.
9” MINIMUM CLEARANCE
FOR PANEL REMOVAL
MANUAL GAS
BASE UNIT
SHUTOFF VALVE
1
/2-in. Size the gas supply line
X
48” MINIMUM
GAS
REGULATOR
*
*
LOW VOLTAGE
CONDUIT
CONNECTOR
HIGH VOLTAGE
CONDUIT
CONNECTOR
BRASS FITTING FOR 3 TO 6 TON UNITS.
Fig. 18 — 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
tach a
1
/2-in. NPT street elbow on the thru-base gas fitting. At-
1
/2-in. pipe nipple with minimum length of 16-in. (406 mm)
(field-supplied) to the street elbow and extend it through the access panel at the gas support bracket. See Fig. 19.
BASE RAIL
FROM
GAS
METER
ROOF
CURB
PER NFGC
*
FIELD-FABRICATED
SUPPORT
*
DRIP LEG
Fig. 17 — Gas Piping Guide
(with Accessory Thru-the-Curb Service Connections)
FACTORY-OPTION THRU-BASE CONNECTIONS (GAS CONNECTIONS)
This service connection kit consists of a
fitting (brass), a
1
/2-in. electrical bulkhead connector and a 3/4-in.
1
/2-in. NPT gas adapter
electrical bulkhead connector, all factory-installed in the embossed
(raised) section of the unit basepan in the condenser section. See
Fig. 18.
EMBOSSMENT
BRASS FITTING
FOR 3-6 TON UNITS
SUPPORT
BRACKET
Fig. 19 — 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. 20 and 21 for typical piping arrangements for gas piping
that has been routed through the sidewall of the curb. See Fig. 22
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.
13
Fig. 20 — Gas Piping, Typical Curb Sidewall Piping
9” (229mm) MIN
UNION
SHUT OFF
VALV E
DRIP
LEG
THRU-CURB ADAPTER
UNIT BASE RAIL
SHUT OFF
VALV E
UNION
9” (229mm) MIN
UNIT BASE RAIL
BURNER
ACCESS
PAN EL
THRU-CURB ADAPTER
DRIP
LEG
(Example 1)
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
1
/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
1
/2 in., follow recom-
mendations of national codes.
• Apply joint compound (pipe dope) sparingly and only to
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
1
) tape, ensure the material is Double
Density type and is labeled for use on gas lines. Apply tape
per manufacturer’s instructions.
• Pressure-test all gas piping in accordance with local and
national plumbing and gas codes before connecting piping
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
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 ground-joint 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).
Fig. 21 — Gas Piping, Typical Curb Sidewall Piping
Fig. 22 — Gas Piping, Typical Thru-Base Connections
(Example 2)
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. 23.
1. Teflon is a registered trademark of DuPont.
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