Bryant 604D024, 604D030, 604D036 Installation Instructions Manual
604D
SINGLE--PACKAGED HEAT PUMP UNITS
WITH PURONR (R--410A) REFRIGERANT
2--5 NOMINAL TONS (SIZES 018--060) 1 & 3 PHASE
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
NOTE: Installer: Make sure the Owner’s Manual and Service
Instructions are left with the unit after installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1........................
INTRODUCTION 2..................................
RECEIVING AND INSTALLATION 2--16................
Check Equipment 2.................................
Identify Unit 2...................................
Inspect Shipment 2................................
Provide Unit Support 2..............................
Roof Curb 2.....................................
Slab Mount 2....................................
Ground Mount 2.................................
Provide Clearances 2................................
Rig and Place Unit 2................................
Inspection 2.....................................
Use of Rigging Bracket 5...........................
Select and Install Ductwork 7..........................
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge Units 7.........................
Provide for Condensate Disposal 7.....................
Install Electrical Connections 8........................
High--Voltage Connections 8........................
Routing Power Leads into Unit 9.....................
Connecting Ground lead to Ground Lug 9..............
Routing Control Power Wires (24--v) 9................
Easy Selectt 9 & 13--16...........................
604D Sequence of Operation 16......................
Special Procedures for 208--V Operation 16.............
P R E -- S T A R T -- U P 1 6 -- 1 7...............................
START--UP 17--20....................................
Check for Refrigerant Leaks 17--18.....................
Start--Up Adjustments 18............................
Check Cooling & Heating Operation 18................
Checking & Adjusting Refrigerant Charge 18...........
Refrigerant Charge 18.............................
No Charge 18....................................
Low Charge Cooling 19............................
To Use Cooling Charging Charts 19...................
Indoor Airflow & Airflow Adjustments 19.............
Defrost Control 19..................................
Quiet Shift 19....................................
Defrost 19--20...................................
MAINTENANCE 20--25...............................
Air Filter 21.......................................
Indoor Blower and Motor 21..........................
Outdoor Coil, Indoor Coil, & Condensate Drain Pan 21.....
Outdoor Fan 23....................................
Electrical Controls and Wiring 23......................
Refrigerant Circuit 23................................
Indoor Airflow 23..................................
Metering Devices-- TXV 23..........................
Pressure Switches 24................................
Loss of Charge Switch 24............................
High Pressure Switch 24.............................
Copeland Scroll compressor (Puron Refrigerant) 24........
Refrigerant System 24...............................
Refrigerant 24...................................
Compressor Oil 24................................
Servicing Systems on Roofs with Synthetic Materials 24...
Liquid Line Filter Drier 25..........................
PuronR (R--410A) Refrigerant Charging 25............
System Information 25...............................
Loss of Charge Switch 25...........................
Check Defrost Thermostat 25........................
TROUBLESHOOTING 25.............................
START--UP CHECKLIST 25...........................
Installation and servicing of this equipment can be hazardous due
to mechanical and electrical components. Only trained and
qualified personnel should install, repair, or service this
equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on this equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. Installation must be in compliance with
local and national building codes. Wear safety glasses, protective
clothing, and work gloves. Have fire extinguisher available. Read
A99338
Fig. 1 -- Unit 604D
SAFETY CONSIDERATIONS
1
these instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit.
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words: DANGER, WARNING, and CAUTION.
These words are used with the safety--alert symbol. DANGER
identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies 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.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
604D
injury or death.
Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch. Turn off accessory heater power switch if
applicable.
!
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury, death or property damage.
A qualified installer or agency must use only
factory--authorized kits or accessories when modifying this
product.
INTRODUCTION
The 604D heat pump is fully self--contained and designed for
outdoor installation. (See Fig. 1) Standard units are shipped in a
horizontal--discharge configuration for installation on a
groundlevel slab. Standard units can be converted to downflow
(vertical) discharge configurations for rooftop applications.
RECEIVING AND INSTALLATION
Step 1 — Check Equipment
IDENTIFY UNIT
The unit model number and serial number are stamped on the
unit identification plate. Check this information against shipping
papers.
INSPECT SHIPMENT
Inspect for shipping damage while unit is still on shipping pallet.
If unit appears to be damaged or is torn loose from its anchorage,
have it examined by transportation inspectors before removal.
Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in
transit. Check all items against shipping list. Immediately notify
the nearest equipment distributor if any item is missing. To
prevent loss or damage, leave all parts in original packages until
installation.
Step 2 — Provide Unit Support
ROOF CURB
Install accessory roof curb in accordance with instructions
shipped with curb (See Fig. 5). Install insulation, cant strips,
roofing, and flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is
critical for a watertight seal. Install gasketing material supplied
.
with the roof curb. Improperly applied gasketing also can result
in air leaks and poor unit performance.
Curb should be level to within 1/4 in. (6 mm)(See Fig. 6). This is
necessary for unit drain to function properly. Refer to accessory
roof curb installation instructions for additional information as
required.
SLAB MOUNT
Place the unit on a solid, level concrete pad that is a minimum of
4 in. (102 mm) thick with 2 in. (51 mm) above grade (See Fig. 7).
The slab should extend approximately 2 in.(51 mm) beyond the
casing on all 4 sides of the unit. Do not secure the unit to the slab
except when required by local codes.
GROUND MOUNT
The unit may be installed either on a slab or placed directly on the
ground if local codes permit. Place the unit on level ground
prepared with gravel for condensate discharge.
Step 3 — Provide Clearances
The required minimum service clearances are shown in Fig. 2 and
3. Adequate ventilation and outdoor air must be provided. The
outdoor fan draws air through the outdoor coil and discharges it
through the top fan grille. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
corner or under an overhead obstruction. The minimum clearance
under a partial overhang (such as a normal house overhang) is 48
in. (1219 mm) above the unit top. The maximum horizontal
extension of a partial overhang must not exceed 48 in. (1219
mm)
IMPORTANT: Do not restrict outdoor airflow. An air restriction
at either the outdoor--air inlet or the fan discharge may be
detrimental to compressor life.
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting or other combustible materials. Slab--mounted units
should be at least 4 in. (102 mm) above the highest expected
water and runoff levels. Do not use unit if it has been under water.
Step 4 — Rig and Place Unit
Rigging and handling of this equipment can be hazardous for many
reasons due to the installation location (roofs, elevated structures,
etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment, and
any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the
lifts to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting
kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
INSPECTION
The lifting/rigging bracket is engineered and designed to be
installed only on Small Packaged Products. This bracket is to be
used to rig/lift a Small Packaged Product onto roofs or other
elevated structures.
2
*
604D
REQUIRED CLEARANCE TO COMBUSTIBLE MATL
(
R
efe
r t
o
M
aximu
m
O
perating
C
learance
TOP OF UNIT...................................................................................14.00 [355.6]
DUCT SIDE OF UNIT.........................................................................2.00 [50.8]
SIDE OPPOSITE DUCTS ................................................................14.00 [355.6]
BOTTOM OF UNIT.............................................................................0.50 [12.7]
NEC. REQUIRED CLEARANCES.
BETWEEN UNITS, POWER ENTRY SIDE....................................42.00 [1066.8]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00 [1066.8]
UNIT
ELECTRICAL
CHARACTERISTICS
.
s
)
INCHES [mm]
INCHES [mm]
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
EVAP. COIL ACCESS SIDE............................................................36.00 [914.0]
POWER ENTRY SIDE....................................................................42.00 [1066.8]
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP.......................................................................................48.00 [1219.2]
SIDE OPPOSITE DUCTS ..............................................................36.00 [914.0]
DUCT PANEL .................................................................................12.00 [304.8]
*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 304.8 [12.00] FROM
WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.
UNIT WEIGHT
lb kg X Y Z
UNIT HEIGHT
IN. [MM]
“A”
CENTER OF GRAVITY
INCHES [mm]
IN. [MM]
A05162
604D024 208/230--1--60 350 159 39.02[991.1] 20.0 [508] 19.3 [489] 17.6 [447]
604D030 208/230--1--60 350 159 39.02[991.1] 20.0 [508] 19.3 [489] 17.6 [447]
604D036 208/230 --1--60, 208/230--3--60 373 169 41.02[1041.9] 20.0 [508] 14.0 [355.6] 13.0 [330.2]
Fig. 2 -- 604D024--036 Unit Dimensions
3
*
[
]
604D
REQUIRED CLEARANCE TO COMBUSTIBLE MATL
(
R
efe
r t
o
M
aximu
m
O
perating
C
learance
TOP OF UNIT...................................................................................14.00 [355.6]
DUCT SIDE OF UNIT.........................................................................2.00 [50.8]
SIDE OPPOSITE DUCTS ................................................................14.00 [355.6]
BOTTOM OF UNIT.............................................................................0.50 [12.7]
NEC. REQUIRED CLEARANCES.
BETWEEN UNITS, POWER ENTRY SIDE ....................................42.00 [1066.8]
UNIT AND UNGROUNDED SURFACES, POWER ENTRY SIDE .36.00 [914.0]
UNIT AND BLOCK OR CONCRETE WALLS AND OTHER
GROUNDED SURFACES, POWER ENTRY SIDE.........................42.00
UNIT
604D042 208/230--1--60, 208/230--3--60 440 200 42.98 [1091.7] 21.0 [533.4] 20.5 [520.7] 16.6 [421.6]
604D048 208/230--1--60, 208/230--3--60 463 210 44.98 [1142.5] 19.5 [495.3] 21.3 [539.8] 18.0 [457.2]
604D060 208/230--1--60, 208/230--3--60 499 226 46.98 [1193.3] 21.0 [533.4] 20.0 [508.0] 17.6 [447.0]
.
s
)
ELECTRICAL
CHARACTERISTICS
INCHES [mm]
INCHES [mm]
1066.8
UNIT WEIGHT
lb kg X Y Z
Fig. 3 -- 604D 042--060 Unit Dimensions
REQUIRED CLEARANCE FOR OPERATION AND SERVICING
EVAP. COIL ACCESS SIDE............................................................36.00 [914.0]
POWER ENTRY SIDE....................................................................42.00 [1066.8]
(EXCEPT FOR NEC REQUIREMENTS)
UNIT TOP.......................................................................................48.00 [1219.2]
SIDE OPPOSITE DUCTS ..............................................................36.00 [914.0]
DUCT PANEL .................................................................................12.00 [304.8]
*MINIMUM DISTANCES: IF UNIT IS PLACED LESS THAN 304.8 [12.00] FROM
WALL SYSTEM, THEN SYSTEM PERFORMANCE MAYBE COMPROMISE.
UNIT HEIGHT
IN. [MM]
“A”
CENTER OF GRAVITY
IN. [MM]
INCHES [mm]
A05126
4
12
34
A07216
CORNER WEIGHTS (SMALL CABINET) CORNER WEIGHTS (LARGE CABINET)
Unit
Total Weight 350 159
Corner
Weight 1
Corner
Weight 2
Corner
Weight 3
Corner
Weight 4
024
lb kg
70 32
54 25
84 38
141 64
030 036
lb kg lb kg
350 159 373 169
70 32 75 34
54 25 58 26
84 38 90 41
141 64 150 68
Unit
Total Weight 440 200 463 210 499 226
Corner
Weight 1
Corner
Weight 2
Corner
Weight 3
Corner
Weight 4
DETAIL A
042 048 060
lb kg lb kg lb kg
88 40 98 44 107 49
68 31 61 28 70 32
106 48 127 58 136 62
177 80 177 80 186 84
A05161
604D
Fig. 4 -- Corner Weights
Prior to initial use, and at monthly intervals, all rigging brackets and
straps should be visually inspected for any damage, evidence of
wear, structural deformation, or cracks. Particular attention should
be paid to excessive wear at hoist hooking points and load support
areas. Brackets or straps showing any kind of wear in these areas
must not be used and should be discarded.
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal injury
or death.
Never stand beneath rigged units or lift over people.
!
WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
Rigging brackets for one unit use only. When removing a
unit at the end of its useful life, use a new set of brackets.
USE OF RIGGING BRACKET
Field Installation of Rigging Bracket (if not already
1. Remove unit from shipping carton. Leavetop shipping skid
on the unit for use as a spreader bar to prevent the rigging
straps from damaging the unit.If theskidis not available,use
a spreader bar of sufficient length to protect the unit from
damage.
2. Remove 4 screws in unit corner posts.
3. Attach each of the 4 metal rigging brackets under the panel
rain lip (SeeFig. 4). Use the screwsremoved in step 2 above
to secure the brackets to the unit.
installed)
!
WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
Rigging bracket MUST be under the rain lip to provide
adequate lifting.
!
WARNING
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
Do not strip screws when re--securing the unit. If a screw is
stripped, replace the stripped one with a larger diameter screw
(included). When straps are taut, the clevis should be a
minimum of 36 in. (914.4 mm) above the unit top cover.
Rigging/Lifting of Unit
1. Bend top of brackets down approximately 30 degrees from
the corner posts.
2. Attach straps of equal length to the rigging brackets at
oppositeends of the unit. Be sure straps are rated to hold the
weight of the unit (See Fig. 4).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unitis lifted level
with the ground.
4. Remove corner post screws and rigging brackets, then
re--install screws.
After the unit is placed on the roof curb or mounting pad, remove
the top crating.
5
HVAC unit
Scre w
(NO TE A)
*Gask eting
outer flange
Flashing field
supplied
Roofing material
field supplied
Cant str ip
field supplied
base
Gask eting
inner flange*
Wood nailer*
Roofcurb*
Insulation (field
supplied)
Duct wo rk
field supplied
HVAC unit
Scre w
(NOTE A)
*Gask eting
outer flange
Flashing field
supplied
Roofing material
field supplied
Cant str ip
field supplied
base
Gask eting
inner flange*
Duct wo rk
field supplied
Wood nailer*
Roofcurb*
Insulation (field
supplied)
Roof
604D
*Provided with roofcurb
Roof Curb for Small Cabinet
Note A: When unit mounting scre w is used,
retainer bra cke t must also be used.
Supply opening
(B x C)
B Typ.
5
/
16
"
44
Insulated
deck pan
Return opening
(B X C)
UNIT SIZE
604D024--036
604D042--060
ODS CATALOG
NUMBER
CPRFCURB006A00 8 (203) 11 (279) 16--1/2 (419) 28--3/4 (730)
CPRFCURB007A00 14 (356) 11 (279) 16--1/2 (419) 28--3/4 (730)
CPRFCURB008A00 8 (203) 16--3/16 (411) 17--3/8 (441) 40--1/4 (1022)
CPRFCURB009A00 14 (356) 16 --3/16 (411) 17--3/8 (441) 40--1/4 (1022)
NOTES:
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
4. Dimension in ( ) are in millimeters.
5. Roof curb is made of 16--- gauge steel.
6. Attach ductwork to curb (flanges of duct rest on curb).
7. Insu lated panels: 1 ---in. thick fibergl ass 1 lb. den sity.
8. When unit mounting screw is used (see Note A), a retainer bracket
must be used as well. This bracket must also be used when required by
code for hurricane or seismic conditions. This bracket is available through
Micrometl.
C Typ.
D
Long
Support
A
Short
Support
A
IN. (MM)
B
IN. (MM)
Fig. 5 -- Roof Curb Dimensions
*Provided with roofcurb
Roof Curb for Large Cabinet
Note A: When unit mounting scre w is used,
retainer bra cket must also be used.
R/A
Gask et around
duct
Insulated
deck pan
Gask et around
outer edge
C
IN. (MM)
Roof
S/A
D
IN. (MM)
C00076
6
OPTIONAL
RETURN
AIR
OPENING
OPTIONAL
SUPPLY
AIR
OPENING
A
B
C
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
A-B B-C A-C
1/4 1/4 1/4
C99065
Fig. 6 -- Unit Leveling Tolerances
Step 5 — Select and Install Ductwork
The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
non--residence type air conditioning and ventilating systems,
NFPA 90A or residence--type, NFPA 90B and/or local codes and
ordinances.
Select and size ductwork, supply--air registers, and return air
grilles according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers)
recommendations.
The unit has duct flanges on the supply-- and return--air openings
on the side of the unit.
When designing and installing ductwork, consider the following:
!
WARNING
PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal
injury or death.
For vertical supply and return units, tools or parts could
drop into ductwork Install a 90 degree turn in the return
ductwork between the unit and the conditioned space. If a
90 degree elbow cannot be installed, then a grille of
sufficient strength and density should be installed to prevent
objects from falling into the conditioned space. Units with
electric heaters require 90 degree elbow in supply duct.
1. All units should have field--supplied filters or accessory
filter rack installed in the return--air side of the unit.
Recommended sizes for filters are shown in Table 1.
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
ensure weather tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
connector between ductwork and unit discharge connection. If
flexible duct is used, insert a sheet metal sleeve inside duct. Heat
resistant duct connector (or sheet metal sleeve) must extend
24--in. (6 mm) from electric heater element.
3. Size ductwork for cooling air quantity (cfm). The
minimum air quantity for proper electric heater operation
is listed in Table 2. Heater limit switches may trip at air
quantities below those recommended.
4. Seal, insulate, and weatherproof all external ductwork.
Seal, insulate and cover with a vapor barrier all ductwork
passing through conditioned spaces. Follow latest Sheet
Metal and Air Conditioning Contractors National
Association (SMACNA) and Air Conditioning
Contractors Association (ACCA) minimum installation
standards for residential heating and air conditioning
systems.
2"
EVAP. COIL COND. COIL
C99096
Fig. 7 -- Slab Mounting Detail
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration--isolate duct openings in wall or roof
according to good construction practices.
CONVERTING HORIZONTAL DISCHARGE UNITS T
DOWNFLOW (VERTICAL) DISCHARGE
!
WARNING
UNITS
O
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch.
1. Open all electrical disconnects before starting any service
work.
2. Remove horizontal duct covers to access bottom return
and supply knock out panels.
3. Use a screwdriver and hammer to remove the panels in the
bottom of the unit base.
NOTE: These panels are held in place with tabs similar to an
electrical knockout.
4. Reinstall the horizontal duct covers (Fig. 10) to block off
the horizontal air openings.
NOTE: Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
Step 6 — Provide for Condensate Disposal
NOTE: Ensure that condensate--water disposal methods comply
with local codes, restrictions, and practices.
The 604D units dispose of condensate through a 3/4 in. NPT
female fitting that exits on the compressor end of the unit.
Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground
level installations. Install a field--supplied condensate trap at end
of condensate connection to ensure proper drainage. Make sure
that the outlet of the trap is at least 1 in. (25 mm) lower than the
drain--pan condensate connection to prevent the pan from
overflowing. Prime the trap with water. When using a gravel
apron, make sure it slopes away from the unit.
If the installation requires draining the condensate water away
from the unit, install a field--supplied 2--in. (51 mm) trap at the
condensate connection to ensure proper drainage. Condensate
trap is available as an accessory or is field--supplied. Make sure
that the outlet of the trap is at least 1 in. (25 mm) lower than the
unit drain--pan condensate connection to prevent the pan from
overflowing. Connect a drain trough using a minimum of
field--supplied 3/4--in. PVC or field--supplied 3/4--in. copper pipe
at outlet end of the 2--in. (51 mm) trap. (See Fig. 11) Do not
undersize the tube. Pitch the drain trough downward at a slope of
at least 1 in. (25 mm) every 10 ft. (3 m) of horizontal run. Be sure
to check the drain trough for leaks. Prime the trap at the
beginning of the cooling season start--up.
604D
7
604D
914-137"
“A”
“B”
INSTALL SAFETY STRAPS TO
RIGGING CLEVIS AT 4 RIGGING BRACKETS
PLACE RIGGING BRACKET ASSEMBLY IN 4
HAND HOLES AND INSTALL TIE DOWN STRAP
AROUND PERIMETER OF UNIT AND THROUGH
SEE DETAIL A
UNIT 604D
024 372 169 19.0 482.6 18.25 463.6
030 372 169 19.0 482.6 18.25 463.6
036 395 179 20.0 508.0 19.0 482.6
042 462 210 20.0 508.0 21.25 539.8
048 485 220 20.0 508.0 21.25 539.8
060 521 236 21.0 533.4 20.0 508.0
MAXIMUM SHIPPING WEIGHT A B
lb kg in. mm in. mm
SPACE IN BRACKET ASSEMBLY
(36"-54")
SCALE 0.250
TIGHTEN STRAPPING SECURELY
WITH TENSION BUCKLE
DETAIL A
Fig. 8 -- Suggested Rigging
C99075
Step 7 — Install Electrical Connections
!
UNIT COMPONENT DAMAGE HAZARD
Failure to followthis cautioncould resultin damage to theunit
being installed.
1. Make all electrical connections in accordance with NEC
ANSI/NFPA (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part 1 and applicable
local codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between
field--supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high--voltage power to unit is within
operating voltage range indicated on unit rating plate. On
3--phase units, ensure phases are balanced within 2
percent. Consult local power company for correction of
improper voltage and/or phase imbalance.
4. Insulate low--voltage wires for highest voltage contained
within conduit when low--voltage control wires are in
same conduit as high--voltage wires.
5. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit,
etc.
CAUTION
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
The unit cabinet must have an uninterrupted, unbroken
electrical ground. This ground may consist of an electrical
wire connected to the unit ground screw in the control
compartment,or conduit approved forelectrical ground when
installed in accordance with NEC, ANSI/NFPA American
National Standards Institute/National Fire Protection
Association (latest edition) (in Canada, Canadian Electrical
Code CSA C22.1) and local electrical codes.
HIGH--VOLTAGE CONNECTIONS
The unit must have a separate electrical service with a
field--supplied, waterproof disconnect switch mounted at, or
within sight from the unit. Refer to the unit rating plate, NEC and
local codes for maximum fuse/circuit breaker size and minimum
circuit amps (ampacity) for wire sizing.
The field--supplied disconnect may be mounted on the unit over
the high--voltage inlet hole (See Fig. 2 and 3).
If the unit has an electric heater, a second disconnect may be
required. Consult the Installation, Start--Up, and Service
Instructions provided with the accessory for electrical service
connections.
Operation of unit on improper line voltage constitutes abuse and
may cause unit damage that could affect warranty.
8
Table 1 –
Physical Data -- Unit 604D
UNIT SIZE 604D024 604D030 604D036 604D042 604D048 604D060
NOMINAL CAPACITY (ton) 2 2.5 3 3.5 4 5
OPERATING WEIGHT (lb)
OPERATING WEIGHT (kg)
COMPRESSOR QUANTITY 1
REFRIGERANT METERING DEVICE I n d oo r --- T X V O u t do o r --- A cc u R a te r
Refrigerant (R --- 410A) Quantity (lb)
Diameter Motor HP (RPM)
HIGH --- PRESSURE SWITCH (psig)
L O S S --- O F --- C H A R G E / L O W --- P R E S -
RETURN--- AIR FILTERS (in.)*{
*Required filter sizes shown are based on the larger of the ARI (Air conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of
300 ft/minute for throwaway type or 450 ft/minute for high ---capacity type. Air filter pressure drop for non --- standard filters must not exceed 0.08 in. wc.
{ If using accessory filter rack refer to the filter rack installation instructions for correct filter size and quantity.
TYPE SCROLL COMPRESSOR
REFRIGERANT R--- 410A
Quantity (kg)
METERING DEVICE ID TXV TXV TXV TXV TXV TXV
ORIFICE OD (in.)
ORIFICE OD (mm)
OUTDOOR COIL
Rows... Fins/in.
face area (sq. ft.)
OUTDOOR FAN
Nominal Airflow (CFM)
INDOOR COIL
Rows... Fins/in.
face area (sq. ft.)
INDOOR BLOWER
Nominal Airflow (CFM)
Size (in.)
Size (mm)
Motor (HP)
Cutout
Reset (Auto)
SURE SWITCH
(Liquid Line) (psig)
Cutout
Reset (Auto)
throwaway
350
159
7.5
3.4
0.035 (2)
.89
2...21
12.3
2350
22
1/8 (825)
3...15
3.7
800
10x10
254x254
1/2
20x24x1 20x24x1 24x30x1 24x36x1 24x36x1 24x36x1
350
159
8.2
3.7
0.035 (2)
.89
2...21
12.3
2350
22
1/8 (825)
3...15
3.7
1000
10x10
254x254
1/2
373
169
9.7
4.4
0.038 (2)
.97
2...21
13.6
2800
22
1/8 (825)
4...15
3.7
1100
11x10
279x254
3/4
440
200
11.0
5.0
0.038 (2)
.97
2...21
15.4
2800
22
1/8 (825)
3...15
4.7
1400
11x10
279x254
3/4
463
210
11.5
5.2
0.038 (Left OD C oil) (.97 mm)
0.046 (Right OD Coil)(1.2 mm)
2...21
17.2
3300
22
1/4 (1100)
4...15
4.7
1450
11x10
279x254
3/4
610±15
420±25
20±5
45±10
499
226
13.5
6.1
0.042 (Left OD C oil) (1.1 mm)
0.052 (Right OD Coil)(1.3 mm)
2...21
19.4
3300
22
1/4 (1100)
4...15
5.7
1750
11x10
279x254
1.0
Table 2 – Minimum Airflow for Reliable Electric Heater Operation (Cfm)
SIZE 604D024 604D030 604D036 604D042 604D048 604D060
AIRFLOW (CFM) 750 1025 1250 1285 1710 1800
ROUTING POWER LEADS INTO UNIT
Use only copper wire between disconnect and unit. The
highvoltage leads should be in a conduit until they enter the duct
panel; conduit termination at the duct panel must be watertight.
Run the high--voltage leads through the power entry knockout on
the power entry side panel. (See Fig. 2 and 3 for location and
size) When the leads are inside the unit, run leads up the
high--voltage raceway to the line wiring splice box (See Fig. 12
through 16). For singlephase units, connect leads to the black and
yellow wires; for 3--phase units, connect the leads to the black,
yellow, and blue wires.
CONNECTING GROUND LEAD TO GROUND
LUG
Refer to Fig. 14 and 15. Connect the ground lead to the chassis
using the ground lug in the wiring splice box.
ROUTING CONTROL POWER WIRES
(24--V)
Form a drip--loop with the thermostat leads before routing them
into the unit. Route the thermostat leads through grommeted,
low--voltage hole provided in unit into unit control power splice
box. (See Fig. 2 and 3) Connect thermostat leads to unit control
power leads as shown in Fig. 14.
The unit transformer supplies 24--v power for complete system
including accessory electrical heater. An manual reset circuit
breaker (See Fig. 16) is provided in the 24--v circuit (See Fig. 17).
Transformer is factory wired for 230--v operation. If supply
voltage is 208--v, rewire transformer primary as described in
Special Procedures for 208--v Operation section.
EASY SELECT
EASY SELECT CONFIGURATION TAPS FOR
Easy Select taps are used by the installer to configure a system.
The ECM motor uses the selected taps to modify its operation to
a pre--programmed table of airflows. The unit must be configured
to operate properly with system components with which it is
installed. To successfully configure a basic system (see
information printed on circuit board label located next to select
pins), move the 6 select wires to the pins which match the
components used.
a. AUX HEAT kW/CFM--SELECT HEATER RANGE
t -- 604D
604D
FOR SIZE OF ELECTRIC HEATER INSTALLED
Installer must select the auxiliary heat airflow
approved for application with kW size heater installed.
If no heater is installed, this step can be skipped. Each
select pin is marked with a range of heaters for which
airflow (also marked), is approved. For increased
comfort, select the narrowest kW range matching the
heater size, for example, 0--10 for 10--kW heater. This
airflow must be greater than the minimum for CFM
for electric heater application with the size system
installed for safe and continuous operation. (See Tables
3, 4, 5, 6 & 7 for airflow delivery and minimum
CFM.) Note that airflow marked is the airflow which
will be supplied in emergency heat mode and heating
mode on air conditioners when electric heat is the
primary heating source. In heat pump heating mode
when electric heaters are energized, the ECM will run
the higher of heat pump heating airflow and electric
heater airflow to ensure safe heater operation. The
factory selection is the largest heater range approved
(See Fig. 18, A as indicated).
604D
9
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