Bryant 604D-A User Manual

Page 1

604D----A LEGACYt 13 SEER SINGLE--PACKAGED HEAT PUMP SYSTEM WITH PURONR (R--410A) REFRIGERANT SINGLE AND T HREE PHASE NOMINAL 2-- 5 TONS (SIZES 24--60)

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--2.......................

INTRODUCTION 2...................................

RECEIVING AND INSTALLATION 2--10.................

Check Equipment 2..................................

Identify Unit 2....................................

Inspect Shipment 2.................................

Provide Unit Support 2...............................

Roof Curb 2......................................

Slab Mount 2.....................................

Provide Clearances 2.................................

Rig and Place Unit 3.................................

Inspection 3......................................

Rigging/Lifting of Unit 7............................

Select and Install Ductwork 7...........................

Converting Horizontal Discharge Units to Downflow

(Vertical) Discharge Units 8..........................

Provide for Condensate Disposal 9......................

Install Electrical Connections 9.........................

High--Voltage Connections 9.........................

Special Procedures for 208--V Operation 10..............

Control Voltage Connections 10.......................

Standard Connections 10............................

Transformer Protection 10...........................

Accessory Electric Heaters Installation 10...............

PRE--START--UP 18...................................

START--UP 18--22.....................................

Checking Cooling & Heating Control Operation 18........

Check for Refrigerant Leaks 18.........................

Start--Up Adjustments 18.............................

604D---- A Sequence of Operation 19...................

Checking & Adjusting Refrigerant Charge 19............

Indoor Airflow & Airflow Adjustments 19..............

Continuous Fan Operation 20........................

Defrost Control 22...................................

Quiet Shift 22.....................................

Defrost 22.......................................

MAINTENANCE 22--28................................

Air Filter 22........................................

Indoor Blower and Motor 22...........................

Outdoor Coil, Indoor Coil, & Condensate Drain Pan 23......

Outdoor Fan 23.....................................

Electrical Controls and Wiring 26.......................

Refrigerant Circuit 26.................................

Indoor Airflow 27...................................

Metering Devices-- TXV & Piston 27....................

Pressure Switches 27.................................

Loss of Charge Switch 27.............................

High Pressure Switch 27..............................

Copeland Scroll compressor (Puron Refrigerant) 27.........

Refrigerant System 27................................

A09034

Fig. 1 -- Unit 604D----A

Refrigerant 27....................................

Compressor Oil 27.................................

Servicing Systems on Roofs with Synthetic Materials 27....

Liquid Line Filter Drier 28...........................

PuronR (R--410A) Refrigerant Charging 28.............

System Information 28................................

Loss of Charge Switch 28............................

Check Defrost Thermostat 28.........................

TROUBLESHOOTING 28..............................

START--UP CHECKLIST 28............................

VERTICAL ECONOMIZER 32--50.......................

General 32.........................................

Accessories 32......................................

Installation 32......................................

Small Chassis 32--33...............................

Large Chassis 36--38...............................

CONFIGURATION 39--48..............................

OPERATION 49......................................

TROUBLESHOOTING 50..............................

SAFETY CONSIDERATIONS

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. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes, the current editions of the National Electrical Code (NEC) NFPA 70.

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In Canada refer to the current editions of the Canadian electrical Code CSA C22.1.

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 injury or death.

Before installing or servicing system, always turn off main

604D-- --A

power to system and install lockout tag. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable.

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK 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.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

When removing access panels (see Fig. 20) or performing maintenance functions inside your unit, be aware of sharp sheet metal parts and screws. Although special care is taken to reduce sharp edges to a minimum, be extremely careful when handling parts or reaching into the unit.

INTRODUCTION

The 604D ----A 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 before removing packaging materials. 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.

If the unit is to be mounted on a curb in a downflow application, review Step 5 to determine which method is to be used to remove the downflow panels before rigging and lifting into place. The panel removal process may require the unit to be on the ground.

IMPORTANT: The unit must be secured to the curb by installing screws through the bottom of the curb flange and into the unit base rails. When installing large base units onto the common curb, the screws must be installed before allowing the full weight of the unit to rest on the curb. A minimum of six screws are required for large base units. Failure to secure unit properly could result in an unstable unit. See Warning near Rigging/Lifting information and accessory curb instructions for more details.

Step 2 — Provide Unit Support

Roof Curb

Install accessory roof curb in accordance with instructions shipped with curb (See Fig. 4). 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.

Installation on older “G” series roof curbs.

Two accessory kits are available to aid in installing a new “G” series unit on an old “G” roof curb.

1. Accessory kit number CPADCURB001A00, (small chassis) and accessory kit number CPADCURB002A00, (large chassis) includes roof curb adapter and gaskets for the perimeter seal and duct openings. No additional modifications to the curb are required when using this kit.

2. An alternative to the adapter curb is to modify the existing curb by removing the outer horizontal flange and use accessory kit number CPGSKTKIT001A00 which includes spacer blocks (for easy alignment to existing curb) and gaskets for the perimeter seal and duct openings. This kit is used when existing curb is modified by removing outer horizontal flange.

UNIT/STRUCTURAL DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Ensure there issufficient clearance for saw blade when cutting the outer horizontal flange of the roof curb so there is no damage to the roof or flashing.

CAUTION

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. 8). 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.

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

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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.

Trainingforoperatorsof the liftingequipment 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

Prior to initial use, and at monthly intervals, all rigging shackles, clevis pins, and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attentionshould be paid to excessivewearat hoisthooking points and loadsupport areas. Materials showing any kind of wear in theseareas must not be used and should be discarded.

UNIT FALLING HAZARD

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

Never stand beneath rigged units or lift over people.

PROPERTY DAMAGE HAZARD

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

When strapsare taut, the clevis should be a minimum of 36 in. (914 mm) above the unit top cover.

WARNING

604D-- --A

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604D-- --A

Fig. 2 -- 604D-- --A24-- 36 Unit Dimensions

A09471

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604D-- --A

Fig. 3 -- 604D-- --A42-- 60 Unit Dimensions

A09472

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HVAC unit base rails

Anchor screw

Flashing field supplied

Roofing material field supplied

Cant strip field supplied

HVAC unit basepan

Sealing Gasket

Roofcurb

Wood nailer*

Roofcurb*

Insulation (field supplied)

Dashed lines show cross support location for large basepan units.

*Provided with roofcurb

604D-- --A

ROOF CURB DETAIL

A09090

SMALL/COMMON CURB

A09413

SUPPLY

AIR

RETURN

AIR

SMALL BASE UNIT

LARGE BASE UNIT

UNIT PLACEMENT ON

LARGE CURB

A09415

COMMON CURB

SMALL OR LARGE BASE UNIT

A09094

UNIT SIZE

Small

Large

* Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small and large basepan units. The cross supports must be located based on whether the unit is a small basepan or a large basepan. NOTES:

1. Roof curb must be set up for unit being installed.

2. Seal strip must be applied, as required, to unit being installed.

3. Roof curb is made of 16--gauge steel.

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

5. Insulated panels: 1--in. (25.4 mm) thick fiberglass 1 lb. density.

CATALOG

NUMBER

IN. (mm)

CPRFCURB010A00 11 (279)

CPRFCURB011A00 14 (356)

CPRFCURB012A00 11 (279) CPRFCURB013A00 14 (356)

(small/common

base)

IN. (mm)*

10 (254)

14 (356)

(large base)

IN. (mm)*

IN. (mm)DIN. (mm)EIN. (mm)FIN. (mm)GIN. (mm)HIN. (mm)

14 (356) 16 (406)

47.8

(1214)

32.4

(822)

43.9

(1116)

2.7 (69)

30.6 (778)

42.2 (1072)

46.1

(1170)

Fig. 4 -- Roof Curb Dimensions

A09414

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CAUTION - NOTICE TO RIGGERS

PRUDENCE - AVIS AUX MANIPULATEUR

PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.

Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition

ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.

DUCTS

MINIMUM HEIGHT: 36" (914.4 mm) HAUTEUR MINIMUM

UNIT HEIGHT HAUTEUR D'UNITÉ

SEE DETAIL A VOIR DÉTAIL A

CORNER WEIGHTS (SMALL CABINET) CORNER WEIGHTS (LARGE CABINET)

Unit

Rigging

Weight

*For 460 Volt units add 14 lb (6.35 kg) to the rigging weight. NOTE: See dimensional drawing for corner weights.

24 30 36

lb kg lb kg lb kg lb kg lb kg lb kg

327 148 340 154 343 156

Fig. 5 -- Rigging Weights

Rigging/Lifting of Unit (See Fig. 5.)

UNIT FALLING HAZARD

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

Large base units must be secured to common curb before allowing full weight of unit to rest on curb. Install screws through curb into unit base rails while rigging crane is still supporting unit.

Lifting holes are provided in base rails as shown in Fig. 2 and 3.

1. Leave top shipping skid on the unit for use as a spreader bar to prevent the rigging straps from damaging the unit. If the skid is not available, use a spreader bar of sufficient length to protect the unit from damage.

2. Attach shackles, clevis pins, and straps to the base rails of the unit. Be sure materialsare rated to hold the weight of the unit. (See Fig. 5).

3. Attacha clevisof sufficientstrengthin the middle of thestraps. Adjust the clevis location to ensure unit is lifted level with the ground.

After the unit is placed on the roof curb or mounting pad, remove the top skid.

WARNING

BANDE SCELLANT DOIT ÊTRE EN PLACE AVANT DE PLACER L'UNITÉ SUR LA BASE DE TOIT

50CY502286 2.0

MAXIMUM ALLOWABLE

DIFFERENCE in. (mm)

B-C

(6.35)

1/4

A-C

(6.35)

DETAIL A

VOIR DÉTAIL A

Unit

Rigging

Weight

SEAL STRIP MUST BE IN PLACE BEFORE PLACING UNIT ON ROOF CURB

42 48 60

419 190 429 195 454 206

A-B

(6.35)

1/4

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.

604D-- --A

A09051

A07925

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WARNING

PERSONAL INJURY AND ELECTRICAL OPERATION 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.

When designing and installing ductwork, consider the following:

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.

604D-- --A

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. (610 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.

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 to Downflow (Vertical) Discharge

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 and install lockout tag. There may be more than one disconnect switch.

Units

WARNING

Basepan Downflow (Vertical) Supply Knockout

Horizontal Duct Covers

A09061

Basepan Downflow (Vertical) Return Knockout

A09088

Fig. 7 -- Supply and Return Duct Openings

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Collect ALL screws that were removed. DO NOT leave screws on rooftop as permanent damage to the roof may occur.

To remove downflow return and supply knockout covers, break front and right side connections tabs with a screwdriver and hammer. Push cover down to break rear and left side tabs.

NOTE: These panels are held in place with tabs similar to an electrical knockout. Reinstall horizontal duct covers (Fig. 7) shipped on unit from factory. Insure openings are air and watertight.

NOTE: 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.

OPTIONAL

RETURN

AIR

OPENING

OPTIONAL

SUPPLY

AIR

OPENING

1. Open all electrical disconnects and install lockout tag before starting any service work.

2. Remove horizontal (metal) ductcovers to access vertical (downflow) discharge duct knockouts in unit basepan. (See Fig. 7.)

3. After completing unit conversion, perform all safety checks and power up unit.

2˝

(50.8mm)

EVAP. COIL COND. COIL

A07926

Fig. 8 -- Slab Mounting Detail

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Step 6 — Provide for Condensate Disposal

NOTE: Ensure that condensate--water disposal methods comply

with local codes, restrictions, and practices.

The 604D ----A 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 2--in. (51 mm) 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. (51mm) 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. 10) 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.

Step 7 — Install Electrical Connections

UNIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit being installed.

1. Make all electrical connections in accordance with NEC NFPA 70 (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. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.

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 for electricalground when installed in accordance with NEC,NFPA 70 National Fire Protection Association (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes.

CAUTION

WARNING

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 when the standard power and low-- voltage entry points are used. See Fig. 2 and 3 for acceptable location. Remove high voltage knockout.

See unit wiring label (Fig. 11 --13) and Fig. 9 for reference when making high voltage connections. Proceed as follows to complete the high--voltage connections to the unit.

Single phase units:

1. Run the high-- voltage (L1, L2) and ground lead into the control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line side of the contactor.

HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL

)

3-PHASE SHOWN 1-PHASE USES TWO POWER LEADS

CONTROL BOX

LOW-VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL

)

EQUIP GR

SPLICE BOX

FIELD-SUPPLIED FUSED DISCONNECT

WHT(W1)

VIO (W2)

YEL(Y)

GRN(G)

RED(R)

BRN(C)

ORN(O)

BLU(DH)

GRA(Y2)

Fig. 9 -- High-- and Control-- Voltage Connections

4. Connect field L1 to black wire on connection 11 of the compressor contactor.

5.ConnectfieldwireL2toyellowwireonconnection23of the compressor contactor.

Three--phase units:

1. Run the high-- voltage (L1, L2, L3) and ground lead into the control box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line side of the contactor.

4. Connect field L1 to black wire on connection 11 of the compressor contactor.

5.ConnectfieldwireL3toyellowwireonconnection13of the compressor contactor.

6. Connect field wire L2 to blue wire from compressor.

3-Phase Only

POWER SUPPLY

THERMOSTAT (TYPICAL)

A09071

604D-- --A

Page 10

Special Procedures for 208--V Operation

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 and install lockout tag. With disconnect switch open, move black wire from transformer (3/16 in.) terminal marked 230 to terminal marked 200. This retaps transformer to primary voltage of 208 vac.

WARNING

Control Voltage Connections

NOTE: Do not use any type of power--stealing thermostat. Unit

control problems may result.

Use no. 18 American Wire Gage (AWG) color--coded, insulated (35°C minimum) wires to make the control voltage connections between the thermostat and the unit. If the thermostat is located more than 100 ft (30.5 m) from the unit (as measured along the

604D-- --A

control voltage wires), use no. 16 AWG color--coded, insulated (35° C minimum) wires.

Standard Connections

Locate the eight (nine on 3--phase) low voltage thermostat leads in 24 volt splice box. See Fig. 9 for connection diagram. Run the low--voltage leads from the thermostat, through the control wiring inlet hole grommet (Fig. 2 and 3), and into the low--voltage splice box. Provide a drip loop before running wires through panel. Secure and strain relief all wires so that they do not interfere with operation of unit. A gray wire is standard on 3--phase units for connection to an economizer.

If an accessory electric heater is installed, low voltage leads from heater must be connected to factory supplied control leads from Indoor Fan Board P4 connector. Factory wires are provided for electric heat staging W1 and W2 (W2 and W3 on IFB). If room thermostat has only one stage of supplemental heat, connect white and violet wires shown in Fig. 9 to second stage heat field wire.

Some electric heaters have four control wires (plus common wire). Consult unit wiring diagram and electric heater wiring diagram for additional details.

Transformer Protection

The transformer is of the energy--limiting type. It is set to withstand a 30-- second overload or shorted secondary condition. If an overload or short is present, correct overload condition and check for blower fuse on Interface Fan Board. Replace fuse as required with correct size and rating.

Accessory Electric Heaters Installation

Electric heaters may be installed with the 604D---- A units per instructions supplied with electric heater package. See unit rating plate for factory--approved electric heater kits.

TRAP OUTLET

1-in. (25 mm) min.

2-in. (51 mm) min.

A09052

Fig. 10 -- Condensate Trap

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Table 1 – Physical Data -- Unit 604D----A

UNIT SIZE 604D--- ---A24 604D--- -- -A30 604D- -- ---A36 604D--- ---A42 604D --- ---A48 604D- -- ---A60

NOMINAL CAPACITY (ton) 2 2.5 3 3.5 4 5

SHIPPING WEIG HT} (lb)

COMPRESSOR QUANTITY 1

Refrigerant (R --- 410A) Quantity (lb)

Diameter Motor HP (RPM)

Nominal Cooling Airflow (CFM)

HIGH --- PRESSURE SWITCH (psig)

L O S S --- O F --- C H A R G E / L O W --- P R E S S U R E

RETURN---AIR FILTERS*{

*Required filter sizes shown are based on the larger of the AHRI (Air Conditioning, Heating 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. W.C .

{ If using accessory filter rack refer to the filter rack installation instructions for correct filter size and quantity. } For 460 volt units, add 14 lb (6.4 kg) to the weight.

TYPE SCROLL COMPRESSOR

REFRIGERANT R--- 410A

Quantity (kg)

METERING DEVICE ID TXV

ORIFICE OD (in.)

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

Size (in.)

Motor (HP)

Cutout

Reset (Auto)

SWITCH

(Liquid Line) (psig)

Cutout

Reset (Auto)

throwaway (in.)

(kg)

(mm)

327 148

8.3

3.8

0.032 (2) .81

2...21

11.9

2000

1/5 (810)

3...17

3.7

800

10x10

254x254

1/2

20x20x1

508x508x25

340 154

10.2

4.6

0.035 (2) .89

2...21

11.9

2700

1/5 (810)

3...17

3.7

1000

10x10

254x254

1/2

20x24x1

508x610x25

343 156

7.9

3.6

0.037 (2) .94

2...21

11.9

2700

1/5 (810)

3...17

3.7

1200

11x10

279x254

3/4

419 190

10.0

4.5

0.038 (Left OD Coil)

0.040 (Right OD Coil) .97/1.02

2...21

13.6

3100

1/5 (810)

3...17

4.7

1400

11x10

279x254

3/4

650±15 420±25

20±5

45±10

20±5

45±10

24x30x1

610x762x25

429 195

9.6

4.4

0.046 (2)

1.2

2...21

13.6 3100

1/5 (810)

3...17

4.7

1600

11x10

279x254

1.0

24x36x1

610x914x25

454 206

12.3

5.6

0.052 (2)

1.3

2...21

17.5

3500

1/5 (810)

3...17

5.7

1800

11x10

279x254

1.0

604D-- --A

Table 2 – Minimum Airflow for Reliable Electric Heater Operation (CFM)

SIZE 604D---- A24 604D -- -- A30 604D -- -- A36 604D -- --A42 604D -- --A48 604D-- -- A60

AIRFLOW (CFM) 800 1025 1250 1400 1710 1800

Page 12

604D-- --A

Fig. 11 -- Connection Wiring Schematics 208/230--1--60

A10197

Page 13

604D-- --A

Fig. 11 Cont. -- Ladder Wiring Schematics 208/230--1--60

A10197

Page 14

604D-- --A

Fig. 12 -- Connection Wiring Schematics -- 208/230--3-- 60

A10194

Page 15

604D-- --A

Fig. 12 Cont. -- Ladder Wiring Schematics -- 208/230--3--60

A10194

Page 16

604D-- --A

Fig. 13 -- Connection Wiring Diagram 460--3--60

A10195

Page 17

604D-- --A

Fig. 13 Cont. -- Ladder Wiring Diagram 460--3--60

A10195

Page 18

PRE-- START--UP

FIRE,EXPLOSION, ELECTRICAL SHOCKHAZARD

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

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

2. Relieve and recover all refrigerant from system before touching or disturbing compressor plug if refrigerant leak is suspected around compressor terminals.

3. Do not remove compressor plug until all electrical sources are disconnected and tagged.

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

5. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and

604D-- --A

proceed as follows:

a. Shut off electrical power to unit and install lockout

tag.

b. Relieve and reclaim all refrigerant from system

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

c. Cut component connecting tubing with tubing

cutter and remove component from unit.

d. Carefully unsweat remaining tubing stubs when

necessary. Oil can ignite when exposed to torch flame.

Use the Start--Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start--up:

1. Remove all access panels (see Fig. 20).

2. Read and follow instructions on all DANGER, WARNING, CAUTION, and INFORMATION labels attached to, or shipped with, unit.

3. Make the following inspections:

a. Inspect for shipping and handling damages such as

broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and

on unit base. Detecting oil generally indicates a refrigerant leak. Leak-- test all refrigerant tubing connections using electronic leak detector, or liquid-- soap solution. If a refrigerant leak is detected, see following Check for Refrigerant Leaks section.

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

that connections are completed and tight. Ensure wires do not touch refrigerant tubing or sharp sheet metal edges.

d. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

4. Verify the following conditions:

a. Make sure that outdoor-- fan blade is correctly positioned

in fan orifice.

b. Make sure that air filter(s) is in place.

c. Make sure that condensate drain pan and trap are filled

with water to ensure proper drainage.

d. Make sure that all tools and miscellaneous loose parts

have been removed.

5. Each unit system has 2 Schrader--type ports, one low--side Schrader fitting located on the suction line, and one high--side Schrader fitting located on the compressor discharge line. Be sure that caps on the ports are tight.

WARNING

START--UP

Checking Cooling and Heating Control Operation

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

(1.) Place room thermostat SYSTEM switch or MODE

control in OFF position. Observe that blower motor starts when FAN mode is placed in FAN ON position and shuts down when FAN MODE switch is placed in AUTO position.

(2.) Thermostat:

When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat, the thermostat completes the circuit between thermostat terminal R to terminals Y, O and G.These completed circuits through the thermostat connect contactor coil (C) (through unit wire Y) and Indoor Fan board (through unit wire G) across the 24--v. secondary of transformer (TRAN).

(3.) Place system switch or MODE control in HEAT

position. Set control above room temperature. Observe that compressor, outdoor fan, and indoor blower motors start. Observe that heating cycle shuts down when control setting is satisfied.

(4.) When using an automatic changeover room

thermostat place both SYSTEM or MODE control and FAN mode switches in AUTO positions. Observe that unit operates in Cooling mode when temperature control is set to “call for Cooling” (below room temperature), and unit operates in Heating mode when temperature control is set to

“call for Heating” (above room temperature). NOTE: Once the compressor has started and then has stopped, it should not be started again until 5 minutes have elapsed. The defrost board has a built--in 5 minute delay between cycles. The 5 minute compressor delay also applies to heat pump heating mode.

Step 1 — Check for Refrigerant Leaks

Proceed as follows to locate and repair a refrigerant leak and to charge the unit:

1. Locate leak and make sure that refrigerant system pressure has been relieved and reclaimed from both high-- and low-- pressure ports.

2. Repair leak following Refrigerant Service procedures.

NOTE: Install a bi--flow filter drier whenever the system has been opened for repair.

3. Add a small charge of R--410A refrigerant vapor to system and leak--test unit.

4. Recover refrigerant from refrigerant system and evacuate to 500 microns if no additional leaks are not found.

5. Charge unit with Puron (R--410A) refrigerant, using an electronic scale. Refer to unit rating plate for required charge.

Step 2 — Start--Up Adjustments

Complete the required procedures given in the Pre--Start-- Up section before starting the unit. Do not jumper any safety devices when operating the unit. Do not operate the unit in Cooling mode when the outdoor temperature is below 40_F(4_C) (unless accessory low--ambient kit is installed).

IMPORTANT: Three--phase, scroll compressors are direction oriented. Unit must be checked to ensure proper compressor 3--phase power lead orientation. If not corrected within 5 minutes, the internal protector will shut off the compressor. The 3--phase power leads to the unit must be reversed to correct rotation. When turning backwards, the difference between compressor suction and discharge pressures may be near zero.

Page 19

604D-- --A Sequence of Operation

a. CONTINUOUS FAN

(1.) Thermostat closes circuit R to G energizing the

blower motor for continuous fan.

b. COOLING MODE

(1.) If indoor temperature is above temperature set

point, thermostat closes circuits R to G, R to Y and R to O--The unit delivers cooling airflow.

c. ELECTRIC HEATING MODE

(1.) Thermostat closes circuit R to W/W1, or W2 and R to G. There are no on or off delays.

d. HEAT PUMP HEATING MODE

(1.) Thermostat closes circuits R to G and R to Y. The

compressor, indoor and outdoor fans are energized.

e. HEAT PUMP HEATING WITH AUXILIARY

ELECTRIC HEAT

(1.) Thermostat closes circuits R to G, R to Y and R to

W/W1 or W2. The compressor, indoor and outdoor fans are energized, as well as the electric heat relays.

f. DEFROST MODE

The defrost mode is automatically energized by the defrost board during heating mode. The defrost board energizes “O” (reversing valve) and “W2” (electric heat). It also de--energizes the outdoor fan. When defrost is complete, unit will return to heating mode. If room thermostat is satisfied during defrost, unit will shut down and restart in defrost on next call for heat.

Checking and Adjusting Refrigerant Charge

The refrigerant system is fully charged with Puron (R--410A) refrigerant and is tested and factory sealed.

NOTE: Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper Puron (R--410A) charge.

A subcooling charging chart is attached to the inside of the compressor access panel (see Fig. 20). The chart includes the required liquid line temperature at given discharge line pressures and outdoor ambient temperatures.

An accurate thermocouple-- or thermistor--type thermometer, and a gauge manifold are required when using the subcooling charging method for evaluating the unit charge. Do not use mercury or small dial--type thermometers because they are not adequate for this type of measurement.

NOTE: Allow system to operate for a minimum of 15 minutes before checking or adjusting refrigerant charge.

IMPORTANT: When evaluating the refrigerant charge, an indicated adjustment to the specified factory charge must always be very minimal. If a substantial adjustment is indicated, an abnormal condition exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils.

Proceed as follows:

1. Remove caps from low-- and high--pressure service fittings.

2. Using hoses with valve core depressors, attach low-- and high--pressure gauge hoses to low-- and high--pressure service fittings, respectively.

3. Start unit and let run until system pressures stabilize.

4. Measure and record the following:

a. Outdoor ambient--air temperature (°F[°C] db).

b. Liquid line temperature (°F[°C]) at TXV.

c. Discharge (high--side) pressure (psig).

d. Suction (low--side) pressure (psig) (for reference only).

5. Using Cooling Charging Charts compare outdoor--air temperature (°F[°C] db) with the discharge line pressure

(psig) to determine desired system operating liquid line temperature (See Fig. 17).

6. Compare actual liquid line temperature with desired liquid

line temperature. Using a tolerance of ±2°F(±1.1°C), add refrigerant if actual temperature is more than 2°F(1.1°C) higher than proper liquid line temperature, or remove refrigerant if actual temperature is more than 2°F(1.1°C) lower than required liquid line temperature.

NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to Check for Refrigerant Leaks section.

Indoor Airflow and Airflow Adjustments

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage.

For cooling operation, the recommended airflow is 350 to 450 cfm for each 12,000 Btuh of rated cooling capacity. For heating operation, the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate.

NOTE: Be sure that all supply--and return--air grilles are open, free from obstructions, and adjusted properly.

WARNING

ELECTRICAL SHOCK HAZARD

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

Disconnect electrical power to the unit and install lockout tag before changing blower speed.

This unit has independent fan speeds for gas heating and cooling. In addition, this unit has the field-selectable capability to run two different cooling fan speeds: A normal cooling fan speed (350~400 CFM/Ton) and an enhanced dehumidification fan speed (As low as 320 CFM/Ton) for use with either a dehumidistat or a thermostat that supports dehumidification.

The cooling speed is marked “LOW” on the interface fan board (IFB) (See. Fig. 15) . The factory-shipped settings are noted in Table 4. There are 4 additional speed tap wires available for use in either electric heating or cooling (For color coding on the indoor fan motor leads, see Table 3). The additional 4 speed tap wires are shipped loose with vinyl caps and are located in the control box, near the interface fan board (IFB) (See Fig. 15).

Single Cooling Fan Speed Set-up (Dehumidification feature not

To change cooling speed:

1. Remove the vinyl cap off of the desired speed tap wire

2. Remove the current speed tap wire from the “LOW”

3. Connect the desired speed tap wire to the “LOW” terminal

used)

(Refer to Table 3 for color coding). Add the wet coil pressure drop in Table 5 to the system static to determine the correct cooling airflow speed in Table 4 that will deliver the nominal cooling airflow as listed in T able 1 for each size.

terminal on the interface fan board (IFB) (See Fig. 15) and place vinyl cap over the connector on the wire.

on the interface fan board (IFB). NOTE: If accessory electric heat is installed, and the

electric heat fan speed is chosen to be the same as the normal cooling fan speed, the dry airflow must meet or exceed the minimum airflow speed specified in Table 2 for the specific size unit.

604D-- --A

Page 20

Two Cooling Fan Speeds Set-up (Dehumidification feature

IMPORTANT: Dehumidification control must open control

circuit on humidity rise above set point.

Use of the dehumidification cooling fan speed requires use of either a 24 VAC dehumidistat or a thermostat which includes control of a 24 VAC dehumidistat connection. In either case, the dehumidification control must open the control circuit on humidity rise above the dehumidification set point. Dehumidification controls are available with the reverse logic; these must not be used.

604D-- --A

used)

1. Using Fig. 15, move the two pin DEHUM jumper from the “STD” position to the “DEHUM” position.

2. Remove fan speed tap wire from the “LOW” terminal on the interface fan board (IFB) (See Fig. 15).

3. Determine correct normal cooling fan speed for unit and application. Add the wet coil pressure drop in Table 5 to the system static to determine the correct cooling airflow speed in Table 4 that will deliver the nominal cooling airflow as listed in Table 1 for each size.

NOTE: If accessory electric heat is installed, the dry airflow must meet or exceed the minimum airflow speed specified in Table 2 for the specific size unit. The electric heat fan speed will be the same as the normal cooling fan speed.

4. Remove the vinyl cap off of the desired speed tap wire (Refer to Table 3 for color coding) for the normal cooling fan speed and place desired speed tap wire on “HIGH” on the interface board.

5. Refer to airflow tables (Table 4) to determine allowable speeds for the dehumidification cooling fan speed. In Table 4, speeds that are not allowed for dehumidification cooling are shaded.

6. Remove the vinyl cap off of the desired speed tap wire (Refer to Table 3 for color coding) for the dehumidification cooling fan speed and place desired speed tap wire on the “LOW” connection on the interface board (IFB). Verify that static pressure is in the acceptable range for the speed tap to be used for dehumidification cooling.

7. Use any spare vinyl plugs to cap any unused speed tap wires.

Table 3 – Color Coding for Indoor Fan Motor Leads

Black = High Speed

Orange = Med--High Speed

Red = Med Speed

Pink = Med --Low Speed

Blue = Low Speed

Single Speed Cooling With Higher Electric Heat Speed

This unit can also be configured to operate with single speed cooling and a higher speed for an accessory electric heater.

1. Using Fig. 15, move the two pin DEHUM jumper from the “STD” position to the “DEHUM” position.

2. See Table 2 for minimum airflow for electric heat operation. Add electric heater and filter pressure drop to duct system static pressure to determine total external static pressure.

3. Select speed tap from Table 4 that will achieve required airflow from Table 2.

4. Remove the vinyl cap off of the desired speed tap wire (Refer to Table 3 for color coding).

5. Connect the desired speed tap wire to the “HIGH” terminal on the interface fan board (IFB).

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit component damage or improper operation.

To use this mode, a speed connection must be made on the “HIGH” terminal that meets or exceeds the minimum airflow found in Table 2.

ELECTRICAL SHOCK HAZARD

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

Disconnect electrical power to the unit and install lockout tag before changing blower speed.

CAUTION

WARNING

Continuous Fan Operation

When the DEHUM feature is not used, the continuous fan speed will be the same as cooling fan speed. When the DEHUM feature is used, the continuous fan will operate on IFB “LOW” speed when the DH control lead is not energized, or IFB “HIGH” speed when the DH lead is energized (see Fig. 15).

Page 21

ACCUMULATOR

COMPRESSOR

LEGEND

HPS – High Pressure Switch LCS – Loss of Charge Switch

Accurater Arrow indicates direction of flo w

OUTDOOR COIL

TXV in Metering

Position

LCS

HP S

Bypass Position

Metering De vice

Fig. 14 -- Typical Heat Pump Operation, Cooling Mode

HIGH LOW COM

QC5

STD

DEHUM

QC4

QC3

DCR QCR

INDOOR COIL

C03011

604D-- --A

QCB

R13 C8 R11 Q1

ALO

A7 R9 AB A15

JW5

R3 R5 R6

P2 JW3

R W2 Y C W3W3W2 W2C

Y2 Y1

W2W3

GCR

JWZ

YDH

07 09 080L0

QIL Z2 06 04

D5 D3

SDL

SSTZ-8

Fig. 15 -- Interface Fan Board (IFB)

OUTDOOR COIL

JW4

QC1

AL2

R4 RL4

24VAC/R3AMP CDM/C

TXV in Bypass

Position

A09059

INDOOR COIL

HP S

ACCUMULATOR

COMPRESSOR

LEGEND

HPS – High Pressure Switch LCS – Loss of Charge Switch

Accurater

Metering De vice

Arrow indicates direction of flo w

LCS

Metering Position

Fig. 16 -- T ypical Heat Pump Operation, Heating Mode

C03012

Page 22

Step 3 — Defrost Control

Quiet Shift

Quiet Shift is a field--selectable defrost mode, which will eliminate occasional noise that could be heard at the start of defrost cycle and restarting of heating cycle. It is selected by placing DIP switch 3 (on defrost board) in ON position.

When Quiet Shift switch is placed in ON position, and a defrost is initiated, the following sequence of operation will occur. Reversing valve will energize, outdoor fan will turn off, compressor will turn off for 30 sec and then turn back on to complete defrost. At the start of heating after conclusion of defrost reversing valve will de--energize, compressor will turn off for another 30 sec, and the outdoor fan will stay off for 40 sec, before starting in the Heating mode.

Defrost

The defrost control is a time/temperature control which includes a field--selectable time period (DIP switch 1 and 2 on the board) between defrost cycles of 30, 60, 90, or 120 minutes (factory set at 60 minutes). To initiate a forced defrost, two options are available depending on the status of the defrost thermostat.

604D-- --A

If defrost thermostat is closed, speed-- up pins (J1) must be shorted by placing a flat head screw driver in between for 5 sec and releasing, to observe a complete defrost cycle. When the Quiet Shift switch is selected, compressor will be turned off for two 30 sec intervals during this complete defrost cycle, as explained previously. When Quiet Shift switch is in factory default OFF position, a normal and complete defrost cycle will be observed.

If defrost thermostat is in open position, and speedup pins are shorted (with a flat head screw driver) for 5 sec and released, a short defrost cycle will be observed (actual length is dependent upon the selected Quiet Shift position). When Quiet Shift switch is in ON position, the length of defrost is 1 minute (30 sec compressor off period followed by 30 sec of defrost with compressor operation). On return to heating operation, compressor will again turn off for an additional 30 sec and the outdoor fan for 40 sec. When the Quiet Shift is in OFF position, only a brief 30 sec. cycle will be observed.

NOTE: Unit will remain in defrost until defrost thermostat reopens at approximately 65_F(18_C) coil temperature at liquid line or remainder of defrost cycle time.

MAINTENANCE

To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This heat pump unit should be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Table 9.

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

PERSONAL INJURY AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury or death and unit component damage.

The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attemptto perform any maintenanceon this equipment,other than those procedures recommended in the Owner’s Manual.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow these warnings could result in personal injury or death:

1. Turn off electrical power to the unit and install a lockout tag before performing any maintenance or service on this unit.

2. Use extreme caution when removing panels and parts.

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

CUT HAZARD

Failure to follow this caution may result in personal injury.

UNIT OPERATION HAZARD

Failure to follow this caution may result in improper operation.

Errors made when reconnecting wires may cause improper and dangerous operation. Label all wires prior to disconnecting when servicing.

The minimum maintenance requirements for this equipment are as follows:

1. Inspect air filter(s) each month. Clean or replace when necessary.

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

3. Inspect blower motor and wheel for cleanliness each cooling season. Clean when necessary.

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

WARNING

CAUTION

Step 1 — Air Filter

IMPORTANT: Never operate the unit without a suitable air filter

in the return--air duct system. Always replace the filter with the same dimensional size and type as originally installed. See Table 1 for recommended filter sizes.

Inspect air filter(s) at least once each month and replace (throwaway--type) or clean (cleanable--type) at least twice during each cooling season and twice during the heating season, or whenever the filter becomes clogged with dust and lint.

Indoor Blower and Motor

NOTE: All motors are pre--lubricated. Do not attempt to lubricate

these motors. NOTE: 460 volt units have a stepdown autotransformer that supplies approximately 230 volts to a nominal 230 volt indoor blower motor. For longer life, operating economy, and continuing efficiency, clean accumulated dirt and grease from the blower wheel and motor annually.

Page 23

ELECTRICAL SHOCK HAZARD

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

Disconnect and install lockout tag on electrical power to the unit before cleaning and lubricating the blower motor and wheel.

To clean the blower motor and wheel:

1. Remove and disassemble blower assembly as follows: a. Remove blower access panel (see Fig. 20).

b. Disconnect 5 pin plug and 4 pin plug from indoor

blower motor. Remove capacitor if required.

c. On all units remove blower assembly from unit.

Remove screws securing blower to blower partition and slide assembly out. Be careful not to tear insulation in blower compartment.

d. Ensure proper reassembly by marking blower wheel and

motor in relation to blower housing before disassembly.

e. Loosen setscrew(s) that secures wheel to motor shaft,

remove screws that secure motor mount brackets to housing, and slide motor and motor mount out of housing.

2. Remove and clean blower wheel as follows: a. Ensure proper reassembly by marking wheel orientation.

b. Lift wheel from housing. When handling and/or

cleaning blower wheel, be sure not to disturb balance weights (clips) on blower wheel vanes.

c. Remove caked--on dirt from wheel and housing with a

brush. Remove lint and/or dirt accumulations from wheel and housing with vacuum cleaner, using soft brush attachment. Remove grease and oil with mild solvent.

d. Reassemble wheel into housing.

e. Reassemble motor into housing. Be sure setscrews are

tightened on motor shaft flats and not on round part of shaft. Reinstall blower into unit. Reinstall capacitor if required.

f. Connect 5 pin plug and 4 pin plug to indoor blower

motor.

g. Reinstall blower access panel (see Fig. 20).

3. Restore electrical power to unit. Start unit and check for

proper blower rotation and motor speeds during cooling cycles.

WARNING

Step 2 — Outdoor Coil, Indoor Coil, and Condensate Drain Pan

Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year.

The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season. Remove all obstructions, including weeds and shrubs, that interfere with the airflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint, clean the coils with a vacuum cleaner, using the soft brush attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a mild detergent--and--water solution. Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors, insulation, wiring, or air filter(s). For best results, spray condenser coil fins from inside to outside the unit. On units with an outer and inner condenser coil, be sure to clean between the coils. Be sure to flush all dirt and debris from the unit base.

Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain trough with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain trough is restricted, clear it with a plumbers snake or similar probe device.

Step 3 — Outdoor Fan

Keep the condenser fan free from all obstructions to ensure proper cooling operation. Never place articles on top of the unit. Damage to unit may result.

1. Remove 6 screws holding outdoor grille and motor to top cover.

2. Turn motor/grille assembly upside down on top cover to expose fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen setscrew and slide fan off motor shaft.

5. When replacing fan blade, position blade back to same position as before.

6. Ensure that setscrew engages the flat area on the motor shaft when tightening.

7. Replace grille.

604D-- --A

Page 24

Table 4 – Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -- Unit 604D----A24--60 Series A

UNIT

604D------ A24

604D------ A30

604D------ A36

604D------ A42

604D------ A48

604D-- --A

604D------ A60

* Air delivery values are without air filter and are for dry coil (See 604D ------ A Wet Coil Pressure Drop Table).

Factory---shipped cooling speed NOTE: Deduct field---supplied air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting. Shaded areas indicate speed/static combinations that are not permitted for dehumidification speed.

MOTOR

SPEED

Low Blue CFM 754 650 538 429 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

M e d --- L ow Pink CFM 851 777 675 591 475 --- --- --- --- --- --- --- --- --- --- --- ---

Medium

M e d --- H ig h Orange CFM 1009 917 840 759 667 577 447 --- --- --- --- --- ---

High Black CFM 1241 1167 1111 1036 969 881 818 731 640

Low Blue CFM 741 638 547 415 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

M e d --- L ow Pink CFM 973 887 823 733 665 538 451 --- --- --- --- --- ---

Medium Red CFM 1088 1023 954 881 800 723 658 563 461

M e d --- H ig h

M e d --- L ow Pink CFM 1290 1223 1154 1090 1027 977 894 828 762

M e d --- H ig h Orange CFM 1606 1546 1489 1430 1371 1316 1258 1208 1140

M e d --- L ow Pink CFM 1345 1282 1235 1194 1140 1095 1027 974 921

M e d --- H ig h

M e d --- L ow Pink CFM 1457 1404 1367 1318 1284 1233 1197 1144 1104

M e d --- H ig h Orange CFM 2149 2111 2062 2026 1980 1945 1905 1864 1793

M e d --- L ow Pink CFM 1678 1635 1602 1558 1513 1474 1438 1404 1349

M e d --- H ig h Orange CFM 2131 2088 2065 2013 1982 1941 1888 1860 1785

High Black CFM 1202 1140 1082 1015 961 881 810 732 631

Low Blue CFM 1234 1168 1093 1021 961 894 825 759 687

Medium

High Black CFM 1630 1580 1517 1463 1407 1339 1277 1210 1131

Low Blue CFM 1295 1234 1182 1126 1075 1016 955 898 857

Medium Red CFM 1505 1452 1413 1358 1323 1282 1234 1169 1130

High Black CFM 1705 1643 1607 1568 1518 1483 1448 1404 1360

Low Blue CFM 1402 1351 1311 1263 1224 1172 1136 1080 1041

Medium

High Black CFM 2344 2306 2259 2203 2141 2070 1991 1902 1803

Low Blue CFM 1445 1389 1341 1281 1236 1189 1139 1072 1027

Medium

High Black CFM 2461 2409 2339 2286 2192 2140 2062 1968 1874

WIRE

COLOR

Red CFM 941 851 774 684 576 479 --- --- --- --- --- --- --- --- ---

Orange CFM 1140 1064 996 915 840 758 687 564 480

Red CFM 1354 1290 1226 1158 1102 1046 981 918 843

Orange CFM 1545 1492 1449 1411 1362 1313 1278 1231 1188

Red CFM 1736 1695 1642 1601 1553 1512 1465 1427 1381

Red CFM 1927 1893 1858 1824 1791 1759 1720 1689 1640

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

EXTERNAL STATIC PRESSURE (IN. W.C.)

Table 5 – 604D-- --A Wet Coil Pressure Drop (IN. W.C.)

UNIT SIZE

24 0.06 0.07 0.08 0.09 0.1 30 0.12 0.15 0.19 0.23 0.27 36 0.07 0.11 0.18 0.26 0.35 42 0.04 0.07 0.1 0.15 0.21 48 0.11 0.14 0.17 0.22 0.28 60 0.1 0.17 0.23 0.31 0.36

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

STANDARD CFM (S.C.F.M)

Table 6 – Wet Coil Air Delivery (CFM) -- Downflow -- High Speed with 1-- in. (25 mm) Filter and Economizer

UNIT SIZE

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 36 1333 1289 1256 1214 1152 1118 1076 1035 997 950 42 1612 1569 1527 1481 1451 1393 1351 1317 1278 1242 48 2166 2085 2002 1919 1798 1709 1582 1467 1270 988 60 2298 2239 2180 2110 2044 1951 1862 1777 1697 1591

EXTERNAL STATIC PRESSURE (IN. W.C.)

Table 7 – Filter Pressure Drop Table (IN. W.C.)

FILTER SIZE

in. (mm)

20X20X1

(508X508X25)

20X24X1

(508X610x25)

24X30X1

(610X762x25)

24X36X1

(610X914X25)

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

0.05 0.07 0.08 0.1 0.12 0.13 0.14 0.15 — — — — — — — — — — —

— — — .0 9 .10 .11 .13 .14 .1 5 .16 — — — — — — — — —

— — — 0.04 0.05 0.06 0.07 0.07 0.08 0.09 0.1 — — — — — — — —

— — — — — — — 0.06 0.07 0.07 0.08 0.09 0.09 0.10 0.11 0.12 0.13 0.14 0.14

CFM

Table 8 – Electric Heat Pressure Drop Table (IN. W.C.)

Small Cabinet: 24--36 cfm

5kw 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07

7.5 kw 0.00 0.00 0.00 0.00 0.00 0.00 0.02 0.03 0.05 0.07 0.08 0.09 10 kw 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07 0.09 0.10 0.11 15 kw 0.00 0.00 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 20 kw 0.00 0.00 0.02 0.04 0.06 0.08 0.09 0.11 0.13 0.15 0.17 0.19

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600

Electric Heat Pressure Drop Table (IN. W.C.)

Large Cabinet 42--60 cfm

5kw 0.00 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12

7.5 kw 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 10 kw 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 15 kw 0.00 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 20 kw 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16

1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500

Page 25

604D-- --A

Fig. 17 -- Cooling Charging Table--Subcooling

A09070

Page 26

O R W

Y C

SPEEDUP

604D-- --A

T2 C C O

DFT

T1 Y

DFT

INTERVAL TIMER

OFF

SHIFT

OF1

OF2

120

QUIET

Speedup Pins

Quiet Shift

Fig. 18 -- Defrost Control

Step 4 — Electrical Controls and Wiring

Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit.

Remove access panels (see Fig. 20) to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any discolored or burned connections are noticed, disassemble the connection, clean all the parts, restrip the wire end and reassemble the connection properly and securely.

After inspecting the electrical controls and wiring, replace all the panels. Start the unit, and observe at least one complete cooling cycle to ensure proper operation. If discrepancies are observed in operating cycle, or if a suspected malfunction has occurred, check each electrical component with the proper electrical instrumentation. Refer to the unit wiring label when making these checkouts.

Step 5 — Refrigerant Circuit

Inspect all refrigerant tubing connections and the unit base for oil accumulation annually. Detecting oil generally indicates a refrigerant leak.

If oil is detected or if low performance is suspected, leak--test all refrigerant tubing using an electronic leak detector, or liquid--soap solution. If a refrigerant leak is detected, refer to Check for Refrigerant Leaks section.

If no refrigerant leaks are found and low performance is suspected, refer to Checking and Adjusting Refrigerant Charge section.

Defrost interval DIP switches

A08020

C99097

Fig. 19 -- Refrigerant Circuit

Page 27

High pressure may be caused by a dirty outdoor coil, failed fan motor, or outdoor air recirculation.

To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have continuity on a good switch.

Step 11 — Copeland Scroll Compressor (Puron Refrigerant)

The compressor used in this product is specifically designed to operate with Puron (R-- 410A) refrigerant and cannot be interchanged.

CONTROL ACCESS PAN EL

A09207

COMPRESSOR ACCESS PANEL

Fig. 20 -- Unit Access Panels

BLOWER ACCESS PAN EL

Step 6 — Indoor Airflow

The heating and/or cooling airflow does not require checking unless improper performance is suspected. If a problem exists, be sure that all supply--air and return--air grilles are open and free from obstructions, and that the air filter is clean. When necessary, refer to Indoor Airflow and Airflow Adjustments section to check the system airflow.

Step 7 — Metering Devices--TXV & Piston

This unit uses 2 types of metering devices. The outdoor metering device is a fixed orifice and is contained in the brass hex--body in each liquid line feeding the outdoor coils. The indoor metering device is a TXV type device.

Step 8 — Pressure Switches

Pressure switches are protective devices wired into control circuit (low voltage). They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit. These pressure switches are specifically designed to operate with Puron (R--410A) systems. R--22 pressure switches must not be used as replacements for the Puron (R--410A) system.

Step 9 — Loss of Charge Switch

This switch is located on the liquid line and protects against low suction pressures caused by such events as loss of charge, low airflow across indoor coil, dirty filters, etc. It opens on a pressure drop at about 20 psig. If system pressure is above this, switch should be closed. To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have continuity on a good switch.

NOTE: Because these switches are attached to refrigeration system under pressure, it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists. If switch must be removed, remove and recover all system charge so that pressure gauges read 0 psi. Never open system without breaking vacuum with dry nitrogen.

Step 10 — High--Pressure Switch

The high--pressure switch is located in the discharge line and protects against excessive condenser coil pressure. It opens at 650 psig.

EXPLOSION HAZARD

Failure to followthis warning could result in personalinjury, death or property damage.

Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerant and oils.

The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll. The scroll compressor has no dynamic suction or discharge valves, and it is more tolerant of stresses caused by debris, liquid slugging, and flooded starts. The compressor is equipped with an internal pressure relief port. The pressure relief port is a safety device, designed to protect against extreme high pressure. The relief port has an operating range between 550 and 625 psig differential pressure.

WARNING

Step 12 — Refrigerant System

This step covers the refrigerant system of the 604D-- -- A, including the compressor oil needed, servicing systems on roofs containing synthetic materials, the filter drier and refrigerant charging.

Refrigerant

PROPERTY HAZARD, PERSONAL INJURY OR ENVIRONMENTAL HAZARD

Failureto followthis warning could result in propertydamage or personal injury or death. This system uses Puron (R-- 410A) refrigerant which has higher operating pressures than R--22 and other refrigerants. No other refrigerant may be used in this system. Gauge set, hoses,and recoverysystem mustbe designed to handle Puron. If you are unsure consult the equipment manufacturer.

Compressor Oil

The Copeland scroll compressor uses 3MAF POE oil. If additional oil is needed, use Uniqema RL32-- 3MAF. If this oil is not available, use Copeland Ultra 32 CC or Mobil Arctic EAL22 CC. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed to HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere.

Servicing Systems on Roofs with Synthetic Materials

POE (polyolester) compressor lubricants are known to cause long term damage to some synthetic roofing materials. Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. When performing any service that may risk exposure of compressor oil to the roof, take appropriate precautions to protect roofing. Procedures which risk oil leakage include, but are not limited to, compressor replacement,

WARNING

604D-- --A

Page 28

repairing refrigerant leaks, replacing refrigerant components such as filter drier, pressure switch, metering device, coil, accumulator, or reversing valve.

Synthetic Roof Precautionary Procedur

1. Cover extended roof working area with an impermeable polyethylene (plastic) drip cloth or tarp. Cover an approximate 10x10 ft (3x3 m) area.

2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run--offs, and protect drop cloth from tears caused by tools or components.

3. Place terry cloth shop towel inside unit immediately under component(s) to be serviced and prevent lubricant run--offs through the louvered openings in the unit base.

4. Perform required service.

5. Remove and dispose of any oil contaminated material per local codes.

Liquid Line Filter Drier

The biflow filter drier is specifically designed to operate with Puron. Use only factory-- authorized components. Filter drier must

604D-- --A

be replaced whenever the refrigerant system is opened. When removing a filter drier, use a tubing cutter to cut the drier from the system. Do not unsweat a filter drier from the system. Heat from unsweating will release moisture and contaminants from drier into system.

Puron (R--410A) Refrigerant Charging

Refer to unit information plate and charging chart. Some R--410A refrigerant cylinders contain a dip tube to allow liquid refrigerant to flow from cylinder in upright position. For cylinders equipped with a dip tube, charge Puron units with cylinder in upright position and a commercial metering device in manifold hose. Charge refrigerant into suction--line.

Step 13 — System Information

Loss of Charge Switch

The loss of charge switch is a protective device wired into control circuit (low voltage). It shuts off the compressor if abnormally low pressures are present in the refrigeration circuit.

Check Defrost Thermostat

The defrost thermostat signals heat pump that conditions are right for defrost or that conditions have changed to terminate defrost. It is a thermally actuated switch clamped to outdoor coil to sense its temperature. Normal temperature range is closed at 32_  3_F(0  1.7_C) and open at 65_  5_F(18 2.8_C).

NOTE: The defrost thermostat is usually located on the lowest liquid leaving circuit of the left condenser coil.

FEEDER TUBE

STUB TUBE

DEFROST THERMOSTAT

C99029

Fig. 21 -- Defrost Thermostat

TROUBLESHOOTING

Refer to the Cooling and Heating Troubleshooting Chart (Table 9) for troubleshooting information.

START--UP CHECKLIST

Use the Start--Up Checklist.

Page 29

PURONR (R--410A) QUICK REFERENCE GUIDE

S Puron refrigerant operates at 50--70 percent higher pressures than R--22. Be sure that servicing equipment and replacement

components are designed to operate with Puron

S Puron refrigerant cylinders are rose colored. S Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400. S Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose when

charging into suction line with compressor operating

S Manifold sets should be minimum 700 psig high side and 180 psig low side with 550 psig low--side retard. S Use hoses with minimum700 psig service pressure rating. S Leak detectors should be designed to detect HFC refrigerant. S Puron, as with other HFCs, is only compatible with POE oils. S Vacuum pumps will not remove moisture from oil. S Do not use liquid-- line filter driers with rated working pressures less than 600 psig. S Do not leave Puron suction line filter driers in line longer than 72 hours. S Do not install a suction-- line filter drier in liquid line. S POE oils absorb moisture rapidly. Do not expose oil to atmosphere. S POE oils may cause damage to certain plastics and roofing materials. S Wrap all filter driers and service valves with wet cloth when brazing.

S A factory approved liquid--line filter drier is required on every unit. S Do NOT use an R--22 TXV. S Never open system to atmosphere while it is under a vacuum. S When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and replace filter

driers. Evacuate to 500 microns prior to recharging.

S Do not vent Puron into the atmosphere. S Observe all wa rnings, cautions,andbold text. S All indoor coils must be installed with a hard shutoff Puron TXV metering device.

604D-- --A

Page 30

SYMPTOM CAUSE REMEDY

Compressor and condenser fan will not start.

Compressor will not start but condenser fan runs

Three--phase scroll compressor makes excessive noise, and there may be a

low pressure differential.

604D-- --A

Compressor cycles (other than normally satisfying thermostat).

Compressor operates continuously

Excessive head pressure

Head pressure too low

Excessive suction pressure

Suction pressure too low

Table 9 – Troubleshooting Chart

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

Defective contactor, transformer, or high--pressure, loss--of--charge or low--pressure switch

Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly

Thermostat setting too high

Faulty wiring or loose connections in compressor circuit

Compressor motor burned out, seized, or Determine cause internal overload open Replace compressor Defective run/start capacitor, overload, start relay Determine cause and replace

One leg of 3--phase power dead

Scroll compressor is rotating in the wrong direction

Refrigerant overcharge or undercharge

Defective compressor Replace and determine cause Insufficient line voltage Determine cause and correct Blocked condenser Determine cause and correct Defective run/start capacitor, overload or start relay Determine cause and replace Defective thermostat Replace thermostat Faulty condenser--fan motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low Reset thermostat Low refrigerant charge Locate leak, repair, and recharge Mechanical damage in compressor Replace compressor

Air in system

Condenser coil dirty or restricted Clean coil or remove restriction Dirty air filter Replace filter Dirty condenser coil Clean coil Refrigerant overcharged Recover excess refrigerant

Air in system

Condenser air restricted or air short--cycling Determine cause and correct Low refrigerant charge Check for leaks, repair, and recharge. Compressor IPR leaking Replace compressor Restriction in liquid tube Remove restriction High heat load Check for source and elimi nate Compressor IPR leaking Replace compressor Refrigerant overcharged Recover excess refrigerant Dirty air filter Replace filter Low refrigerant charge Check for leaks, repair and recharge Metering device or low side restricted Remove source of restriction

Insufficient evaporator airflow

Temperature too low in conditioned area Reset thermostat Outdoor ambient below 55°F (12.7°C) Install low--ambient kit Filter drier restricted Replace filter

Replace component

Lower thermostat setting below room temperature

Check wiring and repair or replace

Replace fuse or reset circuit breaker Determine cause

Correct the direction of rotation by reversing the 3--phase power leads to the unit.

Recover refrigerant, evacuate system, and recharge to capacities shown on rating plate

Recover refrigerant, evacuate system, and recharge

Increase air quantity Check filter–replace if necessary

Page 31

START--UP CHECKLIST

(Remove and Store in Job Files)

I. PRELIMINARY INFORMATION

MODEL NO.:

SERIAL NO.: DATE:

TECHNICIAN:

II. PRESTART--UP (Insert check mark in box as each item is completed)

( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS ( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS ( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE

( ) VERIFY THAT UNIT INSTALLATION IS LEVEL ( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS

III. START-- UP ELECTRICAL

SUPPLY VOLTAGE COMPRESSOR AMPS

INDOOR (EVAPORATOR) FAN AMPS

TEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE DB RETURN--AIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB

HEAT PUMP SUPPLY AIR __________________ ELECTRIC HEAT SUPPLY AIR_______________

PRESSURES

REFRIGERANT SUCTION PSIG, SUCTION LINE TEMP* REFRIGERANT DISCHARGE PSIG, LIQUID TEMP{

( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS

* Measured at suction inlet to compressor { Measured at liquid line leaving condenser.

604D-- --A

Page 32

VERTICAL ECONOMIZER

(FACTORY INSTALLED OPTION)

GENERAL

Economizers are recommended for only commercial packaged products that have X13 motors. The Economizer system utilizes the latest technology available for integrating the use of free cooling with mechanical cooling for rooftop units. The solid state control system optimizes energy consumption, zone comfort, and equipment cycling by operating the compressors when the outdoor air temperature is too warm, integrating the compressor with outdoor air when free cooling is available, and locking out the compressor when outdoor air temperature is too cold. Demand ventilation is supported.

The Economizer system utilizes gear--drive technology with a direct--mount spring return actuator that will close upon loss of power. The Economizer system comes standard with an outdoor air temperature sensor, a supply air temperature sensor, and low temperature compressor lockout switch. Indoor enthalpy, outdoor enthalpy, and CO

Barometric relief dampers provide natural building pressurization

604D-- --A

control. Barometric relief dampers are built into the design and are standard. See Table 10 for Hood Package contents. See Table 11 forsensorusage.

SMALL CHASSIS (Sizes 30 and 36)

Qty Content Description Qty Content Description

1 Hood Side, Right 1 Hood Side, Right

1 Hood Side, Left 1 Hood Side, L eft

2 Angle, Filter 2 Angle, Filter

(20--- 1/2” x 16--- 1/2 x 1”)

(521 x 419 x 25 mm)

(#10 --- 14 x 5/8” w/Seal

( # 8 --- 1 8 x 3 / 4” T y p e B P an

APPLICATION

Outdoor Air Dry Bulb

Single Enthalpy HH57AC078

Differential Enthalpy HH57AC078 and CRENTDIF004A00*

CO2for DCV Control

U s in g a W al l --- M ou nt e d

Sensor

CO2for DCV Control

U s in g a D u c t ---

Mounted CO

*CRENTDIF004A00 accessory is used on ma ny different base units. As such, these kits may contain parts that will not be needed for installation.

{33ZCSENCO2 and CGCDXSEN004A00 are accessory CO **33ZCASPC02 AND CGCDXASP00100 are accessory aspirator boxes

required for duct---mounted applications. {{CRCBDIOX005A00 is an accessory that contains both 33ZCSENCO2

AND 33ZVASPC02 accessories.

sensors are available for field installation.

Table 10 – Package Contents

LARGE CHASSIS

(Sizes 42, 48, and 60)

Aluminum Filter

Screws

Washer)

Screws

Head)

1 Bracket, Sensor

Aluminum Filter

(20--- 1/2” x 16--- 1/2 x 1”)

(521 x 419 x 25 mm)

(#10 --- 14 x 5/8” w/Seal

( # 8 --- 1 8 x 3 / 4” T y p e B P an

Table 11 – Economizer Sensor Usage

Sensor

ECONOMIZER WITH OUTDOOR AIR DRY BULB

None, The outdoor air dry bulb sensor is factory

33ZCSENC02 or CGCDXSEN004A00

33ZCSENC02 or

CGCDXSEN004A00{ and 33ZCASPCO2 or

CGCDXASP00100**

SENSOR

Accessories Required

installed.

or CRCBDIOX005A00{{

Screws

Washer)

Screws

Head)

sensors.

ACCESSORIES

The economizer has several field--installed accessories available to optimize performance. Refer to Table 12 for authorized parts.

Table 12 – Accessory List

DESCRIPTION PART NUMBER

Outdoor Air Enthalpy Sensor HH57AC078

Indoor Air Enthalpy Sensor CRENTDIF004A00

Return Air CO2Sensor (4---20 mA) CRCBDIOX005A00

CO2Room Sensor (4---20 mA)

Aspirator Box for duct Mount CO2Sensor

( 4 --- 2 0 m A )

Space Temperature and CO2Room

Sensor with Override (4--- 20mA)

Space Temperature and CO2Room

Sensor with Override an d Set Point

( 4 --- 2 0 m A)

Heat Pump Relay Package CPRLYKIT001A00

33ZCSENX02 Or

CGCDXSEN004A00

33ZCASPC02 Or

CGCDXASP001A00

33ZCT55C02

33ZCT56C02

INSTALLATION

Small Chassis

To install the Vertical Economizer on the small chassis perform the following procedure:

1. Turn off unit power supply and install lockout tag.

WARNING

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 and install lockout tag. There may be more than one disconnect switch. Turn off accessory heater power switch if applicable.

2. Remove economizer hood top panel from the return side of the unit. See Fig. 22. Keep screws and panel next to the unit.

3. Open economizer hood package found on the top skid.

4. Remove red shipping tape that attaches the outside air temperature (OAT) sensor to the economizer assembly. Using two #8 fasteners, found in the hood package, attach the OAT sensor to the economizer according to Fig. 23.

NOTE: See label attached to economizer for OAT installing details.

5. Remove horizontal return duct cover panel and cut the wire ties that hold the hood divider to the economizer assembly. Slide hood divider off from the two slots holding it in place and place next to the unit. See Fig. 24.

Page 33

OAT Sensor

Fig. 22 -- Economizer Hood Top Panel Removal

Hood Top Panel

A09689

6. Replace horizontal return duct cover panel. Screw in place ensuring all seams are air and watertight.

7. Install the 2 angle filter brackets to the right and left hood side panels respectively with the #10 screws provided. See Fig. 25.

8. Assemble hood according to Fig. 26 screwing together with provided #10 sheet metal screws.

9. Install assembled hood over the economizer opening in the replacement return chamber panel. See Fig. 27. Screw in place through pre-punched holes. Make sure all seams are air and watertight.

NOTE: The two wires that connect to the outside air temperature sensor (OAT) should remain accessible.

10. Connect the outside air temperature sensor (OAT) to the economizer per wiring diagram.

11. Open the filter clips on the inside of the hood top. Insert the aluminum filter into the hood and close the clips to hold in place. See Fig. 28.

12. To replace 12 x 20 x1 (304.8mm x 508mm x 25.4mm) air filters, open the filter access door (horizontal return duct cover panel), remove old filters and install new disposable filters in filter rack. See Table 13 for filter part number.

Table 13 – Filter Part Number

DESCRIPTION PART N UM BER

Indoor Coil Air Filter

12 x 20 x 1

(304.8 x 508 x 25.4 mm)

KH01AA312

604D-- --A

OAT Sensor

Fig. 23 -- Oat Sensor Installed

A09690

NOTE: The economizer control settings and the filters are accessible through the filter access door.

13. Economizer controls are set to a standard factory setting. Nevertheless, you can adjust these settings through the filter access door. Review the settings in the Operation section:

(2.) The standard economizer controller has a factory

setting of “C” for the outdoor air temperature changeover and 63_F(17_C) for the supply air (mixed air) temperature sensor. The outdoor air temperature changeover setting is adjusted on the sensor by setting the dip switches on the sensor. The ABCD potentiometer on the economizer control should be set to the “D” position.

(3.) The low ambient compressor lockout switch setting

is fixed at 42_F(5.6_C).

(4.) The minimum position for the outdoor air damper

can be configured at the controller. When not using

sensor, the DCV Max potentiometer must be

aCO completely closed (CCW) for the Minimum Position potentiometer to function correctly.

(5.) Settings for the optional outdoor enthalpy sensor,

indoor enthalpy sensor, and CO

sensor can also be

configured at the controller.

14. Replace the filter access panel. Screw in place ensuring all seams are air and watertight.

15. Install all economizer accessories then power HVAC unit and test cycle economizer.

Page 34

Hood Divider

Hood Divider (Removed)

604D-- --A

Horizontal Return Duct Cover Panel

A09691

Fig. 24 -- Horizontal Return Duct Cover Panel Removal

Left Hood Side Panel

Right Hood Side Panel

Filter Angle Bracket

Fig. 25 -- Filter Angle Bracket Installation

Filter Angle Bracket

A09692

Page 35

Hood Top Panel

Hood Divider

Left Hood Side Panel

Right Hood Side Panel

Fig. 26 -- Economizer Hood Assembly

A09693

604D-- --A

Fig. 27 -- Economizer Hood Installation

Filter Clips

Aluminum Filter

A09694

A09695

Fig. 28 -- Filter Installation (See Through View)

Page 36

Large Chassis

To install the Vertical Economizer on the large chassis perform the following procedure:

1. Turn off unit power supply and install lockout tag.

WARNING

ELECTRICAL SHOCK HAZARD

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

2. Remove economizer hood top panel from the return side of the unit. See Fig. 29. Keep screws and panel next to the unit.

604D-- --A

3. Remove red shipping tape that attaches the outside air temperature (OAT) sensor to the economizer assembly and place sensor next to the unit.

4. Remove horizontal return duct cover panel and cut the wire ties that hold the hood divider to the economizer assembly. Slide hood divider off from the two slots holding it in place and place next to the unit. See Fig. 30.

5. Replace horizontal return duct cover panel. Screw in place ensuring all seams are air and watertight.

6. Open economizer hood package found on the top skid. Mount OAT sensor to its assigned bracket by screwing together with provided two #8 fasteners. Afterwards install OAT sensor to the right side hood panel with the provided #10 screws. See Fig. 31.

7. Install the 2 angle filter brackets to the right and left hood side panels respectively with the #10 screws provided. See Fig. 32.

8. Assemble hood according to Fig. 33 screwing together with provided #10 sheet metal screws.

9. Install assembled hood over the economizer opening in the replacement return chamber panel. See Fig. 34. Screw in place through pre-punched holes. Make sure all seams are air and watertight.

NOTE: The two wires that connect to the outside air temperature sensor (OAT) should remain accessible.

10. Connect the outside air temperature sensor (OAT) to the economizer per wiring diagram.

Filter Access Panel

Hoop Top Panel

OAT Sensor

A09696

Fig. 29 -- Economizer Hood Top Panel Removal

Horizontal Return Duct Cover Panel

Hood Divider (Removed)

Hood Divider

A09697

Fig. 30 -- Horizontal Return Duct Cover Panel and Hood Divider Removal

Page 37

Fig. 31 -- OAT Bracket Installation

Left Hood Side Panel

Filter Angle Bracket

A09698

604D-- --A

Right Hood Side Panel

Filter Angle Bracket

Left Hood Side

Fig. 32 -- Filter Angle Bracket Installation

Right Hood Side

A09699

Page 38

Left Hood Side Panel

604D-- --A

Right Hood Side Panel

Hood Top Panel

Hood Divider

A09700

Fig. 33 -- Hood Assembly

NOTE: The economizer control settings and the filters are

accessible through the filter access door.

A09701

Fig. 34 -- Economizer Hood Installation

11. Open the filter clips on the inside of the hood top. Insert the aluminum filter into the hood and close the clips to hold in place. See Fig. 35.

12. T o replace air filters, open filter access door remove old filters and install new disposable filters in filter rack. See Table 14 for filter part numbers.

IMPORTANT: On the the bent coil (See Fig. 36 to determine coil type) filter rack, the 18 x 24x1(257.2mm x 609.6mm x25.4mm) filter must be installed through the filter access door first then installthe16x24x1(406.4mm x 609.6mm x 25.4mm) filter.

Table 14 – Filter Part Number

DESCRIPTION PART NUMBER

Straight Indoor

Coil Air Filter

Bent Indoor

Coil Air Filter

14 x 24 x 1

(355.6 x 609.6 x 25.4 mm)

16 x 24 x 1

(406.4 x 609.6 x 25.4 mm)

16 x 24 x 1

(406.4 x 609.6 x 25.4 mm)

18 x 24 x 1

(457.2 x 609.5 x 25.4 mm)

KH01AA314

KH01AA316

KH01AA318

13. Economizer controls are set to a standard factory setting. Nevertheless, you can adjust these settings through the filter access door. Review the settings in the Operation section:

(1.) The standard economizer controller has a factory

(2.) The low ambient compressor lockout switch setting

is fixed at 42_F(5.6_C).

(3.) The minimum position for the outdoor air damper

can be configured at the controller. When not using

sensor, the DCV Max potentiometer must be

aCO completely closed (CCS) for the Minimum Position potentiometer to function correctly.

(4.) Settings for the optional outdoor enthalpy sensor,

indoor enthalpy sensor, and CO

sensor can also be

configured at the controller.

14. Replace the filter access panel. Screw in place ensuring all seams are air and watertight.

15. Install all economizer accessories then power HVAC unit and test cycle economizer.

Page 39

Aluminum Filter

Fig. 35 -- Filter Installation (See through view)

Top filter

Bottom filter rack

Screw

(Note 4 and 5)

rack

Evaporator Coil

RIGHT SIDE

Filter Clips

A09704

CONFIGURATION

Economizer Standard Sensors

OUTDOOR AIR TEMPERATURE (OAT) S ENSOR— The

outdoor air temperature sensor (HH57AC080) is a 10 to 20mA deviceused to measurethe outdoor--air temperature. The outdoor--air temperature is used to determine when the Economizer can be used for free cooling. The operating range of temperature measurement is 40 to 100_F (4.4 to 37.8_C).The sensorhas 8 selectable temperature changeover setpoints. The temperature changeover is set using 3 dip switches on the sensor. The ABCD potentiometer on the controller should be set to the “D” position. See Fig. 39.

SUPPLY AIR TEMPERATURE (SAT) SENSOR—The supply air temperature sensor is a 3 KΩ thermistor located at the inlet of the indoor fan. See Fig. 37. The operating range of temperature measurement is 0_ to 158_F (-- 17.8_ to 70_C). See Table 15 for sensor temperature/resistance values. The temperature sensor looks like an eyelet terminal with wires running to it. The sensor is located in the “crimp end” and is sealed from moisture.

Table 15 – Supply Air Sensor Temperature/Resistance Values

TEMPERATURE

(_F)

--- 2 2 --- 30 53,010

--- 4 --- 2 0 29,091

14 --- 1 0 16,590

32 0 9,795

50 10 5,970

68 20 3,747

77 25 3,000

86 30 2,416

104 40 1,597

122 50 1,080

140 60 746

158 70 525

CELSIUS (_C) RESISTANCE (OHMS)

Supply Air Temperature Sensor (SAT)

604D-- --A

BENT COIL

To p f il t er rack

Bottom filter rack

STRAIGHT COIL

Fig. 36 -- Indoor Coil with Filter Rack

Evaporator Coil

Indoor Blower

A09707

Fig. 37 -- SAT Location

A09714

Page 40

LOW TEMPERATURE COMPRESSOR LOCKOUT SWITCH—The Economizer is equipped with a low ambient

temperature lockout switch located inthe outdoorairstream which is used to lock out the compressors below a 42_F(5.6_C) ambient temperature.

Economizer Control Modes

—Determine the Economizer control

mode before set up of the control. Some modes of operation may require different sensors. Refer to Table 11. The Economizer is supplied from the factory with a supply air temperature sensor, a low temperature compressor lockout switch, and an outdoor air temperature sensor. This allows for operation of the Economizer with outdoor air dry bulb changeover control. Additional accessories can be added to allow for different types of changeover control and operation of the Economizer and unit.

OUTDOOR DRY BULB CHANGEOVER— The standard controller is shippedfromthe factoryconfiguredfor outdoor dry bulb changeover control. The outdoor air and supply air temperature sensors are included as standard.

For this control mode, the outdoor temperature is compared to a selectable set point on the sensor. See Fig. 39. If the outdoor--air

604D-- --A

temperature is above the set point, the Economizer will adjust the outdoor air dampers to minimum position. If the outdoor--air temperature is below the set point, the position of the outdoor--air dampers will be controlled to provide free cooling using outdoor air. When in this mode, the LED next to the free cooling set point potentiometer will be on. The changeover temperature set point is set using the switches on the sensor. See Fig. 39 for the corresponding temperature changeover values.

In this mode of operation, the outdoor-- air temperature is compared to the return--air temperature and the lower temperature airstream is used for cooling. When using this mode of changeover control, turn the free cooling/enthalpy set point potentiometer fully clockwise to the D setting. See Fig. 38 and Fig. 43.

EXHAUST FAN

SETPOINT

LED LIGHTS WHEN

EXHAUST CONTACT

MINIMUM DAMPER

POSITION SETTING

MAXIMUM DAMPER DEMAND

CONTROL VENTILATION

LED LIGHTS WHEN DEMAND CONTROL

VENTILATION INPUT

IS ABOVE SETPOINT

DEMAND CONTROL

VENTILATION SETPOINT

LED LIGHTS WHEN

SUITABLE FOR FREE

IS MADE

SETPOINT

OUTDOOR AIR IS

COOLING

CHANGEOVER SETPOINT

ENTHALPY

Fig. 38 -- Economizer Controller Potentiometer and LED

Locations

A09708

(8.9°C)

(11.7°C)

(12.8°C)

(14.4°C)

(17.2°C)

(20°C)

(22.8°C)

(25.6°C)

A10134

Fig. 39 -- Outdoor Air Temperature Changeover Set Points

ECONOMIZER

RETURN AIR SENSOR

RETURN DUCT (FIELD-PROVIDED)

A09710

Fig. 40 -- Enthalpy Sensor Mounting Location

Page 41

CONTROL

CURVE

A 73 (23) B C D

CONTROL POINT

APPROX ˚F (˚C)

AT 50% RH

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

ENTHALPY – BTU PER POUND DRY AIR

(7) 40 (4)

35 (2)

35 (2)40(4)45(7)50(10)55(13)60(16)65(18)70(21)75(24)80(27)85(29)90(32)95(36)

APPROXIMATE DRY BULB TEMPERATURE — ˚F (˚C)

(16)

(13)

(10)

(18)

(27)

(24)

(21)

100

(29)90(32)95(25)

RELATIVE HUMIDITY (%)

100

105

110

(38)

(41)

(43)

100

105

110

(38)

(41)

(43)

A09711

Fig. 41 -- Enthalpy Changeover Setpoints

6000

5000

4000

3000

2000

800 ppm 900 ppm 1000 ppm 1100 ppm

1000

2 345678

A09713

Fig. 42 -- CO2Sensor Maximum Range Setting

OUTDOOR ENTHALPY CHANGEOVER—For enthalpy

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

When the outdoor air enthalpy rises above the outdoor enthalpy changeover set point, the outdoor--air damper moves to its minimum position. The outdoor enthalpy changeover set point is set with the outdoor enthalpy set point potentiometer on the Economizer controller. The set points are A, B, C, and D. See Fig.

41. The factory--installed 620--ohm jumper must be in place across terminals SR and SR+ on the Economizer controller. See Fig. 43 and Fig. 44.

AQ+

SO+

SR+

EXH

DCV

Free Cool

Set

10V

Min Pos

Open

DCV

Max

10V

DCV

Set

10V

TR TR1

24 Vac

COM

Vac

HOT

EF1EF

A09712

Fig. 43 -- Economizer Controller

DIFFERENTIAL ENTHALPY CONTROL — For differential

enthalpy control, the Economizer controller uses two enthalpy sensors (HH57AC078 and CRENTDIF004A00), one in the outside air and one in the return airstream. The Economizer controller compares the outdoor air enthalpy to the return air enthalpy to determine Economizer use. Thecontroller selectsthe lower enthalpy air(return or outdoor) for cooling. Forexample, when the outdoor air has a lowerenthalpy than the return air and is below theset point, the Economizer opens to bring in outdoor air for freecooling. Replacethe standard outside air dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. Mount the return air enthalpy sensor in the return air duct. See Fig. 40. When using this mode of changeover control, turn the enthalpy set point potentiometer fully clockwise to the D setting.

INDOOR AIR QUALITY (IAQ) SENSOR INPUT —The IAQ input can beused fordemand control ventilation control based on the level of CO

measured in the space or return air duct. Mount the

accessory IAQ sensor according to manufacturer specifications. The IAQ sensor should be wired to the AQ and AQ1 terminals of the controller. Adjust the DCV potentiometersto correspond to theDCV voltage output of the indoor air quality sensor at the user determined set point. See Fig. 42. Ifa separate field--suppliedtransformer is used to power the IAQ sensor, the sensor must not be grounded or the Economizer control board will be damaged.

EXHAUST SET POINT ADJUSTMENT—Theexhaust set point will determine when the exhaust fan runs based on damper position (if power exhaust is installed). The set point is modified with the Exhaust Fan Set Point (EXH SET) potentiometer. See Fig. 44 for Wiring Diagram. The set point represents the damper position above which the exhaust fans will be turned on. When there is a call for exhaust, the Economizercontroller provides a 45 ± 15 second delay beforeexhaust fan activation to allow the dampers to open. Thisdelay allows the damper to reach the appropriate position to avoid unnecessary fan overload.

MINIMUM POSITION CONTROL — There is a minimum damper position potentiometer on the Economizer controller. See Fig. 38 and 44. The minimum damper position maintains the minimumairflowinto the building during theoccupied period.When using demand ventilation, the minimum damper position represents the minimum ventilation position for VOC (volatile organic compound) ventilation requirements. The DCV Max potentiometer must be fully closed (CCW) to allow the Minimum Position potentiometer to function correctly.

604D-- --A

Page 42

When demand ventilation control is not being used, the minimum position potentiometer should beused to setthe occupied ventilation position. The maximum demand ventilation position should be turned fully clockwise. Adjust the minimum position potentiometer to allow the minimum amount of outdoor air, as required by local codes, to enter the building. Make minimum position adjustments with at least 10_F (12.2_C) temperature difference between the outdoor and return--air temperatures. To determine the minimum position setting, perform the following procedure:

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

x OA/100) + (TRx RA/100) = T

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

= Return--Air Temperature

RA = Percent of Return Air

= Mixed--Air Temperature

As an example, if local codes require 10% outdoor air during occupied conditions, outdoor--air temperature is 60_F (15.6_C), and return--air temperature is 75_F

604D-- --A

(23.9_C). (60 x .10) + (75 x .90) = 73.5_F (23.1_C)

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

3. Ensure that the factory--installed jumper is in place across terminals P and P1. If remote damper positioning is being used, make sure that the terminals are wired according to Fig. 44 and that the minimum position potentiometer is turned fully clockwise.

4. Connect 24 vac across terminals TR and TR1.

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

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

Remote control of the Economizer damper is desirable when requiring additional temporary ventilation. If a field--supplied remote potentiometer (Honeywell part number S963B1128) is wired to the Economizer controller, the minimum position of the damper can be controlled from a remote location. To control the minimum damper position remotely, remove the factory installed jumper on the P and P1 terminals on the Economizer controller. Wire the field --supplied potentiometer to the P and P1 terminals on the Economizer controller. See Fig. 43 and Fig. 44.

Page 43

604D-- --A

Fig. 44 -- Economizer Wiring Diagram

A10059

Page 44

DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING

NOTES:

1. IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED, THEY MUST BE REPLACED WITH THE SAME WIRE OR ITS EQUIVALENT.

2. SEE PRICE PAGES FOR THERMOSTATS.

3. USE 75 DEG. COPPER CONDUCTORS FOR FIELD INSTALLATION.

4. SEE INSTALLATION INSTRUCTIONS FOR PROPER HEATING AND COOLING CONNECTIONS FOR YOUR UNIT. INDOOR FAN MOTOR PLUGS

- ”DO NOT DISCONNECT UNDER LOAD”

5. THIS FUSE IS MANUFACTURED BY LITTELFUSE, P/N 257003.

6. REMOVE YELLOW SPLICE WHEN ECONOMIZER AND ECONOMIZER RELAYS ARE USED AND CONNECT TO RELAY R1 AS SHOWN.

7. WHEN ECONOMIZER AND ECONOMIZER RELAYS ARE USED, CONNECT THE YELLOW AND BLACK WIRES TO RELAY ”R” AS SHOWN. RELAY KIT REQURED WITH ECONOMIZER AND HEAT PUMP/DUAL FUEL UNITS.

8. WHEN ECONOMIZER AND ECONOMIZER RELAYS ARE USED, INSTALL WIRES AS SHOWN ONTO THE COILS OF RELAY R AND RELAY R1.

9.DEHUM FEATURE CANNOT BE USED WHEN ECONOMIZER IS INSTALLED. UNIT FACTORY-SHIPPED IN STD MODE.

GRY

YEL

RED

BRN

BLK

INDOOR FAN SECTION

CAP

HC F

LEGEND

DH DEHUMIDIFICATION MODE

DEHUM DEHUMIDIFICATION MODE DR DEFROST RELAY ECON ECONOMIZER

EQUIP EQUIPMENT

FU FUSE

GND GROUND HPS HIGH PRESSURE SWITCH

HR HEATER RELAY

IFB INDOOR FAN BOARD

IFM INDOOR FAN MOTOR

LPS LOW PRESSURE SWITCH

OFM OUTDOOR FAN MOTOR

OFR OUTDOOR FAN RELAY RVS REVERSING VALVE

TRAN TRANSFORMER

T-STAT THERMOSTAT

R ECON RELAY

R1 ECON RELAY STD STANDARD MODE

BLU

WHT

VIO

PNK

OFM

CONTROL BOX AREA

SINGLE PT. CONNECTION FOR ELEC. HEAT

FIELD SPLICE TERMINAL (MARKED) TERMINAL (UNMARKED) SPLICE (IF REQ’D) SPLICE (MARKED) FACTORY WIRING FIELD CONTROL WIRING FIELD POWER WIRING ACCESSORY OR OPTIONAL WIRING

AT AUTO TRANSFORMER

604D-- --A

C CONTACTOR CAP 1 CAPACITOR, COMP CCH CRANK CASE HEATER

COMP COMPRESSOR MOTOR DB DEFROST BOARD DFT DEFROST TEMPERATURE

ECONOMIZER PLUG

SEE 50SD500625

ECONOMIZER LABEL DIAGRAM

UNIT COMPONENT ARRANGEMENT

OUTDOOR FAN SECTION

COMPRESSOR SECTION

LPS

HPS

COMP

460V - 230V

SWITCH

CCH

ECON

SAT

ACCESSORY ELECTRIC HEAT

GRY

BRN

VIO

PNK

GRY

BRN

HR1 (5 KW)

WHT

HR1-4 (20 KW)

HR1 & 2 (10 KW)

HR1-3 (15 KW)

YEL

SEE NOTE 7

BLK

21C11

TRAN

IFB

24V SPLICE BOX

CONNECTION WIRING DIAGRAM

IF USED

BLK

FIELD

SUPPLY

SEE NOTE 6

BLK

YEL

COOLING FAN LOGIC

ENERGIZED

DE-ENERGIZED

HEATING FAN LOGIC

T W

W45BR

ENERGIZED DE-ENERGIZED

MINUTES

11 11133 33322 222

DISCONNECT PER NEC

24V POWER

ENTRY

HR1

HR4

HR2

HR3

T+90

FIELD SELECTABLE OPTIONS FOR TIME PERIOD BETWEEN DEFROST CYCLES (MINUTES)

BLK

YEL

BLU

EQUIP_GND

FOR WIRING WITH ELECTRIC HEATERS SEE SCHEMATIC ON HEATER ACCESSORY.

BRN

YEL

T+45

MINUTES

DEFAULT

DIP SWITCH SETTINGS

MINUTES

T-STAT

BRN

OROR

GRY

RED

BRN

YEL

GRN

BLUDH

WHT

VIO

ORN

RED

WHT

120

MINUTES

CCH

BLK

GRN

BLK

11 21

13 23

BLK

YEL

BRN

YEL

RED

ORN

DEFROST BOARD (DB)

OF1

OF2

Y C

OF1

BLK BLK

OF2

BLK

YEL

CAP1

COMPRESSOR PLUG

YEL

BLK

230COM

PRIMARY

208/230V

SECONDARY

BRN

24 V

G/Y

TRAN

24V

RED

Y1/Y

Y2/DH

7W3

C Y

WHT

BRN

WHT

VIO

PNK

GRY

CTD

QUIET SHIFT

OFF

(DEFAULT)

3 4

W3 W3

603012090UP

SPEED

DFT

SPEED

1) MOMENTARILY SHORT PINS AND RELEASE TO BYPASS COMPRESSOR OFF DELAY.

2) SHORT FOR 5+ SEC. AND RELEASE FOR FORCED

DEFROST.

3) PERMANENT SHORT WILL BE IGNORED.

DEFROST WILL TERMINATE IN 30 SEC. IF DFT OPEN. DEFROST WILL TERMINATE NORMALLY IF DFT IS CLOSED.

THE COMPRESSOR WILL SHUT OFF FOR 30 SEC. ON DEFROST INITIATION AND TERMINATION IN THE ”QUIET SHIFT” ON POSITION

SCHEMATIC 208/230-3-60

BRN

COM

OFM

COMP

C1 C2

BLUBLK

BLKBLK

YEL

BRN

BLK

YEL

BLU

G/Y

G L

BRN

SEE NOTE 5

24VAC

FUSE

COM

LOW

STD

DEHUM

HIGH

IFB

SEE NOTE 9

BLU

BRN

RVS

BLK BRN

DFT

PNK

BLU

HPS LPS

BLK

JUMPERED TEST PINS (USE METAL OBJECT) FIELD SPEED-UP CYCLE

IFM

BLU

BLK

SEE NOTE 8

COLOR CODE

BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE

PNK PINK RED RED

VIO VIOLET

WHT WHITE YEL YELLOW

2435

BLK

ORN

PNK

RED

SEE

NOTE 4

BRN

BLU

Fig. 45 -- Connection Wiring Diagram 230--3

A10200

Page 45

604D-- --A

Fig. 45 Cont. -- Ladder Wiring Diagram 230--3

A10200

Page 46

604D-- --A

Fig. 46 -- Connection Wiring Diagram 460--3

A10199

Page 47

604D-- --A

Fig. 46 Cont. -- Ladder Wiring Diagram 460--3

A10199

Page 48

DAMPER MOVEMENT — Damper movement from full open to full closed (or vice versa) takes 2 1/2 minutes.

THERMOSTATS — The Economizer control works with conventionalthermostats that have a Y1 (cool stage1), Y2 (coolstage2),W1 (heatstage 1), W2 (heat stage2), and G (fan). The Economizercontrol does not supportspacetemperaturesensors. Connections are made at the thermostat terminal connection board located in the maincontrol box.

OCCUPANCY CONTROL — The factory default configuration for the Economizer control is occupied mode. Occupied status is provided by the black jumper from terminal TR to terminal N. When unoccupied mode is desired, install a field supplied time clock function in placeof the jumper betweenTR and N. SeeFig. 44.When the time clock contacts are closed, the Economizer control will be in occupied mode. When the time clockcontactsareopen (removingthe 24--v signal from terminal N), the Economizer will be in unoccupied mode.

DEMAND CONTROLLED VENTILATION (DCV)—When using the Economizer for demand controlled ventilation, there are someequipment selection criteriawhich should be considered.When

604D-- --A

selecting the heat capacity and cool capacity of the equipment, the maximum ventilation rate must be evaluated for design conditions. The maximum damper position must be calculated to provide the desired freshair.Typically the maximum ventilation ratewill beabout 5 to 10% more than the typical CFM required per person, using normal outside air design criteria. An exponential anticipatory strategy should be taken with the following conditions: a zone with a large area, varied occupancy, and equipment that cannot exceed the required ventilation rate at design conditions. Exceeding the required ventilation rate means the equipment can condition air at a maximum ventilation rate that is greater than the required ventilation rate for maximum occupancy. An exponential--anticipatory strategy will causethe freshairsuppliedto increaseasthe room CO even though the CO CO

level reaches the set point, the damper will be at maximum

set point has not been reached. By the time the

level increases

ventilation and should maintain the setpoint.In order to havetheCO sensorcontrolthe economizerdamper in this manner, first determine the damper voltage output for minimum or base ventilation. Base ventilation is the ventilation required to remove contaminants during unoccupied periods. The following equation may be used to determinethe percent of outside--air entering the building for a given damper position. For best results there should be at least a 10_F (12.2_C) difference in outside and return--air temperatures.

x OA/100) + (TRx RA/100) = T

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

= Return--Air Temperature

RA = Percent of Return Air T

= Mixed--Air Temperature

Once base ventilation has been determined, set the minimum damper position potentiometer to the correct position. The same equation can be used to determine the occupied or maximum ventilation rate to the building.For example, an output of 3.6 volts to the actuator provides a base ventilation rate of 5% and an output of 6.7 volts provides the maximum ventilation rate of 20% (or base plus 15 CFM per person). Use Fig. 42 to determine the maximum setting of the CO example,a 1100 ppm set point relatesto a15 CFM per person design. Use the 1100 ppm curve on Fig. 42 to find the point when the CO sensor output will be 6.7 volts. Line up the point on the graph with the left side of the chart to determine that the range configuration for the CO

sensorshould be 1800 ppm.The Economizer controller will

output the 6.7 voltsfrom theCO

sensorto theactuatorwhen theCO

concentration in the space is at 1100 ppm.

sensor. For

The DCV set point may be left at 2 volts since the CO voltage will be ignored by the Economizer controller until it rises above the 3.6 volt setting of the minimum position potentiometer. Once the fully occupied damper position has been determined, set the maximum damper demand control ventilation potentiometer to this position. Do not set to the maximum position as this can result in over ventilation to the space and potential high--humidity levels.

SENSOR CONFIGURATION — The CO2sensor has preset

standard voltage settings that can be selected anytime after the sensor is powered up. Use setting 1 or 2 for equipment. See Table 16.

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

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

3. Use the Up/Down button to select the preset number. See Table 16.

4. Press Enter to lock in the selection.

5. Press Mode to exit and resume normal operation.

The custom settings of the CO

sensor can be changed anytime

after the sensor is energized. Follow the steps below to change the nonstandard settings:

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

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

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

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

5. Press Mode to move through the variables.

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

DEHUMIDIFICATION OF FRESH AIR WITH DCV CONTROL—Information from ASHRAE indicates that the largest

humidity load on any zone is the fresh air introduced. For some applications, an energy recovery unit can be added to reduce the

moisturecontentof the fresh air being brought into the buildingwhen the enthalpy is high. In most cases, the normal heating and cooling processes are more than adequate to remove the humidity loads for most commercial applications.

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

sensor

Page 49

Table16–CO

SETTING EQUIPMENT OUTPUT

1 Proportional Any

3 Exponential Any

4 Proportional 15

5 Economizer Proportional 20

6 Exponential 15

7 Exponential 20

8 Health & Safety Proportional ---

9 Parking/Air Intakes/Loading Docks Proportional ---

Interface w /Standard Building

Control System

Proportional Any

Sensor Standard Settings

VENTILATION

RATE

(CFM/

PERSON)

ANALOG

OUTPUT

0 --- 10 V

4 --- 20 m A

2 --- 10 V

7 --- 20 m A

0 --- 10 V

4 --- 20 m A

0 --- 10 V

4 --- 20 m A

0 --- 10 V

4 --- 20 m A

0 --- 10 V

4 --- 20 m A

0 --- 10 V

4 --- 20 m A

0 --- 10 V

4 --- 20 m A

0 --- 10 V

4 --- 20 m A

CONTROL

RANGE

(PPM)

0--- 2000 1000 50

0--- 2000 1100 50

0--- 1100 1100 50

0 --- 90 0 900 50

1--- 1100 1100 50

0 --- 90 0 900 50

0--- 9999 5000 500

0--- 2000 700 50

OPTIONAL

RELAY

SETPOINT

(PPM)

HYSTERESIS

RELAY

(PPM)

Table17–CO2Sensor Standard Settings Economizer Input/Output Logic

INPUTS OUTPUTS

DEMAND

CONTROL

VENTILATION

(DCV)

Below set (DCV

LED Off)

Above set (DCV

LED On)

* For single enthalpy control, the module compares outdoor enthalpy to the ABCD set point.

{Power at N terminal determines Occupied/Unoccupied setting: 24 vac (Occupied), now powe r (Unoccupied).

**Modulating is based on the supply---air sensor signal.

{{Modulation is based on the DCV signal.

***Modulation is based on the greater of DCV and supply--- air sensor signals, between minimum position and either maximum position (DCV) or fully open (supply---air signal).

{{{Modulating is based on the greater of DCV and supply--- air sensor signals, between closed and wither maximum position (DCV) or fully open (supply---air signal).

Sequence of Operation—When free cooling is not available, the compressor will be controlled by the thermostat. When free cooling is available, the outdoor--air damper is modulatedby theEconomizer control to provide a 50_ to 55_F(10_ to 12.8_C) supply--air temperature into the zone. As the supply--air temperature fluctuates above 55_ (12.8_C) or below 50_F(10_C), the dampers will be modulated (open or close) to bring the supply--air temperature back within the set points. For Economizer operation, there must be a thermostat call for the fan (G). This will move the damper to its minimum position during the occupied mode.

NOTE: The DCV Max potentiometer must be closed (CCW) when not using CO

Above 50_F(10_C) supply--air temperature, the dampers will modulate from 100% open to the minimum open position. From 50_Fto45_F(10_ to 7.2_C) supply--air temperature, the dampers will maintain at the minimum open position. Below 45_F(7.2_C), the dampers will be completely shut. As the supply--air temperature rises, the dampers will come back open to the minimum open

ENTHALPY

OUTDOOR RETURN

High (Free Cooling

LED off)

Low (Free Cooling

LED on)

High (Free Cooling

LED off)

Low (Free Cooling

LED on)

OPERATION

sensor.

Low

High

Low

High

COMPRESSOR NTERMINAL

Y1 Y2

On On On On

Off Off Off Off

On On On Off

On Off Off Off

Off Off Off Off Minimum position Closed

On On On On

On Off On Off

Off Off Off Off

On On On Off

Off Off Off Off

STAGE1STAGE

OCCUPIED UNOCCUPIED

DAMPER

Minimum position ClosedOn Off On Off

Modulating** (between min.

p o s i t io n a n d f u ll --- o p e n)

Modulating{{ (between

min. position and DCV

maximum)

Modulating*** Modulating{{{On Off Off Off

Modulating** (between closed

Modulating{{ (between closed

a n d f u ll --- ope n )

and DCV maximum)

power exhaust is installed, as the outdoor--air damper opens and closes, the power exhaust fans will be energized and deenergized. If field --installed accessory CO

sensors are connected to the

Economizer control, a demand controlled ventilation strategy will begin to operate. As the CO

set point, the minimum position of the damper will be

increased proportionally. As the CO

level in the zone increases above the

level decreases because of the

increase in fresh air, the outdoor--air damper will be proportionally closed. Damper position will follow the higher demand condition from DCV mode or free cooling mode. Damper movement from full closed to full open (or vice versa) will take between 1 1/2 and 2 1/2 minutes. If free cooling can be used as determined from the appropriate changeover command (dry bulb, enthalpy curve, or differential enthalpy), a call for cooling (Y1 closes at the thermostat) will cause the control to modulate the dampers open to maintain the supply air temperature set point at 50_ to 55_F(10_ to 12.8_C). As the supply air temperature drops below the set point range of 50_ to 55_F(10_ to 12.8_C), the control will modulate the outdoor--air dampers closed to maintain the proper supply--air temperature.

position once the supply--air temperature rises to 48_F(8.9_C). If

604D-- --A

Page 50

TROUBLESHOOTING

See Table 17 for Economizer logic. An Economizer simulator program is available to help with Economizer training and troubleshooting.

Economizer Preparation —This procedure is used to prepare the Economizer for troubleshooting. No troubleshooting or testing is done by performing the following procedure.

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

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

2. Disconnect device at P and P1.

3. Jumper P to P1.

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

5. Jumper TR to 1.

6. Jumper TR to N.

604D-- --A

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

and +.

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

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

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

11. Set enthalpy potentiometer to D.

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

Differential Enthalpy — To check differential enthalpy:

1. Make sure Economizer preparation procedure has been performed.

2. Place 620--ohm resistor across S

and +.

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

4. Remove 620--ohm resistor across S

and +. The Free Cool

LED should turn off.

5. Return Economizer settings and wiring to normal after completing troubleshooting.

Single Enthalpy—To check single enthalpy:

1. Make sure Economizer preparation procedure has been performed.

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

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

4. Return Economizer settings and wiring to normal after completing troubleshooting.

DCV (Demand Controlled Ventilation) and Power Exhaust—To check DCV and Power Exhaust:

1. Make sure Economizer IV preparation procedure has been performed.

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

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

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

and +.

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

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

7. Return Economizer settings and wiring to normal after completing troubleshooting.

DCV Minimum and Maximum Position —To check the DCV minimum and maximum position:

1. Make sure Economizer preparation procedure has been performed.

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

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

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

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

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

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

8. Return Economizer settings and wiring to normal after completing troubleshooting.

Supply--Air Input—To check supply--air input:

1. Make sure Economizer preparation procedure has beenperformed.

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

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

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

5. Return Economizer settings and wiring to normal after completing troubleshooting.

Economizer Troubleshooting Completion —This procedure is used to return the Economizer to operation. No troubleshooting or testing is done by performing the following procedure.

1. Disconnect power at TR and TR1.

2. Set enthalpy potentiometer to previous setting.

3. Set DCV maximum position potentiometer to previous setting. Set DVC Max potentiometer to fully closed (CCW) when not using a CO

sensor.

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

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

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

7. Remove jumper from TR to N.

8. Remove jumper from TR to 1.

9. Remove 5.6 kilo--ohm resistor from T and T1. Reconnect wires at T and T1.

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

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

Page 51

REQUIRED CLEARANCES TO COMBUSTIBLE MATL

NEC. REQUIRED CLEARANCES

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

604D-- --A

Fig. 47 -- 604D-- --A 3 0--36 3 Phase with Economizer

A10226

Page 52

NEC. REQUIRED CLEARANCES

REQUIRED CLEARANCES TO COMBUSTIBLE MATL

REQUIRED CLEARANCE FOR OPERATION AND SERVICING

604D-- --A

Fig. 48 -- 604D-- --A 4 2--60 3 Phase with Economizer

E2010 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 04/10

Manufacturer reserves the right to disc ontinue, or change at any time, specifications or designs without notice and without incurring obligations.

A10227

Catalog No. II604D---07

Replaces: II604D--- 06