Bryant 604D-A User Manual
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.
1
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
2
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
WARNING
604D-- --A
3
604D-- --A
Fig. 2 -- 604D-- --A24-- 36 Unit Dimensions
4
A09471
604D-- --A
Fig. 3 -- 604D-- --A42-- 60 Unit Dimensions
5
A09472
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)
B
G
C
F
A
H
D
Dashed lines show cross support
location for large basepan units.
E
*Provided with roofcurb
604D-- --A
ROOF CURB DETAIL
A09090
SMALL/COMMON CURB
A09413
B
C
G
A
F
H
E
SUPPLY
AIR
RETURN
AIR
SMALL
BASE
UNIT
LARGE
BASE
UNIT
D
UNIT PLACEMENT ON
LARGE CURB
A09415
COMMON CURB
SMALL OR LARGE BASE UNIT
A09094
UNIT
SIZE
Small
or
Large
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
A
IN. (mm)
CPRFCURB010A00 11 (279)
CPRFCURB011A00 14 (356)
CPRFCURB012A00 11 (279)
CPRFCURB013A00 14 (356)
B
(small/common
base)
IN. (mm)*
10 (254)
14 (356)
B
(large base)
IN. (mm)*
IN. (mm)DIN. (mm)EIN. (mm)FIN. (mm)GIN. (mm)HIN. (mm)
14 (356) 16 (406)
C
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
6
A09414
CAUTION - NOTICE TO RIGGERS
A
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
C
MAXIMUM ALLOWABLE
DIFFERENCE in. (mm)
B-C
(6.35)
1/4
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
B
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
7
!
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
8
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.
W1
W2
Y
G
R
C
O
DH
3-Phase
Only
POWER
SUPPLY
THERMOSTAT
(TYPICAL)
A09071
604D-- --A
9
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
10
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)
(mm)
(mm)
327
148
8.3
3.8
0.032 (2)
.81
2...21
11.9
2000
24
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
24
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
24
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
26
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
26
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
26
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
11
604D-- --A
Fig. 11 -- Connection Wiring Schematics 208/230--1--60
12
A10197
604D-- --A
Fig. 11 Cont. -- Ladder Wiring Schematics 208/230--1--60
13
A10197
604D-- --A
Fig. 12 -- Connection Wiring Schematics -- 208/230--3-- 60
14
A10194
604D-- --A
Fig. 12 Cont. -- Ladder Wiring Schematics -- 208/230--3--60
15
A10194
604D-- --A
Fig. 13 -- Connection Wiring Diagram 460--3--60
16
A10195
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