Bryant 677C-A User Manual

677C----A
PREFERREDt 14 SEER SINGLE--PACKAGED HYBRID HEATr
DUAL FUEL SYSTEM WITH PURONr (R--410A) REFRIGERANT
SINGLE AND THREE PHASE
2--5 NOMINAL 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.........................

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

RECEIVING AND INSTALLA TION 2--13.................

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

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

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

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

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

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

Field Fabricate Ductwork 2............................

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

Rig and Place Unit 6.................................

Connect Condensate Drain 7...........................

Install Flue Hood 7...................................

Install Gas Piping 7..................................

Install Duct Connections 8.............................

Configuring Units for Downflow (Vertical)

Discharge 8......................................

Install Electrical Connections 11........................

High--Voltage Connections 11........................

Special Procedures for 208--V Operation 11..............

Control Voltage Connections 11.......................

Balance Point Setting Thermidistat or Hybrid Heat

Thermostat 12....................................

Transformer Protection 12...........................

PRE-- START--UP 12...................................

START--UP 13--17.....................................

Check for Refrigerant Leaks 13.........................

Unit Sequence of Operation 13.........................

Start--Up Heating and Make Adjustments 13...............

Checking Heating Control 14.........................

Check Gas Input 14................................

Adjust Gas Input 14................................

Check Burner Flame 15.............................

Start--Up Cooling and Make Adjustments 16...............

Checking Cooling Control Operation 16................

Checking and Adjusting Refrigerant 16.................

Indoor Airflow and Airflow Adjustments 16.............

Continuous Fan Operation 17........................

MAINTENANCE 27--33................................

Air Filter 27........................................

Indoor Blower and Motor 27...........................

Flue Gas Passageways 28..............................

Limit Switch 28.....................................

Burner Ignition 28...................................

Main Burners 28....................................

Outdoor Coil, Indoor Coil, & Condensate Drain Pan 28......

Outdoor Fan 29.....................................

Electrical Controls and Wiring 29.......................

Refrigerant Circuit 29.................................

Gas Input 29........................................

Indoor Airflow 29...................................

Check Defrost Thermostat 29...........................

PuronR Items 29....................................

TROUBLESHOOTING 32..............................

START--UP CHECKLIST 32............................

Improper installation, adjustment, alteration, service maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. 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 Fuel Gas Code
(NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code
(NEC) NFPA 70.

In Canada refer to the current editions of the National Standards of
Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation codes, and 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

A09042

Fig. 1 -- Unit 677C-- --A

SAFETY CONSIDERATIONS

.

1

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
power to system. There may be more than one disconnect
switch. Turn off accessory heater power switch if
applicable. TAG THE DISCONNECT SWITCH WITH A
SUITABLE WARNING LABEL.

!

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD

677C-- --A

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. 19) 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 677C----A unit (see Fig. 1) is a fully self--contained,
combination Category I gas heating/electric heating and cooling
unit designed for outdoor installation (See Fig. 2 and 3 for unit
dimensions). All unit sizes have return and discharge openings for
both horizontal and downflow configurations, and are factory
shipped with all downflow duct openings covered. Units may be
installed either on a rooftop, a cement slab, or directly on the
ground, if local codes permit (See Fig. 4 for roof curb dimensions).

Models with an N in the thirteenth position of the model number
are dedicated Low NOx units designed for California installations.
These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/joule or less as
shipped from the factory and must be installed in California Air
Quality Management Districts or any other regions in North
America where a Low NOx rule exists.

RECEIVING AND INSTALLATION

Step 1 — Check Equipment

IDENTIFY UNIT
The unit model number and serial number are stamped on the unit

information 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 distribution office if any item is missing. To
prevent loss or damage, leave all parts in original packages until
installation.

Step 2 — Provide Unit Support

For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate if required.

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 water tight 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). This is necessary for
unit drain to function properly. Refer to accessory roof curb
installation instructions for additional information as required.

SLAB MOUNT
Place the unit on a solid, level concrete pad that is a minimum of 4

in. (102 mm) thick with 2 in. (51 mm) above grade. The slab
should be flush on the compressor end of the unit (to allow
condensate drain installation) and should extend 2 in. (51 mm) on
the three remaining sides of the unit. Do not secure the unit to the
slab except when required by local codes.

Step 3 — Field Fabricate Ductwork

Secure all ducts to roof curb and building structure on vertical
discharge units. Do not connect ductwork to unit. For horizontal
applications, unit is provided with flanges on the horizontal
openings. All ductwork should be secured to the flanges. Insulate
and weatherproof all external ductwork, joints, and roof openings
with counter flashing and mastic in accordance with applicable
codes.

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

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

Read unit rating plate for any required clearances around ductwork.
Cabinet return--air static shall not exceed --.25 IN. W.C.

Step 4 — Provide Clearances

The required minimum operating and service clearances are shown
in Fig. 2 and 3.

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.

The condenser fan pulls air through the condenser coil and
discharges it through the top grille. Be sure that the fan discharge
does not recirculate to the condenser coil. Do not locate the unit in
either a corner or under an overhead obstruction. The minimum
clearance under a partial overhang (such as a normal house
overhang) is 48--in. (1219 mm) above the unit top. The maximum
horizontal extension of a partial overhang must not exceed 48-- in.
(1219 mm).

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. The unit may be installed
on wood flooring or on Class A, B, or C roof covering materials.

2

677C-- --A

Fig. 2 -- 677C----A24 --30 Unit Dimensions

3

A09146

677C-- --A

Fig. 3 -- 677C----A36 --60 Unit Dimensions

4

A09147

HVAC unit
base rails

HVAC unit
basepan

B

C

Anchor screw

Flashing field
supplied

Roofing material
field supplied

Cant strip
field supplied

*Provided with roofcurb

ROOF CURB DETAIL

Sealing
Gasket

Roofcurb

Wood nailer*

Roofcurb*

Insulation
(field supplied)

A09090

F

A

D

SMALL CURB

E

A09110

677C-- --A

B

C

F

A

D

LARGE CURB

UNIT SIZE

Small

Large

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

CPRFCURB010A00 11 (279)
CPRFCURB011A00 14 (356)
CPRFCURB012A00 11 (279)
CPRFCURB013A00 14 (356)

IMPORTANT: Do not install large base pan HYBRID HEAT
units onto the small base pan (common curb). The center of gravity
on a large base pan HYBRID HEAT unit could overhang the curb
causing an unsafe condition. Before installing any large base pan
unit onto the common curb, check the “Y” distance in the product

A

IN. (mm)

Fig. 4 -- Roof Curb Dimensions

E

A09095

B

IN. (mm)*

10 (254)

C

IN. (mm)

D

IN. (mm)

E

IN. (mm)

32.4 (822)

16 (406) 47.8 (1214)

14 (356) 43.9 (1116)

literature dimensional drawing to ensure that “Y” is greater than 14
in. (356 mm). Do not install any large base pan unit onto the
common curb with a “Y” dimension (center of gravity) less than 14
in. (356 mm).

F

IN. (mm)

2.7 (69)

A09111

5

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

SEAL STRIP MUST BE IN

UNIT HEIGHT
HAUTEUR D'UNITÉ

677C-- --A

SEE DETAIL A
VOIR DÉTAIL A

Unit

Rigging

Weight

NOTE: See dimensional drawing for corner weight distribution.

24 30

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

368 167 378 171

Unit

Rigging

Weight

450 204 491 223 513 233 543 246

DETAIL A

VOIR DÉTAIL A

36 42 48 60

PLACE BEFORE PLACING
UNIT ON ROOF CURB

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

50CY502286 2.0

A09051

Fig. 5 -- 677C----A Suggested Rigging

Step 5 — Rig and Place Unit

Inspection

Prior to initial use, and at monthly intervals, all rigging shackles,

!

WARNING

PERSONAL INJURY OR PROPERTY DAMAGE
HAZARD

Failure to follow this warning could result in personal

clevis pins, and straps should be visually inspected for any
damage, evidence of wear, structural deformation, or cracks.
Particular attention should be paid to excessive wear at hoist
hooking points and load support areas. Materials showing any kind
of wear in these areas must not be used and should be discarded.

injury, death or property damage.

!

When installing the unit on a rooftop, be sure the roof will
support the additional weight.

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

UNIT FALLING HAZARD

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

Never stand beneath rigged units or lift over people.

WARNING

should handle and install this equipment.

When working with this equipment, observe precautions in the

!

WARNING

literature, on tags, stickers, and labels attached to the equipment,
and any other safety precautions that might apply.

Training for operators of the lifting equipment should include, but
not be limited to, the following:

1. Application of the lifter to the load, and adjustment of the
lifts to adapt to various sizes or kinds of loads.

PROPERTY DAMAGE HAZARD

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

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

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.

Rigging/Lifting of Unit (See Fig. 5)

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 materials are rated to hold the weight of the
unit (See Fig. 5).

6

3. Attach a clevis of sufficient strength in the middle of the
straps. 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.

Step 6 — Connect Condensate Drain

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

Model 677C ----A disposes of condensate water through a 3/4 in.
NPT fitting which exits through the compressor access panel (See
Fig. 2 and 3 for location).

Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground
level installations. Install a field--supplied condensate trap at end
of condensate connection to ensure proper drainage. Make sure that

the outlet of the trap is at least 1 in. (25 mm) lower than the
drain--pan condensate connection to prevent the pan from
overflowing (See Fig. 6). 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 2--in. (51 mm) trap at the condensate
connection to ensure proper drainage (See Fig. 6). Make sure that
the outlet of the trap is at least 1 in. (25 mm) lower than the
drain--pan condensate connection. This prevents the pan from
overflowing.

Prime the trap with water. Connect a drain tube -- using a minimum
of 3/4--in. PVC or 3/4--in. copper pipe (all field--supplied) -- at the
outlet end of the 2--in. (51 mm) trap. Do not undersize the tube.
Pitch the drain tube downward at a slope of at least 1--in. (25 mm)
for every 10 ft (3 m) of horizontal run. Be sure to check the drain
tube for leaks.

TRAP
OUTLET

1-in. (25 mm) min.

2-in. (51 mm) min.

A09052

Fig. 6 -- Condensate Trap

Step 7 — Install Flue Hood

The flue assembly is secured and shipped in the return air duct.
Remove duct cover to locate the assembly (See Fig. 8).

NOTE: Dedicated low NOx models MUST be installed in
California Air Quality Management Districts where a Low NOx
rule exists.

These models meet the California maximum oxides of nitrogen
(NOx) emissions requirements of 40 nanograms/joule or less as
shipped from the factory.

NOTE: Low NOx requirements apply only to natural gas
installations.

!

WARNING

CARBON MONOXIDE POISONING HAZARD

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

The venting system is designed to ensure proper venting.
The flue hood assembly must be installed as indicted in this
section of the unit installation instructions.

Install the flue hood as follows:

1. This installation must conform with local building codes
and with the National Fuel Gas Code (NFGC) NFPA 54 /
ANSI Z223.1, (in Canada, CAN/CGA B149.1, and
B149.2) latest revision. Refer to Provincial and local
plumbing or wastewater codes and other applicable local
codes.

2. Remove flue hood from shipping location (inside the return
section of the blower compartment--see Fig. 8). Remove the
return duct cover to locate the flue hood. Place flue hood
assembly over flue panel. Orient screw holes in flue hood
with holes in the flue panel.

3. Secure flue hood to flue panel by inserting a single screw on
the top flange and the bottom flange of the hood.

Step 8 — Install Gas Piping

The gas supply pipe enters the unit through the access hole
provided. The gas connection to the unit is made to the 1/2--in.
(12.7 mm) FPT gas inlet on the gas valve.

Install a gas supply line that runs to the heating section. Refer to
Table 2 and the NFGC for gas pipe sizing. Do not use cast--iron
pipe. It is recommended that a black iron pipe is used. Check the
local utility for recommendations concerning existing lines. Size
gas supply piping for 0.5 IN. W.C. maximum pressure drop. Never
use pipe smaller than the 1/2-- in. (12.7 mm) FPT gas inlet on the
unit gas valve.

For natural gas applications, the gas pressure at unit gas connection
must not be less than 4.0 IN. W.C. or greater than 13 IN. W.C.
while the unit is operating. For propane applications, the gas
pressure must not be less than 11.0 IN. W.C. or greater than 13 IN.
W.C. at the unit connection.

A 1/8--in. (3.2 mm) NPT plugged tapping, accessible for test gauge
connection, must be installed immediately upstream of the gas
supply connection to the gas valve.

When installing the gas supply line, observe local codes pertaining
to gas pipe installations. Refer to the NFGC NFPA 54/ANSI
Z223.1 latest edition (in Canada, CAN/CGA B149.1).

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed
plumber or gas fitter.

2. When flexible connectors are used, the maximum length
shall not exceed 36 in. (915 mm).

3. When lever handle type manual equipment shutoff valves
are used, they shall be T--handle valves.

4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.

In the absence of local building codes, adhere to the following
pertinent recommendations:

1. Avoid low spots in long runs of pipe. Grade all pipe 1/4 in.
(6.35 mm) for every 15 ft (4.6 m) of length to prevent traps.
Grade all horizontal runs downward to risers. Use risers to
connect to heating section and to meter.

2. Protect all segments of piping system against physical and
thermal damage. Support all piping with appropriate straps,
hangers, etc. Use a minimum of one hanger every 6 ft (1.8
m). For pipe sizes larger than 1/2 in., (12.7 mm) follow
recommendations of national codes.

3. Apply joint compound (pipe dope) sparingly and only to
male threads of joint when making pipe connections. Use
only pipe dope that is resistant to action of liquefied
petroleum gases as specified by local and/or national codes.
Never use Teflon tape.

4. Install sediment trap in riser leading to heating section (See
Fig. 7). This drip leg functions as a trap for dirt and
condensate.

677C-- --A

7

IN

made specifically for the detection of leaks (or method
specified by local codes and/or regulations).

Step 9 — Install Duct Connections

The unit has duct flanges on the supply-- and return--air openings
on the side and bottom of the unit. For downshot applications, the
ductwork connects to the roof curb (See Fig. 2 and 3 for
connection sizes and locations).

Configuring Units for Downflow (V ertical) Discharge

TEE

OUT

NIPPLE

CAP

C99020

Fig. 7 -- Sediment Trap

5. Install an accessible, external, manual main shutoff valve in
gas supply pipe within 6 ft (1.8 m) of heating section.

677C-- --A

6. Install ground-- joint union close to heating section between
unit manual shutoff and external manual main shut--off
valve.

7. Pressure test all gas piping in accordance with local and
national plumbing and gas codes before connecting piping
to unit.

NOTE: Pressure test the gas supply system after the gas supply
piping is connected to the gas valve. The supply piping must be
disconnected from the gas valve during the testing of the piping
systems when test pressure is in excess of 0.5 psig. Pressure test the
gas supply piping system at pressures equal to or less than 0.5 psig.
The unit heating section must be isolated from the gas piping
system by closing the external main manual shutoff valve and
slightly opening the ground--joint union.

!

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. There may be more than one disconnect
switch. Tag the disconnect switch with a suitable warning
label.

1. Open all electrical disconnects before starting any service

2. Remove horizontal (metal) duct covers to access vertical

3. Starting in a corner as shown in Fig. 9, score the panel in

4. If unit ductwork is to be attached to vertical opening flanges

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.

!

work.

(downflow) discharge duct knockouts in unit basepan. (See
Fig. 8.)

both directions from the corner. Tap the panel out from the
scored corner using a small hammer. Be careful and not
damage any other part of the unit.

on the unit base (jackstand applications only), do so at this
time.

WARNING

!

CAUTION

FIRE OR EXPLOSION HAZARD

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

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

--Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of
leaks to check all connections.

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

--If a flexible connector is required or allowed by authority
having jurisdiction, black iron pipe shall be installed at
furnace gas valve and extend a minimum of 2 in. (51 mm)
outside furnace casing.

--If codes allow a flexible connector, always use a new
connector. do not use a connector which has previously
serviced another gas appliance.

8. Check for gas leaks at the field--installed and
factory--installed gas lines after all piping connections have
been completed. Use a commercially available soap solution

5. It is recommended that the base insulation around the
perimeter of the vertical return--air opening be secured to
the base with aluminum tape. Applicable local codes may
require aluminum tape to prevent exposed fiberglass.

6. Reinstall both horizontal duct covers. Ensure opening is
air-- and watertight.

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

NOTE: The design and installation of the duct system must be in

accordance with the standards of the NFPA for installation of

nonresidence--type air conditioning and ventilating systems, NFPA

90A or residence--type, NFPA 90B; and/or local codes and

ordinances.

Adhere to the following criteria when selecting, sizing, and
installing the duct system:

1. Units are shipped for horizontal duct installation (by
removing duct covers).

2. Select and size ductwork, supply-- air registers, and
return--air grilles according to American Society of Heating,
Refrigeration and Air Conditioning Engineers (ASHRAE)
recommendations.

3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
ensure weather tight and airtight seal.

8

Table 1 – Physical Data -- Unit 677C ----A

UNIT SIZE 24040 24060 30040 30060 36060 36090 42060 42090

NOMINAL CAPACITY ---ton 2 2 2 --- 1 / 2 2 --- 1 / 2 3 3 3 --- 1 / 2 3 --- 1 / 2

SHIPPING WEIGHT ---lb.

COMPRESSORS Scroll

Quantity 1

REFRIGERANT (R---410A)

Quantity --- lb

REFRIGERANT METERING

Nominal Cooling Airflow --- (CFM)

HIGH---PRESSURE SWITCH

LOW---PRES SURE SWITCH

DEVICE

OUTDOOR ORIFICE

in. (qty)

(mm)

OUTDOOR COIL

Rows...Fins/in.
F a c e A r e a --- s q f t
OUTDOOR FAN

Nominal Cfm

Diameter --- in.

Motor Hp (Rpm)

INDOOR COIL

Rows...Fins/in.
F a c e A r e a --- s q f t

INDOOR BLOWER

S i z e --- i n .

M o t o r --- h p

FURNACE SECTION*

Burner Orifice
Natural Gas Qty...Drill Size
Propane GasQty...Drill Size

( p s i g ) C u t --- o u t

Reset (Auto)

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

(Liquid Line) (psig)

C u t --- o u t

Reset (auto)

RETURN---AIR FILTERS † }

Throwaway (in.)

(kg)

(kg)

(mm)

(mm)

(mm)

*Based on altitude of 0 to 2000 ft (0 ---610 m).
{Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow vel o city of

300 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 filter rack installation instructions for correct filter size and quantity.

368
167

9.5

4.3

0.032 (2)
.81

2...21

13.6

2500

22

559

1/8 (825)

3...17

3.7

800

10x10

254x254

1/2

2...44

2...55

20x20x1

508x508x25

368
167

9.5

4.3

0.032 (2)
.81

2...21

13.6

2500

22

559

1/8 (825)

3...17

3.7

800

10x10

254x254

1/2

2...38

2...53

378
171

10.5

4.8

0.038 (2)
.97

2...21

15.4

2600

22

559

1/8 (825)

3...17

3.7

1000

10x10

254x254

1/2

2...44

2...55

20x24x1

508x610x25

378
171

10.5

4.8

Indoor---TXV, Outdoor---Accurater

0.038 (2)
.97

2...21

15.4

2600

22

559

1/8 (825)

3...17

3.7

1000

10x10

254x254

1/2

2...44

2...53

650 +/--- 15
420 +/--- 25

2 0 + / --- 5

45 +/--- 10

450
204

9.0

4.1

0.040 (2)

1.02

2...21

13.6

3000

22

559

1/4 (1100)

3...17

4.7

1200

11x10

279x254

3/4

2...38

2...53

450
204

9.0

4.1

0.040 (2)

1.02

2...21

13.6

3000

22

559

1/4 (1100)

3...17

4.7

1200

11x10

279x254

3/4

3...38

3...53

24x30x1

610x762x25

491
223

14.0

6.4

0.038 (Left OD Coil)

0.040 (Right OD Coil)
.97/1.02

2...21

19.4

3500

22

559

1/8 (825)

3...17

4.7

1400

11x10

279x254

3/4

2...38

2...53

1/8 (825)

279x254

491
223

14.0

6.4

2...21

19.4

3500

22

559

3...17

4.7

1400

11x10

3/4

3...38

3...53

677C-- --A

Basepan
Downflow
(Vertical)
Supply
Knockout

Horizontal Duct Covers

Fig. 8 -- Supply and Return Duct Opening

A09076

Basepan
Downflow
(Vertical)
Return
Knockout

A09077

3

2

4

1

3

2

INSTRUCTIONS FOR REMOVING DOWNSHOT PANELS

1. Score groove in corner 1 in both directions as far as you can reach.

2. Starting in corner 1, tap-out all sides with a small hammer. Be careful
not to damage any other part of unit.

3. If side from corner 3 to 4 is not accessible due to heat exchanger,
pivot panel up and down by hand until remaining side breaks off.

Fig. 9 -- Vertical (Downflow) Discharge Duct Knockouts

9

4

1

A09054

Table 1 -- Physical Data -- Unit 677C-- --A Cont’d)

NUMBER

OF

MANIFOLD

PRES

SURE

ORIFICES

UNIT SIZE 48090 48115 48130 60090 60115 60130

NOMINAL CAPACITY ---ton 4 4 4 5 5 5

SHIPPING WEIGHT --- lb

COMPRESSORS Scroll

Quantity 1

REFRIGERANT (R ---410A)

Quantity ---lb

REFRIGERANT METERING DEVICE TXV

OUTDOOR ORIFICE ---in. (qty)

OUTDOOR COIL

Rows...Fins ---in.

F a c e A r e a --- s q f t

OUTDOOR FAN

Nominal Cfm
Diameter ---in.

M o t o r H p --- R p m

INDOOR COIL

Rows...Fins ---in.

F a c e A r e a --- s q f t

INDOOR BLOWER

Nominal C ooling Airflow---(CFM)

677C-- --A

Propane GasQty...Drill Size

HIGH -- -PRESSURE SWITCH (psig)

LOW---PRES SURE SWITCH

*Based on altitude of 0 to 2000 ft (0 ---610 m).
{Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow vel o city of

300 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 filter rack installation instructions for correct filter size and quantity.

S i z e --- i n .

M o t o r --- h p

FURNACE SECTION*

Burner Orifice

Natural Gas Qty...Drill Size

C u t --- o u t

Reset (Auto)

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

(Liquid Line) (psig)

C u t --- o u t

Reset (auto)

RETURN---AIR FILTERS †

Throwaway (in.)

(mm)

(kg)

(kg )

(mm)

(mm)

(mm)

513
233

17.0

7.7

2...21

19.4

3500

22

559

1/4 (1100)

3...17

5.7

1600

11x10

279x254

1.0

3...38

3...53

513
233

17.0

7.7

0.040 (2)

1.02

2...21

19.4

3500

22

559

1/4 (1100)

3...17

5.7

1600

11x10

279x254

1.0

3...33

3...51

513
233

17.0

7.7

2...21

19.4

3500

22

559

1/4 (1100)

3...17

5.7

1600

11x10

279x254

1.0

3...31

3...49

650 +/ ---15
420 +/ ---25

2 0 + / --- 5

45 +/ ---10

24x36x1

(610x914x25)

543
246

16.0

7.3

2...21

23.3

3800

22

559

1/3 (1100)

4...17

5.7

1750

11x10

279x254

1.0

3...38

3...53

543
246

16.0

7.3

0.049 (2)

1.24

2...21

23.3

3800

22

559

1/3 (1100)

4...17

5.7

1750

11x10

279x254

1.0

3...33

3...51

546
246

16.0

7.3

2...21

23.3

3800

22

559

1/3 (1100)

4...17

5.7

1750

11x10

279x254

1.0

3...31

3...49

Table 2 – Maximum Gas Flow Capacity*

NOMINAL

IRON

PIPE, SIZE

(IN.)

1/2 .622 175 120 97 82 73 66 61 57 53 50 44 40 — —
3/4 .824 360 250 200 170 151 138 125 118 110 103 93 84 77 72

1 1.049 680 465 375 320 285 260 240 220 205 195 175 160 145 135
1 --- 1/ 4 1.380 1400 950 770 600 580 530 490 460 430 400 360 325 300 280
1 --- 1/ 2 1.610 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430

* Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5--IN. W.C. (based on a 0.60 specific gravity gas). Refer to Table 2
and the NFGC NFPA 54/ANSI.
† This length includes an ordinary number of fittings.

INTERNAL
DIAMETER

(IN.)

10

(3.0)20(6.1)30(9.1)40(12.2)50(15.2)60(18.3)70(21.3)80(24.4)90(27.4)

LENGTH OF PIPE, FT (m)†

100

(30.5)

125

(31.1)

150

(45.7)

175

(53.3)

200

(61.0)

Table 3 – Heating Inputs

HEATING INPUT

(BTUH)

GAS SUPPLY PRESSURE (IN. W.C.)

Natural{ Propane*{

Min Max Min Max Natural{ Propane*†

40,000 2 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0
60,000 2 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0

90,000 3 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0
115,000 3 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0
130,000 3 4.0 13.0 11.0 13.0 3.2∼3.8 10.0∼11.0

*When a unit is converted to propan e, different size orifices must be used. See separate, natural ---to ---propane conversion kit instructions.

{Based on altitudes from sea level to 2000 ft (610 m) above sea level. In th e U.S.A. for altitudes above 2000 ft (610 m), reduce input rating 4 percent for each

additional 1000 ft (305 m) above sea level. In Canada, from 2000 ft (610 m) above sea level to 4500 ft (1372 m) above sea level, derate the unit 10 percent.

MANIFOLD PRESSURE

(IN. W.C.)

10

4. All units must 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.

5. Size all ductwork for maximum required airflow (either

heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.

6. Adequately insulate and weatherproof all ductwork located

outdoors. Insulate ducts passing through unconditioned
space, and use vapor barrier in accordance with latest issue
of Sheet Metal and Air Conditioning Contractors National
Association (SMACNA) and Air Conditioning Contractors
of America (ACCA) minimum installation standards for
heating and air conditioning systems. Secure all ducts to
building structure.

7. Flash, weatherproof, and vibration--isolate all openings in

building structure in accordance with local codes and good
building practices.

Step 10 — Install Electrical Connections

!

WARNING

ELECTRICAL SHOCK HAZARD

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

The unit cabinet must have an uninterrupted, unbroken
electrical ground. This ground may consist of an electrical
wire connected to the unit ground screw in the control
compartment,or conduit approved forelectrical ground when
installed in accordance with NEC, NFPA 70 National Fire
Protection Association (latest edition) (in Canada, Canadian
Electrical Code CSA C22.1) and local electrical codes.

!

CAUTION

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 switch box 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).

See unit wiring label (Fig. 15 and 16) and Fig. 10 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.

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.

Special Procedures for 208--V Operation

677C-- --A

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. Insulate low--voltage wires for highest voltage contained
within conduit when low--voltage control wires are in
same conduit as high-- voltage wires.

5. Do not damage internal components when drilling
through any panel to mount electrical hardware, conduit,
etc.

High--Voltage Connections

When routing power leads into unit, use only copper wire between
disconnect and unit. The high voltage leads should be in a conduit
until they enter the duct panel; conduit termination at the duct
panel must be watertight.

!

ELECTRICAL SHOCK HAZARD

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

Make sure the power supply tothe unit isswitchedOFF before
making any wiring changes. Tag the disconnect switch with a
suitable warning label. 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.

!

ELECTRICAL SHOCK HAZARD

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

Beforemaking any wiring changes,make surethe gas supply
is switched off first. Then switch off the power supply to the
unit and install lockout tag.

WARNING

WARNING

Control Voltage Connections

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

11

more than 100 ft (30.5 m) from the unit (as measured along the
control voltage wires), use no. 16 AWG color--coded, insulated
(35_C minimum) wires.

Locate the seven (eight on 3 --phase) low voltage thermostat leads
in 24 volt splice box. See Fig. 10 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 unit for
connection to an economizer.

HIGH VOLTAGE
POWER LEADS
(SEE UNIT WIRING
LABEL)

POWER
SUPPLY

3. Comfort Balance Temperature: When the heat pump is
operating below this point, the indoor supply air feels
uncomfortable (i.e. too cool). This is purely subjective and
will depend on the homeowner’s idea of comfort. Below
this temperature the gas furnace should operate in order to
satisfy the desire for indoor comfort.

Transformer Protection

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

PRE--START--UP

!

WARNING

EQUIP GR

CONTROL BOX

677C-- --A

LOW-VOLTAGE
POWER LEADS
(SEE UNIT
WIRING LABEL)

SPLICE BOX

FIELD-SUPPLIED
FUSED DISCONNECT

WHT(W1)

YEL(Y)

GRN(G)

RED(R)

BRN(C)

ORN(O)

BLU (DH)

GRA (Y2)

W

Y

G

R

C

O

DH

3-Phase
Only

THERMOSTAT
(TYPICAL)

A09067

Fig. 10 -- High and Control-- Voltage Connections

Balance Point Setting--Thermidistat or Hybrid
Thermostat

BALANCE POINT TEMPERATURE--The “balance point”
temperature is a setting which affects the operation of the heating
mode. This is a field--selected input temperature (range 5 to 55_F)
(--15to12_C) where the Thermidistat or dual fuel thermostat will
monitor outdoor air temperature and decide whether to enable or
disable the heat pump. If the outdoor temperature is above the
“balance point”, the heat pump will energize first to try to satisfy
the indoor temperature demand. If the heat pump does not make a
sufficient improvement within a reasonable time period (i.e. 15
minutes), then the gas furnace will come on to satisfy the indoor
temperature demand. If the outdoor temperature is below the
“balance point”, the heat pump will not be allowed to operate (i.e.
locked out), and the gas furnace will be used to satisfy the indoor
temperature. There are three separate concepts which are related to
selecting the final “balance point” temperature. Read each of the
following carefully to determine the best “balance point” in a
hybrid installation:

1. Capacity Balance Temperature: This is a point where the
heat pump cannot provide sufficient capacity to keep up
with the indoor temperature demand because of declining
outdoor temperature. At or below this point, the furnace is
needed to maintain proper indoor temperature.

2. Economic Balance Temperature: Above this point, the heat
pump is the most cost efficient to operate, and below this
point the furnace is the most cost efficient to operate. This
can be somewhat complicated to determine and it involves
knowing the cost of gas and electricity, as well as the
efficiency of the furnace and heat pump. For the most
economical operation, the heat pump should operate above
this temperature (assuming it has sufficient capacity) and the
furnace should operate below this temperature.

FIRE,EXPLOSION, ELECTRICAL SHOCK HAZARD

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. Do not operate compressor or provide any electric power
to unit unless compressor terminal cover is in place and
secured.

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

4. Relieve and recover all refrigerant from system before
touching or disturbing anything inside terminal box if
refrigerant leak is suspected around compressor
terminals.

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

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

Proceed as follows to inspect and prepare the unit for initial
start--up:

1. Remove access panels (see Fig. 19).

2. Read and follow instructions on all 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.

c. Leak test all refrigerant tubing connections using

electronic leak detector, halide torch, or liquid--soap
solution. If a refrigerant leak is detected, see the Check
for Refrigerant Leaks section.

d. Inspect all field-- and factory--wiring connections. Be

sure that connections are completed and tight.

12

e. Ensure wires do not touch refrigerant tubing or sharp

sheet metal edges.

f. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

!

WARNING

FIRE, EXPLOSION HAZARD

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

Do not purgegas supply intothe combustionchamber. Do not
use a match or other open flame to check for gas leaks. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections.

4. Verify the following conditions:

a. Make sure gas line is free of air. Before lighting the unit

for the first time, perform the following with the gas
valve in the “OFF” position:

NOTE: If the gas supply pipe was not purged before connecting
the unit, it will be full of air. It is recommended that the ground
joint union be loosened, and the supply line be allowed to purge
until the odor of gas is detected. Never purge gas lines into a
combustion chamber. Immediately upon detection of gas odor,
retighten the union. Allow 5 minutes to elapse, then light unit.

b. Make sure that condenser-- fan blade is correctly

positioned in fan orifice. Leading edge of condenser--fan
blade should be 1/2 in. (12 mm) maximum from fan
orifice.

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

d. Make sure that condensate drain trap is filled with water

to ensure proper drainage.

e. Make sure that all tools and miscellaneous loose parts

have been removed.

START--UP

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 — Unit Sequence of Operation

677C----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. HEAT PUMP HEATING MODE

Outdoor temperature above balance point setpoint of
thermostat.

(1.) On a call for heating, terminals “Y” and “G“ of the

Hybrid thermostat are energized. The “Y“ signal is
sent to the Defrost Board (DB) terminal “Y”. The
DB has a built in five minute anti--short cycle timer
which will not allow the compressor to restart
before the time delay has expired.

(2.) “T2” energizes the compressor contactor via the

High Pressure Switch (HPS) and Low Pressure
Switch (LPS). The compressor and outdoor fan
start. Thermostat “G” energizes the Interface Fan
Board terminal “G”. The blower motor is energized
through contacts of the IFB.

(3.) When the thermostat removes the “Y” and “G”

calls, the compressor contactor and outdoor fan are
de--energized. The evaporator motor is de--ener­gized after a 90 sec. delay.

d. GAS HEATING MODE

Outdoor temperature below balance point setpoint of
thermostat.

Heating Sequence of Operation

(See Fig. 15 and 16 and unit wiring label.)

On a call for heating, terminal W of the thermostat is energized,
starting the induced--draft motor. When the pressure switch senses
that the induced--draft motor is moving sufficient combustion air,
the burner sequence begins. This function is performed by the
integrated gas unit controller (IGC). The indoor (evaporator)--fan
motor is energized 45 sec after flame is established. When the
thermostat is satisfied and W is de--energized, the burners stop
firing and the indoor (evaporator) fan motor shuts off after a
45--sec time--off delay. Please note that the IGC has the capability
to automatically reduce the indoor fan motor on delay and increase
the indoor fan motor off delay in the event of high duct static
and/or partially--clogged filter.

NOTE: An LED (light--emitting diode) indicator is provided on
the control board to monitor operation. The control board is
located by removing the burner access panel (see Fig. 19). During
normal operation, the LED is continuously on.

Step 3 — Start--up Heating and Make Adjust­ments

!

UNIT COMPONENT DAMAGE HAZARD

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

Completethe required procedures given in the Pre--Start--Up
section before starting the unit. Do not jumper any safety
devices when operating the unit.

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. Make sure that burner orifices are
properly aligned. Unstable operation my occur when the burner
orifices in the manifold are misaligned.

Follow the lighting instructions on the heating section operation
label (located on the inside of the control access panel) to start the
heating section.

NOTE: Make sure that gas supply has been purged, and that all
gas piping has been checked for leaks.

CAUTION

677C-- --A

13

specific gravity, or propane gas with a heating value of 2500

3

at 1.5 specific gravity.

Btu/ft

IN THE U.S.A.:
The input rating for altitudes above 2,000 ft (610 m) must be

reduced by 4% for each 1,000 ft (305 m) above see level.
For installations below 2,000 ft (610 m), refer to the unit rating

plate.

For installations above 2,000 ft (610 m) multiply the input by on
the rating plate by the derate multiplier in Table 4 for correct input
rate.

Table 4 – Altitude Derate Multiplier for U.S.A.*

ALTITUDE FT (M) PERCENT OF DERATE

0---2000

Pipe Plug

Manifold

A07679

Fig. 11 -- Burner Assembly

BURNER FLAME

BURNER

677C-- --A

MANIFOLD

(0---610)

2001---3000*

(610---914)

3001---4000
(315---1219)

4001---5000

(1220---1524)

5001---6000

(1524---1829)

6001---7000

(1829---2134)

7001---8000

(2134---2438)

8001---9000

(2439---2743)

9001---10,000

(2744---3048)

* In Canada see Canadian Altitude Adjustment.
{Derate multiplier factors are based on midpoint altitude for altitude ran ge.

0 1.00

8 --- 12 0.90

12---16 0.86

16---20 0.82

20---24 0.78

24---28 0.74

28---32 0.70

32---36 0.66

36---40 0.62

DERATE MULTIPLIER

FACT OR{

IN CANADA:

The input rating for altitudes from 2,000 to 4,500 ft (610 m to

C99021

Fig. 12 -- Monoport Burner

1372 m) above sea level must be derated 10% by an authorized
Gas Conversion Station or Dealer.

EXAMPLE:

Check Heating Control

Start and check the unit for proper heating control operation as
follows (see furnace lighting instructions located on the inside of
the control access panel:

1. Place room thermostat SYSTEM switch in the HEAT
position and the fan switch is placed in AUTO position.

2. Set the heating temperature control of the thermostat above
room temperature.

3. The induced--draft motor will start.

4. On a call for heating, the main burner should light within 5
sec. of the spark being energized. If the burners do not light,
there is a 22--sec. delay before another 5--sec. try. If the
burners still do not light, this sequence is repeated. If the
burners do not light within 15 minutes from the initial call
for heat, there is a lockout. To reset the control, break the
24--v power to W.

5. The evaporator fan will turn on 45 sec. after the flame has
been established. The evaporator fan will turn off 45 sec.
after the thermostat has been satisfied. Please note that the
integrated gas unit controller (IGC) has the capability to
automatically reduce the evaporator “ON” delay and in­crease the evaporator “OFF” delay in the event of high duct
static and/or partially-- clogged filter.

Check Gas Input

Check gas input and manifold pressure after unit start--up (See
Table 3). If adjustment is required proceed as follows:

S The rated gas inputs shown in Table 3 are for altitudes from sea

level to 2000 ft (610 m) above sea level. These inputs are based

3

on natural gas with a heating value of 1025 Btu/ft

at 0.60

90,000 Btu/hr Input Furnace Installed at 4300 ft (1311 m).

Furnace Input Rate at
Sea Level

90,000 X 0.90 = 81,000

XDerateMultiplier

Facto r

= Furnace Input Rate at

Installation Altitude

When the gas supply being used has a different heating value or
specific gravity, refer to national and local codes, or contact your
distributor to determine the required orifice size.

!

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in reduced unit
and/or component life.

Do Not redrill an orifice. Improper drilling (burrs,
out--of--round holes, etc.) can cause excessive burner noise
and misdirection of burner flame. If orifice hole appears
damaged or it is suspected to have been redrilled, check
orifice hole with a numbered drill bit of correct size.

Adjust Gas Input

The gas input to the unit is determined by measuring the gas flow
at the meter or by measuring the manifold pressure. Measuring the
gas flow at the meter is recommended for natural gas units. The
manifold pressure must be measured to determine the input of
propane gas units.

Measure Gas Flow (Natural Gas Units)

Minor adjustment to the gas flow can be made by changing the
manifold pressure. The manifold pressure must be maintained
between 3.2 and 3.8 IN. W.C.

14

REGULATOR
COVER SCREW

PLASTIC

ADJUSTMENT

ON/OFF SWITCH

INLET
PRESSURE TAP

SCREW

REGULATOR SPRING
(PROPANE - WHITE)

(

NATURAL - SILVER)

GAS PRESSURE
REGULATOR
ADJUSTMENT

MANIFOLD
PRESSURE TAP

A07751

Fig. 13 -- Single--Stage Gas Valve

If larger adjustments are required, change main burner orifices
following the recommendations of national and local codes.

NOTE: All other appliances that use the same meter must be
turned off when gas flow is measured at the meter.

Proceed as follows:

1. Turn off gas supply to unit.

2. Remove pipe plug on manifold (See Fig. 11) and connect
manometer. Turn on gas supply to unit.

3. Record number of seconds for gas meter test dial to make
one revolution.

4. Divide number of seconds in Step 3 into 3600 (number of
seconds in one hr).

5. Multiply result of Step 4 by the number of cubic feet (cu ft)
shown for one revolution of test dial to obtain cubic feet (cu
ft) of gas flow per hour.

6. Multiply result of Step 5 by Btu heating value of gas to
obtain total measured input in Btuh. Compare this value
with heating input shown in Table 3 (Consult the local gas
supplier if the heating value of gas is not known).

EXAMPLE: Assume that the size of test dial is 1 cu ft, one
revolution takes 32 sec, and the heating value of the gas is 1050

3

. Proceed as follows:

Btu/ft

1. 32 sec. to complete one revolution.

2. 3600 ÷ 32 = 112.5.

3.112.5x1=112.5ft

3

of gas flow/hr.

4. 112.5 x 1050 = 118,125 Btuh input.

If the desired gas input is 115,000 Btuh, only a minor change in the
manifold pressure is required.

Observe manifold pressure and proceed as follows to adjust gas
input:

1. Remove regulator cover screw over plastic adjustment
screw on g as valve (See Fig. 13).

2. Turn plastic adjustment screw clockwise to increase gas
input, or turn plastic adjustment screw counterclockwise to
decrease input (See Fig. 13). Manifold pressure must be
between 3.2 and 3.8 IN. W.C.

!

WARNING

FIRE AND UNIT DAMAGE HAZARD

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

Unsafe operation of the unit may result if manifold pressure
is outside this range.

3. Replace regulator cover screw on gas valve (See Fig. 13).

4. Turn off gas supply to unit. Remove manometer from
pressure tap and replace pipe plug on gas valve. (See Fig.

11.) Turn on gas to unit and check for leaks.

Measure Manifold Pressure (Propane Units)

Refer to propane kit installation instructions for properly checking
gas input.

NOTE: For installations below 2,000 ft (610 m), refer to the unit
rating plate for proper propane conversion kit. For installations
above 2,000 ft (610 m), contact your distributor for proper propane
conversion kit.

Check Burner Flame

With control access panel (see Fig. 19) removed, observe the unit
heating operation. Watch the burner flames to see if they are light
blue and soft in appearance, and that the flames are approximately
the same for each burner. Propane will have blue flame (See Fig.

12). Refer to the Maintenance section for information on burner
removal.

Normal Operation

An LED (light--emitting diode) indicator is provided on the
integrated gas unit controller (IGC) to monitor operation. The IGC
is located by removing the control access panel (see Fig. 19).
During normal operation, the LED is continuously on (See Table 5
for error codes).

Airflow and Temperature Rise

The heating section for each size unit is designed and approved for
heating operation within the temperature--rise range stamped on the
unit rating plate.

Table 10 shows the approved temperature rise range for each
heating input, and the air delivery cfm at various temperature rises
for a given external static pressure. The heating operation airflow
must produce a temperature rise that falls within the approved
range.

Refer to Indoor Airflow and Airflow Adjustments section to adjust
heating airflow when required.

Limit Switches

Normally closed limit switch (LS) completes the control circuit.
Should the leaving--air temperature rise above the maximum
allowable temperature, the limit switch opens and the control
circuit “breaks.” Any interruption in the control circuit instantly
closes the gas valve and stops gas flow to the burners and pilot.
The blower motor continues to run until LS resets.

When the air temperature at the limit switch drops to the
low--temperature setting of the limit switch, the switch closes and

677C-- --A

15

completes the control circuit. The direct--spark ignition system
cycles and the unit returns to normal heating operation.

Table 5 – LED Indications

STATUS CODE LED INDICATION

Normal Operation

No Power Hardware Failure Off

Limit Switch Fault 2 Flashes
Flame Sense Fault 3 Flashes

Four Consecutive Limit Switch Faults 4 Flashes

Ignition Lockout Fault 5 Flashes
Pressure Switch Fault 6 Flashes

Rollout Switch Fault 7 Flashes

Internal Control Fault 8 Flashes

Temporary 1 hr auto reset

NOTES:

1.This code indicates an internal processor fault that will reset itself in one
hr. Fault can be caused by stray RF signals in the structure or nearby. T h is
is a UL requirement.

2. LED indicates acceptable operation. Do not change ignition control
board.

3. When W is energized the burners will remain on for a minimum of 60 sec.

4.IfmorethanoneerrormodeexiststheywillbedisplayedontheLEDin
sequence.

677C-- --A

Rollout Switch

The function of the rollout switch is to close the main gas valve in
the event of flame rollout. The switch is located above the main
burners. When the temperature at the rollout switch reaches the
maximum allowable temperature, the control circuit trips, closing
the gas valve and stopping gas flow to the burners. The indoor
(evaporator) fan motor (IFM) and induced draft motor continue to
run until switch is reset. The IGC LED will display FAUL T CODE

7.

2

1

On

9 Flashes

Step 4 — Start--up Cooling and Make 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 compressor when the
outdoor temperature is below 40°F(4.4°C) (unless accessory
low--ambient kit is installed). Do not rapid--cycle the compressor.
Allow 5 minutes between on cycles to prevent compressor damage.

Checking Cooling Control Operation

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

1. Place room thermostat SYSTEM switch in OFF position.
Observe that blower motor starts wh en FAN switch is
placed in ON position and shuts down when FAN switch is
placed in AUTO position.

2. Place SYSTEM switch in COOL position and FAN switch
in AUTO position. Set cooling control below room
temperature. Observe that compressor, condenser fan, and
evaporator blower motors start. Observe that cooling cycle
shuts down when control setting is satisfied. The evaporator
fan will continue to run for 90 sec.

IMPORTANT: Three--phase, scroll compressors units 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 will be near zero.

Checking and Adjusting Refrigerant Charge

The refrigerant system is fully charged with PuronR (R--410A)
refrigerant and is tested and factory sealed. Allow system to operate
a minimum of 15 minutes before checking or adjusting charge.

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

The charging label and the tables shown refer to system
temperatures and pressures in cooling mode only. A refrigerant
charging label is attached to the inside of the compressor access
panel. 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.

!

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

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 in Cooling Mode and let unit 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).

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 the Check for Refrigerant Leaks section.

CAUTION

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.

16

!

WARNING

ELECTRICAL SHOCK HAZARD

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

Before making any indoor wiring adjustments, shut off gas
supply. Then 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.

This unit is factory-set up for use with a single cooling fan speed.
The cooling speed is marked “LOW” on the interface fan board
(IFB) (Fig. 14) . The factory-shipped settings are noted in Table

10. There are 3 additional speed tap wires available for use in
either gas heating or cooling (For color coding on the indoor fan
motor leads, see Table 6). The additional 3 speed tap wires are
shipped loose with vinyl caps and are located in the control box,
near the interface fan board (IFB) (Fig. 14).

Gas Heating Fan Speed Set-up

To change the gas heating speed:

1. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 6 for color coding). Table 10 shows the
temperature rise associated with each fan speed for a given
static pressure. Make sure that the speed chosen delivers a
temperature rise within the rise range listed on the unit
rating plate.

2. Remove the current speed tap wire from the “GAS HEAT”
terminal on the interface fan board (IFB) (Fig.14) and place
vinyl cap over the connector on the wire.

3. Connect the desired speed tap wire to the “GAS HEAT”
terminal on the interface fan board (IFB).

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”

used)

(Refer to Table 6 for color coding). Add the wet coil
pressure drop in Table 8 to the system static to determine the
correct cooling airflow speed in Table 10 that will deliver
the nominal cooling airflow as listed in Table 1 for each
size.

terminal on the interface fan board (IFB) (Fig. 14) and place
vinyl cap over the connector on the wire.

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

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.

NOTE: For heat pump operation, the recommended airflow is 350
to 450 CFM for each 12,000 Btuh of rated cooling capacity.

used)

1. Remove fan speed tap wire from the “LOW” terminal on
the interface fan board (IFB) (Fig. 14).

2. Determine correct normal cooling fan speed for unit and
application. Add the wet coil pressure drop in Table 8 to
the system static to determine the correct cooling airflow
speed in Table 10 that will deliver the nominal cooling
airflow as listed in Table 1 for each size.

3. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 6 for color coding) for the normal cooling
fan speed and place desired speed tap wire on “HIGH” on
the interface board.

4. Refer to airflow tables (Table 10) to determine allowable
speeds for the dehumidification cooling fan speed. In Table
10, speeds that are not allowed for dehumidification cooling
are shaded.

5. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 6 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.

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

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. 14).

Table 6 – Color Coding for Indoor Fan Motor Leads

Black = High Speed

Orange = Med---High Speed

Red=MedSpeed

P i n k = M e d --- L o w S pe e d

Blue = Low Speed

677C-- --A

17

GAS
HEAT

QC6 QC7 QC4 QC3

K2 K1

COMLOWHIGH

DCR QCR

RI0

Q1R1LC8RL3

JM6

Q3

C

D2

RI2

CDM/C

QC1

24VAC/R

C9

C4

D4D6C2OILL

A7

R9 AB A15

U1

P2

JW1

W2

C3

P1

Y2/ Y1/

GCR

D3D5

C7

P3

677C-- --A

SDL

JW7

SSTZ-8

R2

QCB

Y

R3 R5 R6

Y R U C 24VAC

G1

G2

YDH

JM5

JW3

JW2

RI DL

C0

R4 RL4

JW4

3 AMP

F1

A09058

Fig. 14 -- Interface Fan Board (IFB)

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 — — — — — — — — — — —

— — — — 0.09 0.10 0.11 0.13 0.14 0.15 0.16 — — — — — — — —

— — — 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 – 677C----A Wet Coil Pressure Drop

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 9 – Wet Coil Air Delivery - Downflow -- High Speed with 1--in. 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, 42 1612 1569 1527 1481 1451 1393 1351 1317 1278 1242

48 2298 2239 2180 2110 2044 1951 1862 1777 1697 1591
60 2000 1926 1825 1820 1759 1705 1634 1496 1412 1328

EXTERNAL STATIC PRESSURE (in. W.C.)

18

UNIT

677C--- ---A24040

677C--- ---A24060

677C--- ---A30040

Table 10 – Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -- Unit 677C-- --A24--60

HEATING

RISE

RANGE

30 - 60oF

(17 - 33

25 - 55oF

(14 - 31

30 - 60oF

(17 - 33

MOTOR

SPEED

Low Blue

Med-Low

Medium

o

C)

Med-High Orange

High Black

Low Blue

Med-Low

Medium Red

o

C)

Med-High Orange

High

Low Blue

Med-Low Pink

Medium

o

C)

Med-High2Orange

High Black

WIRE

COLOR

CFM 741 638 547 415 --- --- --- --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 898 820 738 662 536 --- --- --- --­Heating

2

Pink

1

Red

2

Pink

1

Black

1

Red

o

Rise (
Heating

o

Rise (
CFM 973 887 823 733 665 538 451 --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 1140 1064 996 915 840 758 687 564 480
Heating

o

Rise (
Heating

o

Rise (
CFM 1202 1140 1082 1015 961 881 810 732 631
Heating

o

Rise (
Heating

o

Rise (
CFM 741 638 547 415 --- --- --- --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 898 820 738 662 536 --- --- --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 973 887 823 733 665 538 451 --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 1140 1064 996 915 840 758 687 564 480
Heating

o

Rise (
Heating

o

Rise (
CFM 1202 1140 1082 1015 961 881 810 732 631
Heating

o

Rise (
Heating

o

Rise (
CFM 741 638 547 415 --- --- --- --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 898 820 738 662 536 --- --- --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 973 887 823 733 665 538 451 --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 1140 1064 996 915 840 758 687 564 480
Heating

o

Rise (
Heating

o

Rise (
CFM 1202 1140 1082 1015 961 881 810 732 631
Heating

o

Rise (
Heating

o

Rise (

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

41 47 55 NA NA NA NA NA NA

23 26 31 NA NA NA NA NA NA

34 37 41 46 56 NA NA NA NA

19 20 23 25 31 NA NA NA NA

31 34 37 41 45 56 NA NA NA

17 19 20 23 25 31 NA NA NA

NA NA 30 33 36 40 44 54 NA

NA NA 17 18 20 22 24 30 NA

NA NA NA 30 31 34 37 41 48

NA NA NA 17 17 19 21 23 27

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

49 54 NA NA NA NA NA NA NA

27 30 NA NA NA NA NA NA NA

46 50 54 NA NA NA NA NA NA

25 28 30 NA NA NA NA NA NA

39 42 45 49 53 NA NA NA NA

22 23 25 27 29 NA NA NA NA

37 39 41 44 46 50 55 NA NA

21 22 23 24 26 28 30 NA NA

41 47 55 NA NA NA NA NA NA

23 26 31 NA NA NA NA NA NA

34 37 41 46 56 NA NA NA NA

19 20 23 25 31 NA NA NA NA

31 34 37 41 45 56 NA NA NA

17 19 20 23 25 31 NA NA NA

NA NA 30 33 36 40 44 54 NA

NA NA 17 18 20 22 24 30 NA

NA NA NA 30 31 34 37 41 48

NA NA NA 17 17 19 21 23 27

EXTERNAL STATIC PRESSURE (in. W.C.)

677C-- --A

19

Table 10 -- Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -- Unit 677C-- -- A24--60 Cont

UNIT

677C--- ---A30060

HEATING

RISE

RANGE

25 - 55oF

(14 - 31

677C-- --A

677C--- ---A36060

677C--- ---A36090

25 - 55oF

(14 - 31

35 - 65oF

(19 - 36

MOTOR

SPEED

Low Blue

Med-Low Pink

Medium Red

o

C)

Med-High2Orange

High

Low

Med-Low Pink

Medium Red

o

C)

Med-High2Orange

High Black

Low Blue

Med-Low Pink

Medium

o

C)

Med-High2Orange

High Black

WIRE

COLOR

CFM 741 638 547 415 --- --- --- --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 898 820 738 662 536 --- --- --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 973 887 823 733 665 538 451 --- --­Heating

o

Rise (
Heating

o

Rise (
CFM 1140 1064 996 915 840 758 687 564 480
Heating

o

Rise (
Heating

o

Rise (
CFM 1202 1140 1082 1015 961 881 810 732 631
Heating

1

Black

1

Blue

1

Red

o

Rise (
Heating

o

Rise (
CFM 1295 1234 1182 1126 1075 1016 955 898 857
Heating

o

Rise (
Heating

o

Rise (
CFM 1345 1282 1235 1194 1140 1095 1027 974 921
Heating

o

Rise (
Heating

o

Rise (
CFM 1505 1452 1413 1358 1323 1282 1234 1169 1130
Heating

o

Rise (
Heating

o

Rise (
CFM 1545 1492 1449 1411 1362 1313 1278 1231 1188
Heating

o

Rise (
Heating

o

Rise (
CFM 1705 1643 1607 1568 1518 1483 1448 1404 1360
Heating

o

Rise (
Heating

o

Rise (
CFM 1295 1234 1182 1126 1075 1016 955 898 857
Heating

o

Rise (
Heating

o

Rise (
CFM 1345 1282 1235 1194 1140 1095 1027 974 921
Heating

o

Rise (
Heating

o

Rise (
CFM 1505 1452 1413 1358 1323 1282 1234 1169 1130
Heating

o

Rise (
Heating

o

Rise (
CFM 1545 1492 1449 1411 1362 1313 1278 1231 1188
Heating

o

Rise (
Heating

o

Rise (
CFM 1705 1643 1607 1568 1518 1483 1448 1404 1360
Heating

o

Rise (
Heating

o

Rise (

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

NA NA NA NA NA NA NA NA NA

F)

NA NA NA NA NA NA NA NA NA

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

49 54 NA NA NA NA NA NA NA

27 30 NA NA NA NA NA NA NA

46 50 54 NA NA NA NA NA NA

25 28 30 NA NA NA NA NA NA

39 42 45 49 53 NA NA NA NA

22 23 25 27 29 NA NA NA NA

37 39 41 44 46 50 55 NA NA

21 22 23 24 26 28 30 NA NA

34 36 38 39 41 44 47 49 52

19 20 21 22 23 24 26 27 29

33 35 36 37 39 41 43 46 48

18 19 20 21 22 23 24 25 27

30 31 31 33 34 35 36 38 39

16 17 17 18 19 19 20 21 22

29 30 31 31 33 34 35 36 37

16 17 17 17 18 19 19 20 21

26 27 28 28 29 30 31 32 33

14 15 15 16 16 17 17 18 18

53 55 58 60 63 NA NA NA NA

29 31 32 34 35 NA NA NA NA

51 53 55 57 60 62 NA NA NA

28 29 31 32 33 35 NA NA NA

45 47 48 50 51 53 55 58 60

25 26 27 28 29 29 31 32 33

44 46 47 48 50 52 53 55 57

24 25 26 27 28 29 30 31 32

40 41 42 43 45 46 47 48 50

22 23 24 24 25 25 26 27 28

EXTERNAL STATIC PRESSURE (in. W.C.)

20

UNIT

677C--- ---A42060

677C--- ---A42090

677C--- ---A48090

Table 10 -- Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -- Unit 677C-- -- A24--60 Cont

HEATING

RISE

RANGE

25 - 55oF

(14 - 31

35 - 65oF

(19 - 36

35 - 65oF

(19 - 36

MOTOR

SPEED

Low

Med-Low Pink

Medium Red

o

C)

Med-High2Orange

High Black

Low Blue

Med-Low Pink

Medium

o

C)

Med-High2Orange

High Black

Low

Med-Low

Medium Red

o

C)

Med-High Orange

High Black

WIRE

COLOR

CFM 1295 1234 1182 1126 1075 1016 955 898 857
Heating

1

1

Blue

1

Red

Blue

2

Pink

o

Rise (
Heating

o

Rise (
CFM 1345 1282 1235 1194 1140 1095 1027 974 921
Heating

o

Rise (
Heating

o

Rise (
CFM 1505 1452 1413 1358 1323 1282 1234 1169 1130
Heating

o

Rise (
Heating

o

Rise (
CFM 1545 1492 1449 1411 1362 1313 1278 1231 1188
Heating

o

Rise (
Heating

o

Rise (
CFM 1705 1643 1607 1568 1518 1483 1448 1404 1360
Heating

o

Rise (
Heating

o

Rise (
CFM 1295 1234 1182 1126 1075 1016 955 898 857
Heating

o

Rise (
Heating

o

Rise (
CFM 1345 1282 1235 1194 1140 1095 1027 974 921
Heating

o

Rise (
Heating

o

Rise (
CFM 1505 1452 1413 1358 1323 1282 1234 1169 1130
Heating

o

Rise (
Heating

o

Rise (
CFM 1545 1492 1449 1411 1362 1313 1278 1231 1188
Heating

o

Rise (
Heating

o

Rise (
CFM 1705 1643 1607 1568 1518 1483 1448 1404 1360
Heating

o

Rise (
Heating

o

Rise (
CFM 1445 1389 1341 1281 1236 1189 1139 1072 1027
Heating

o

Rise (
Heating

o

Rise (
CFM 1678 1635 1602 1558 1513 1474 1438 1404 1349
Heating

o

Rise (
Heating

o

Rise (
CFM 1962 1915 1880 1843 1794 1753 1711 1675 1628
Heating

o

Rise (
Heating

o

Rise (
CFM 2131 2088 2065 2013 1982 1941 1888 1860 1785
Heating

o

Rise (
Heating

o

Rise (
CFM 2461 2409 2339 2286 2192 2140 2062 1968 1874
Heating

o

Rise (
Heating

o

Rise (

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

34 36 38 39 41 44 47 49 52

19 20 21 22 23 24 26 27 29

33 35 36 37 39 41 43 46 48

18 19 20 21 22 23 24 25 27

30 31 31 33 34 35 36 38 39

16 17 17 18 19 19 20 21 22

29 30 31 31 33 34 35 36 37

16 17 17 17 18 19 19 20 21

26 27 28 28 29 30 31 32 33

14 15 15 16 16 17 17 18 18

53 55 58 60 63 NA NA NA NA

29 31 32 34 35 NA NA NA NA

51 53 55 57 60 62 NA NA NA

28 29 31 32 33 35 NA NA NA

45 47 48 50 51 53 55 58 60

25 26 27 28 29 29 31 32 33

44 46 47 48 50 52 53 55 57

24 25 26 27 28 29 30 31 32

40 41 42 43 45 46 47 48 50

22 23 24 24 25 25 26 27 28

47 49 51 53 55 57 60 63 NA

26 27 28 29 31 32 33 35 NA

41 42 42 44 45 46 47 48 50

23 23 24 24 25 26 26 27 28

35 36 36 37 38 39 40 41 42

19 20 20 20 21 22 22 23 23

NA NA NA NA NA 35 36 37 38

NA NA NA NA NA 19 20 20 21

NA NA NA NA NA NA NA 35 36

NA NA NA NA NA NA NA 19 20

EXTERNAL STATIC PRESSURE (in. W.C.)

677C-- --A

21

Table 10 -- Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -- Unit 677C-- -- A24--60 Cont

UNIT

677C--- ---A48115

HEATING

RISE

RANGE

30 - 60oF

(17 - 33

677C-- --A

677C--- ---A48130

677C--- ---A60090

35 - 65oF

(19 - 36

35 - 65oF

(19 - 36

MOTOR

SPEED

Low Blue

Med-Low

Medium Red

o

C)

Med-High1Orange

High Black

Low Blue

Med-Low

Medium Red

o

C)

Med-High1Orange

High Black

Low

Med-Low Pink

Medium

o

C)

Med-High Orange

High Black

WIRE

COLOR

CFM 1445 1389 1341 1281 1236 1189 1139 1072 1027
Heating

o

Rise (
Heating

o

Rise (
CFM 1678 1635 1602 1558 1513 1474 1438 1404 1349
Heating

2

Pink

2

Pink

1

Blue

2

Red

o

Rise (
Heating

o

Rise (
CFM 1962 1915 1880 1843 1794 1753 1711 1675 1628
Heating

o

Rise (
Heating

o

Rise (
CFM 2131 2088 2065 2013 1982 1941 1888 1860 1785
Heating

o

Rise (
Heating

o

Rise (
CFM 2461 2409 2339 2286 2192 2140 2062 1968 1874
Heating

o

Rise (
Heating

o

Rise (
CFM 1445 1389 1341 1281 1236 1189 1139 1072 1027
Heating

o

Rise (
Heating

o

Rise (
CFM 1678 1635 1602 1558 1513 1474 1438 1404 1349
Heating

o

Rise (
Heating

o

Rise (
CFM 1962 1915 1880 1843 1794 1753 1711 1675 1628
Heating

o

Rise (
Heating

o

Rise (
CFM 2131 2088 2065 2013 1982 1941 1888 1860 1785
Heating

o

Rise (
Heating

o

Rise (
CFM 2461 2409 2339 2286 2192 2140 2062 1968 1874
Heating

o

Rise (
Heating

o

Rise (
CFM 1448 1362 1296 1226 1168 1108 1071 998 905
Heating

o

Rise (
Heating

o

Rise (
CFM 1722 1675 1614 1543 1499 1442 1408 1356 1308
Heating

o

Rise (
Heating

o

Rise (
CFM 1887 1847 1783 1726 1677 1625 1578 1527 1432
Heating

o

Rise (
Heating

o

Rise (
CFM 2055 2008 1958 1927 1900 1768 1685 1581 1458
Heating

o

Rise (
Heating

o

Rise (
CFM 2292 2238 2158 2049 1935 1840 1732 1635 1513
Heating

o

Rise (
Heating

o

Rise (

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

60 NA NA NA NA NA NA NA NA

33 NA NA NA NA NA NA NA NA

52 53 54 56 57 59 60 NA NA

29 30 30 31 32 33 34 NA NA

44 45 46 47 48 50 51 52 53

25 25 26 26 27 28 28 29 30

41 42 42 43 44 45 46 47 49

23 23 23 24 24 25 26 26 27

35 36 37 38 40 41 42 44 46

20 20 21 21 22 23 23 25 26

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

57 59 60 62 64 65 NA NA NA

32 33 33 34 35 36 NA NA NA

49 50 51 52 54 55 56 57 59

27 28 28 29 30 31 31 32 33

45 46 47 48 49 50 51 52 54

25 26 26 27 27 28 28 29 30

39 40 41 42 44 45 47 49 51

22 22 23 23 24 25 26 27 29

47 50 52 55 58 61 63 NA NA

26 28 29 31 32 34 35 NA NA

39 41 42 44 45 47 48 50 52

22 23 23 24 25 26 27 28 29

36 37 38 39 41 42 43 45 47

20 20 21 22 23 23 24 25 26

NA NA 35 35 36 38 40 43 47

NA NA 19 20 20 21 22 24 26

NA NA NA NA 35 37 39 42 45

NA NA NA NA 20 21 22 23 25

EXTERNAL STATIC PRESSURE (in. W.C.)

22

Table 10 -- Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -- Unit 677C-- -- A24--60 Cont

UNIT

677C--- ---A60115

677C--- ---A60130

* Air delivery values a r e without air filter and a re for dry coil (See 677C --- ---A Wet Coil Pressure Drop table).

1

Factory---shipped gas heating speed

2

Factory ---shipped heat pump speed

HEATING

RISE

RANGE

30 - 60oF

(17 - 33

35 - 65oF

(19 - 36

MOTOR

SPEED

Low Blue

Med-Low Pink

Medium

o

C)

Med-High1Orange

High Black

Low Blue

Med-Low Pink

Medium

o

C)

Med-High1Orange

High Black

WIRE

COLOR

CFM 1448 1362 1296 1226 1168 1108 1071 998 905
Heating

o

Rise (
Heating

o

Rise (
CFM 1722 1675 1614 1543 1499 1442 1408 1356 1308
Heating

o

Rise (
Heating

o

Rise (
CFM 1887 1847 1783 1726 1677 1625 1578 1527 1432
Heating

2

Red

2

Red

o

Rise (
Heating

o

Rise (
CFM 2055 2008 1958 1927 1900 1768 1685 1581 1458
Heating

o

Rise (
Heating

o

Rise (
CFM 2292 2238 2158 2049 1935 1840 1732 1635 1513
Heating

o

Rise (
Heating

o

Rise (
CFM 1448 1321 1282 1235 1192 1145 1101 1057 1011
Heating

o

Rise (
Heating

o

Rise (
CFM 1722 1675 1614 1543 1499 1442 1408 1356 1308
Heating

o

Rise (
Heating

o

Rise (
CFM 1887 1847 1783 1726 1677 1625 1578 1527 1432
Heating

o

Rise (
Heating

o

Rise (
CFM 2055 2008 1958 1927 1900 1768 1685 1581 1458
Heating

o

Rise (
Heating

o

Rise (
CFM 2292 2238 2158 2049 1935 1840 1732 1635 1513
Heating

o

Rise (
Heating

o

Rise (

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

F)

C)

60 NA NA NA NA NA NA NA NA

33 NA NA NA NA NA NA NA NA

50 52 54 56 58 60 NA NA NA

28 29 30 31 32 33 NA NA NA

46 47 49 50 52 53 55 57 NA

26 26 27 28 29 30 31 32 NA

42 43 44 45 46 49 52 55 60

23 24 25 25 25 27 29 31 33

38 39 40 42 45 47 50 53 57

21 22 22 24 25 26 28 30 32

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

56 57 60 62 64 NA NA NA NA

31 32 33 35 36 NA NA NA NA

51 52 54 56 57 59 61 63 NA

28 29 30 31 32 33 34 35 NA

47 48 49 50 51 54 57 61 NA

26 27 27 28 28 30 32 34 NA

42 43 45 47 50 52 56 59 64

23 24 25 26 28 29 31 33 35

NA --- Not allowed for heating 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.

EXTERNAL STATIC PRESSURE (in. W.C.)

677C-- --A

23

677C-- --A

Fig. 15 -- 208/230--1--60 Wiring Diagram, Unit 677C----A

24

A09068

677C-- --A

Fig. 16 -- 208/230--3--60 Wiring Diagram, Unit 677C----A

25

A09209

677C-- --A

Fig. 17 -- Cooling Charging Table-- Subcooling

26

50VT500173 REV 4.0

A09099

MAINTENANCE

To ensure continuing high performance and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment. This combination
heating/cooling unit should be inspected at least once each year by
a qualified service person. To troubleshoot cooling or heating of
units, refer to Tables 10, 11 and 12.

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

!

WARNING

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.

5. Check and inspect heating section before each heating
season. Clean and adjust when necessary.

6. Check flue hood and remove any obstructions, if necessary.

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 heating and cooling season or whenever the filter(s) becomes
clogged with dust and/or lint.

Indoor Blower and Motor

NOTE: All motors are prelubricated. Do not attempt to lubricate

these motors.

For longer life, operating economy, and continuing efficiency,
clean accumulated dirt and grease from the blower wheel and
motor annually.

!

WARNING

!

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.

4. Should overheating occur or the gas supply fail to shut
off, turn off external main manual gas valve to the unit.
Then shut off electrical supply.

!

CAUTION

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. Certain geographical locations may require more
frequent inspections.

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

3. Inspect blower motor and wheel for cleanliness at the
beginning of each heating and cooling season. Clean when
necessary. For first heating and cooling season, inspect
blower wheel bi--monthly to determine proper cleaning
frequency.

4. Check electrical connections for tightness and controls for
proper operation each heating and cooling season. Service
when necessary. Ensure electrical wiring is not in contact
with refrigerant tubing or sharp metal edges.

ELECTRICAL SHOCK HAZARD

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

Disconnect and tag electrical power to the unit before cleaning
the blower motor and wheel.

Cleaning the Blower Motor and Wheel

1. Remove and disassemble blower assembly as follows:
a. Remove blower access panel (see Fig. 19).

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.

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

motor.

g. Reinstall blower access panel (see Fig. 19).

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

proper blower rotation and motor speeds during heating and
cooling cycles.

677C-- --A

27

Integrated
Gas Unit
Controller
(IGC)

Auto Transformer
fuses used on 460
volt units only.
(Hidden)

Interface Fan
Board (IFB)

Induced Draft
Motor

1. Remove the induced draft blower assembly according to

directions in the Induced Draft Blower Assembly section.

2. Remove the 11 screws holding the flue collector box cover

(See Fig. 18) to the heat exchanger assembly. Inspect the
heat exchangers.

3. Clean all surfaces, as required, using a wire brush.

Limit Switch

Remove blower access panel (see Fig. 19). Limit switch is located
on the fan partition.

Burner Ignition

Unit is equipped with a direct spark ignition 100 percent lockout

Fan Partition
Mounting
Bracket

Flue
Collector
Box

Inducer
Blower
Housing

Burner
Rack

Mounting
Screw

Fig. 18 -- Blower Housing and Flue Collector Box

Rollout
Switch

A09199

system. Ignition module (IGC) is located in the control box (See
Fig. 18). Module contains a self--diagnostic LED. During
servicing, refer to label diagram or Table 5 in these instructions for
LED interpretation.

If lockout occurs, unit may be reset by either momentarily
interrupting power supply to unit or by turning selector switch to
OFF position at the thermostat.

Main Burners

At the beginning of each heating season, inspect for deterioration
or blockage due to corrosion or other causes. Observe the main
burner flames and adjust, if necessary.

677C-- --A

Removal of Gas T

To remove the gas train for servicing:

1. Shut off main gas valve.

2. Shut off power to unit and install lockout tag.

3. Remove control access panel (See Fig. 19).

4. Disconnect gas piping at unit gas valve.

5. Remove fan partition mounting bracket (2 screws located

on the left side of the control compartment on the fan parti-

Control
Access
Panel

A09210

Compressor
Access Panel

Blower
Access
Panel

Fig. 19 -- Unit Access Panels

Induced Draft (combustion air) Blower Assembly

The induced--draft blower assembly consists of the inducer motor,
the blower housing, and the induced--draft blower wheel.

Clean periodically to assure proper airflow and heating efficiency.
Inspect blower wheel every fall and periodically during the heating
season. For the first heating season, inspect blower wheel
bimonthly to determine proper cleaning frequency.

To inspect blower wheel, remove draft hood assembly. Shine a
flashlight into opening to inspect wheel. If cleaning is required,
remove induced--draft blower assembly as follows:

1. Remove control access panel (See Fig. 19).

2. Remove the 5 screws that attach induced--draft blower as­sembly to the flue collector box cover.

3. Slide the assembly out of the unit. (See Fig. 21). Clean the
blower wheel. If additional cleaning is required, continue
with Steps 4 and 5.

4. To remove blower wheel, remove 2 setscrews.

5. To remove inducer motor, remove screws that hold the
inducer motor to the blower housing.

6. To reinstall, reverse the procedure outlined above.

Flue Gas Passageways

To inspect the flue collector box and upper areas of the heat
exchanger:

tion panel). Slide bracket forward, bottom first, to remove
(see Fig. 18).

6. Remove wires connected to gas valve. Mark each wire.

7. Remove ignitor and sensor wires at the ignitor module.

8. Remove the mounting screw that attaches the burner rack to
the unit base (See Fig. 18).

9. Slide the burner rack out of the unit (See Fig. 18 and 21).

10. T o reinstall, reverse the procedure outlined above.

Outdoor Coil, Indoor Coil, and Condensate Drain Pan

Inspect the outdoor coil, indoor 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 outdoor 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 tube with
clear water. Do not splash water on the insulation, motor, wiring, or
air filter(s). If the drain tube is restricted, clear it with a “plumbers
snake” or similar probe device. Ensure that the auxiliary drain port
above the drain tube is also clear.

rain

28

Outdoor Fan

BLOWER
HOUSING

2 SETSCREWS
(HIDDEN)

Fig. 20 -- Removal of Motor and Blower Wheel

Fig. 21 -- Burner Rack Removed

FEEDER TUBE

STUB TUBE

C99085

A07680

!

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in damage to unit
components.

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

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

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

3. Inspect the fan blades for cracks or bends.

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

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

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

7. Replace grille.

Electrical Controls and Wiring

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

Remove access panels (see Fig. 19) 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, re--strip the wire end and reassemble the connection properly
and securely.

After inspecting the electrical controls and wiring, replace the
access panels (see Fig. 19). Start the unit, and observe at least one
complete heating cycle and one complete cooling cycle to ensure
proper operation. If discrepancies are observed in any 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.

NOTE: Refer to the heating and/or cooling sequence of operation
in this publication as an aid in determining proper control
operation.

Refrigerant Circuit

Annually inspect all refrigerant tubing connections and the unit
base for oil accumulations. Detecting oil generally indicates a
refrigerant leak.

677C-- --A

DEFROST
THERMOSTAT

Fig. 22 -- Defrost Thermostat Location

C99029

!

EXPLOSION, PERSONAL INJURY AND
ENVIRONMENTAL HAZARD

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

System under pressure. Relieve pressure and recover all
refrigerant before system repair or final unit disposal. Use all
service ports and open all flow--control devices, including
solenoid valves.

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

29

WARNING

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

Gas Input

The gas input does not require checking unless improper heating
performance is suspected. If a problem exists, refer to the Start--Up
section.

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-- and return-- air grilles are open and free from
obstructions, and that the air filter is clean. When necessary, refer to
the Indoor Airflow and Airflow Adjustments section to check the
system airflow.

Check Defrost Thermostat

The defrost thermostat is usually located on the lowest liquid
leaving circuit of the left condenser coil (see Fig. 22). The
thermostat closes at 32_F(0_C) and opens at 65_F(18_C).

T2 C C O

Puron Items
Metering Device

(Thermostatic Expansion Valve &

Piston)

This unit uses both a hard shutoff, balance port TXV in the indoor
coil and a piston in each side of the outdoor coil. The TXV
maintains a constant superheat at the evaporator coil exit (cooling
mode) resulting in higher overall system efficiency.

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.

677C-- --A

OF2

DFT

O R W

T1 Y

2

Y C

P1

SPEEDUP

30

60

OF1

J1

P3

DFT

INTERVAL TIMER

90

OFF

30

SHIFT

120

60

ON

QUIET

Speedup
Pins

Quiet
Shift

Fig. 23 -- Defrost Control

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.

Defrost interval
DIP switches

A08020

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.

30

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.

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.

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.

The compressor is an electrical (as well as mechanical) device.
Exercise extreme caution when working near compressors. Power
should be shut off, if possible, for most troubleshooting techniques.
Refrigerants present additional safety hazards.

!

EXPLOSION HAZARD

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

Wear safety glasses and gloves when handling refrigerants.
Keep torches and other ignition sources away from
refrigerants 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 psi differential
pressure.

WARNING

677C-- --A

Fig. 24 -- Refrigerant Circuit

31

C99097

INDOOR COIL

ACCUMULATOR

LEGEND

HP S

COMPRESSOR

OUTDOOR COIL

Bypass

Position

TXV in Metering

Position

LCS

HPS – High Pressure Switch
LCS – Loss of Charge Switch

Accurater

®

Metering De vice

Arrow indicates direction of flo w

C03011

Fig. 25 -- Typical Heat Pump Operation, Cooling Mode

677C-- --A

OUTDOOR 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

Fig. 26 -- Typical Heat Pump Operation, Heating Mode

!

WARNING

UNIT OPERATION AND SAFETY HAZARD

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

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 recovery systemmustbe designedto handlePuron.
If you are unsure, consult the equipment manufacturer.

Refrigerant System

This information covers the refrigerant system of the 677C----A
including the compressor oil needed, servicing systems on roofs
containing synthetic materials, the filter drier and refrigerant
charging.

INDOOR COIL

TXV in Bypass

Position

LCS

Metering

Position

C03012

Compressor Oil

If additional oil is needed use Uniqema RL32--3MAF. If this oil is
not available, use Copeland Ultra 32CC or Mobil Artic EAL22CC.
This oil is extremely hygroscopic, meaning it absorbs water
readily. POE oils can absorb 15 times as much water as other oils
designed for HCFC and CFC refrigerants. Take all necessary
precautions to avoid exposure of the oil to the atmosphere.

Servicing Systems on Roofs and 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, repairing refrigerant leaks,

32

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

Synthetic Roof Precautionary Procedure

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

This filter drier is specifically designed to operate with Puron. Use
only factory--authorized components. Filter drier must be replaced

PURONR (R--410A) QUICK REFERENCE GUIDE

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.

TROUBLESHOOTING

Use the Troubleshooting Guides (See Tables 10--12) if problems
occur with these units.

START--UP CHECKLIST

Use Start-- Up checklist to ensure proper start--up procedures are
followed.

677C-- --A

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 minimum 700 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 hrs.
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 u se 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 warnings, cautions,andbold text.
S All indoor coils must be installed with a hard shutoff Puron TXV metering device.

33

Table 11 – Troubleshooting Guide -- Cooling o r Heat Pump Heating Mode

SYMPTOM CAUSE REMEDY

Compressor and Outdoor fan will not
start.

Compressor will not start but Outdoor
fan runs.

Three---phase scroll compressor makes
excessive noise, and there may
be a low pressure differential.

Compressor cycles (other than normally
satisfying thermostat).

677C-- --A

Compressor operates continuously.

Excessive head pressure.

Head pressure too low.

Excessive suction pressure.

Suction pressure too low.

Compressor runs but outdoor fan does
not

Powe r Failure Call power company.
Fuse blown or circuit breaker tripped Replacefuseorresetcircuitbreaker.
Defective thermostat, contactor, transformer, or control
relay
Insufficient line voltage Determine cause and correct.
Incorrect or faulty wiring Check wiring diagram and rewire correctly.
Thermostat setting too high Lower thermostat setting below room temperature.
Faulty wiring or loose connections in compressor circuit Check wiring and repair or replace.
Compressor motor burned out, seized, or internal over­load open
Defective run/start capacitor, overload, start relay D etermine cause and replace.

Onelegof3---phasepowerdead

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 Outdoor Determine cause and correct.
Defective run/start capacitor, overload or start relay Determine cause and replace.
Defective thermostat Replace thermostat.
Faulty Outdoor---fan motor or capacitor Replace.
Damaged reversing valve Determine cause and correct
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 Recover refrigerant, evacuate system, and recharge.

Frosted coil with incorrect defrost operation

Outdoor coil dirty or restricted Clean coil or r emove restriction .
Dirty air filter Replace filter.
Dirty Indoor or Outdoor coil Clean coil.
Refrigerant overcharged Recover excess refrigerant.
Air in system Recover refrigerant, evacuate system, and recharge.
Indoor or Outdoor air restricted or air short ---cycling Determine cause and correct.
Low refrigerant charge Check for leaks, repair, and recharge.
Compressor IPR leaking Replace compressor.
Restrictioninliquidtube Remove restriction.
High heat load Check for source and eliminate.
Compressor IPR leaking Replace compressor.
Refrigerant overcharged Recover excess refrigerant.
Reversing valve hung up or leaking internally Replace valve
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 Indoor airflow

Temperature too l ow in conditioned area Reset thermostat.
Outdoor ambient below 55°F (12.8°C) Install low--- ambient kit.
Field ---installed filter - --drier restricted Replace.

(Heat) Outdoor coil frosted

NC (normally closed) contacts on defrost board open

Replace component.

Determine cause Replace compressor.

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 nameplate.

Check defrost time settings, Reset as necessary
Check defrost temperature switch, Replace as nec­essary

Increase air quantity. Check filter — replace if neces­sary.

Move timer on control board to 30 minutes between
defrost cycles
Check condition of relay on board Replace if neces­sary

34

Table 12 – Troubleshooting Guide–Heating

SYMPTOM CAUSE REMEDY

Burners will not ignite

Inadequate heating

Poor flame characteristics

Water in gas line Drain. Install drip leg.
No power to furnace Check power supply fuses, wiring or circuit breaker.

No 24--v power supply to control circuit

Mis--wired or loose connections Check all wiring and wire nut connections

Misaligned spark electrodes

No gas at main burners

Dirty air filter Clean or replace filter as necessary
Gas input to furnace too low Check gas pressure at manifold match with that on unit nameplate
Unit undersized for application Replace with proper unit or add additional unit
Restricted airflow Clean or replace filter. Remove any restriction.

Limit switch cycles main burners

Incomplete combustion results in: Aldehyde odors,
carbon monoxide, sooting flame, floating flame

Check transformer.
NOTE: Some transformers have internal over --current protection
that requires a cool--down period to reset.

Check flame ignition and sense electrode positioning.
Adjust as necessary.

1. Check gas line for air. Purge as necessary. NOTE: After purging
gas line of air, wait at least 5 minutes for any gas to dissipate be­fore attempting to light unit.

2. Check gas valve.

Check rotation of blower, temperature rise of unit. Adjust as neces­sary.

1. Tighten all screws around burner compartment

2. Cracked heat exchanger. Replace.

3. Unit over --fired. Reduce input (change orifices or adjust gas line
or manifold pressure).

4. Check burner alignment.

5. Inspect heat exchanger for blockage. Clean as necessary.

Table 13 – Troubleshooting Guide–LED Status Codes

SYMPTOM CAUSE REMEDY

No Power Hardware failure
(LED OFF)

Limit switch faults
(LED 2 flashes)

Flame sense fault
(LED 3 flashes)

4 consecutive limit switch
faults
(LED 4 flashes)

Ignition lockout
(LED 5 flashes)

Pressure Switch motor fault
(LED 6 flashes)

Rollout switch fault
(LED 7 flashes)

Internal control fault
(LED 8 flashes)

Temporary 1 hr auto reset
(LED 9 flashes)

*WARNING : If the IGC must be replaced, be sure to ground yourself to dissipate any electrical charge that my be present before handling new control
board. The IGC is sensitive to static electricity and my be damaged if the necessary precautions are not taken.

IMPORTANT: Refer to Table 12---Troubleshooting Guide ---Heating for additional troubleshooting analysis.
LEGEND

IGC—Integrated Gas U nit Controller
LED—Light---Emitting Diode

Loss of power to control module (IGC)*.

High temperature limit switch is open.

The IGC* sensed flame that should not be present. Reset unit. If problem persists, replace control board.

Inadequate airflow to unit.

Unit unsuccessfully attempted ignition for 15 minutes.

Open pressure switch.

Rollout switch has opened.

Microprocessor has sensed an error in the software
or hardware.

Electrical interference impeding IGC software

Check 5--amp fuse son IGC*, power to unit, 24--v circuit breaker,
and transformer. Units without a 24--v circuit breaker have an
internal overload in the 24--v transformer. If the overload trips,
allow 10 minutes for automatic reset.

Check the operation of the indoor (evaporator) fan motor. Ensure
that the supply--air temperature rise is in accordance with the
range on the unit nameplate. Clean or replace filters.

Check the operation of the indoor (evaporator) fan motor and that
supply--air temperature rise agrees with range on unit nameplate
information.

Check ignitor and flame sensor electrode spacing, gaps, etc.
Ensure that fame sense and ignition wires are properly terminated.
Verify that unit is obtaining proper amount of gas.

Verify wiring connections to pressure switch and inducer motor.
Verify pressure switch hose is tightly connected to both inducer
housing and pressure switch. Verify inducer wheel is properly
attached to inducer motor shaft. Verify inducer motor shaft is turn­ing.

Rollout switch will automatically reset, but IGC* will continue to
lockout unit. Check gas valve operation. Ensure that induced--draft
blower wheel is properly secured to motor shaft. Inspect heat
exchanger. Reset unit at unit disconnect.

If error code is not cleared by resetting unit power, replace the
IGC*.

Reset 24--v. to control board or turn thermostat off, then on again.
Fault will automatically reset itself in one (1) hour.

677C-- --A

35

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 GAS PIPING FOR LEAKS (WHERE APPLICABLE)

( ) 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

677C-- --A

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__________________

GAS HEAT SUPPLY AIR

PRESSURES

GAS INLET PRESSURE IN. W.C.

GAS MANIFOLD PRESSURE IN. W.C.
REFRIGERANT SUCTION PSIG, SUCTION LINE TEMP*
REFRIGERANT DISCHARGE PSIG, LIQUID TEMP{
( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS
GAS HEAT TEMPERATURE RISE

TEMPERATURE RISE (See Literature) RANGE
MEASURED TEMPERATURE RISE

* Measured at suction inlet to compressor

{ Measured at liquid line leaving condenser.

E2009 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 04/09

Manufacturer reserves the right to discontinue, or c hange at any time, specifications or designs without notice and without incurr ing obligations.

36

Catalog No. II677C--- 05

Replaces: II677C---04