Bryant 677CNWC24040AA, 677CNWC30040NA, 677CNWC30040AA, 677CNWC30060AA, 677CNWC30060NA Installation Instructions Manual

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677C----C LEGACYt 14 SEER SINGLE-- PACKAGED HYBRID HEATr DUAL FUEL SYSTEM WITH PURONr (R--410A) REFRIGERANT SINGLE PHASE 2--5 NOMINAL TONS (SIZES 24--60) THREE PHASE 3--5 NOMINAL TONS (SIZES 36--60)

Installation Instructions

IMPORTANT: Effective January 1, 2015, all split system and

packaged air conditioners must be installed pursuant to applicable regional efficiency standards issued by the Department of Energy.

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 6.....................................

Field Fabricate Ductwork 6............................

Provide Clearances 6.................................

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 12........................

High--Voltage Connections 12........................

Special Procedures for 208--V Operation 12..............

Control Voltage Connections 12.......................

Balance Point Setting Thermidistat or Hybrid Heat

Thermostat 13....................................

Transformer Protection 13...........................

PRE-- START--UP 13...................................

START--UP 14--19.....................................

Check for Refrigerant Leaks 14.........................

Unit Sequence of Operation 14.........................

Start--Up Heating and Make Adjustments 15...............

Checking Heating Control 15.........................

Check Gas Input 15................................

Adjust Gas Input 16................................

Check Burner Flame 16.............................

Start--Up Cooling and Make Adjustments 17...............

Checking Cooling Control Operation 17................

Checking and Adjusting Refrigerant 17.................

Indoor Airflow and Airflow Adjustments 18.............

Continuous Fan Operation 19........................

MAINTENANCE 49--52................................

Air Filter 49........................................

Indoor Blower and Motor 49...........................

Flue Gas Passageways 50..............................

Limit Switch 50.....................................

Burner Ignition 50...................................

Main Burners 50....................................

Outdoor Coil, Indoor Coil, & Condensate Drain Pan 50......

Outdoor Fan 51.....................................

Electrical Controls and Wiring 51.......................

Refrigerant Circuit 51.................................

Gas Input 52........................................

Indoor Airflow 52...................................

Check Defrost Thermostat 52...........................

PuronR Items 52....................................

TROUBLESHOOTING 56..............................

START--UP CHECKLIST 56............................

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 or death. WARNING signifies hazards which could result in per-

A09034

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

SAFETY CONSIDERATIONS

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

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.

If the unit is to be mounted on a curb in a downflow application, review Step 9 to determine which method is to be used to remove the downflow panels before rigging and lifting into place. The panel removal process may require the unit to be on the ground.

Step 2 — Provide Unit Support

For hurricane tie downs, contact distributor for details and PE

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

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

677C-- --C

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 and wear appropriate protective clothing, safety glasses and gloves when handling parts or reaching into the unit.

INTRODUCTION

This unit (see Fig. 1) is a fully self--contained, combination Category I gas heating/electric h eating 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).

In gas heating mode, this unit is designed for a minimum continuous return--air temperature of 55_F(13_C) db and a maximum continuous return--air temperature of 80_F(27_C) db. Failure to follow these return-- air temperature limits may affect reliability of heat exchangers, motors, and other components.

Models with an N in the 13th 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.

(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.

Installation on older “G” series roof curbs.

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

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

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

CAUTION

UNIT/STRUCTURAL DAMAGE HAZARD

Failure to follow this caution may result in property damage.

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

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.

677C-- --C

A150538

Fig. 2 -- 24--30 Unit Dimensions

677C-- --C

A150539

Fig. 3 -- 36--60 Unit Dimensions

HVAC unit base rails

Anchor screw

Flashing field supplied

Roofing material field supplied

Cant strip field supplied

HVAC unit basepan

Sealing Gasket

Roofcurb

Wood nailer*

Roofcurb*

Insulation (field supplied)

*Provided with roofcurb

ROOF CURB DETAIL

SMALL CURB

A09090

A09418

677C-- --C

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

IN. (mm)BIN. (mm)*

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

10 (254)

16 (406)

14 (356)

47.8

(1214)

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).

Fig. 4 -- Roof Curb Dimensions

A09415

32.4 (822)

43.9

(1116)

2.7 (69)

A09419

30.6 (778)

46.1 (1170)

42.2 (1072)

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-- --C

Unit

Rigging

Weight

NOTE: See dimensional drawing for corner weight distribution.

SEE DETAIL A VOIR DÉTAIL A

24 30

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

365 166 395 179

Unit

Rigging

Weight

440 200 475 215 500 227 515 234

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 -- Suggested Rigging

SLAB MOUNT

Place the unit on a solid, level pad that is at least 2 in. (51 mm) above grade. The pad should extend approximately 2 in. (51 mm) beyond the casing on all 4 sides of the unit. Do not secure the unit to the pad 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.

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.

Step 5 — Rig and Place Unit

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

WARNING

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.

PERSONAL INJURY OR PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal 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 should handle and install this equipment.

When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply.

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

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

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work gloves.

Inspection

Prior to initial use, and at monthly intervals, all rigging shackles, clevis pins, and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular 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.

WARNING

UNIT FALLING HAZARD

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

Never stand beneath rigged units or lift over people.

WARNING

PROPERTY DAMAGE HAZARD

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

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

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).

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.

Unit 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/CSA 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

677C-- --C

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/CSA 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

677C-- --C

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.

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

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

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. A fire or explosion may result causing property damage, personal injury or loss of life.

--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 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).

TEE

OUT

Configuring Units for Downflow (Vertical) Discharge

Fig. 7 -- Sediment Trap

NIPPLE

CAP

C99020

ELECTRICAL SHOCK HAZARD

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

Before installing or servicing system, always turn off main power to system and install lockout tag. There may be more than one disconnect switch.

WARNING

1. Open all electrical disconnects before starting any service work.

2. Remove horizontal (metal) duct covers to access vertical (downflow) discharge duct knockouts in unit basepan. (See Fig. 8.)

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property damage.

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

3. For single--phase models only, on the discharge side only, remove the insulation covering the downshot (plastic) knockout. Insulation is held in place with aluminum tape. Please note that large chassis units have 2 pieces of insulation, and only the piece over the downshot knockout needs to be removed. Discard insulation.

4. To remove the downshot (plastic) knockouts for both supply and returns, break front and right side connecting tabs with a screwdriver and hammer. Push cover down to break rear and left side tabs. These plastic knockouts are held in place with tabs similar to an electrical knockout. Discard plastic knockout covers.

5. Set unit on roof curb.

6. Verify that the downshot ducts are aligned with the downshot knockout areas.

7. Re--install horizontal (metal) covers as needed to seal unit. Ensure opensings are air and watertight.

NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of 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.

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.

Horizontal Duct Covers

Basepan Downflow (Vertical) Supply Knockout

Basepan Downflow (Vertical) Return Knockout

Fig. 8 -- Supply and Return Duct Opening

677C-- --C

A09061

A09088

Table 1 – Physical Data

Unit Size 24040 24060 30040 30060 36060 36090

Nominal Capacity --- ton 2 2 2.5 2.5 3 3 Shipping Weight (lb)

Compressor / Quantity Scroll / 1 Refrigerant R---410A Refrigerant Quantity (lb)

Refrigerant Metering Device Indoor TXV, Outdoor Dual Accuraters Orifice OD (in)

Outdoor Coil Rows… Fins/in, face area (sq. ft.)

Outdoor Fan Nominal Airflow (cfm) Diameter (in.) Diameter (mm) Motor hp (rpm)

Indoor Coil Rows… Fins/in, face area (sq. ft.)

Indoor Blower Nominal Airflow (cfm) Size (in.)

677C-- --C

Size (mm) Motor hp Furnace Secti on* Burner Orifice 1--- Ph ase Natural Gas Qty…Drill Size 1 --- P h a s e P ro p a n e G a s Q t y…Drill Size 3--- Ph ase Natural Gas Qty…Drill Size 3 --- P h a s e P ro p a n e G a s Q t y…Drill Size High Pressure Switch (psig) Cutout Reset (Auto)

Loss --- of---Charge/Low Pressure Switch (psig) Cutout Reset (Auto)

Return Air Filters{} disposable

*Based on altitude of 0 to 2000 ft (0 ---610 m). {Required filter sizes shown are based on the larger of the AHRI (Air Conditioning Heating and Refrigeration Institute) r ated cooling airfl ow or the heating airflow

velocity of 300 to 350 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.

(kg)

Quantity (kg)

(mm)

365 166

7.5

3.4

0.032 (2)

0.81 (2)

1…21

15.4

2500

610

1/12 (810)

3…17

3.7

800

10 x 10

254 x 254

1/2

2…44 2…55 2…44 2…55

365 166

7.5

3.4

0.032 (2)

0.81 (2)

1…21

15.4

2500

610

1/12 (810)

3…17

3.7

800

10 x 10

254 x 254

1/2

3…44 3…55

2…38

2…53

2 each 20x12x1 in.

508x305x25 mm

395 179

9.0

4.1

0.035 (2)

0.89 (2)

1…21

18.8

3000

610

1/10 (810)

3…17

3.7

1000

10 x 10

254 x 254

1/2

2…44 2…55 2…44 2…55

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

2 0 + / --- 5

45 +/--- 10

395 179

9.0

4.1

0.035 (2)

0.89 (2)

1…21

18.8

3000

610

1/10 (810)

3…17

3.7

1000

10 x 10

254 x 254

1/2

3…44 3…55

2…38

2…53

440 200

8.9

4.0

0.040 (2)

1.02 (2)

1…21

17.5

3500

660

1/5 (810)

2…15

5.6

1200

11 x 10

279 x 254

1/2

3…44 3…55

2…38

2…53

1each24x16x1in.

610x406x25 mm

24x18x1 in.

510x457x25 mm

440 200

8.9

4.0

0.040 (2)

1.02 (2)

1…21

17.5

3500

660

1/5 (810)

2…17

5.6

1200

11 x 10

279 x 254

1/2

3…38 3…53 3…38 3…53

Table 1 -- Physical Data Cont’d)

NUMBER

MANIFOLD

PRES

SURE

ORIFICES

Unit Size 42060 42090 48090 48115 48130 60090 60115 60130

Nominal Capacity --- ton 3.5 3.5 4 4 4 5 5 5 Shipping Weight (lb)

Compressor / Quantity Scroll / 1 Refrigerant R---410A Refrigerant Quantity (lb)

Refrigerant Metering Device

Orifice ID (in)

Orifice OD (in)

Outdoor Coil Rows… Fins/in, face area (sq. ft.)

Outdoor Fan Nominal Airflow (cfm) Diameter (in.) Diameter (mm) Motor hp Motor (rpm)

Indoor Coil Rows… Fins/in, face area (sq. ft.)

Indoor Blower Nominal Airflow (cfm) Size (in.) Size (mm) Motor hp

Furnace Secti on* Burner Orifice 1PhaseNaturalGasQty…Drill Size 1 Phase Propane Gas Qty…Drill Size 3PhaseNaturalGasQty…Drill Size 3 Phase Propane Gas Qty…Drill Size

High Pressure Switch (psig) Cutout Reset (Auto)

L o ss --- o f --- C h a rg e / L o w P re s su r e Switch (psig) Cutout Reset (Auto)

Return Air Filters{} disposable

velocity of 300 to350 ft/minute for h igh - -- 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.

(kg)

Quantity (kg)

(mm)

475 215

11.2

5.1 Indoor TXV,

Outdoor Dual

Accuraters

0.046 (2)

1.17 (2)

1…21

23.3

3500

660

1/5

(810)

3…17

4.7

1350

11 x 10

279 x 254

1/2

3…44 3…55

2…38

2…53

N/A

475 215

11.2

5.1

0.046 (2)

1.17 (2)

1…21

23.3

3500

660

1/5

(810)

3…17

4.7

1350

11 x 10

279 x 254

1/2

3…38 3…53 3…38 3…53

1 each 24x14x1 (610x356x25)

500 227

9.9

4.5

Outdoor Dual Accuraters

0.046 (2)

1.17 (2)

1…21

23.3

3500

660

1/5

(810)

3…17

4.7

1600

11 x 10

279 x 254

3…38 3…53 3…38 3…53

24x15x1 (610x406x25)

500 227

9.9

4.5

Indoor Accurater,

0.080 (1)

2.03 (1)

0.046 (2)

1.17 (2)

1…21

23.3

3500

660

1/5

(810)

3…17

4.7

1600

11 x 10

279 x 254

3…33 3…51 3…33 3…51

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

2 0 + / --- 5

45 +/--- 10

500 227

9.9

4.5

0.046 (2)

1.17 (2)

1…21

23.3

3500

660

1/5

(810)

3…17

4.7

1600

11 x 10

279 x 254

3…31 3…49 3…31 3…49

515 234

11.9

5.4

Outdoor Dual Accuraters

0.052 (2)

1.32 (2)

2…21

17.5

3500

660

1/4

(810)

3…17

5.6

1750

11 x 10

279 x 254

3…38 3…53 3…38 3…53

1 each 24x16x1 (610x406x25)

24x18x1 (610x457x25)

515 234

11.9

5.4

Indoor TXV,

N/A

0.052 (2)

1.32 (2)

2…21

17.5

3500

660

1/4

(810)

3…17

5.6

1750

11 x 10

279 x 254

3…33 3…51 3…33 3…51

515 234

11.9

5.4

0.052 (2)

1.32 (2)

2…21

17.5

3500

660

1/4

(810)

3…17

5.6

1750

11 x 10

279 x 254

3…31 3…49 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 Z 223.1. † This length includes an ordinary number of fittings.

INTERNAL

DIAMETER

(IN.)

(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)

Table 3 – Heating Inputs

HEATING INPUT

(BTUH)

40,000 2 4.0 13.0 11.0 13.0 3.23.8 10.0 60,000 3 4.0 13.0 11.0 13.0 3.23.8 10.0

90,000 3 4.5 13.0 11.0 13.0 3.23.8 10.0 115,000 3 4.5 13.0 11.0 13.0 3.23.8 10.0 130,000 3 4.5 13.0 11.0 13.0 3.23.8 10.0

*When a un it is converted to propane, 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 C a nada, from 2000 ft (610 m) above sea level to 4500 ft (1372 m) above sea level, derate the unit 10 percent.

GAS SUPPLY PRES SURE (IN. W.C.) MANIFOLD PRESSURE

Natural{ Propane*{

(IN. W.C.)

Min Max Min Max Natural{ Propane*†

677C-- --C

200

(61.0)

Step 10 — Install Electrical Connections

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

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

677C-- --C

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.

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).

NOTE: Field supplied disconnect switch box should be positioned so that it does not cover up any of the unit gas combustion supply air louvers.

See unit wiring label (Fig. 15 and 16) and Fig. 9 for reference when making high voltage connections. Proceed as follows to complete the high--voltage connections to the unit.

Single phase units:

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

2. Connect ground lead to chassis ground connection.

WARNING

CAUTION

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

ELECTRICAL SHOCK HAZARD

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

Make sure the power supply to the unit isswitchedOFF before making any wiring changes. Tagthe 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 anywiring changes,make sure thegas supply is switched off first. Then switch off the power supply to the unit and install lockout tag.

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

HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)

CONTROL BOX

LOW-VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL)

EQUIP GR

SPLICE BOX

FIELD-SUPPLIED FUSED DISCONNECT

WHT(W1)

YEL(Y)

GRN(G)

RED(R)

BRN(C)

ORN(O)

BLU (DH)

GRA (Y2)

3-Phase Only

POWER SUPPLY

THERMOSTAT (TYPICAL)

A09067

Fig. 9 -- 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.

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

FIRE,EXPLOSION, ELECTRICAL SHOCKHAZARD

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

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

2. 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 all field-- and factory -- wiring connections. Be

sure that connections are completed and tight.

c. Ensure wires do not touch refrigerant tubing or sharp

sheet metal edges.

d. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

WARNING

677C-- --C

5. Charge unit with Puron (R-- 410A) refrigerant, using an

FIRE, EXPLOSION HAZARD

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

Do not purgegas supply into the combustion chamber. 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. A fire or explosion may result causing property damage, personal injury or loss of life.

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,

677C-- --C

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.

WARNING

START--UP

Step 1 — Check for Refrigerant Leaks

WARNING

EXPLOSION HAZARD

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

Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion.

electronic scale. Refer to unit rating plate for required charge.

Step 2 — Unit 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 (Single Phase Models)

(See Fig. 15 and unit wiring label) On a call for heating, terminal W of the thermostat is energized, starting the induced-draft motor for a 5 second pre-purge. When the pressure switch senses that the induced-draft motor is moving sufficient combustion air, the burner sequence begins. This function is controlled by the integrated gas unit controller (IGC). The indoor (evaporator) –fan motor is energized 30 seconds 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 90 second 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 a partially-clogged filter .

Heating Sequence of Operation (3--Phase Models)

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.

(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.

Pipe Plug

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 HEA T position and the fan switch is placed in AUTO position.

CAUTION

Manifold

A07679

Fig. 10 -- Burner Assembly

BURNER FLAME

BURNER

MANIFOLD

C99021

Fig. 11 -- Monoport Burner

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

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

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

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) P ERCENT OF DERATE

0---2000 (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 altitu de range.

0 1.00

8 --- 1 2 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

IN CANADA:

The input rating for altitudes from 2,000 to 4,500 ft (610 m to 1372 m) above sea level must be derated 10% by an authorized Gas Conversion Station or Dealer.

EXAMPLE: 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

at 0.60

FACT OR{

Installation Altitude

677C-- --C

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.

3.112.5x1=112.5ft

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 gas valve (See Fig. 12).

2. Turn plastic adjustment screw clockwise to increase gas input, or turn plastic adjustment screw counterclockwise to decrease input (See Fig. 12). Manifold pressure must be between 3.2 and 3.8 IN. W.C.

WARNING

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

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.

propane gas units.

Measure Gas Flow (Natural Gas Units)

677C-- --C

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.

REGULATOR COVER SCREW

PLASTIC

ADJUSTMENT

ON/OFF SWITCH

INLET PRESSURE TAP

SCREW

REGULATOR SPRING (PROPANE - WHITE) (

NATURAL - SILVER)

GAS PRESSURE REGULATOR ADJUSTMENT

3. Replace regulator cover screw on gas valve (See Fig. 12).

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

10.) 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.

MANIFOLD PRESSURE TAP

A07751

Fig. 12 -- 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. 10) 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

. Proceed as follows:

Btu/ft

1. 32 sec. to complete one revolution.

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 8 and 9 show 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. The blower motor continues to run until LS resets.

2. 3600  32 = 112.5.

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

Check fuse, low voltage circuit 1Flash

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. This 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.

9 Flashes

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

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.

WARNING

EXPLOSION HAZARD

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

Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion.

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

NOTE: Some units have fixed orifice refrigerant metering devices. There is a different charging procedure for both expansion devices. Refer to the correct procedure for your unit.

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. (See Fig. 17 Subcool chart for units with TXV and superheat chart for units with fixed orifice.) The chart includes the required liquid line temperature at given discharge line pressures and outdoor ambient temperatures.

A superheat chart is attached to the inside of the compressor access panel for the unit with fixed metering device. Refer to the charging procedure on the label.

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.

CAUTION

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

677C-- --C

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.

Indoor Airflow and Airflow Adjustments

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).

Cooling Fan Speed Set--up (Dehumidification feature

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage.

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

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

WARNING

ELECTRICAL SHOCK HAZARD

677C-- --C

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 modes. Single phase units also have a dedicated continuous fan speed All models (1 phase and 3 phase), have a field--selectable capability to run two different cooling speeds: A normal cooling fan speed (350--450 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 for use with a single cooling fan speed. For single phase models, the cooling speed is marked “COOL” on the IGC (See Fig. 13). For 3-- phase models, the cooling speed is marked “LOW” on the interface board (IFB) (See Fig. 14). The factory --shipped settings are noted in Tables 7 and 8. There are up to 3 additional speed tap wires available for use in either gas heating mode, cooling mode, or continuous fan mode (For color coding on the indoor fan motor leads, see Table 6). For single phase models, one of the additional speed tap wires is connected to the continuous fan, with the other 2 wires shipped loose in the control box near the IGC. For three phase models, 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) (See Fig. 14).

Gas Heating Fan Speed Set--up (Single Phase Models):

To change the gas heating speed:

1. Remove existing speed tap wire from the “HEAT” terminal on the IGC.

2. Connect the desired speed tap wire on the “HEA T” terminal on the IGC board. Make sure that the speed chosen delivers temperature rise within the rise range listed on the unit.

Gas Heating Fan Speed Set-up (3--Phase Models)

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 8 and 9 show 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.

not used) (Single Phase

To change cooling speed:

1. Remove existing speed tap wire from the “COOL” terminal on the IGC board. Add the wet coil pressure drop in Table 10 to the system static to determine the correct cooling airflow speed in Table 7 that will deliver the nominal cooling airflow listed in Table 1 for each size.

2. Connect the desired speed tap wire on the “COOL” terminal on the IGC board.

Single Cooling Fan Speed Set-up (Dehumidification feature not used) (3--Phase

To change cooling speed:

1. Remove the vinyl cap off of the desired speed tap wire (Refer to Table 6 for color coding). Add the wet coil pressure drop in Table 10 to the system static to determine the correct cooling airflow speed in Table 8 or 9 that will deliver the nominal cooling airflow as listed in Table 1 for each size.

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

Dehumidification Cooling Fan Speed Set--up (Single

Models):

Phase

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.

1. Move shunt jumper on IGC board to “DH” (See Fig. 13).

2. Refer to airflow table (Table 7) to determine allowable speeds for the dehumidification cooling fan speed. Speeds that are not allowed are shaded in Table 7.

3. Connect selected speed tap wire to “DHUM” terminal on the IGC board. Verify that static pressure is in the acceptable range for the speed tap to be used for dehumidification cooling.

Two Cooling Fan Speeds Set-up (Dehumidification feature used) (3--Phase

IMPORTANT: Dehumidification control must open control

circuit on humidity rise above set point.

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 10 to the system static to determine the correct cooling airflow speed in Table 8 or 9 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

Models):

Models)

+ 42 hidden pages

Bryant 677CNWC24040AA, 677CNWC30040NA, 677CNWC30040AA, 677CNWC30060AA, 677CNWC30060NA Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual