Bryant Installation, Start-up And Service Instructions Manual
Specifications and Main Features
Frequently Asked Questions
User Manual
installation, start-up and
service instructions
SINGLE PACKAGE ROOFTOP
GAS HEATING/ELECTRIC COOLING UNITS
Cancels: II 580F-90-2II 580F-90-3
580F
Dura
Pac
Series
Sizes 090-151
71/2to 121/2Tons
2/1/04
IMPORTANT — READ BEFORE INSTALLING
1. Read and become familiar with these installation
instructions b efore installing this unit. (See Fig. 1A
and 1B.)
2. Be sure the installation conforms to all applicable
local and national codes.
3. These instructions contai n importa nt inform ation for
the proper maintenance and repair of this equipment.
Retain these instructions for futu re use.
Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should
install, repair, or servic e air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe
precautions in the literature, tags and labels attached to the
unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire
extinguishers available for all brazing operations.
CAUTION: Ensure voltage listed on unit data plate
agrees with electrical supply provided for the unit.
WARNING: Disconnect gas piping from unit when
leak testing at pressure greater than 1/2 psig. Pressures greater tha n
resulting in hazardous condition. If gas valve is ever
subjected to pressure greater than
replaced before use. When pressure testing fieldsupplied gas piping at pressures of
unit connected to such piping must be isolated by manually closing the gas valve(s).
WARNING: Before performing service or maintenance operations on unit, turn off main power switch
to unit and install lockout tag. Electrical shock could
cause personal injury.
Unit is shipped in the vertical discharge configuration. To
convert to horizontal configuration, remove screws from side
duct opening covers and remove covers. Using the same
screws, install covers on vertical duct openings with the
insulation side down. Seals around duct openings must be
tight. See Fig. 2.
Confirm before installation of unit that voltage, amperage
and circuit protection requirements listed on unit data plate
agree with power supply provided.
I. STEP 1 — PROVIDE UNIT SUPPORT
A. Roof Curb
Assemble and install access ory roof curb in accorda nce with
instructions shipped with curb. See Fig. 3. Install insulation,
cant strips, roofi ng fe lt, and counter flashing as shown. Duct-work must be attached to curb. If gas or electr ical co nnec tion s
are to be routed through the curb, attach the access ory thruthe-curb service connectio n plate to the roof curb in accordance with the accessory installation instructions. Connections must be installed before unit is set on roof curb.
IMPORTANT: The gasketing of the unit to the roof curb is
critical for a watertight seal. Install gasket supplied with the
roof curb as shown in Fig. 3. Improperly applied gasket can
also result in air or water leaks and poor unit performance.
Curb should be level. Unit leveling tolerances are shown in
Fig. 4. This is necessary for unit drain to function properly.
Refer to Accessory Roof Curb Installation Instructions for
additional information as required.
If gas or electrical connections are to be routed through the
bottom of the unit, attach accessory thru-the-bottom service
connections to the basepan in accordance with the accessory
installation instructions.
1
/2 psig will cause g as valve damage
1
/
psig, it must be
2
1
/2 psig or less, a
INSTALLATION
Fig. 1A — Base Unit Dimensions — 580F090,102,120,150
—2—
Fig. 1B — Base Unit Dimensions — 580F091,103,121,151
—3—
B. Alternate Unit Support
When the curb or adapter cannot be used, su pport unit with
sleepers using un it curb or adapter supp ort area. If sleeper s
cannot be used, support long sides of unit with a minimum of
three 4-in. x 4-in. pads, two at the corners and one at the
unit’s center of gravity. If more than 3 pads are used, equally
space them along the side.
C. Slab Mount (Horizontal Units Only)
Provide a level concrete slab tha t extends a min imum of 6 in.
beyond unit cabinet. Ins tall a 6-in. g ravel apron in f ront of
condenser coil air inlet to prevent grass and foliage from
obstructing airflow.
NOTE: Horizontal units may be installed on a roof curb if
required.
II. STEP 2 — FIELD FABRICATE DUCTWORK
Secure all ducts to roof curb and building s tructure on verti cal units. Do not connect ductwork to unit. For horizontal
applications, field-supplied flanges should be attached to
horizontal discharge openings and all ductwork 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 a n unc ondit i one d spa ce 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.
A minimum clearance is not required around ductwork. Cabinet return-air static shall not exceed –.30 in. wg with
EconoMi$er+ or .45 in. wg without economizer.
These units are designed for a minimum heating operation
continuous return-air te mperature of 50 F (dry bulb), o r an
intermittent operation down to 45 F (dry bulb), such as when
used with a night set-back thermostat.
To operate at lower return air temperatures, a field-supplied
outdoor-air temperature control must be used to initiate both
stages of heat when the temperature is below 45 F. Indoor
comfort may be compromised wh en these lo wer ai r temperatures are used with insufficient heating temperature ri se.
III. STEP 3 — INSTALL EXTERNAL TRAP FOR CONDENSATE DRAIN
The unit’s
3
/4-in. condensate drain connections ar e located on
the bottom and side of the unit. Unit discharge connections
do not determine the use of drain connections; either
drain connection can be used with vertical or horizontal
applications.
When using the standard side drain connection, make sure
the plug (Red) in the alternate bottom connection is tight
before installing the unit.
To use the bottom drain connection for a roof curb installation, relocate the factory-installed plug (Red) from the
bottom connection to the side connection. See Fig. 5A. The
piping for the condensate drain and external trap can be
completed after the unit is in place.
All units must have an external trap for condensate drainage. Install a trap a minimum of 4-in. deep and protect
against freeze-up. If drain line is installed downstream from
the external trap, pitch the line away from the unit at 1 in.
per 10 ft of run. Do not use a pipe size smaller than the unit
connection (
3
/4 in.). See Fig. 5B .
The center drain plug looks lik e a star conne ctio n, however it
can be removed with a
1
/2 in. socket drive extension.
IV. STEP 4 — RIG AND PLACE UNIT
Inspect unit for transportation damage. File any claim with
transportation agency. Keep unit upright and do not drop.
Spreader bars are not required if top crating is left on unit.
Rollers may be used to move unit across a roof. Level by
using unit frame as a reference. See Tables 1A and 1B and
Fig. 6 for additional inf ormat ion. Op era ting we ight is s hown
in Table 1 and Fig. 6.
Lifting holes are provided in base rails as shown in Fig. 1
and 6. Refer to rigging instructions on unit.
5. Attach ductwork to curb (flanges of duct rest on curb).
6. Service clearance 4 ft on each side.
“A”UNIT SIZE
580F
090-151
7.Direction of airflow.
8. Connector packages CRBTMPWR001A01 and 2A01
areforthru-the-curbgastype.Packages
CRBTMPWR003A01 and 4A01 are for thru-the-bottom
type gas connections.
Fig. 3 — Roof Curb Details
—5—
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
A-BB-CA-C
0.51.01.0
Fig. 4 — Unit Leveling Tolerances
DRAIN OUTLET
NOTE: Drain plug is shown in factory-installed position.
DRAIN PLUGHORIZONTAL
Fig. 5A — Condensate Drain Pan (Side View)
3/4” FPT
DRAIN CONNECTION
(HALF COUPLING)
8 1/2-IN. (FIELDSUPPLIED) NIPPLE
2-IN. (FIELD-SUPPLIED) NIPPLE
A. Positioning
Maintain clearan ce around and above un it to provide minimum distance from combustible materials, proper airflow,
and service access. See Fig. 1A and 1B Notes.
Do not install unit in an indoor l ocation. Do not locate unit
air inlets near exhaust vents or other sources of contaminated air.
Be sure that unit is installed so that sn ow will not b lock the
combustion intake or flue outlet.
Unit may be installed directly on wood flooring or on Class
A, B, or C roof-covering material when roof curb is used.
Although unit is weatherproof, guard against water from
higher level runoff and overhangs.
Position unit on roof curb so that the following clearances are
1
maintained:
rails on each side and duct end of unit; 3
/4-in. clearance between roof curb and base
5
/16-in. clearance
between roof curb and condenser section end. (See Fig. 3,
section C-C.)
Locate mechanical draft system flue assembly at least 48 in.
from an adjacent building or combustible material. When
unit is located adjacent to public walkways, flue assembly
must be at least 7 ft above grade.
Flue vent discharge must have a minimum horizontal clearance of 48 in. from electric and gas meters, gas regulators,
and gas relief equipment.
Flue gas can deteriorate building materials. Orient unit so
that flue gas will not affect building materials.
Adequate combustion-air space must be provided for proper
operation of this equipment. Be sure that installation complies with all local codes and Section 5.3, Air for Combustion
and Ventilation, NFGC (National Fuel Gas Code), ANSI
3”
(American National Standards Institute) Z223.1-latest year
and addendum Z223.1A-latest year. In Canada, installation
must be in accordance with the CAN1. B149.1 and
CAN1.B149.2 installation codes for gas burning appliances.
4”
Fig. 5B — Condensate Drain Piping Details
—6—
NOTES:
1. Dimension in ( ) is in millimeters.
2. Hook rigging shackles through holes in base rail as shown in detail
‘‘A.’’ Holes in base rails are centered around the unit center of gravity. Use wooden top skid when rigging to prevent rigging straps
from damaging unit.
3. Weights include base unit without economizer. See Table 1 for
economizer weights.
CAUTION: All panels must be in place when rigging.
**Rollout switch lockout is manually reset by interrupting power to unit or resetting
thermostat.
NOTE: High-static motor not available on size 150 and 151 units.
—11—
V. STEP 5 — INSTALL FLUE HOOD
Flue hood is shipped screwed to the burner compartment
access panel. Remove from shipping location and, using
screws provided, install flue hood and screen in location
shown in Fig. 7.
VI. STEP 6 — INSTALL GAS PIPING
Unit is equipp ed for use with type of gas shown on nameplate. Refer to local building codes, or in the absence of local
codes, to ANSI Z223.1-latest year and addendum Z223.1Alatest year entitled National Fuel Gas Code. In Canada,
installation must be in accordance with the CAN1.B149.1
and CAN1.B149.2 installation codes for gas burning appliances when installing gas piping.
For natural gas applications, gas pressure at unit gas connection must not be less than 4.0 in. wg (5.0 in. wg in high
heat units) or greater than 13.0 in. wg while unit is operating. For liquid propane applications, the pressure must not
be less than 5.0 in. wg or greater than 13.0 in. wg at the unit
connection.
Size gas supply piping for 0.5 i n. wg ma ximum pre ssure drop .
Do not use supply pip e smaller than unit gas connection.
CAUTION: When installing gas piping to gas valve
inlet, use properly sized back-up wrench on inlet flange
flats to prevent valve damage.
Support gas piping as shown in the table in Fig. 8. For exam-
3
ple, a
/4-in. gas pipe must have one field-fabricated support
beam every 8 ft.
See Fig. 8 for typical pipe guide and locations of external
manual gas shutoff valve.
NOTE: If field-installed thru-the-bottom connections are
used, refer to the accessory installation instructions for
power wiring and gas connections. Refer to Fig. 1A and 1B
for drilling holes in basepan.
VII. STEP 7 — MAKE ELECTRICAL CONNECTIONS
WARNING: Unit cabinet must have an uninter-
rupted, unbroken electrical ground to minimize the
possibility of personal injury if an electrical fault
should occur. This ground may consist of electric al wir e
connected to unit ground lug in control compartment,
or conduit approved for electrical ground when
installed in accordance with NEC (National Electrical
Code), ANSI/NFPA (National Fire Protection Association), latest edition, and local electrical codes. Do notuse gas piping as an electrical ground. Failure to follow
this warning could result in the installer being liable
for personal injury of other s.
A. Field Power Supply
All units except 208/230-v units are factory wired for the
voltage shown on the na meplate. If the 208/230-v u nit is to
be connected to a 208-v power supply, the transformer must
1
be rewired by moving the black wire from the 230- v
/4-in.
male spade terminal on the transformer and connecting it to
the 208-v
1
/4-in. male spade terminal from the transformer.
Refer to unit label diagram for additional information. Pigtails are provided for field service.
When installing units, provide a disconnect per NEC. Use
copper conductors only when splice connectors are used.
All field wiring must comply with NEC and local requirements. In Canada, electrical connections must be in accordance with CSA (Canadian Standards Association) C22.1
Canadian Electrical Code Part One.
Fig. 7 — Flue Hood Details
SPACING OF SUPPORTS
LEGEND
NFGC —
*Field supplied.
NOTE: Follow all local codes.
National Fuel
Gas Code
STEEL PIPE
NOMINAL
DIAMETER (in.)
1
/
2
3
/
or 1
4
1
1
/
or larger
4
X
DISTANCE
(feet)
6
8
10
Fig.8—GasPipingGuide(With Accessory
Thru-the-Curb Service Connections)
Install conduit through side panel openings indicated in
Fig. 1A and 1B. Route power lines through connector to terminal connections as shown in Fig. 9.
On 3-phase units, voltages between ph ase s must be balanced
within 2% and the current within 10%. Use the formula
shown in Tables 2A and 2B, Note 2 to determine the percentage of voltage im balance. Operation on improper line voltage
or excessive phase imbalance constitutes abuse and may
cause damage to electrical components. Such operation
would invalidate any applicable Bryant warranty.
NOTE: If field-installed thru-the-bottom connections are
used, refer to the accessory installation instructions for
power wiring and gas connectio ns. Refer to Fig. 1A and 1B
for drilling holes in basepan.
B. Field Control Wiring
Install a Bryant-approved accessory thermostat assembly
according to installation instructions included with the
accessory. Locate thermostat assembly on a solid wall in the
conditioned space to sense average temperature in accordance with thermostat installation instructions.
NOTE: For wire runs up to 50 ft, use no. 18 AWG (American
Wire Gage) insulated wire (35 C minimum). For 50 to 75 ft,
use no. 16 AWG insulated wire (35 C minimum). For over
75 ft, use no. 14 AWG insulated wire (35 C minimum). All
wire larger than n o. 18 AWG cannot be dir ectly con nect ed to
the thermos tat and wi ll req uire a j unction box and s plice a t
the thermostat.
—12—
Route thermostat cable or equivalent single leads of colored
wire from thermostat subbase terminals to low-voltage connections on unit (shown in Fig. 10) as described in Steps 1-4
below.
If unit is mounted on roof curb and accessory thru-the-curb
service plate connection is used, route wire through connection plate.
Pass control wires through the hole provided on unit (see
connection D in Connection Sizes table in Fig. 1A and 1 B).
Feed wires through the raceway built into the corner post to
the 24-v barrier located on the left side of the control box.
Table 2A — Electrical Data (Without Convenience Outlet)
UNIT
580F
090
(71/2Ton s)
091
(71/2Ton s)
102
(81/2Ton s)
103
(81/2Ton s)
120
(10 Tons)
121
(10 Tons)
150
1
(12
/2Ton s)
151
1
(12
/2Ton s)
NOMINAL
VO LTAGE
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
VO LTAGE
IFM
TYPE
RANGE
Min Max QtyRLALRAQty Hp FLA F LAMCAMOCP**FLALRA
Std
187254214.091.021/41.4
Alt5.840.1/40.145/4542/42229/229
High10.644.9/44.950/5048/48273/273
Std
41450826.442.021/40.7
Alt2.618.42019108
High4.820.62522130
Std
51863225.239.021/40.7
Alt2.614.9201697
High4.816.72018114
Std
187254214.091.021/41.4
Alt5.840.1/40.145/4542/42229/229
High10.644.9/44.950/5048/48273/273
Std
41450826.442.021/40.7
Alt2.618.42019108
High4.820.62522130
Std
51863225.239.021/40.7
Alt2.614.9201697
High4.816.72018114
Std
187254216.0137.021/41.4
High10.649.4/49.460/6052/52365/365
Std
41450828.369.021/40.7
High4.824.93026184
Std
51863226.458.021/40.7
High4.819.42520152
Std
187254217.3***120.0***21/41.4
High10.649.1/49.160/6052/52316/316
Std
41450827 .9***70.0***21/40.7
High4.823.23024171
Std
51863225 .5***50.0***21/40.7
High4.818.52519126
Std
187254215.8130.021/41.4
Alt7.545.9/45.950/5048/48326/326
High15.053.4/53.460/6057/57374/374
Std
41450827.964.021/40.7
Alt3.422.62524191
High7.426.63028185
Std
Alt3.418.72520155
51863226.652.02
High7.421.93023150
Std
187254216.0125.021/41.4
Alt7.546.3/46.360/6049/49316/316
High15.053.4/53.460/6057/57374/374
Std
41450828.062.521/40.7
Alt3.422.82524191
High7.426.83029182
Std
51863226.350.021/40.7
Alt3.418.02019151
High7.421.22523146
Std
187254223.0146.021/41.4
Alt15.069.6/69.680/80††73/73406/406
Std
414508210.473.021/40.7
Alt7.432.24534203
Std
51863228.358.42
Alt7.425.73027162
Std
187254219.0156.02
Alt15.060.6/60.670/70††64/64378/378
Std
41450829.075.02
Alt7.429.13531213
Std
51863227.454.021/40.7
Alt7.423.73025159
COMPR
(ea)
See Fig. 11. The raceway provides the UL-required (Underwriters’ Laboratories) clearance between high- and lowvoltage wiring.
Connect thermostat wires to sc rew terminal s on low-voltage
connecti on board.
C. Heat Anticipator Settings
Set heat anticipator settings at .14 amp for the first stage
and .20 amp for second-stage heating.
OFM
(ea)
1
/40.7
1
/40.7
1
/41.4
1
/40.7
IFM
5.8
2.6
2.6
5.8
2.6
2.6
5.8
2.6
2.6
5.8
2.6
2.6
5.8
2.6
2.6
5.8
2.6
2.6
10.6
4.8
4.8
10.6
4.8
4.8
COMBUSTION
FAN M OTO R
FLA
.6
.3
.3
.6
.3
.3
.6
.3
.3
.6
.3
.3
.6
.3
.3
.6
.3
.3
.6
.3
.3
.6
.3
.3
POWER SUPPLY*
40.1/40.145/4542/42229/229
18.42019108
14.9201697
40.1/40.145/4542/42229/229
18.42019108
14.9201697
44.6/44.650/5047/47321/321
22.72524162
17.62018135
44.3/44.350/5046/46272/272
21.02522149
16.72017109
44.2/44.250/5046/46307/307
21.82523152
18.12519123
44.6/44.650/5047/47297/297
22.02524188
17.42018119
65.2/65.280/80††68/68383/383
29.64031192
23.63025154
56.2/56.270/70††59/59359/359
26.53028174
21.62523127
DISCONNECT
SIZE†
—13—
LEGEND AND NOTES FOR TABLES 2A AND 2B
LEGEND
FLA — Full Load Amps
HACR— Heating, Air Conditioning and Refrigeration
IFM — Indoor (Evaporator) Fan Motor
LRA — Locked Rotor Amps
MCA — Minimum Circuit Amps
MOCP— Maximum Overcurrent Protection
NEC — National Electrical Code
OFM — Outdoor (Condenser) Fan Motor
RLA — Rated Load Amps
*The values listed in this table do not include power exhaust. See table
below for power exhaust requirements.
†Used to determine minimum disconnect per NEC.
**Fuse or HACR circuit breaker.
††Fuse only.
***Compressor no. 1 data indicated in table.
208/230-3-60: Compressor no. 2 RLA is 14.1 amps and LRA is
105 amps.
460-3-60: Compressor no. 2 RLA is 7.1 amps and LRA is 55 amps.
575-3-60: Compressor no. 2 RLA is 6.4 amps and LRA is 40 amps.
1. In compliance with NEC requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be fuse or HACR breaker.
Canadian units may be fuse or circuit breaker.
2. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is
greater than 2%.
of voltage imbalance.
% Voltage Imbalance
= 100 x
Example: Supply voltage is 460-3-60.
Determine maximum deviation from average voltage.
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
% Voltage Imbalance = 100 x
This amount of phase imbalance is satisfactory as it is below the
maximum allowable 2%.
IMPORTANT: If the supply voltage phase imbalance is more than 2%,
contact your local electric utility company immediately.
Use the following formula to determine the percent
max voltage deviation from average voltage
AB = 452 v
BC = 464 v
AC = 455 v
average voltage
Average Voltage =
457
=1.53%
452 + 464 + 455
3
1371
=
3
= 457
7
NOTE: If a single power source is to be used, size wire to include power
exhaust MCA and MOCP. Must be in accordance with NEC or local
codes.
Check MCA and MOCP when power exhaust is powered through the
unit. Determine the new MCA including the power exhaust using the following formula:
MCA New = MCA unit only + MCA of Power Exhaust
For example, using a 580FPV090 unit with MCA = 40.1 and MOCP
= 45, with CRPWREXH030A00 power exhaust.
MCA New = 40.1 amps + 1.6 amps = 41.7 amps
If the new MCA does not exceed the published MOCP, then MOCP
would not change. The MOCP in this example is 45 amps and the MCA
New is below 45; therefore the MOCP is acceptable. If “MCA New” is
larger than the published MOCP, raise the MOCP to the next larger size.
For separate power, the MOCP for the power exhaust will be 15 amps
per NEC.
—14—
Table 2B — Electrical Data (With Convenience Outlet)
Splice Connection
(Factory Supplied)
Field Wiring
Factory Wiring
COOL STAGE 1
FAN
HEAT STAGE 1
COOL STAGE 2
HEAT STAGE 2
24 VAC HOT
24 VAC COM
N/A
OUTDOOR AIR
SENSOR
THERMOSTAT DIPSWITCH SETTINGS
ON
OFF
B
A
C
Y1/W2
G
W/W1
Y/Y2
O/W2
R
C
S1
S2
D
R
G
Y1
Y2
W1
W2
C
IPD/X
WIRE
CONNECTIONS
TO
LOW-VOLTAGE
SECTION
(CONNECTION
BOARD)
LEGEND
Field Wiring
NOTE: Underlined letter indicates active thermostat output when
configured for A/C operation.
Fig. 10 — Low-Voltage Connections
UNIT LOW VOLTAGE
CONNECTION
BOARD
RACEWAY
COMPRESSOR
NO. 2
Fig. 11 — Field Control Wiring Raceway
and Compressor Location
INTEGRATED
GAS UNIT
CONTROLLER
(IGC)
COMPRESSOR
NO.1
—16—
VIII. STEP 8 — ADJUST FACTORY-INSTALLED OPTIONS
A. Manual Outdoor-Air Damper
The outdoor-air hood and screen are attached to the basepan
at the bottom of the unit for shipping.
Assembly:
1. Determine quantity of ventilation required for building. Record amount for use in Step 8.
2. Remove filter access panel by raising panel and
swinging panel outward. Panel is now disengaged
from track an d can be re moved. No to ols are required
to remove the filt er ac cess pa nel. Remove outdoo r-air
opening panel. Save panels and screws. See Fig. 12.
3. Separate hood and screen from basepan by removing
the screws and brackets securing them. Save all
screws and discard brackets.
4. Replace outdoor air o pening panel wi th screws saved
from Step 2.
5. Place hood on front of outdoor-air opening panel. See
Fig. 13 for hood details. Secure top of hood with the 6
screws removed in Step 3. See Fig. 14.
6. Remove and save 6 screws (3 on each side) from sides
of the manual outdo or-air damper.
7. Align screw holes on hood with screw holes on side of
manual outdoor-air damper. See Fig. 13 and 14.
Secure hood with 6 screws from Step 6.
8. Adjusting the manual outdoor-air adjustment screws
on the front of the damper blade. See Fig. 12. Slide
blade vertically until it is in the appropriate position
determined by Fig. 15. Tighten screws.
9. Remove and save screws currently on sides of hood.
Insert screens. Secure screens to hood using the
screws. See Fig. 14.
10. Replace filter access panel. Ensure filter acces s panel
slides along the tracks and is securely engaged.
Fig. 13 — Outdoor-Air Hood Details
HOOD
OUTDOOR
AIR OPENING
PANEL
3 SCREWS
(SIDE)
Fig. 12 — Damper Panel with Manual
Outdoor-Air Damper Installed
NOT
SHOWN)
Fig. 14 — Optional Manual Outdoor-Air Damper
with Hood Attached
Fig. 15 — Outdoor-Air Damper Position Setting
—17—
B. Optional EconoMi$er+
See Fig. 16 for EconoMi$er+ component locations.
NOTE: These instructions are for the factory-installed optional
EconoMi$er+ only. Refer to the accessory EconoMi$er+
installation instr uc t ion s w hen f iel d ins t all ing an Ec o noMi$er+
accessory.
1. To remove the existing unit filter access panel, raise
the panel and swing the bottom outward. The panel is
now disengaged from the track and can be removed.
See Fig. 17.
2. The box with the EconoMi$er+ hood components is
shipped in the compartment behind the EconoMi$er+.
The EconoMi$er+ does not have to be removed to
retrieve the hood box. Remove the screw holding the
hood box bracket to the top of the EconoMi$er+. Slide
the hood box out of the unit. See Fig. 18.
IMPORTANT: If a power exhaust accessory will be installed
on the unit, the hood shipped with the unit will not be used
and must be discarded. Save the aluminum filter for use in
the power exhaust.
3. The indoor coil access panel will be used as the top of
the hood. Remove the screws a long t he bottom of the
indoor coil access panel. See Fig. 19.
4. Swing out the indoor coil access panel and insert the
hood sides under the panel (hood top). Use the screws
provided to attach the hood sides to the hood top. Use
the screws provided to attach the hoo d sides to the
unit. See Fig. 20.
5. Remove the shipping tape holding the EconoMi$er+
barometric relief damper in place.
6. Insert the hood divider between the hood side s. See
Fig. 20. Secure hood divider with 2 screws on each
hood side. The hood divider is also used as the bottom
filter rack for the aluminum filter.
7. Open the filter clips which are located underneath
the hood top. Insert the aluminum filter into the
bottom filter rack (hood divider) . Push the filter into
position pa st th e op en fi lter c lip s . Cl ose the f ilt er c lip s
to lock the filter into place. See Fig. 21.
8. Caulk the ends of the joint between the unit top panel
and the hood top. See Fig. 19.
9. Replace the filter access panel.
10. Install all Eco noMi$ er+ acc essori es . Econ oMi$er + wir ing
is shown in Fig. 22.
Barometric flow capacity is shown in Fig. 23. Outdoor air
leakage is shown in Fig. 24. Return air pressure drop is
shown in Fig. 25.
FILTER ACCESS PANEL
INDOOR COIL ACCESS PANEL
Fig. 17 — Typical Access Panel Locations
x
o
B
H
d
o
o
HOOD BOX
BRACKET
Fig. 18 — Hood Box Removal
ECONOMI$ER+
PLUG
OUTDOOR AIR
TEMPERATURE
SENSOR
ECONOMI$ER+
CONTROLLER
(UNDER COVER)
OUTDOOR
AIR HOOD
Fig. 16 — EconoMi$er+ Component Locations
HOOD
SHIPPING
BRACKET
ECONOMI$ER+
CONTROLLER
LABELS
GEAR
DRIVEN
DAMPER
BAROMETRIC
RELIEF
DAMPER
—18—
SIDE
PANEL
TOP
SIDE
PANEL
INDOOR
COIL
ACCESS
PANEL
INDOOR
COIL
ACCESS
PANEL
CAULK
HERE
Fig. 19 — Indoor Coil Access Panel Relocation
TOP
PANEL
INDOOR COIL
ACCESS PANEL
22 1/4”
LEFT
HOOD
SIDE
B
24 9/16”
HOOD DIVIDER
SCREW
Fig. 20 — Outdoor-Air Hood Construction
40 3/8”
BAROMETRIC
RELIEF
DIVIDER
OUTSIDE
AIR
CLEANABLE
ALUMINUM
FILTER
FILTER
Fig. 21 — Filter Installation
HOOD
FILTER
CLIP
(FIELD-SUPPLIED)
LEGEND
ECON — EconomizerOAT — Outdoor-Air Temperature
IAQ— Indoor-Air Quality (4 to 20 mA)ORH — Outdoor-Air Relative Humidity (Sensor)
IARH — Indoor-Air Relative Humidity (Signal) POT — Potentiometer
IRH— Indoor-Air Relative Humidity (Sensor) RAT — Return-Air Temperature
OARH — Outdoor-Air Relative Humidity (Signal) SAT — Supply-Air Temperature
NOTES:
1. Terminals 13-17 are wired to 5-pin plug assembly (P/N CRE+PLUG001A00).
2. Pin numbers are not printed on the controller. They are provided in this book as a reference.
Fig. 22 — EconoMi$er+ Wiring
—19—
2500
2000
FLOW IN CUBIC FEET PER MINUTE (cfm)
1500
1000
500
0
0.05
0.15
STATIC PRESSURE (in. wg)
0.25
71/2-121/2Ton
Fig. 23 — Barometric Flow Capacity
30
25
20
15
10
5
0
0.13 0.2 0 0. 22 0.25 0.30 0.35 0.40 0 .45 0.5 0
FLOW IN CUBIC FEET PER MINUTE (cfm)
STATIC PRESSURE (in. wg)
7 1/2-12 1/2 Ton
Fig. 24 — Outdoor-Air Damper Leakage
6000
5000
4000
3000
2000
1000
0
0.050.100.15 0.200.250.300. 35
FLOW IN CUBIC FEET PER MINUTE (cfm)
STATIC PRESSURE (in. wg)
7 1/2-12 1/2 Ton
Fig. 25 — Return-Air Pressure Drop
C. EconoMi$er+ Control Mode
Determine the EconoMi$er+ control mode before installing
sensors and accessories. Different sensors are required for
different control modes, and a number of accessories are
available. Refer to Tables 3 and 4.
Outdoor Dry Bulb Changeover
The standard control mode for the EconoMi$er+ is Outdoor
Dry Bulb Changeover. The outdoor air an d supply air temperature sensors are also included as standard.
EconoMi$er+ control is based on the outdoor temperature
relative to a set point in the software. If the outdoor-air temperature is above the set point then the EconoMi$er should
be in minimum position. If the outdoor-air temperature is
below the set point, the position should be controlled to
maintain the l eav ing a ir t emper ature set po in t. The s et po int
range is 45 to 70 F.
Differential D r y Bulb Changeover
The control supports differential dry bulb changeover con-
trol. This requires an accessory return air temperature
sensor CRTEMPSN001A00 installed in the return airstream. Refer to the Start-up section for details on how to
configure and enable the control mode. The user can check
the operation of the s ensor using the Read function.
Outdoor Air Enthalpy Changeover
The control support s ou tdoor air e nthal py cha ngeo ver con trol.
This mode requires a factory-supplied outdoor air temperature
sensor (OAT) and an accessory outdoor air humidity sensor
(ORH) (part no. CRHUMDSN001B00). Refer to the Start-Up
section fo r details on how to con figure and enable th e control
mode. The user ca n check the operation of the sensors using
the Read function.
Differential Ent halpy Changeover
The control supports differential enthalpy changeover con-
trol. This requires the factory-supplied outdoor air temperature sensor, an accessory outdoor air humidity sensor, an
accessory return air temperature sensor, and an accessory
indoor air humidit y sensor. Refer to the Start-Up section fo r
details on how to configure and enable the control mode. The
user can check the o peration of the sens ors using the Read
function.
D. Damper Movement
When the EconoMi$e r+ board receives initia l power, it will
take the damper up to 2
1
/2 minutes before it begins to position itself. After the initial positioning, subsequent changes
to damper position will take up to 30 seconds to initiate.
Damper movement from full open to full closed (or vice
versa) takes 2
1
/2 minutes.
If the damper is in the process of changing positions (for
example it is trying to open to 100%) and the fan signal is
turned off, the damper will con tinue to its 100% open position before closing.
NOTE: Occupied minimum position can not be set lower than
+1% higher than the value of IAQ minimum ec onomizer position. Refer to the setup examples on page 56.
E. EconoMi$er+ Controller Wiring
The EconoMi$er+ is sup plied fr om the factor y with a suppl y
air temperature sensor and an outside air temperature
sensor. This allows for operation of the EconoMi$er+ with
outdoor air dry bulb changeover control. Additional accessories can be added to allow for different types of change over
control and operation of the EconoMi$er+ and unit.
F. T hermostats
The EconoMi$er+ control works with conventional thermostats that have a Y1 (cool stage 1), Y2 (cool stage 2), W1 (heat
stage 1), W2 (heat stage 2) , and G (fan). The EconoMi$er+
control does not support sensor thermostats l ike the T56 and
T57. Connections are made at the thermos tat terminal connection board located in the main control box.
—20—
Table 3 — EconoMi$er+ Sensor Usage
APPLICATION
Standard UnitIncluded — HH79NZ039———
Differential
Dry Bulb
Outdoor Air
Enthalpy
Differential EnthalpyIncluded — HH79NZ039
NOTES:
Sensors (Optional, 5-Pin sensor wiring plug CRE+PLUG001A00 required for installation.).
1. CO
2
33ZCSENCO2 — Room sensor (adjustable). Aspirator box is required for duct mounting of the sensor.
33ZCASPCO2 — Aspirator box used for duct-mounted CO
33ZCT55CO2 — Space temperature and CO
33ZCT56CO2 — Space temperature and CO2room sensor with override and set point.
CRCBDIOX002A00 — Return air CO
2. All units include the following Standard Sensors:
Outdoor-Air Sensor — set point adjustable from 45 F to 70 F, factory set at 65 F.
Supply-Air Sensor — set point adjustable from 40 F to 65 F. Factory set at 55 F.
All temperature adjustments are made at the EconoMi$er+ controller.
STANDARD OUTDOOR AIR
TEMPERATURE SENSOR
Included — HH79NZ039
Included — HH79NZ039—
room sensor with override.
2
sensor.
2
Table 4 — EconoMi$er+ Field-Installed Accessories
1
7
/2-121/2Ton Powe r E xhaust
208-230 v 1 Ph
1
7
/2-121/2Ton Powe r E xhaust
460 v 3 Ph
Return Air Temperature Sensor with
Harness
Outdoor Air Humidity Sensor with
Harness
Indoor Air Humidity Sensor w/HarnessCRHUMDSN001B00
Return Air CO
Room Sensor33ZCSENCO2*
CO
2
Aspirator Box for Duct Mount
Sensor
CO
2
Space Temperature and CO
Room Sensor with Override
Space Temperature and CO
Room Sensor with Override
and Set Point
5-Pin Sensor Wiring PlugCRE+PLUG001A00*
*5-pin sensor wiring plug accessory (P/N CRE+PLUG001A00) is
required to install IAQ sensor.
DESCRIPTIONPART NUMBER
CRPWREXH022A00
CRPWREXH023A00
CRTEMPSN001A00
CRHUMDSN001B00
SensorCRCBDIOX002A00*
2
33ZCASPCO2
2
2
33ZCT55CO2*
33ZCT56CO2*
ACCESSORY RETURN AIR
TEMPERATURE SENSOR
Required —
CRTEMPSN001A00
Required —
CRTEMPSN001A00
room sensor.
2
The user can read the value of the sensor using the Read
mode, described in the EconoMi$er+ Controller section.
I. Indoor Air Quality (IAQ) Sensor
Any indoor air quality or CO
20 mA output can be used as the IAQ sensor. The controller
will modulate the outdoor-air damper to provide ventilation
based on the sensor output and the IAQ se tting of the con troller. The CO
the minimum position (IAQ minimum damper position set
point) to the maximum position (occupied minimum damper
position). When there is no CO
unoccupied minimum pos ition. When there is a CO
damper will be between the IAQ minimum economizer set
point position and the occup ied min imum da mper pos ition.
Mount the sensor according to manufacturer specifications.
In order to wire this sensor, an accessory 5-pin plug (part
number CRE+PLUG001A00) is required. See Fig. 22.
The IAQ sensor is wired to the g round an d IAQ w ires in the
harness. The accessory 5-pin wiring plug is connected to pins
13-17 of J3 on the EconoMi$er+ controller. Push the plug
down onto the pins of the EconoMi$e r+ controller to instal l.
sensor will modulate the outdoor-air damper from
2
ACCESSORY
OUTDOOR AIR
HUMIDITY SENSOR
——
Required —
CRHUMDSN001B00
Required —
CRHUMDSN001B00
sensor that provides a 4 to
2
call, the damper will go to the
2
Pins 13 and 14 are used for the IAQ sensor. Pins 15-17 are
G. Outdoor Air Temperature (OAT) Sensor (Provided)
The outdoor air temperature sensor is a 10K thermistor used
to measure the outdoor-air temperature. The sensor controls
EconoMi$er+ changeover and compressor lockout. The sensor
is factory-installed on the EconoMi$er+ in the outdoor airstream. The operating range of temperature measurement is
0° to158 F. See Tables 5 and 6 for thermistor resistan ce and
resolution values.
The temperature sensor l ooks like an eyelet terminal with
wires running to it. The sensor is located in the “crimp end”
and is sealed from moisture.
The user can read the value of the sensor using the Read
mode, described in the Start-Up section.
H. Supply Air Temperature (SAT) Sensor (Provided)
The supply air temperature sensor is a 10K thermistor
located at the inlet to the indoor fan. This sensor must be
field installed . Th e o per ating range of temperature me as ur ement is 0° to158 F. See Tables 5 and 6 for thermistor resistance and resolution values.
The temperature sensor l ooks like an eyelet terminal with
wires running to it. The sensor is located in the “crimp end”
and is sealed from moisture.
used for the field-installed remote potentiometer. Connect
the IAQ sensor to the BRN and WHT wires o f the accessor y
5-pin plug.
NOTE: Pin numbers are not sh own on th e cont roller. They are
provided only as reference for the installer. On the
EconoMi$er+ board, they numbered 1-17 from left to right, but
only the 1 and the 17 are printed on the board.
Sensor wiring should be extended with wire and wire nuts
and routed to the IAQ sensor location. Adjust the IAQ setting at the controller to correspond to the IAQ voltage output
of the sensor at the user-determined set point. See Fig. 26.
Power the sensor with a field-supplied transformer.
J. Return Air Temperature (RAT) Sensor
The EconoMi$er+ controller will accept input from the accessory 10K return air temperature sensor (CRTEMPSN001A00)
in addition to the outdoor air temperature sensor shipped
with the EconoMi$er+. By using both sensors, the outdoor air
and the return air temperatures are compared (differential
dry bulb) for optimal energy savings. See Tables 5 and 6 for
thermistor resistance and resolution values.
The temperature sensor looks like an eye let terminal with
wires running to it. The sensor is located in the “crimp end”
and is sealed from moisture.
ACCESSORY INDOOR
RETURN AIR
HUMIDITY SENSOR
—
Required —
CRHUMDSN001B00
call, the
2
—21—
The user can read the value of the sensor using the Read
mode, described in the EconoMi$er+ Controller section.
Mount the return air temp erature sens or on the Eco noMi$er+,
through pre-punched holes. See F ig . 2 7.
The return air temperature (RAT) sensor is provided with a
2-wire, 42-in. long wiring harness with a 2-pin connector.
The plug is installed on pins 5 and 6 on J3 of the
EconoMi$er+ controller. The pins are labeled with a ground
symbol and RAT on the EconoMi$er+ controller. See Fig. 22.
The red wire of the harness is connected to pin 5 (ground).
The black wire of the harness is connected to pin 6 (RAT).
The wiring harness should be routed from the EconoMi$er+
controller to the sensor. The controller compares the temperatures of the two ai rstream s, chooses the be st one, and mod ulates the EconoMi$er+ actuator accordingly.
This 10K thermistor is used to measure the return air
temperature vs. resistance curve, per Table 5. The range of
temperature measurement is between 0° and 158 F. See
Table 6 for resolution.
K. Outdoor Air Humidity Sensor
The EconoMi$er+ controller accepts input from the accessory
outdoor air humidity sensor in ad dition to the out door air temperature sensor shipped with the EconoMi$er+. By using both
sensors, the total ent halpy of the out sid e air is ca lcula ted.
Mount the outdoor-air humidity sensor in to the
EconoMi$er+, through the pre-punched holes. See Fig. 28.
The outdoor-air humidity senso r is provided with a 2-wire,
42-in. wiring harness with a 2-pin connector. The plug is
installed on pins 11 and 12 on J3 of the EconoMi$er+ controller. The pins are labeled ORH and VREF on the
EconoMi$er+ controller. See Fig. 22. The orange wire of the
harness is connected to pin 11 (ORH). The blue wire of the
harness is connected to pin 12 (VREF). The wiring harness
should be rout ed from the Eco noMi$ er+ cont roll er to the se nsor location.
The outdoor enthalpy changeover curve is set at the
EconoMi$er+ controller. The factory default is curve “A.” See
Fig. 29. See Fig. 30 for Sensor Curve vs. Humidity.
L. Indoor Air Humidity Sensor
For differential enthalpy sensing, the EconoMi$er+ controller uses the standard outdoor air temperature sensor, the
outdoor air humidity sensor, and the optional indoor air
humidity sensor, an optional return air t emperature sensor
(RAT). The indoor-air humidity sensor is provided with a
2-wire, 42-in. wiring harness with a 2-pin connector. The
plug is installed on pins 8 and 9 on J3 of the EconoMi$er+
controller. The pins are labeled IRH and VREF on the
EconoMi$er+ controller. See Fig. 22. The orange wire of the
harness is connected to pin 8 (IRH). The blue wire of th e harness is connected to pin 9 (VREF). The wiring harness
should be extended with wires and wire nuts and routed
from the EconoMi$er+ controller to the sensor location. The
EconoMi$er+ controller compares the outdoor air enthalpy
to the return air enthalpy to determine EconoMi$er+ use.
The controller select s the lower enthalpy air (return or outdoor) for cooling. For example, when the outdoor air has a
lower enthalpy than the return air , the EconoMi$er+ controller opens the damp er to bring in outdoor air for free cooling.
Mount the return-air humidity sensor in the return-air duct.
See Fig. 31.
The outdoor enthalpy changeover curve is set with at the
EconoMi$er+ controller. The selectable curves are A, B, C,
and D. The factory default is curve “A.” See Fig. 29. See
Fig. 30 for Sensor Curve vs. Humidity.
CO SENSOR MAX RANGE SETTING
2
6000
5000
4000
3000
2000
1000
RANGE CONFIGURATION (ppm)
0
2345678
DAMPER VOLTAGE FOR MAX VENTILATION RATE
800 ppm
900 ppm
1000 ppm
1100 ppm
Fig. 26 — Indoor Air Quality Voltage Setting
ECONOMI$ER+ CONTROLLER
ACTUATOR
RETURN AIR
TEMP SENSOR
(HIDDEN)
CURB
VERTICAL ECONOMI$ER+
(3 TO 12 1/2 TON UNITS)
(SIDE VIEW)
HOOD
GROMMET
INDOOR AIR
HUMIDITY SENSOR
Fig. 27 — Return Air Temperature Sensor
—22—
Table 5 — Outdoor Air, Return Air, and Supply Air Temperature Sensors
(CRTEMPSN001A00 or HH79NZ039) — 10K Thermistor Curve