installation, start-up and service instructions

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1 installation, start-up and service instructions SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNITS Cancels: New 580E Sizes to 27 Tons II 580E /15/94 IMPORTANT READ BEFORE INSTALLING 1. Read and become familiar with these installation instructions before installing this unit (Fig. 1). 2. Be sure the installation conforms to all applicable local and national codes. 3. These instructions contain important information for the proper maintenance and repair of this equipment. Retain these instructions for future use. CONTENTS Page SAFETY CONSIDERATIONS...1,2 INSTALLATION I. Locate the Unit...2 II. Duct Connections...5 III. Rig and Place Unit...5 IV. Field Connections...7 V. Accessory Installation...15 VI. Outdoor-Air Inlet Adjustments...18 PRE-START-UP...19,20 I. Pre-Start-Up Procedures...19 II. Refrigerant Service Ports...20 III. Internal Wiring...20 IV. Evaporator Fan, Belt, and Sheaves...20 V. Economizer Inlet Screens...20 VI. Economizer Dampers and Potentiometer Settings...20 START-UP I. Compressor Oil...20 II. Condenser Fans and Motors...23 III. Operating Sequences...23 IV. Ventilation-Air Circulation (Continuous Fan)...24 V. Automatic Changeover Using Automatic Changeover Thermostat...24 VI. Head Pressure Control...24 SERVICE I. Service Access...24 II. Cleaning...25 III. Lubrication...26 IV. Evaporator-Fan Adjustments...26 V. Condenser-Fan Adjustments...27 VI. Gas Heat Adjustments...27 VII. Main Burner Removal...28 VIII. Switch Adjustment...28 IX. Enthalpy Control, MAT, Economizer Damper Linkage, and Economizer Damper Vent Position...29 X. Refrigerant Charge...29 XI. Refrigerant Feed Components...29 XII. Protective Devices...30 XIII. Gas Heat...31 TROUBLESHOOTING I. Economizer...32 II. Control Board Checkout...33 START-UP CHECKLIST...CL-1 Fig.1Typical Unit SAFETY CONSIDERATIONS WARNING: Improper installation, adjustment, alteration, service, maintenance or use can cause carbon monoxide poisoning, explosion, fire, electric shock or other occurrences which may cause injury or property damage. Consult a qualified installer, service agency or the gas supplier for information or assistance. The qualified installer or agency must use only factory-authorized kits and accessories when modifying this product. 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 the 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 indicates a condition that could result in personal injury. Caution is used to identify unsafe practices which would result in minor personal injury or product and property damage. WARNING: Disconnect gas piping from unit when leak testing at pressure greater than 1 2 psig. Pressures greater than 1 2 psig will cause gas valve damage resulting in hazardous condition. If gas valve is subject to pressure greater than 1 2 psig, it must be replaced before use. When pressure testing field-supplied gas piping at pressures of 1 2 psig or less, a 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. Electrical shock could cause personal injury.

2 1. The power supply (volts, hertz, and phase) must correspond to that specified on unit rating plate. 2. The electrical supply provided by the utility must be sufficient to handle load imposed by this unit. 3. Refer to Locate the Unit section on this page and Fig. 2-4 for locations of gas inlet, electrical inlets, condensate drain, duct connections, and required clearances before setting unit in place. 4. Locate the unit where the vent cap will be a minimum of 4 ft from openable windows or doors. 5. This installation must conform with local building codes and with NFGC (National Fuel Gas Code) ANSI (American National Standards Institute) Z or NFPA (National Fire Protection Association) Refer to local plumbing or wastewater codes and other applicable local codes. 6. Approved for outdoor installation only on wood flooring or on class A, B, or C roof covering materials when installed on roof curb. INSTALLATION Unit is shipped in the vertical airflow configuration (see Fig. 1). To convert to horizontal discharge, horizontal conversion package (240) or (300,324) is recommended. These units are equipped with an energy-saving, automatic, electric direct-spark ignition system that does not have a continuously burning pilot. All units are manufactured with natural gas controls. These units are designed for a minimum continuous returnair temperature of 55 F (dry bulb) or an intermittent operation down to 45 F (dry bulb), such as when used with a night setback thermostat. All units can be connected into existing duct systems that are properly sized and designed to handle an airflow of 300 to 500 cfm per each 12,000 Btuh of rated cooling capacity. Fig. 2 Service and Operational Clearances NOTE: When installing any accessory item, see the manufacturer s installation instructions packaged with the accessory. A qualified agency must use factory-authorized kits and accessories when modifying this unit. I. LOCATE THE UNIT A. Clearance Maintain clearance around and above unit to provide minimum distance from combustible materials, proper airflow, and service access (see Fig. 2 and 3). Minimum recommended clearance is 72 in. on all sides and 144 in. on top of unit for service access. Minimum clearance to combustibles is 48 in. on flue side, zero inches on all other sides. Minimum clearance on all sides to block walls or any other grounded surface is 42 inches. Minimum clearance of 72 in. should be provided on side with outdoor-air intake, if unit is so equipped. Minimum distance between unit and other electrically live parts is 48 inches. Do not install unit in an indoor location. Do not locate unit air inlets near exhaust vents or other sources of contaminated air. Be sure that unit is installed so that snow will not block the combustion intake or flue outlet. Although unit is weatherproof, guard against water from higher level runoff and overhangs. Slab-mounted units should be at least 4 in. above the highest expected water, flood, and runoff levels. Do not use the unit if it has been under water. Locate mechanical draft system flue assembly at least 48 in. from any opening through which combustion products could enter the building, and at least 48 in. from an adjacent building. When unit is located adjacent to public walkways, flue assembly must be at least 7 ft above grade. 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. Flue vent discharge must have a minimum horizontal clearance of 4 ft from electric and gas meters, gas regulators, and gas relief equipment. B. Roof Curb Mount Check building codes for weight distribution requirements. Unit weight is shown in Table 1. Assemble and install accessory roof curb in accordance with instructions shipped with curb (see Fig. 4). Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork must be attached to curb. IMPORTANT: The gasketing of the unit to the roof curb is critical for water integrity. Install gasket with the roof curb as shown in Fig. 4. Improperly applied gasket can also result in air 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. 2

3 UNIT 580E WEIGHT* A B C D E F G lb kg mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in *Weights include economizer, but not hood. LEGEND CONN Connection DIM Dimension SS Horizontal Supply/Return NOTES: 1. Dimensions in [ ] are in millimeters. 2. Center of gravity. 3. Allow 12-0 (3658) at top and 6-0 (1829) on sides for service and operational clearance. 4. On multiunit applications allow 12-0 (3658) between adjacent condensers and economizers. 5. For smaller service and operational clearances, contact your local representative. 6. Bottom ducts designed to be attached to accessory roof curb. If unit is mounted on dunnage, it is recommended the ducts be supported by cross braces as done on the accessory roof curb. 7. Always line up condenser end of unit tight against the roof curb. 8. Units with bottom return and power exhaust require a 90 elbow in return-air duct. 9. When unit is slab mounted, locate the condensate drain as low as possible on vertical face of base rail at the same location as the standard condensate drain using factory supplied fitting. Plug factory drilled condensate hole. Fig. 3 Base Unit Dimensions 3

4 NOTE: To prevent the hazard of stagnant water build-up in the drain pan of the indoor section, unit can only be pitched as shown. DIMENSIONS (degrees and inches)* NOTES: 1. Roof curb accessory is shipped disassembled. 2. Dimensions in ( ) are millimeters. 3. Roof curb: 18 gage steel. 4. The 300 and 324 units overhang the roof curbs on the return-air end. B C D UNIT Deg. in. Deg. in. Deg. in. 580E UNIT LEVELING TOLERANCES *From edge of unit to horizontal. Fig. 4 Roof Curb 4

5 C. Slab Mount (Horizontal Units Only) Provide a level concrete slab that extends a minimum of 6 in. beyond unit cabinet. The slab should be 8 in. thick with 4 in. above grade. Install a gravel apron in front 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. D. Alternate Unit Support Methods Where the preferred curb or slab mount cannot be used, support unit with sleepers on perimeter, using curb support area. However, if sleepers cannot be used, support long sides of unit (see Fig. 3) with three 4-in. x 4-in. pads, equally spaced. Unit may sag if supported by corners only. II. DUCT CONNECTIONS The 580E are field-convertible units. They are shipped from the factory as vertical supply/return, but may be field converted to horizontal supply/return. A. Vertical Supply/Return Units Field-fabricated ductwork must be attached to the roof curb. The return-air duct connection (inside dimensions) is in. long x in. wide; the supply-air duct connection (inside dimensions) is in. long x 27 in. wide. Connect ductwork to roof curb. Secure all ducts to the building structure using flexible duct connectors between roof curb and ducts as required. Outlet grilles must not lie directly below unit discharge. The return duct must have a 90-degree elbow before opening into the occupied building space if unit is equipped with power exhaust. 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 1.0 in. wg. NOTE: Connection must be made to roof curb before unit is set in place. B. Horizontal Supply/Return Units Units may be connected to horizontal supply/return ductwork with the use of the accessory horizontal conversion package, part number (240) or (300,324). III. RIG AND PLACE UNIT IMPORTANT: These units are not designed for handling by forklift trucks. Inspect unit for transportation damage. File claim with transportation agency. Do not drop unit; keep upright. Use spreader bars over unit to prevent sling or cable damage. Rollers may be used to move unit across a roof. Level by using unit frame as reference. See Fig. 5 for additional information. Unit weight is shown in Fig. 5. NOTES: 1. Rig with 4 cables and spread with two 95 in. (2413 mm) and 2 A long suitable spreader bars. 2. Center of gravity and unit weight include economizer, but not hood. CAUTION: All panels must be in place when rigging. Unit is not designed for handling by forklift trucks. NOTICE TO RIGGERS UNIT 580E UNIT WEIGHT* A B C Lb Kg in. mm in. mm in. mm *Weights include economizer, but not hood. ROOF CURB ECONOMIZER WITHOUT HOOD ACCESSORY/OPTION WEIGHTS ECONOMIZER HOOD POWER EXHAUST/ BAROMETRIC RELIEF HOOD Lb Kg Lb Kg Lb Kg Lb Kg Fig. 5 Rigging Label 5

6 Table 1 Specifications BASE UNIT 580E NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb)* Unit COMPRESSORS (2 each unit) Semi-Hermetic, 1750 Rpm Capacity Steps (%) Standard 62, , , 100 Accessory 21, 42, 62, 80, , 40, 60, 80, , 37, 55, 65, 83, 100 REFRIGERANT R-22 Controlled by Thermostatic Expansion Valve Operating Charge (lb), Circuit 1/Circuit / / /18.3 CONDENSER COILS 3-Row, 3 8-in. Tube Diameter Face Area (sq ft) Fins Per in. Al Cu EVAPORATOR COILS 4-Row, 1 2-in. Tube Diameter Face Area (sq ft) Fins Per in. 15 FURNACE SECTION Number of Heat Exchangers Input (MBtuh) Output (MBtuh) Temperature Rise Range ( F) Burner Orifice Diameter (in....drill no.) Pilot Orifice Diameter (in....drill no.) Firing Stages Number of Gas Valves Manifold Pressure (in. wg) CONDENSER FANS (2 each unit) Propeller Type, 30-in. Diameter, 1140 Rpm Nominal Cfm 10,000 13,000 15,000 Nominal Hp Watts Input (Total) EVAPORATOR FANS (1 each unit) Centrifugal Type, 18 x 15 in., 1750 Rpm Nominal Cfm 8,000 10,000 10,800 Maximum Allowable Cfm 10,000 12,500 12,500 Maximum Allowable Rpm 1,200 1,200 1,200 Standard Motor and Drive in. Fan Pulley Bore Motor Hp Full Load Efficiency (%) Standard High Motor Frame Size 184T 213T 215T Fan Pulley Pitch Diameter (in.) Motor Pulley Pitch Diameter (in.) Pulley A Pulley B Resulting Fan Rpm Pulley A Pulley B Belts Quantity Length (in.) Optional Motor and Drive in. Fan Pulley Bore Motor Hp Full Load Efficiency (%) Standard High Motor Frame Size 213T 215T 254T Fan Pulley Pitch Diameter (in.) Motor Pulley Pitch Diameter (in.) Pulley A Pulley B Resulting Fan Rpm Pulley A Pulley B Belts Quantity Length (in.) OPTIONAL POWER EXHAUST** Propeller Type, 1140 Rpm Motors...Hp Fans...Diameter (in.) FILTERS Throwaway (Quantity...L xwxd) 20% Standard Efficiency x 24 x x 24 x x 24 x x 24 x x 24 x x 24 x 2 LEGEND Al Aluminum Cu Copper *Weights do not include economizer. See Fig. 5 for weights of options and accessories. Standard fan motor is supplied with standard fan drive and belts. Optional fan motor is supplied with optional fan drive, pulleys, and belts. Other combinations are field supplied. Pulley A is installed in base unit. Pulley B is field supplied. **Optional power exhaust unit-mounted on vertical supply/return applications only. Accessory power exhaust can be duct mounted on horizontal supply/return applications. 6

7 IV. FIELD CONNECTIONS A. Condensate Disposal Two condensate drain holes are located in the unit base rail to allow greater flexibility during installation. One hole must be selected for a condensate drain (see Fig. 6), and the other hole must be sealed. The drain assembly consists of a 10-gage steel plate with in. half coupling welded to it, and is shipped in the unit fan section. Also included is a 16-gage metal seal plate to cover the drain hole not selected for use. Open the access door marked FILTER SECTION and find the drain assembly, 16-gage metal seal plate and 8 screws necessary for mounting taped to the unit basepan. After the unit has been set in place on the roof: 1. Select the appropriate drain location. See Fig Remove the drain assembly and attach it to the bottom of the unit base rail at the preferred drain location using 4 of the screws provided. See Fig. 7. NOTE: Use a trap at least 4-in. deep. 3. Cover the remaining drain hole with the 16-gage metal seal plate and attach the plate using the other 4 screws provided. See Fig Apply a bead of RTV or similar sealant around the drain assembly and 16-gage metal seal plate where they attach to the rail. See Fig. 9. If drain line is run to a roof drain, pitch line away from unit at one in. per 10 ft of run. Do not use a pipe size smaller than the unit connection. On slab mount applications, and when mounted on sleepers, seal hole in bottom of base rail and attach drain assembly as low as possible to side of base rail. NOTE: Drain hole must be drilled in the rail. There is no factory-supplied drain hole in the side of the base rail. Fig. 7 Condensate Drain Location Fig. 8 Seal Plate Location B. Installing Flue/Inlet Hoods The flue/inlet hoods are shipped in a bag taped to the basepan under the unit fan. Remove the shipping blockoffs and install hoods as shown in Fig. 3 and 10. Use RTV sealant to provide rainproof seal between hoods and door. C. Gas Piping (Fig. 11) The gas supply pipe enters the unit through the access hole provided. The gas connection to the unit is made to the in. NPT gas inlet on the manifold. Install a separate gas supply line that runs directly from the meter or regulator to the heating section. Refer to Table 2 and NFGC for gas pipe sizing. Do not use cast iron pipe. Check the local utility for recommendations concerning existing lines. Choose a supply pipe that is large enough to keep the pressure loss as low as practical. Never use pipe smaller than the in. NPT gas inlet on the unit. For natural gas applications, the gas pressure at unit gas connection must not be less than 5 in. wg or greater than 13 in. wg while the unit is operating. ROOF MOUNT DRAIN SLAB MOUNT DRAIN Fig. 9 Condensate Drain Piping Details Fig. 6 Drain Location Selection 7

8 When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to NFGC ANSI Z or NFPA 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. in every 15 ft 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. For pipe sizes larger than 1 2 in., 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 coated tape. 4. Install sediment trap in riser leading to heating section. This drip leg functions as a trap for dirt and condensate. Install trap where condensate cannot freeze. Install this sediment trap by connecting a piping tee to riser leading to heating section, so that straightthrough section of tee is vertical (see Fig. 11). Then, connect capped nipple into lower end of tee. Extend capped nipple below level of gas controls. 5. Install an accessible, external, manual main shutoff valve in gas supply pipe within 6 ft of heating section. 6. Install ground-joint union close to heating section between unit manual shutoff and external manual main shutoff valve. 7. Pressure-test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit. NOTE: When pressure testing the gas supply system after the gas supply piping has been connected to the unit gas valve, the supply piping must be disconnected from the gas valve during any pressure testing of the piping systems at test pressure in excess of 0.5 psig. When pressure testing the gas supply piping system at test 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. (1) REGULAR INLET HOOD (2) HOOD WITHOUT BAFFLE (LOW HEAT ONLY) (3) HOOD WITH BAFFLE (HIGH HEAT ONLY) CAUTION: Unstable operation may occur when the gas valve and manifold assembly are forced out of position while connecting improperly routed rigid gas piping to the gas valve. Use a backup wrench when making connection to avoid strain on, or distortion of, the gas control piping. CAUTION: If a flexible conductor is required or allowed by the authority having jurisdiction, black iron pipe shall be installed at the manifold and extend a minimum of 9 in. outside the unit casing. WARNING: Never use a match or other open flame when checking for gas leaks. Never purge gas line into combustion chamber. Failure to adhere to this warning could result in an explosion causing personal injury or death. Installation Locations for Flue Hood Assemblies UNIT LOCATION TYPE A B High Heat Hood With Baffle (3) Hood With Baffle (3) Low Heat Hood Without Baffle (2) NOTE: Numbers in ( ) refer to type of hood to install in location indicated. Fig. 10 Flue Hood Details 8

9 Fig. 11 Gas Piping 8. Check for gas leaks at all field- and factory-installed gas lines after all piping connections have been completed. Use soap-and-water solution (or method specified by local codes and/or regulations). D. Field Duct Connections NOTE: The design and installation of the duct system must be in accordance with the standards of the NFPA for the installation of nonresidence-type air conditioning and ventilating systems, NFPA No. 90A or residence-type, NFPA No. 90B; and/or local codes and ordinances. Adhere to the following criteria when selecting, sizing, and installing the duct system: 1. Units are factory configured for vertical discharge only. For horizontal discharge, use accessory horizontal discharge conversion package. 2. Select and size ductwork, supply-air registers and returnair grilles according to ASHRAE (American Society of Heating, Refrigeration and Air Conditioning Engineers) 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- and airtight seal. 4. Size all ductwork for maximum required airflow (either heating or cooling) for unit being installed. Avoid abrupt duct size increases or decreases. 5. Adequately insulate and weatherproof all ductwork located outdoors. Insulate ducts passing through unconditioned space, and use vapor barrier in accordance with latest issue of SMACNA (Sheet Metal and Air Conditioning Contractors National Association) and ACCA (Air Conditioning Contractors of America) minimum installation standards for heating and air conditioning systems. Secure all ducts to building structure. 6. Flash, weatherproof, and vibration isolate all openings in building structure in accordance with local codes and good building practices. E. Electrical Connections WARNING: The unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to the unit ground lug in the control compartment, or conduit approved for electrical ground when installed in accordance with the NEC (National Electrical Code) ANSI/NFPA and local electrical codes. Do not use gas piping as an electrical ground. Failure to adhere to this warning could result in personal injury. CAUTION: Failure to adhere to the following electrical connection procedures could result in damage to the unit being installed. Table 2 Maximum Gas Flow Capacity of Pipe in Cubic Ft of Gas Per Hour for Gas Pressures of 0.5 Psig or Less and a Pressure Drop of 0.5 in. wg (Based on a 0.60 Specific-Gravity Gas) NOMINAL IRON PIPE SIZE (in.) INSIDE DIAMETER (in.) LENGTH OF PIPE (ft) , ,000 15,800 12,800 10, Refer to Table C-4, NFPA *This length includes an ordinary number of fittings. NOTE: Typical natural gas heating value is 1000 Btuh per cubic ft. For example: A 180,000 Btuh input unit equals 180, cubic ft per hour or = 180 cubic ft/hour. 1,000 9

10 Field Power Supply (Fig. 12 and 13) 1. Make all electrical connections in accordance with NEC ANSI/NFPA and local electrical codes governing such wiring. Refer to unit wiring diagram attached to unit. 2. Use only copper or copper clad conductor for connections between field-supplied electrical disconnect switch and unit. The use of aluminum wire is not recommended. Maximum wire size is number 2/0 AWG (American Wire Gage). 3. Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate (also see Tables 3A-3C). Voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in Table 3, Note 1 to determine the percent voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable warranty. 4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are run in same conduit as high-voltage wires. 5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc. Table 3A Electrical Data, 580E240 Units NOMINAL V-PH-HZ VOLTAGE RANGE COMPR NO. 1 COMPR NO. 2 Min Max RLA LRA RLA LRA OFM Total FLA 208/ IFM POWER EXHAUST FAN MOTOR* POWER SUPPLY Hp FLA FLA MCA MOCP Fuse Only / / / / / / / / / / ** / / / / / ** / / / / / ** ** CSA Canadian Standards Association FLA Full Load Amps Hp Nominal Horsepower IFM Indoor (Evaporator) Fan Motor LRA Locked Rotor Amps MCA Minimum Circuit Amps (for wire sizing) MOCP Maximum Overcurrent Protection OFM Outdoor (Condenser) Fan Motor RLA Rated Load Amps *Unit mounted on vertical discharge applications. Standard efficiency. **High efficiency. NOTES: 1. Unbalanced 3-Phase Supply Voltage Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percent voltage imbalance. % Voltage Imbalance max voltage deviation from average voltage = 100 x average voltage Example: Supply voltage is AB = 452 v BC = 464 v AC = 455 v Average Voltage = = 3 = 457 Determine maximum deviation from average voltage. (AB) =5v (BC) =7v (AC) =2v Maximum deviation is 7 v. Determine percent voltage imbalance. 7 % Voltage Imbalance = 100 x 457 = 1.53% 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. 2. Minimum wire size is based on 75 C copper wire. If other than 75 C wire is used, or if length exceeds wire length in table, determine size from NEC. 3. Voltage drop of wire must be less than 2% of rated voltage. 10

11 Table 3B Electrical Data, 580E300 Units NOMINAL V-PH-HZ VOLTAGE RANGE COMPR NO. 1 COMPR NO. 2 Min Max RLA LRA RLA LRA OFM Total FLA 208/ IFM POWER EXHAUST FAN MOTOR* POWER SUPPLY Hp FLA FLA MCA MOCP Fuse Only / / / / / / / / / / ** / / / / / ** / / / / / ** ** Table 3C Electrical Data, 580E324 Units NOMINAL V-PH-HZ VOLTAGE RANGE COMPR NO. 1 COMPR NO. 2 Min Max RLA LRA RLA LRA OFM Total FLA 208/ IFM POWER EXHAUST FAN MOTOR* POWER SUPPLY Hp FLA FLA MCA MOCP Fuse Only / / / / / / / / / / ** / / / / / ** / / / / / ** **

12 C Compressor Contactor CB Circuit Breaker CCB Control Circuit Breaker CV Constant Volume DU Dummy Terminal EQUIP Equipment LEGEND GND Ground IDCI Induced Draft Motor Contactor IFC Indoor (Evaporator) Fan Motor Contactor IFCB Indoor (Evaporator) Fan Motor Circuit Breaker NEC National Electrical Code OFC Outdoor (Condenser) Fan Motor Contactor Fig. 12 Unit Control Box Component Arrangement P Terminal Strip PEO Power Exhaust Option PI Plug TB Terminal Block TRAN Transformer 12

13 Fig. 13 Field Control Thermostat Wiring Field Wire Routing Field wiring can be brought into unit from bottom (through basepan and roof curb) or through side of unit (corner post next to control box). See Fig. 3. A3 1 2-in. NPT coupling for field power wiring and a 3 4-in. NPT coupling for 24-v control wiring are provided in basepan. In the side post, there are two in. knockouts for the field power wiring. If control wiring is to be brought in through the side of unit, a 7 8-in. diameter hole must be drilled in the condenser side post next to the control box. There are 2 large block-off plates in the corner post. The smaller block-off (5 in. x 5 in.) is used to provide access to main unit control box during installation of power wiring. If disconnect box is mounted to corner post, be careful not to drill any screws into the condenser coil. The corner post is marked to indicate the area where it is safe to drill holes and install screws. Routing Through Bottom of Unit If wiring is brought in through bottom of unit, use field supplied watertight conduit to run power wiring from basepan out through bottom in. knockout to the disconnect box and back into unit to the main control box. When 200-amp or smaller disconnect is used, the disconnect box should be located so that wiring can be run from back of disconnect box to unit through top in. knockout. Watertight strain relief (field-supplied) must be used in knockout. When 400-amp disconnect is used, remove in. x 20-in. block-off in corner post and use field-supplied elbow to route conduit through corner post to the control box. Use strain relief going into control box through in. diameter hole provided. After wires are in unit control box, connect to power terminal block (see Power Wiring section on this page). Low-voltage wiring must be run in watertight conduit from the basepan to control box and through one-in. diameter hole provided in upper right-hand corner of unit control box. Fieldsupplied strain relief must be used going into the box. After wiring is in control box, make connections to proper terminals on terminal blocks (see Control Wiring section on page 14). Routing Through Side of Unit When 200-amp or smaller disconnect is used, route power wiring in field-supplied watertight conduit into unit through in. knockout. Strain relief (field-supplied) must be used in knockout. When 400-amp disconnect is used, remove in. x 20-in. block-off in corner post and use field-supplied elbow to route conduit through corner post to the control box. Use field-supplied strain relief going into control box through in. diameter hole provided. After wires are in unit control box, connect to power terminal block (see Power Wiring section on this page). Bring low voltage control wiring through field-drilled 7 8-in. diameter hole in condenser side post. Use strain relief going into one-in. diameter hole in upper right-hand corner of unit control box. After wiring is in control box, make connection to proper terminals on terminal blocks (see Control Wiring section on page 14). Power Wiring Units are factory wired for the voltage shown on the unit nameplate. The main terminal block is suitable for use with copper wires. When installing units, provide a disconnect per NEC of adequate size (MOCP [Maximum Overcurrent Protection] of unit is on the informative plate). All field wiring must comply with NEC and all local codes. Size wire based on MCA (Minimum Circuit Amps) is on the unit informative plate and in Table 3. See Fig. 14 for power wiring connections to the unit power terminal block and equipment ground. Operating voltage to the compressor must be within the voltage range indicated on the unit nameplate. Voltages between phases must be balanced within 2% and the current must be balanced within 10%. See Table 3 for unit electrical data. High-Voltage Connections (Fig. 12) The unit must have a separate electrical service with a fieldsupplied, waterproof, fused disconnect switch mounted at, or within sight from, the unit. Refer to the unit rating plate for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing. See Field Wire Routing section on this page for field-supplied disconnect switch location and mounting instructions. Proceed as follows to complete the high-voltage connections to the unit: 1. Connect ground lead to chassis ground connection when using separate ground wire. 2. Connect power wires to main terminal block. Special Procedures for 230-V Operation DANGER: Make sure that the power supply to the unit is switched OFF before making any wiring changes. Electrical shock can cause personal injury or death. For operation on 230 v: 1. Disconnect the blue and yellow wires on TRAN 1 and connect them to terminal H3. 2. Disconnect the blue wire on TRAN 2 and connect it to the 230-v lead. 13

14 Table 4 Recommended Thermostats TYPE THERMOSTAT SUBBASE Manual Changeover (Standard) 2 Heat/2 Cool P P Auto. Changeover (Standard) 2 Heat/2 Cool P P Auto. Changeover (Electronic Setback) 2 Heat/2 Cool HH07AX008* *Includes subbase. LEGEND EQUIP Equipment GND Ground NEC National Electrical Code TB Terminal Board Fig. 14 Field Power Wiring Connections Control Voltage Connections Install a factory-approved room thermostat. See Table 4. Locate the thermostat on an inside wall in the space to be conditioned where it will not be subjected to either a cooling or heating source or direct exposure to sunlight. Mount the thermostat 4 to 5 ft above the floor. NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated wire (35 C minimum). For 50 to 80 ft, use no. 16 AWG insulated wire (35 C minimum). For 81 to 125 ft, use no. 14 AWG insulated wire (35 C minimum). All wire larger than no. 18 AWG cannot be connected directly to the thermostat and will require a junction box and splice at the thermostat. Heat Anticipator Setting The room thermostat heat anticipator must be adjusted correctly to ensure proper heating performance. Set the heat anticipator, using an ammeter to determine the exact required setting. NOTE: For thermostat selection purposes, set heat anticipator settings at 1.2 amp for the first stage and 0.4 amp for the second-stage heating. Failure to make a proper heat anticipator adjustment may result in improper operation, discomfort to the occupants of the conditioned space, and inefficient energy utilization. However, the required setting may be changed slightly to provide a greater degree of comfort for a particular installation. Control Wiring Install an approved accessory thermostat assembly (Table 4) according to the installation instructions shipped with the accessory. Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature (where airflow is stable and thermostat is not in direct line of supply air duct). Route thermostat cable or equivalent leads of no. 18 AWG colored wire from subbase terminals to 24-v terminal strip (P1). The terminal strip is located on the constant volume control board on units with no economizer and on the economizer board on units with the economizer option. The total wire length between the unit and the thermostat and the return wire from the thermostat to the unit should not exceed the following limits: 50 ft of 18 AWG, 80 ft of 16 AWG or 125 ft of 14 AWG. See Fig. 13 for field wiring connections between the thermostat and the unit 24-v terminal block. There are no required 115-v field wiring connections, therefore no provisions have been made in the unit for running 115-v wiring. If any of the field-installed options requiring 115-v connections are desired, the unit must be modified in the field for 115-v wiring. Options requiring 24-v or 115-v control wiring are listed below. Building Pressurization or Smoke Purge Mode See Fig. 15 and unit wiring label for wiring details. 24-V Connections 1. Firestat or smoke detector (field-supplied switch 1). Remove factory-installed jumper wire and wire a fieldsupplied firestat or smoke detector between terminals 2 and 3 on terminal block 2 (TB2) in the unit control box (see Fig. 12 for the location of TB2 in the control box). Unit will shut down completely when this normallyclosed switch opens. 2. Switch to supply 24-v power to the economizer motor during building pressurization or smoke purge (fieldsupplied switch 5). Wire a normally-open switch between terminal 3 on TB2 and terminal T1 in the economizer motor. This makes 24-v power available to the economizer motor when firestat or smoke detector switch has shut down unit. 3. Switch to open economizer outdoor-air damper during building pressurization or smoke purge (field-supplied switch 6). Wire a field-supplied switch between terminals Y and Z on the economizer motor (in top of economizer motor). When this switch is manually opened, it will drive the outdoor-air damper fully open. 115-V Connections 1. Building pressurization switch (field-supplied switch 2). Wire a field-supplied switch between terminal 4 on terminal block 2 (TB2) and the C1 connection on the indoor (evaporator) fan contactor coil (IFC1 on unit label diagram). This initiates evaporator fan operation when firestat or smoke detector switch has shut unit down. 2. Smoke purge switch (field-supplied switch 4). Wire a fieldsupplied switch between terminal 4 on TB2 (in the unit control box) and the C1 connection on the power exhaust contactor coil (PEC1 on unit label diagram). This initiates power exhaust motor operation. 3. Switch to isolate evaporator-fan motor from power exhaust motor during building pressurization or smoke purge (field-supplied switch 3). Wire a field-supplied switch in series with the wire from the C1 connection on IFC1 to the red wire on the economizer damper motor end switch (EDMS on unit label diagram). 14

15 Switch 1 Firestat or smoke detector normally closed. Switch 2 Building pressurization switch (energize evaporator-fan motor) normally open. Switch 3 Switch to isolate evaporator-fan motor from power exhaust motor normally closed. Switch 4 Smoke purge switch (energize power exhaust motor) normally open. Switch 5 Switch to provide 24 v to economizer motor normally open. Switch 6 Switch to drive economizer outdoor-air damper full open normally closed. (Remove jumper.) Switch 7 Switch to isolate evaporator-fan motor from economizer motor or CV board normally closed. BUILDING PRESSURIZATION SMOKE PURGE Switch 1 Switch 1 Switch 2 Switch 3 Switch 3 (if unit equipped with power exhaust) Switch 4 Switch 5 Switch 5 Switch 6 Switch 6 Switch 7 LEGEND C Contactor ECON Economizer IFC Indoor (Evaporator) Fan Contactor MTR Motor PEC Power Exhaust Contactor TB Terminal Block Field Wiring Factory Wiring NOTES: 1. Power exhaust option available only on bottom supply-return units. 2. In order to install Switch 1, field must remove factory jumper between terminals 2 and 3 on terminal block is field wiring. 3. is factory wiring. 5. All switches are field supplied. 6. Switches 1, 2, 3 (units with power exhaust), 5, and 6 are for building pressurization. Switches 1 and 3 through 7 are for smoke purge. Fig. 15 Field Wiring for Building Pressurization and Smoke Purge Convenience Outlet 115-V Connection: Convenience outlet can be mounted on panel containing control circuit breakers CB3 and CB4. (See Fig. 12.) Remove sheet metal cover that conceals by in. hole and install outlet in hole. Wire between terminals 4 and 5 on terminal block 2 (TB2) in the unit control box (see Fig. 16). The convenience outlet should be ground fault protected. Convenience outlet is to be used only when the unit is not operating. V. ACCESSORY INSTALLATION Any required accessories should be installed on the unit at this time. Refer to Table 5 for available accessories. Control wiring information is provided in the unit wiring book. A. 25% Outdoor-Air Damper and Hood Assembly The damper is shipped separately from the base unit, in a crate marked This crate contains: 1 Panel assembly 1 Installation instructions 1 Hood package The hood package contains: 1 Hood top 1 Hood side, right 1 Hood side, left 1 Fastener package (containing 20 screws 1 4 in. x 5 8 in. long and 6 ft of 1 8 in. x 1 2 in. seal strip) LEGEND TB Terminal Block Field Wiring Factory Wiring Fig V Field Wiring 15

16 Table 5 Accessory List ACCESSORY PART NUMBER 25% Outdoor-Air Damper and Hood Assembly Economizer Hood Assembly* (Must Be Separate Order) Barometric Relief Assembly Includes Hood 300, Power Exhaust Assembly Includes Hood 300, Roof Curb Horizontal Supply/Return Conversion Package 300, Coil Hail Guard Package Time Guard II (2 Required) Differential Enthalpy Control Sensor Low Ambient 20 F 208/230-3, F 460 V Auto. Changeover Thermostat Subbase See Table 4 Remote Status Panel Use with P Thermostat and See Table 4 P or P Subbase Manual Changeover Thermostat 2H/2C Subbase See Table 4 Auto. Changeover 2H/2C Electronic Thermostat and Subbase See Table 4 LP Conversion Kits 580E Compressor Unloader E Compressor Unloader Fig % Outdoor-Air Damper Location NOTE: Accessory 25% outdoor-air damper is installed on the return-air end of the unit. 1. Remove 2 channel panels and access panel as shown in Fig. 17. Save all screws for use later. 2. Open accessory package and verify the contents per list above. See Fig. 18 and Using the screws saved in Step 1, install the panel assembly on the unit. See Fig Reinstall the 2 channel panels removed in Step Open the hood package and verify the contents per list above. 6. Remove the 2 screws holding the 25% outdoor-air damper assembly to the panel. 7. Apply seal strip from the fastener package to the outside edge of the damper assembly, making sure the seal strip covers the holes in the flanges. To ensure a good seal against water, cut the top piece of seal strip approximately 30-in. long, and place it so it extends about one in. past the flange on each side. Cut the side pieces approximately in. each and butt them against the top flange seal strip, running them down the side flanges. 8. With a punch or some other tool, locate the holes in the flanges. Using 6 of the screws from the fastener package, attach both hood sides, flanges pointing outward. 9. Using 4 screws from the fastener package, attach hood top to unit. Be sure side flanges on hood top go outside the hood sides. 10. Using 8 screws from the fastener package, attach hood top to hood sides. See Fig The 2 places where the hood top meets the hood sides are potential locations for water leakage into the damper opening. Carefully seal both places with field-supplied RTV sealant. Fig % Outdoor-Air Hood Installation 12. Loosen the blade limiter screws and move the damper to the desired position. See Fig. 19. Retighten the blade limiter screws to secure the damper. NOTE: To make this adjustment, it is necessary to climb into the return-air compartment. Access is through the panel marked FILTER SECTION. B. Economizer Hoods These hoods are shipped separately from the base unit, in a carton marked This carton contains: 3 preassembled economizer hoods 1 filter angle 3 filter retainers 6 aluminum mesh cleanable filters, 16 in. x 20 in. x2in. 2 channel panels see Fig. 20 for cross-section 1 channel clip } 1 fastener package (taped to a hood) The fastener package contains: 8 capscrew bolts, x 1 2-in. long 8 nuts, screws, 1 4 AB x 5 8-in. long 8.3 ft of 1 8-in. thick x 1 2-in. wide seal strip with pressuresensitive adhesive on one side. 16

17 Fig. 20 Economizer Hood Assembly Holes Fig % Outdoor-Air Damper/Panel Accessory To install hoods: 1. Remove the lagscrews holding the economizer hoods and channel panels to the shipping skid (there are 4 lagscrews per side). 2. Remove the lagscrews holding the filter angle and channel clip to the shipping skid (there are 2 lagscrews per part). 3. The filters are wrapped to prevent shipping damage. Remove the screws holding the filter retainers to the hoods (there are 4 screws per retainer). 4. Remove wrap from filters. Do not reinstall until after the hoods are mounted to the unit. IMPORTANT: If unit is to be equipped with either barometric relief or power exhaust, the barometric relief/power exhaust hood must be installed prior to the installation of the economizer hoods. If installing barometric relief or power exhaust, proceed to Barometric Relief/Power Exhaust Hood section on page 18, and install before proceeding any further. Then return to this point. 5. Place the hoods on a flat surface. 6. Insert the top flange of the middle hood flush with the bottom flange of the top hood AND the top flange of the bottom hood flush with the bottom flange of the middle hood. When properly laid out, the side flanges of the 3 hoods should form one continuous flange. 7. See Fig. 20, and insert the capscrew bolts through the flange holes as shown, from the back side, threads facing outward. Note that though there are 12 holes (4 per hood) per side, only the 3 shown per side are to be used. 8. If unit is not to be equipped with barometric relief or power exhaust, discard the channel clip. If unit is to be equipped with barometric relief or power exhaust, discard one of the channel panels. 9. Cut 2 pieces of seal strip in. long for placement on the channel panels (or one channel panel and one channel clip if barometric relief or power exhaust is used) on the flanges with the holes. Begin 1 in. from the top of the flange and center the seal strip on the flange, covering the holes. NOTE: If seal strip is too high or too low, water leakage may occur. Maintain the 1-in. dimension for placement. 10. Using a punch or other tool, make holes in the seal strip for screws. 11. Place channel panels on the hood flanges, using the middle 3 holes. If using barometric relief or power exhaust, use the channel clip in place of the previously discarded channel panel, attaching it to the left side of the economizer hoods (left side when facing hoods). 12. Secure channel panels and/or channel clip to the hoods using 6 of the nuts from the fastener package. 13. See Fig. 21 and place economizer hood assembly over outdoor-air opening. CAUTION: Economizer hood assembly is heavy. At least 2 people should handle it. 14. Line up the holes in the channel panels with the holes in the flanges of corner post. Fig. 21 Economizer Hood Installation 17