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installation, start-up and
580G,H
service instructions
Sizes 240-360
SINGLE PACKAGE ROOFTOP
ELECTRIC COOLING/GAS HEATING UNITS
Cancels: II 580G,H-240-1 II 580G,H-240-2
11/1/97
CONTENTS SAFETY CONSIDERATIONS
Page Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
SAFETY CONSIDERATIONS ...................... 1
nents. Only trained and qualified service personnel should
INSTALLATION ................................ 2-20
install, repa
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INSTALLATION NOTE: Onretrofitjobs,ductworkmaybeattachedtooldunit insteadofroofcurb.Becarefulnottodamageductworkwhen I. PROVIDE UNIT SUPPORT removing old unit. CAUTION: All panels must be in place when rig- B. Alternate Unit Support ging. Unit is not designed for handling by fork truck. When the preferred curb or adapter cannot be used, support unitwithsleepersusingunitcurboradaptersupportarea.If A. Roof Curb sleepers cannot be used, support long sides of unit (refer to Assemble and install access
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NOTES: 1. Weights include economizer (STD). 2. Center of gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min. clearances to be: Adjacent Units: 158-09 Top of Units: No Overhang Condenser Coil: 48-09 Economizer Side: 68-09 Heat Side: 48-09 FilterAccessSide:108-09(ForRemovalofEvapo- rator Coil) 4. Forsmallerserviceandoperationalclearances,con- tact CarrierApplication Engineering department. 5. Bottom ducts designed to be attached to acces- soryroofcurb.Ifunitis
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NOTES: 1. Weights include economizer (STD). 2. Center of gravity. 3. Do not locate adjacent units with flue discharge facing economizer inlet. Min. clearances to be: Adjacent Units: 158-09 Top of Units: No Overhang Condenser Coil: 48-09 Economizer Side: 68-09 Heat Side: 48-09 Filter Access Side: 108-09 (For Removal of Evapora- tor Coil) 4. For smaller service and operational clearances, con- tactApplication Engineering department. 5. Dimensions are in inches. 6. For side supply/return application
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CAUTION: NOTICE TO RIGGERS: ALL PANELS MUST BE IN PLACE WHEN RIGGING. NOTE: Rig with four cables and spread with two 92 in. (2337 mm) spreader bars. Maintain a distance of 74 in. (1880 mm) from top of unit to eyehook. NOTE: Add 32 lb (14.5 kg) for domestic crating. Add 312 lb (142 kg) for export crating. Add 220 lb (100 kg) for copper condenser coil. Add 250 lb (113 kg) for power exhaust. WEIGHT A B C UNIT 580G,H lb kg in. mm in. mm in. mm 240 350 4176 1894 72.4 1839 42.4 1072 240 525 4256 1930
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Table 1 — Specifications UNIT 580G,H 240 300 324 360 NOMINAL CAPACITY (tons) 20 25 27 30 OPERATING WEIGHT (lb) Unit Al/Al* (Lo Heat/Hi Heat) 4176/4256 4262/4342 4262/4342 4262/4342 Al/Cu* (Lo Heat/Hi Heat) 4396/4476 4482/4562 4482/4562 4482/4562 Roof Curb (14-in. curb) 365 365 365 365 COMPRESSOR Type Ckt 1 06D328 06D328 06D537 06D537 Ckt 2 06D818 06D328 06D328 06D537 Number of Refrigerant Circuits 22 2 2 Oil (oz) (Ckt 1, Ckt 2) 115, 88 115 ea. 115 ea. 115 ea. REFRIGERANT TYPE R-22 Operating Charg
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Table 2 — Evaporator Fan Motor Data MOTOR FAN MOTOR FAN BELT UNIT SHEAVE BUSHING SHEAVE BUSHING OUTSIDE MOTOR SHAFT SHAFT MOTOR FAN BELT TENSION SIZE PITCH DIAMETER PITCH DIAMETER BELT HP DIA. SPEED SHEAVE SHEAVE (QUANTITY) (lb at 580G,H DIAMETER (in.) DIAMETER (in.) LENGTH (in.) (rpm) .24 in.) (in.) (in.) 5 1.12 717 BK55 4.8 None-1.125 1B5V124 12.4 B-1.9375 BX59 62 5.10 240 10 1.38 924 2BK50 4.4 None-1.375 2B5V86 8.6 B-1.9375 (2) BX51 54 5.21 15 1.62 1096 2B5V56 5.7 B-1.625 2B5V90 9.1 B-1.9375
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V. FLUE HOOD Fluehoodisshippedinsidegassectionofunit.Toinstall,se- cure flue hood to access panel. See Fig. 7. NOTE: When properly installed, flue hood will line up with combustion fan housing. See Fig. 8. Fig. 9 — Condensate Drain Connections (Typical Roof Curb or Slab Mount Shown) Condensatepansareslopedsothatwaterwillcompletelydrain from the condensate pan to comply with indoor air quality guidelines. VII. GAS PIPING Unit is equipped for use with natural gas. Installation must conform with loca
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VIII. ELECTRICAL CONNECTIONS local codes requirements, of adequate size (Table 3). When- ever external electrical sources are used, unit must be elec- A. Controls Options tricallygroundedinaccordancewithlocalcodes,orinabsence The standard constant volume (CV) units, as shipped, are of local codes, with NEC,ANSI C1-latest year. operable as stand-alone units, using a standard (mechanical All field wiring must comply with NEC and local code or electronic) 2-stage heat, 2-stage cool thermostat. requi
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—10— LEGEND COM — Common R— Relay D— Diode SIO — Serial Input/Output LED — Light-Emitting Diode SW — Switch N.C. — Normally Closed T— Terminal N.O. — Normally Open *Where X is the unit control software version number (1 or 2). Fig. 11 — Control Board Diagram
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3. Cap orange wire. JUMPER CONNECTION 4. Splice red wire and black unit power wire. Cap wires. FOR VOLTAGE OUTPUT IMPORTANT: Becertainunusedwiresarecapped.Failureto do so may damage the transformers. D. Field Control Wiring Install an approved accessory thermostat. Control box dia- gram is shown in Fig. 14. Thermostat Wiring Installanapprovedaccessorythermostatassembly(percur- rentpricepages)accordingtotheinstallationinstructionsin- JUMPER CONNECTION cludedwiththeaccessory,ortheseinstructions.Lo
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Table 3— Electrical Data — 580G,H240-360 COMPRESSOR VOLTAGE POWER COMBUSTION OFM IFM POWER SUPPLY UNIT NOMINAL RANGE EXHAUST FAN MOTOR No. 1 No. 2 SIZE VOLTAGE FLA 580G,H (3 Ph 60 Hz) Min Max RLA LRA RLA LRA Qty Hp Hp FLA FLA LRA FLA MCA MOCP* (ea) 16.7/ — — 0.96 101.8/100.3 125/125 5 15.2 23.6 41.6 0.96 125.4/123.9 150/150 30.8/ — — 0.96 115.9/113.1 150/150 208/230 187 254 39.1 228 25.6 160 2 1 5.3 10 28.0 23.6 41.6 0.96 139.5/136.7 175/175 46.2/ — — 0.96 131.3/127.1 150/150 15 42.0 23.6 41.6 0
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Table 3— Electrical Data — 580G,H240-360 (cont) COMPRESSOR VOLTAGE POWER COMBUSTION OFM IFM POWER SUPPLY UNIT NOMINAL RANGE EXHAUST FAN MOTOR No. 1 No. 2 SIZE VOLTAGE FLA 580G,H (3 Ph 60 Hz) Min Max RLA LRA RLA LRA Qty Hp Hp FLA FLA LRA FLA MCA MOCP* (ea) 30.8/ — — 0.96 151.9/149.1 200/200 10 28.0 23.6 41.6 0.96 175.5/172.7 225/225 46.2/ — — 0.96 167.3/163.1 200/200 208/230 187 254 57.1 266 39.1 228 2 1 5.3 15 42.0 23.6 41.6 0.96 190.9/186.7 225/225 59.4/ — — 0.96 180.5/175.1 225/225 20 54.0 23.
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TOP FLANGE BLACK HOOD SIDE SEAL STRIP Fig. 16 — Adding Seal Strip to Top of Hood Sides Fig. 15 — Field Control Thermostat Wiring IX. OUTDOOR-AIR INLET ASSEMBLY A. Economizer NOTE: Ifaccessorypowerexhaustorbarometricreliefpack- ages are being added to the unit, install power exhaust or barometric relief before installing economizer hoods. Economizer HoodAssembly The economizer hood is shipped in a package secured to the outside of the unit and must be field assembled. There are 2 hoods on every un
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HOOD SIDE (SLOTTED) MOUNTING HOOD FLANGE TOP HOOD SIDE Fig. 21 — Adding Foam Strip to Hood Side Fig. 18 — Adding Seal Strip to Mounting Flange of Hood Sides HOOD TOP HOOD SIDE BLOCKOFF BAFFLE GRAY FOAM STRIP Fig. 19 — Add Seal Strip to Hood Top Mounting Flange GRAY FOAM STRIP Fig. 22 — Adding Foam Strip To Blockoff Baffle CROSS MEMBER Fig. 20 — Adding Foam Strip to Cross Member —15—
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4. Remove screws along bottom of damper assembly. Lo- MOUNTING ANGLE (WITHOUT TABS) cate and mount blockoff baffle using these screws. 5. Assemble 2 filter tracks side-by-side with the as- sembled ends together. FILTER TRACK 6. a. Attach mounting angle (without tabs) to the as- ASSEMBLY sembled end of the filter track. See Fig. 23. b. Attach 6 green clips (provided) to mounting angles. Engagement section of clip faces inside of rack. c. Attachremainingmountingangle(withtabs)toother end of the filte
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C7400A1004 + HH57AC077 ENTHALPY CONTROL NOTE: Switches shown in high enthalpy state. Termi- nals 2 and 3 close on enthalpy decrease. Fig. 27 — Wire Connections for Solid-State Enthalpy Control (HH57AC077) HH57AC078 CONTROL POINT ENTHALPY SENSOR (USED WITH CONTROL (APPROX. DEG.) ENTHALPYCONTROLFORDIFFER- CURVE AT 50% RH ENTIAL ENTHALPY OPERATION) A 73 (23) B 70 (21) C 67 (19) D 63 (17) Fig. 26 — Enthalpy Control and Sensor 3. Mount the outdoor air enthalpy sensor inside the right economizer hood
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8. Usefield-suppliedwiretiestoattachthevioletwireto X. POWEREXHAUST/BAROMETRICRELIEFDAMPERHOOD the + terminal and the blue wire to the SR terminal. Allelectricalconnectionshavebeenmadeandadjustedatthe 9. Replace economizer filters. factory.Thepowerexhaustblowersandbarometricreliefdamp- ers are shipped assembled and tilted back into the unit for 10. Return power to unit. shipping. Brackets and extra screws are shipped in shrink Disable Economizer wrap around the dampers. If ordered, each unit will
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NOTES: 1. Unless otherwise specified, all dimensions are to outside of part. 2. Dimensions are in inches. Fig. 30 — Barometric Relief Damper and Power Exhaust Mounting Details XI. ACCESSORIES 1 BOTH SIDES Afterallthefactory-installedoptionshavebeenadjusted,in- stall all field-installed accessories. Refer to the accessory in- 18 stallation instructions included with each accessory. A. MotormasterT III Control Installation 77.7 Install Field-Fabricated Wind Baffles 0.312 DIA HOLES Wind baffles must
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3. Make the following inspections: a. Inspectforshippingandhandlingdamagessuchas broken lines, loose parts, disconnected wires, etc. b. Inspect for oil at all refrigerant tubing connections and on unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connectionsusingelectronicleakdetector,halidetorch, or liquid-soap solution. c. Inspectallfield-andfactory-wiringconnections.Be sure that connections are completed and tight. d. Inspect coil fins. If damaged
