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574D----A

LEGACYt 13 SEER SINGLE--PACKAGED AIR CONDITIONER AND

GAS FURNACE SYSTEM WITH PURONR (R--410A) REFRIGERANT

SINGLE AND THREE PHASE

2--5 NOMINAL TONS (SIZES 24--60)

Installation Instructions

NOTE: Read the entire instruction manual before starting the

installation.

NOTE: Installer: Make sure the Owner’s Manual and Service

Instructions are left with the unit after installation.

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS 1.........................

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

RECEIVING AND INSTALLATION 2--13.................

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

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

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

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

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

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

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

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

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

Inspection 6......................................

Rigging/Lifting 6..................................

Connect Condensate Drain 9...........................

Install Flue Hood 9...................................

Install Gas Piping 9..................................

Install Duct Connections 10............................

Configuring Units for Downflow (Vertical)

Discharge 10.....................................

Install Electrical Connections 12........................

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

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

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

Standard Connection 12.............................

Heat Anticipator Setting 13..........................

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

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

START--UP 14--22.....................................

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

Start--Up Heating & Make Adjustments 14................

Check Heating Control 14...........................

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

Adjust Gas Input 15................................

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

Normal Operation 20...............................

Airflow and Temperature Rise 20......................

Heating Sequence of Operation 20.....................

Limit Switches 20.................................

Rollout Switch 20.................................

Start--Up Cooling & Make Adjustments 20................

Checking Cooling Control Operation 20................

Checking & Adjusting Refrigerant Charge 20............

Indoor Airflow and Airflow Adjustments 21.............

Continuous Fan Operation 21........................

Cooling Sequence of Operation 22.....................

MAINTENANCE 29--30................................

Air Filter 29......................................

A09034

Fig. 1 -- Unit 574D----A

(Low NOx Model Available)

Indoor Blower and Motor 29.........................

Induced Draft (Combustion Air) Blower 30..............

Flue Gas Passageways 30............................

Limit Switch 30...................................

Burner Ignition 30.................................

Main Burners 30...................................

Removal of Gas Train 30............................

Outdoor Coil, Indoor Coil, & Condensate Drain Pan 30....

Outdoor Fan 31...................................

Electrical Controls and Wiring 32.....................

Refrigerant Circuit 32...............................

Gas Input 32......................................

Evaporator Airflow 32..............................

Puron Items 32....................................

TROUBLESHOOTING 33..............................

START--UP CHECKLIST 33............................

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service maintenance,

or use can cause explosion, fire, electrical shock, or other

conditions which may cause death, personal injury, or property

damage. Consult a qualified installer, service agency, or your

distributor or branch for information or assistance. The qualified

installer or agency must use factory--authorized kits or accessories

when modifying this product. Refer to the individual instructions

packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions

included in literature and attached to the unit. Consult local

building codes, the current editions of the National Fuel Gas Code

(NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code

(NEC) NFPA 70.

In Canada refer to the current editions of the National Standards of

Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane

Installation codes, and Canadian Electrical Code CSA C22.1

Recognize safety information. This is the safety--alert symbol

When you see this symbol on the unit and in instructions or manu-

als, be alert to the potential for personal injury. Understand these

signal words: DANGER, WARNING, and CAUTION. These

Summary of content (38 pages)

PAGE 1
574D----A LEGACYt 13 SEER SINGLE--PACKAGED AIR CONDITIONER AND GAS FURNACE SYSTEM WITH PURONR (R--410A) REFRIGERANT SINGLE AND THREE PHASE 2--5 NOMINAL TONS (SIZES 24--60) Installation Instructions NOTE: Read the entire instruction manual before starting the installation. NOTE: Installer: Make sure the Owner’s Manual and Service Instructions are left with the unit after installation. TABLE OF CONTENTS PAGE SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . .
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words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.
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574D -- -- A A09469 Fig.
PAGE 4
574D -- -- A A09470 Fig.
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Dashed lines show cross support location for large basepan units.
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OPTIONAL RETURN AIR OPENING Training for operators of the lifting equipment should include, but not be limited to, the following: 1. Application of the lifter to the load, and adjustment of the lifts to adapt to various sizes or kinds of loads. 2. Instruction in any special operation or precaution. 3. Condition of the load as it relates to operation of the lifting kit, such as balance, temperature, etc. Follow all applicable safety codes. Wear safety shoes and work gloves.
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CAUTION - NOTICE TO RIGGERS PRUDENCE - AVIS AUX MANIPULATEUR ACCESS PANELS MUST BE IN PLACE WHEN RIGGING. PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION. Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition DUCTS MINIMUM HEIGHT: 36" (914.
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Table 1 – Physical Data -- Unit 574D----A 574D -- -- A UNIT SIZE NOMINAL CAPACITY (ton) SHIPPING WEIGHT** lb. SHIPPING WEIGHT** (kg) COMPRESSORS Quantity REFRIGERANT (R --- 410A) Quantity lb. Quantity (kg) REFRIGERANT METERING DEVICE OUTDOOR COIL Rows...Fins/in. Face Area (sq ft) OUTDOOR FAN Nominal CFM Diameter in. Diameter (mm) Motor Hp (Rpm) INDOOR COIL Rows...Fins/in. Face Area (sq ft) INDOOR BLOWER Nominal Cooling Airflow (Cfm) Size in. Size (mm.) Motor HP (RPM) FURNACE SECTION* Burner Orifice No.
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Step 6 — Connect Condensate Drain TRAP OUTLET 1-in. (25 mm) min. 2-in. (51 mm) min. A09052 Fig. 7 -- Condensate Trap Step 7 — Install Flue Hood The flue assembly is secured and shipped in the return air duct. Remove duct cover to locate the assembly (See Fig. 9). NOTE: Dedicated low NOx models MUST be installed in California Air Quality Management Districts where a Low NOx rule exists.
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Table 2 – Maximum Gas Flow Capacity* NOMINAL IRON PIPE SIZE (IN.) INTERNAL DIAMETER (IN.) 1/2 3/4 1 1--- 1/4 1--- 1/2 .622 .824 1.049 1.380 1.610 10 (3) 175 360 680 1400 2100 20 (6) 120 250 465 950 1460 30 (9) 97 200 375 770 1180 40 (12) 82 170 320 600 990 50 (15) 73 151 285 580 900 LENGTH OF PIPE FT (m)† 60 70 80 90 (18) (21) (24) (27) 66 61 57 53 138 125 118 110 260 240 220 205 530 490 460 430 810 750 690 650 *Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less.
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NOTE: On large chassis units remove sheet metal shields on panels by using a screw driver to shear off retainers and discard. CAUTION ! UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the unit being installed. When cutting duct panels, do not contact or damage any internal components (heat exchanger, electric heat). Do not use a saw blade that protrudes more than 1 in. (25 mm) into unit.
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heating and air conditioning systems. Secure all ducts to building structure. 7. Flash, weatherproof, and vibration isolate all openings in building structure in accordance with local codes and good building practices. Step 10 — Install Electrical Connections ! WARNING ELECTRICAL SHOCK HAZARD 574D -- -- A Failure to follow this warning could result in personal injury or death. The unit cabinet must have an uninterrupted, unbroken electrical ground.
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PRE--START--UP ! HIGH VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL) 3-PHASE SHOWN 1-PHASE USES TWO POWER EQUIP GR LEADS ENVIRONMENTAL, FIRE, ELECTRICAL SHOCK HAZARD POWER SUPPLY CONTROL BOX YEL(Y) GRN(G) RED(R) LOW-VOLTAGE POWER LEADS (SEE UNIT WIRING LABEL) BRN(C) BLU(DH) GRA(Y2) W Y G R THERMOSTAT (TYPICAL) C DH 3-Phase Only SPLICE BOX A09053 Fig.
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! WARNING FIRE, EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death or property damage. 574D -- -- A Do not purge gas supply into the combustion chamber. Do not use a match or other open flame to check for gas leaks. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. 4. Verify the following conditions: a. Make sure gas line is free of air.
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IN THE U.S.A.: The input rating for altitudes above 2,000 ft (610 m) must be reduced by 4% for each 1,000 ft (305 m) above sea level. For installations below 2,000 ft (610 m), refer to the unit rating plate. For installations above 2,000 ft (610 m). multiply the input by on the rating plate by the derate multiplier in Table 3 for correct input rate. Table 3 – Altitude Derate Multiplier for U.S.A.* ALTITUDE FT (M) PERCENT OF DERATE DERATE MULTIPLIER FACTOR{ 0--- 2000 (0--- 610) 0 1.
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4. Turn off gas supply to unit. Remove manometer from pressure tap and replace pipe plug on gas valve. (See Fig. 12.) Turn on gas to unit and check for leaks. Measure Manifold Pressure (Propane Units) Refer to propane kit installation instructions for properly checking gas input. NOTE: For installations below 2,000 ft (610 m), refer to the unit rating plate for proper propane conversion kit. For installations above 2,000 ft (610 m), contact your distributor for proper propane conversion kit.
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574D -- -- A A09282 Fig.
PAGE 18
574D -- -- A A09264 Fig.
PAGE 19
574D -- -- A A09265 Fig.
PAGE 20
Normal Operation An LED (light--emitting diode) indicator is provided on the integrated gas unit controller (IGC) to monitor operation. The IGC is located by removing the control access panel (see Fig. 20). During normal operation, the LED is continuously on (See Table 5 for error codes). Airflow and Temperature Rise The heating section for each size unit is designed and approved for heating operation within the temperature--rise range stamped on the unit rating plate.
PAGE 21
Indoor Airflow and Airflow Adjustments ! CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in unit damage. For cooling operation, the recommended airflow is 350 to 450 cfm for each 12,000 Btuh of rated cooling capacity. For heating operation, the airflow must produce a temperature rise that falls within the range stamped on the unit rating plate. NOTE: Be sure that all supply--and return--air grilles are open, free from obstructions, and adjusted properly.
PAGE 22
Table 6 – Color Coding for Indoor Fan Motor Leads speed when the DH control lead is not energized, or IFB “HIGH” speed when the DH lead is energized (see Fig. 18).
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574D -- -- A Table 7 – Cooling Charging Chart A08490 23
PAGE 24
Table 8 – Filter Pressure Drop Table (IN. W.C.) FILTER SIZE in. (mm) 20X20X1 (508X508X25) 20X24X1 (508X610x25) 24X30X1 (610X762x25) 24X36X1 (610X914X25) 500 600 0.05 0.07 700 800 0.08 0.10 CFM 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 0.12 0.13 0.14 0.15 — — — — — — — — — — — — — — — 0.09 0.10 0.11 0.13 0.14 0.15 0.16 — — — — — — — — — — — 0.04 0.05 0.06 0.07 0.07 0.08 0.09 0.10 — — — — — — — — — — — — 0.10 0.
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Table 9 -- Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -Unit 574D----A24--60 HEATING RISE RANGE oF (oC) MOTOR SPEED Low Med--Low1 574D(N,P,E)WA30040 30 --- 60 (17 --- 33) Medium Med--High2 High Low Med--Low 574D(N,P,E)WA30060 25 --- 55 (14 --- 31) Medium Med--High2 High1 Low1 Med--Low 574D(N,P,E)WA36060 25 --- 55 (14 --- 31) Medium2 Med--High High EXTERNAL STATIC PRESSURE (IN. W.C.
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Table 9 -- Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -Unit 574D----A24--60 UNIT HEATING RISE RANGE oF (oC) MOTOR SPEED Low Med--Low 574D(N,P,E)WA36090 35 --- 65 (19 --- 36) Medium2 574D -- -- A Med--High High1 Low1 Med--Low 574D(N,P,E)WA42060 25 --- 55 (14 --- 31) Medium Med--High2 High Low Med--Low 574D(N,P,E)WA42090 35 --- 65 (19 --- 36) Medium1 Med--High2 High EXTERNAL STATIC PRESSURE (IN. W.C.
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Table 9 -- Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -Unit 574D----A24--60 HEATING RISE RANGE oF (oC) MOTOR SPEED Low1 Med--Low 574D(N,P,E)WA48090 35 --- 65 (19 --- 36) Medium2 Med--High High Low Med--Low 574D(N,P,E)WA48115 30 --- 60 (17 --- 33) Medium2 Med--High1 High Low Med--Low 574D(N,P,E)WA48130 35 --- 65 (19 --- 36) Medium2 Med--High1 High EXTERNAL STATIC PRESSURE (IN. W.C.
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Table 9 -- Dry Coil Air Delivery* -- Horizontal and Downflow Discharge -Unit 574D----A24--60 574D -- -- A UNIT HEATING RISE RANGE oF (oC) MOTOR SPEED WIRE COLOR EXTERNAL STATIC PRESSURE (IN. W.C.) 0.1 0.2 0.3 0.4 0.5 0.
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Table 10 – 574D----A Wet Coil Pressure Drop (IN. W.C.) UNIT SIZE 24 30 36 42 48 60 600 0.030 ----------- 700 0.037 0.037 --------- 800 0.044 0.044 --------- 900 0.053 0.053 0.055 ------- 1000 0.063 0.063 0.060 0.045 ----- 1100 --0.072 0.090 0.050 ----- STANDARD CFM (S.C.F.M) 1200 1300 1400 ------0.081 0.105 --0.100 0.110 0.140 0.060 0.065 0.075 0.041 0.063 0.085 ------- 1500 ------0.080 0.100 0.060 1600 ------0.090 0.104 0.065 1700 ------0.094 0.110 0.072 1800 ------0.110 0.120 0.
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! 1. Remove the induced draft blower assembly according to directions in the Induced Draft Blower Assembly section. 2. Remove the 11 screws holding the flue collector box cover (See 19) to the heat exchanger assembly. Inspect the heat exchangers. 3. Clean all surfaces, as required, using a wire brush. WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death.
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Integrated Gas Unit Controller (IGC) BLOWER HOUSING Auto Transformer fuses used on 460 volt units only. (Hidden) Interface Fan Board (IFB) Induced Draft Motor Fan Partition Mounting Bracket Flue Collector Box Inducer Blower Housing Burner Rack Mounting Screw 2 SETSCREWS (HIDDEN) Rollout Switch A09193 C99085 Fig. 21 -- Removal of Motor and Blower Wheel COMPRESSOR ACCESS PANEL BLOWER ACCESS PANEL CONTROL ACCESS PANEL A07680 Fig. 22 -- Burner Rack Removed Outdoor Fan A09207 ! Fig.
PAGE 32
FAN GRILLE MOTOR A MOTOR SHAFT A08505 MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE “A” 574D -- -- A SIZE IN. 7.3 7.3 7.3 7.6 7.6 7.6 24 30 36 42 48 60 MM 185 185 185 193 193 193 Fig. 23 -- Fan Blade Position Electrical Controls and Wiring Gas Input Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit. Remove access panels (see Fig. 20) to locate all the electrical controls and wiring.
PAGE 33
charge so that pressure gauges read 0 psig. Never open system without breaking vacuum with dry nitrogen. designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere. High-- Pressure Switch Servicing Systems on Roofs with Synthetic Materials The high--pressure switch is located in the discharge line and protects against excessive condenser coil pressure. It opens at 650 psig.
PAGE 34
PURONR (R--410A) QUICK REFERENCE GUIDE S Puron refrigerant operates at 50--70 percent higher pressures than R--22. Be sure that servicing equipment and replacement components are designed to operate with Puron S Puron refrigerant cylinders are rose colored. S Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400. S Puron systems should be charged with liquid refrigerant.
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Table 12 – Troubleshooting Chart Compressor and condenser fan will not start.
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Table 13 – Troubleshooting Guide–Heating SYMPTOM CAUSE Water in gas line No power to furnace No 24--v power supply to control circuit Burners will not ignite Mis--wired or loose connections Misaligned spark electrodes No gas at main burners Inadequate heating Dirty air filter Gas input to furnace too low Unit undersized for application Restricted airflow 574D -- -- A Limit switch cycles main burners Poor flame characteristics Incomplete combustion results in: Aldehyde odors, carbon monoxide, sooti
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START--UP CHECKLIST (Remove and Store in Job Files) II.
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574D -- -- A E2009 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 08/09 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. 38 Catalog No.