bryant SM547K Single Package Rooftop Heat Pump Instruction Manual

bryant SM547K Single Package Rooftop Heat Pump

Specifications

• Catalog No.: 04-53547008-01
• Printed in: U.S.A.
• Form No.: SM547K-8-14-01

Start-Up Checklist

Refer to the provided start-up checklist (CL-1) for initial setup and operational guidance.

Safety Considerations
Installation and servicing of air-conditioning equipment require trained and qualified personnel due to system pressure and electrical components. Only trained service personnel should install, repair, or service the equipment. When working on the equipment, follow all safety precautions mentioned in the literature, tags, and labels attached to the unit. Wear safety glasses, work gloves, and use appropriate safety equipment for brazing operations.

Electrical Operation Hazard

Before performing any service or maintenance operations on the unit, ensure to LOCKOUT/TAGOUT the main power switch to prevent electrical shock. Failure to do so could result in personal injury or death.

R-410A Refrigerant Systems
Caution: R-410A refrigerant systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on R-410A refrigerant equipment to prevent hazards.

Fire and Explosion Hazard
Warning: Never use air or gases containing oxygen for leak testing or operating refrigerant compressors as it can lead to fire or explosion hazards. Follow proper procedures for refrigerant handling.

FAQs

Q: Can untrained personnel service the equipment?
A: Untrained personnel can only perform basic maintenance functions like replacing filters. Trained service personnel should handle all other operations to ensure safety and proper functioning of the equipment.

Q: What should be done before starting any service operation on the unit?
A: Before starting any service operation, make sure to LOCKOUT/TAGOUT the main power switch to prevent electrical shock and rotating equipment hazards.

SAFETY CONSIDERATIONS
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 service air-conditioning equipment. Untrained personnel can perform the basic maintenance functions of replacing filters. Trained service personnel should perform all other operations.
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.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and National Electrical Code (NEC) for special requirements. Recognize safety information. This is the safety ALERT symbol . When you see this symbol on the unit and in instructions or
manuals, be aware of the potential for physical injury hazards. Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety ALERT symbol. DANGER indicates a hazardous situation which, if not avoided, will result in death or severe personal injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or personal injury. CAUTION indicates a hazardous situation which, if not avoided, could result in minor to moderate injury or product and property damage. IMPORTANT is used to address practices not related to physical injury. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury or death.
Before performing service or maintenance operations on unit, LOCKOUT/TAGOUT the main power switch to unit. Electrical shock and rotating equipment could cause severe injury.

WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury or death.
Units with convenience outlet circuits may use multiple disconnects. Check convenience outlet for power status before opening unit for service. Locate its disconnect switch, if appropriate, and open it. Lock-out and tag-out this switch, if necessary.

WARNING
UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury, death and/or equipment damage. R-410A refrigerant systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on R-410A refrigerant equipment.

WARNING
FIRE, EXPLOSION HAZARD Failure to follow this warning could result in death, serious personal injury and/or property damage. Never use air or gases containing oxygen for leak testing or for operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion.

WARNING
FIRE, EXPLOSION HAZARD Failure to follow this warning could result in death, serious personal injury and/or property damage. Never use non-certified refrigerants in this product. Noncertified refrigerants could contain contaminates that could lead to unsafe operating conditions. Use ONLY refrigerants that conform to AHRI Standard 700.

CAUTION
UNIT DAMAGE HAZARD Failure to follow this caution may result in reduced unit performance or unit shutdown. High velocity water from a pressure washer, garden hose, or compressed air should never be used to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pressure drop.
IMPORTANT: Lockout/Tag-out is a term used when electrical power switches are physically locked preventing power to the unit. A placard is placed on the power switch alerting service personnel that the power is disconnected.

UNIT ARRANGEMENT AND ACCESS

General
Figures 1 and 2 show general unit arrangement and access locations.

Filter Access Panel Indoor Coil Access Panel
Fig. 1 — Typical Access Panel Locations

Control Box Access Panel

Indoor Access Panel

Fig. 2 — Blower Access Panel Location
Routine Maintenance
These items should be part of a routine maintenance program, to be checked every month or two, until a specific schedule for each can be identified for this installation:
QUARTERLY INSPECTION (AND 30 DAYS AFTER INITIAL START) · Return air filter replacement · Outdoor hood inlet filters cleaned · Condenser coil cleanliness checked · Condensate drain checked
SEASONAL MAINTENANCE These items should be checked at the beginning of each season (or more often if local conditions and usage patterns dictate): Air Conditioning · Ensure outdoor fan motor mounting bolts are tight · Ensure compressor mounting bolts are tight · Inspect outdoor fan blade positioning · Ensure control box is clean · Check control box wiring condition

· Ensure wire terminals are tight · Check refrigerant charge level · Ensure indoor coils are clean · Check supply blower motor amperage
Electric Heating · Inspect power wire connections · Ensure fuses are operational · Ensure manual reset limit switch is closed
Economizer or Outside Air Damper · Check inlet filters condition · Check damper travel (economizer) · Check gear and dampers for debris and dirt
Air Filters and Screens Each unit is equipped with return air filters. If the unit has an economizer, it will also have an outside air screen. If a manual outside air damper is added, an inlet air screen will also be present. Each of these filters and screens will need to be periodically replaced or cleaned.
Filters

RETURN AIR FILTERS
CAUTION
EQUIPMENT DAMAGE HAZARD Failure to follow this CAUTION can result in premature wear and damage to equipment. DO NOT OPERATE THE UNIT WITHOUT THE RETURN AIR FILTERS IN PLACE. Dirt and debris can collect on heat exchangers and coils possibly resulting in a small fire. Dirt buildup on components can cause excessive current used resulting in motor failure.
Return air filters are disposable fiberglass media type. Access to the filters is through the small lift-out panel located on the rear side of the unit, above the evaporator/return air access panel. (See Fig. 3.) To remove the filters: 1. Grasp the bottom flange of the upper panel. 2. Lift up and swing the bottom out until the panel disen-
gages and pulls out. 3. Reach inside and extract the filters from the filter rack. 4. Replace these filters as required with similar replacement
filters of same size. To re-install the access panel: 1. Slide the top of the panel up under the unit top panel. 2. Slide the bottom into the side channels. 3. Push the bottom flange down until it contacts the top of
the lower panel (or economizer top).

OUTSIDE AIR HOOD
Outside air hood inlet screens are permanent aluminum-mesh type filters. Check these for cleanliness. Remove the screens when cleaning is required. Clean by washing with hot lowpressure water and soft detergent and replace all screens before restarting the unit. Observe the flow direction arrows on the side of each filter frame.

ECONOMIZER INLET AIR SCREEN
This air screen is retained by filter clips under the top edge of the hood. (See Fig. 3.)

To remove the filter, open the filter clips. Re-install the filter by placing the frame in its track, then closing the filter clips.

MANUAL OUTSIDE AIR HOOD SCREEN
This inlet screen is secured by a retainer angle across the top edge of the hood. (See Fig. 4.)

Screws

SUPPLY FAN (BLOWER) SECTION
WARNING
ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death. Before performing service or maintenance operations on unit, LOCKOUT/TAGOUT the main power switch to unit. Electrical shock and rotating equipment could cause severe injury.
Supply Fan (Direct-Drive)
All 547K units have the AxionTM Fan Technology direct drive vane axial fan system. The fan is driven by an ECM motor with speed that is user set through the Unit Control Board (UCB). Speeds are fully configurable from 40% to 100% of motor’s maximum speed. (See Fig. 5 and 6.)
Motor Plug
Fan Motor

ECM Motor

Fig. 4 — Screens Installed on Outdoor-Air Hood
To remove the screen, loosen the screws in the top retainer and slip the retainer up until the filter can be removed. Re-install by placing the frame in its track, rotating the retainer back down, and tightening all screws.

Fig. 5 — Direct-Drive Supply Fan Assembly

Serial (R/T)

WHITE

CTL Signal Common

10 vdc Source 0-10 vdc signal

PINK ORANGE
GRAY
RED Safety Relay

123 456 789 10 11 12

BLACK YELLOW
BLUE YEL/GRN

RED VIOLET

Power L1 Power L2 Power L3 Earth Ground
Safety Relay PWM signal

Fig. 6 — ECM Motor Plug Connectors
EVALUATING MOTOR SPEED
The direct drive ECM blower motor uses a constant speed design. Motor speed is controlled by a 0-10 vdc signal, where 10 vdc is equal to motor’s maximum rpm.

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SELECTING FAN SPEED

All units come factory set for 9.0 vdc or approximately 90% of the motor’s maximum speed. Fan speed should be set per job specification CFM (cubic feet per minute) and ESP (external static pressure) required and per Fan speed set up label included on the unit’s high voltage cover. In some cases, the Fan Speed Set Up label may already include the field setting if unit was previously installed. Check the box on the lower half of the label to see if the field voltage setting was filled in and if so, set fan speed to that voltage. Otherwise see detailed instructions below.
NOTE: Fan Speed Set-Up is for full load airflow. If the unit has multiple stages of cooling, low cool and ventilation may operate at lower fan rpms. This offset is factory set and controlled by the UCB. If fan speed verification is being done with a strobe, fan speed should be verified in all unit operation modes.

Units with Electro-Mechanical Controls
The Fan Speed set up controls are located on the lower section of the Unit Control Board (UCB). See Fig. 7 for location.
1. Check the job specifications for the CFM (cubic feet per minute) and ESP (external static pressure) required.
2. Using the chart on the Fan Speed Set Up labels (see Fig. 8), calculate the vdc from the CFM and ESP for the base unit.
3. If installing any accessories listed at the bottom of the Set Up Label, add accessory vdc to base unit vdc in upper portion of label. For electric heaters use only one adder. (ex. 2 stage heater uses only 2 stage adder, not 1 stage plus 2 stage).
NOTE: The Fan Speed Set Up labels are located on the High Voltage cover in the Control Box. 4. Connect a multimeter to the vdc terminals on the UCB. 5. Set the Range Switch to either A, B, or C per the Switch Range table. 6. Using a straight blade screwdriver turn the vdc control dial to fine tune the vdc reading. 7. Record the reading in the Field Setting field.
NOTE: When replacing the UCB cut JMP 1,2 and 3 in the REHEAT/HP section of the replacement UCB.

Fan Speed Set Up Controls
Fig. 7 — UCB Fan Speed Controls

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VDC Calculator

ESP in. wg

0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

1500 5.4 6.2 6.9 7.5 8.1 8.6 9.1 9.6

UNIT MODEL NUMBER CFM

1625 5.8 6.5 7.1 7.7 8.3 8.8 9.3 9.8

1750 6.1 6.8 7.4 8.0 8.5 9.0 9.5 9.9

1875 6.5 7.1 7.7 8.2 8.7 9.2 9.7

2000 6.8 7.4 7.9 8.5 9.0 9.5 9.9

2125 7.2 7.7 8.2 8.7 9.2 9.7

2250 7.6 8.0 8.5 9.0 9.5 10.0

2375 7.9 8.4 8.8 9.3 9.8

2500 8.3 8.7 9.2 9.6

Field Accessories:

Economizer 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

1 Stage E Heat 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2

2 Stage E Heat 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

Factory Setting: 9.0 VDC
Field Setting:
Record field setting here
V
Switch Range: * ABC
A 4.1 – 7.5 B 6.9 – 8.7 C 7.7 – 10.0

• Overlap in A, B, C switch range designed for maximum field adjustment potential. For example 7.2 can be set at either A or B.

NOTE: Values in the Field Accessories section are VDC adders.
Fig. 8 — Example of Fan Speed Set Up Labels for Electro-Mechanical Controls

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TROUBLESHOOTING THE ECM MOTOR
AxionTM Fan Technology motors are designed with several builtin protections included in the motor software. If the motor detects a fault it will safely shut down. See Table 16, “Supply Fan Motor Logic and Safety Relays” on page 42 for a complete list.
Troubleshooting the motor requires a voltmeter.
1. Disconnect main power to the unit. 2. Disconnect motor plug in supply section of the unit. 3. Restore main unit power. 4. Check for proper line voltage at motor power leads Black
(PL1-1), Yellow (PL1-2), and Blue (PL1-3). Blue is only present on 3-phase motors. See the following table.

559K UNIT VOLTAGE

MOTOR VOLTAGE MIN-MAX VOLTS

208/230

230

187-253

460

460

360-506

575

575

517-633

5. Disconnect main power. 6. Reconnect motor plug in supply section of unit. 7. Restore main power. 8. Check for proper motor control voltage signal of 9.7 vdc
to 10.3 vdc at IFM-1 and IFM-3 on Unit Control Board (UCB). See Fig. 9. 9. Using a jumper wire from unit control terminals R to G, engage motor operation. 10. Verify control signal from user speed selection switch by placing voltmeter taps in provided terminals marked vdc. Signal should be between 3.8 vdc and 10.3 vdc. 11. If the motor does not start and run, remove the fan assembly and replace the motor with one having the same part number. Do not substitute with an alternate design motor as the voltage/speed programming will not be the same as that on an original factory motor.

NOTE: 2-PIN LOW SPEED DIP SWITCH POSITIONS ARE FACTORY SET AS SHOWN FOR T1 UNITS. ON T2 UNITS THE SETTINGS IS “ON-OFF”.
Fig. 9 — Supply Fan Control Wiring Diagram

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Removing the Motor and Fan Assembly NOTE: Due to press fit design of composite Rotor on Motor, it is highly recommended that any time a motor is replaced the fan rotor is replaced as well. The rest of the assembly may be reused. See Fig. 10. 1. Unplug motor harness from control box harness and cut
wire tie at the fan deck. 2. Unplug connectors from stator temperature limit switch. 3. Remove eight screws at front of stator on fan deck. 4. Slide fan assembly forward a couple of inches to clear rear
brackets and lift assembly out.
4 1
2 3
Fig. 10 — Fan Assembly Removal
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Disassembling Standard/Medium Motor and Fan Assembly
See Fig. 11.
NOTE: Refer to “Model Number Nomenclature” on page 68, position 13 for specific unit requirements.
1. Remove 4 screws from U-clips in fan casing. 2. Remove casing from assembly. 3. Remove 3 screws connecting rotor to motor flange. 4. Remove rotor from motor. 5. Remove 4 screws connecting motor to stator. 6. Remove stator from motor. 7. If required, remove fan limit switch from stator.

Disassembling High Static Motor and Fan Assembly
See Fig. 12.
NOTE: Refer to “Model Number Nomenclature” on page 68, position 13 for specific unit requirements.
1. Remove 4 screws from U-clips in fan casing. 2. Remove casing from assembly. 3. Remove 3 screws connecting rotor to motor flange. 4. Remove rotor from motor. 5. Remove 6 screws connecting motor to stator. 6. Remove motor from stator. 7. If required, remove fan limit switch from stator.

Fig. 11 — Disassembling Standard or Medium Static Motor and Fan Assembly

Fig. 12 — Disassembling High Static Motor and Fan Assembly

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Reassembly of Standard/Medium Motor and Fan Assembly
See Fig. 13.
NOTE: Refer to “Model Number Nomenclature” on page 68, position 13 for specific unit requirements.
1. Place motor on flat surface. 2. If required, reinstall limit switch on stator with two plastic
fastener plugs (P/N: 48TM005675). 3. Line up keying features on stator and motor and set stator
onto motor. Install four 1/4-20 x 1-in. screws (P/N: AC67AP170) to attach stator to motor. Tighten to 50 in.-lb (5.65 Nm). 4. Set rotor onto motor flange. Install three 1/4-20 x 1-in. screws (P/N: AC67AP170) to attach rotor to motor. Tighten to 50 in.-lb (5.65 Nm). 5. Set casing onto stator. Install four #10-16 x 3/4-in. screws (P/N: AP13AD128) through U-Clips in casing. Tighten to 14 in.-lb (1.58 Nm). 6. Pull motor harness out through guide feature in stator if not already completed.

Reassembly of High Static Motor and Fan Assembly
See Fig. 14.
NOTE: Refer to “Model Number Nomenclature” on page 68, position 13 for specific unit requirements.
1. Place stator on flat surface. 2. If required, reinstall limit switch on stator with two plastic
fastener plugs (P/N: 48TM005675). 3. Line up keying features on stator and motor and set motor
onto stator. Motor wire Harness should align with guide feature in stator. Install six 1/4-20 x 1-in. screws (P/N: AC67AP170) to attach stator to motor. Tighten to 30 in.-lb (3.39 Nm). 4. Set rotor onto motor flange. Install three 1/4-20 x 1-in. screws (P/N: AC67AP170) to attach rotor to motor. Tighten to 50 in.-lb (5.65 Nm). 5. Set casing onto stator. Install four #10-16 x 3/4-in. screws (P/N: AP13AD128) through U-Clips in casing. Tighten to 14 in.-lb (1.58 Nm). 6. Pull motor harness out through guide feature in stator if not already completed.

Fig. 13 — Standard/Medium Fan System ReAssembly

Fig. 14 — High Static Fan System Re-Assembly

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Reinstalling Motor and Fan Assembly See Fig. 15. 1. Align motor harness/grommet at ~7 o’clock (facing
installer) and align the bottom flats on right and left sides of fan stator with fan deck ribs. Drop fan assembly down into fan deck opening and slide back until aluminum stator is under the rear fan deck brackets. 2. Align (if necessary) two front holes and fasten stator to fan deck with 8 #10 x 5/8-in. hex head screws (P/N: AL48AM217). Tighten to 50 in.-lb (5.65 Nm). 3. Reconnect wires for stator temperature limit switch. 4. Pull motor harness tight through grommet and plug it in to the control box harness and secure in the corner with snap-in wire tie.
1 4
3 2
Fig. 15 — Fan Assembly Installation
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2- Speed Indoor Fan Motor
All 547K units with AxionTM Fan Technology come factory set to automatically adjust the indoor fan motor speed in sequence with the unit’s ventilation, cooling, and heating operation. See Table 1 for fan operation for various modes.

Table 1 — Percentage of Vdc Setting

UNIT 547K08 547K09 547K12 547K14

HIGH COOL 100% 100% 100% 100%

HEAT 100% 100% 100% 100%

LOW COOL 60% 50% 60% 60%

VENT 60% 50% 60% 60%

COOLING

WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal injury, death and/or equipment damage.
This system uses R-410A refrigerant, which has higher pressures than R-22 and other refrigerants. No other refrigerant may be used in this system. Gauge set, hoses, and recovery system must be designed to handle R-410A refrigerant. If unsure about equipment, consult the equipment manufacturer.

Condenser Coil (Outdoor)
The condenser coil is fabricated with round tube copper hairpins and plate fins of various materials and/or coatings (see Model Number Nomenclature in Appendix A to identify the materials provided in this unit). The coil may be one-row or composite-type two-row. Composite two-row coils are two single-row coils fabricated with a single return bend end tubesheet.
Evaporator Coil (Indoor)
The evaporator coil is traditional round-tube, plate-fin technology. Tube and fin construction is of various optional materials and coatings (See “Model Number Nomenclature” on page 68.). Coils are multiple-row.
Condenser Coil Maintenance and Cleaning Recommendation
Routine cleaning of coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and removal of harmful residues will greatly increase the life of the coil and extend the life of the unit. The following maintenance and cleaning procedures are recommended as part of the routine maintenance activities to extend the life of the coil.

REMOVE SURFACE LOADED FIBERS
Surface loaded fibers or dirt should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges can be easily bent over and damage to the coating of a protected coil) if the tool is applied across the fins.
NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse.

PERIODIC CLEAN WATER RINSE
A periodic clean water rinse is very beneficial for coils that are applied in coastal or industrial environments. However, it is very important that the water rinse is made with a very low velocity water stream to avoid damaging the fin edges. Monthly cleaning as described below is recommended. Rinsing coils in the opposite direction of airflow is recommended.

ROUTINE CLEANING OF COIL SURFACES
Periodic cleaning with Totaline® environmentally balanced coil cleaner is essential to extend the life of coils. This cleaner is available from Replacement Components Division as part number P902-0301 for a one gallon container, and part number P902-0305 for a 5 gallon container. It is recommended that all coils, including standard aluminum, pre-coated, copper/copper or e-coated coils be cleaned with the Totaline environmentally balanced coil cleaner as described below. Coil cleaning should be part of the unit’s regularly scheduled maintenance procedures to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment.
Avoid use of:
· coil brighteners
· acid cleaning prior to painting
· high pressure washers
· poor quality water for cleaning
Totaline environmentally balanced coil cleaner is nonflammable, hypo- allergenic, non-bacterial, and a USDA accepted biodegradable agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces, or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.
Clean coil as follows:
1. Turn off unit power, tag disconnect. 2. Remove all screws from the top panel except the screws
securing the condenser fan to the top panel. (See Fig. 16.)

Remove screws from all sides of top panel

Top Panel

Remove Screws

Condenser Fan

Center Post Compressor Access Panel
Condenser Coil Corner Post

Condenser Coil

Fig. 16 — Location of Screws and Coil Corner Post
3. Lift and rotate the top panel at the condenser fan end and rotate the panel 90 degrees. Support the top panel so it remains level while resting on the condenser fan as shown in Fig. 17.

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Top Panel

Support (FieldSupplied)
Center Baffle

Fig. 17 — Top Panel Position
4. Remove the compressor access panel to access the lower coil clip. The condenser coil corner post may also be removed.
5. Remove the screws from both sides of the 4 coil retaining clips on the hairpin end of the coil tube sheets. (See Fig. 18.)
6. Remove the 4 retaining clips.

Fig. 19 — Separating Coil Sections (Top View)
CAUTION
UNIT DAMAGE HAZARD Failure to follow this caution may result in reduced unit performance or unit shutdown. High velocity water from a pressure washer, garden hose, or compressed air should never be used to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pressure drop.

Fig. 18 — Condenser Coil Clips
7. Draw the inner coil inward to separate the coils for cleaning. 8. Insert a spacer (field-supplied) between the tube sheets to
hold the coils apart. (See Fig. 19.) 9. Clean the outer coil surface to remove surface loaded
fibers or dirt. See “Remove Surface Loaded Fibers” on page 12 for details. 10. Use a water hose or other suitable equipment to flush down between the 2 coil sections to remove dirt and debris. If a coil cleaner is used be sure to rinse the coils completely before reassembly. 11. Move the inner coil back into position. Reinstall the 4 coil clips. Reinstall the top panel and replace all screws.

CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in accelerated corrosion of unit parts.
Harsh chemicals, household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils of any kind. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in contact. If there is dirt below the surface of the coil, use the environmentally balanced coil cleaner.
Totaline Environmentally Balanced Coil Cleaner Application Instructions
1. Proper eye protection such as safety glasses is recommended during mixing and application.
2. Remove all surface loaded fibers and dirt with a vacuum cleaner as described above.
3. Thoroughly wet finned surfaces with clean water and a low velocity garden hose, being careful not to bend fins.
4. Mix Totaline environmentally balanced coil cleaner in a 2-1/2 gallon garden sprayer according to the instructions included with the cleaner. The optimum solution temperature is 100°F.
NOTE: Do NOT USE water in excess of 130°F, as the enzymatic activity will be destroyed. 5. Thoroughly apply Totaline environmentally balanced coil cleaner solution to all coil surfaces including finned area, tube sheets and coil headers. 6. Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize potential for fin damage.

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7. Ensure cleaner thoroughly penetrates deep into finned areas. Interior and exterior finned areas must be thoroughly cleaned. Finned surfaces should remain wet with cleaning solution for 10 minutes. Ensure surfaces are not allowed to dry before rinsing. Reapply cleaner as needed to ensure 10-minute saturation is achieved.
8. Thoroughly rinse all surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle.
Evaporator Coil
Cleaning the Evaporator Coil:
1. Turn unit power off. Install lockout tag. Remove evaporator coil access panel.
2. If economizer or two-position damper is installed, remove economizer by disconnecting Molex® 1 plug and removing mounting screws.
3. Slide filters out of unit. 4. Clean coil using a commercial coil cleaner or dishwasher
detergent in a pressurized spray canister. Wash both sides of coil and flush with clean water. For best results, backflush toward return-air section to remove foreign material. Flush condensate pan after completion. 5. Reinstall economizer and filters. 6. Reconnect wiring. 7. Replace access panels.
Typical Unit Piping
Each heat pump system includes two compressors, a reversing valve, dual- function outdoor and indoor coils, a common liquid line with bi-flow TXV, and dedicated cooling and heating TXVs. 547K08 and 547K09 unit outdoor coils contain a vapor header check valve. 547K*08-14 unit indoor coils contain a vapor header check valve. See Fig. 20-27 and Tables 2-10 for typical unit piping schematic of parallel coil circuits during evaporator-function operation and converging coil circuits during the condenser-function operation.

Table 2 — 547K*08-09 ­ Cooling Mode

COMPONENT Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F

STATUS/POSITION Energized Closed Open Open Open Closed Closed

Table 3 — 547K*08-09 ­ Heating Mode

COMPONENT Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F

STATUS/POSITION De-energized Open Closed Closed Closed Open Open

Table 4 — 547K*08-09 ­ Defrost Mode

COMPONENT Defrost Thermostat
Outdoor Fan(s) Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F

STATUS/POSITION Closed Off
Energized Closed Open Open Open Closed Closed

Table 5 — 547K*12 ­ Cooling Mode

COMPONENT Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F

STATUS/POSITION Energized N/A Open Open Open Closed Closed

Table 6 — 547K*12 ­ Heating Mode

COMPONENT Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F

STATUS/POSITION De-energized N/A Closed Closed Closed Open Open

Table 7 — 547K*12 ­ Defrost Mode

COMPONENT Defrost Thermostat
Outdoor Fan(s) Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F

STATUS/POSITION Closed Off
Energized N/A Open Open Open
Closed Closed

Table 8 — 547K*14 ­ Cooling Mode

COMPONENT Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F Check Valve G

STATUS/POSITION Energized Closed Open Open Open Open Closed Closed

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Table 9 — 547K*14 ­ Heating Mode

COMPONENT Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F Check Valve G

STATUS/POSITION De-energized Open Closed Closed Closed Closed Open Open

Table 10 — 547K*14 ­ Defrost Mode

COMPONENT Defrost Thermostat
Outdoor Fan(s) Reversing Valve Check Valve A Check Valve B Check Valve C Check Valve D Check Valve E Check Valve F Check Valve G

STATUS/POSITION Closed Off
Energized Closed Open Open Open Open Closed Closed

F Heating TXV
DFT

Filter Drier

LPS/LOC

B

C E

Cooling TXV

A

HPS

Reversing

Valve

D

Outdoor Coil

Fig. 20 — Piping Schematic — 547K*08 Cooling Mode

Indoor Coil

15

F Heating TXV
DFT

Filter Drier

LPS/LOC

B

A

HPS

Reversing

Valve

C E

Cooling TXV

D

Outdoor Coil

Fig. 21 — Piping Schematic — 547K*08 Heating Mode

Indoor Coil

F Heating TXV
DFT

Filter Drier

LPS/LOC

B

C E

Cooling TXV

A

HPS

Reversing

Valve

D

Outdoor Coil

Fig. 22 — Piping Schematic — 547K*09 Cooling Mode

Indoor Coil

16

F Heating TXV
DFT

Filter Drier

LPS/LOC

B

A

HPS

Reversing

Valve

C E

Cooling TXV

D

Outdoor Coil

Fig. 23 — Piping Schematic — 547K*09 Heating Mode

Indoor Coil

F
Heating TXV B

Filter Drier

LPS/LOC

C E

Cooling TXV

HPS

Reversing

DFT

Valve

D

Outdoor Coil

Fig. 24 — Piping Schematic — 547K*12 Cooling Mode

Indoor Coil

17

F Heating TXV
B
DFT

Filter Drier

LPS/LOC

C E

Cooling TXV

HPS

Reversing Valve

D

Outdoor Coil

Fig. 25 — Piping Schematic — 547K*12 Heating Mode

Indoor Coil

C F
E

Cooling TXV Cooling TXV

Filter Drier

LPS/LOC

B

HPS

Reversing

Valve

A

G Heating TXV
DFT

D

Indoor Coil

Fig. 26 — Piping Schematic — 547K*14 Cooling Mode

Outdoor Coil

18

C F
E

Cooling TXV Cooling TXV

Filter Drier

LPS/LOC

B

HPS

Reversing

Valve

A

G Heating TXV
DFT

D

Indoor Coil

Fig. 27 — Piping Schematic — 547K*14 Heating Mode

Outdoor Coil

19

THERMOSTATIC EXPANSION VALVE (TXV)
All 547K 08-14 units include TXV control. The TXV is a bi-flow, bleed port expansion valve with an external equalizer. The TXVs are specifically designed to operate with Puron® refrigerant (R-410A). Use only factory-authorized TXVs.
TXV Operation
The TXV is a metering device that is used in air conditioning and heat pump systems to adjust to the changing load conditions by maintaining a preset superheat temperature at the outlet of the evaporator coil.
The volume of refrigerant metered through the valve seat is dependent upon the following:
1. Superheat temperature is sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil. This temperature is converted into pressure by refrigerant in the bulb pushing downward on the diaphragm, which opens the valve using the push rods.
2. The suction pressure at the outlet of the evaporator coil is transferred through the external equalizer tube to the underside of the diaphragm.
3. The pin is spring loaded, which exerts pressure on the underside of the diaphragm. Therefore, the bulb pressure works against the spring pressure and evaporator suction pressure to open the valve. If the load increases, the temperature increases at the bulb, which increases the pressure on the top side of the diaphragm. This opens the valve and increases the flow of refrigerant. The increased refrigerant flow causes the leaving evaporator temperature to decrease. This lowers the pressure on the diaphragm and closes the pin. The refrigerant flow is effectively stabilized to the load demand with negligible change in superheat.
Replacing TXV
1. Recover refrigerant. 2. Remove TXV support clamp using a 5/16-in. nut driver. 3. Remove TXV using a wrench and an additional wrench on
connections to prevent damage to tubing. 4. Remove equalizer tube from suction line of coil. Use file
or tubing cutter to cut brazed equalizer line approximately 2 inches above suction tube. 5. Remove bulb from vapor tube inside cabinet. 6. Install the new TXV using a wrench and an additional wrench on connections to prevent damage to tubing while attaching TXV to distributor. 7. Attach the equalizer tube to the suction line. If the coil has a mechanical connection, then use a wrench and an additional wrench on connections to prevent damage. If the coil has a brazed connection, use a file or a tubing cutter to remove the mechanical flare nut from the equalizer line. Then use a new coupling to braze the equalizer line to the stub (previous equalizer line) in suction line. 8. Attach TXV bulb in the same location where the original (in the sensing bulb indent) was when it was removed, using the supplied bulb clamps. (See Fig. 28 on page 20.) 9. Route equalizer tube through suction connection opening (large hole) in fitting panel and install fitting panel in place. 10. Sweat the inlet of TXV marked “IN” to the liquid line. Avoid excessive heat which could damage the TXV valve. Use quenching cloth when applying heat anywhere on TXV.

VIEW WITH TXV BULB INSULATION COVER REMOVED
SUCTION LINE

TXV BULB

BULB CAPILLARY TUBE TXV BULB PROCESS TUBE

Fig. 28 — TXV Valve and Sensing Bulb Location
Refrigerant System Pressure Access Ports
There are two access ports in the system: on the suction tube near the compressor and on the discharge tube near the compressor. These are brass fittings with black plastic caps. The hose connection fittings are standard 1/4-in. SAE male flare couplings.
The brass fittings are two-piece high flow valves, with a receptacle base brazed to the tubing and an integral spring-closed check valve core screwed into the base. See Fig. 29. This check valve is permanently assembled into this core body and cannot be serviced separately; replace the entire core body if necessary. Service tools are available from RCD that allow the replacement of the check valve core without having to recover the entire system refrigerant charge. Apply compressor refrigerant oil to the check valve core’s bottom o-ring. Install the fitting body with 96 ± 10 in.-lb (10.85 ± 1.1 Nm) of torque; do not over-tighten.

PURON (R-410A) REFRIGERANT
This unit is designed for use with Puron® (R-410A) refrigerant. Do not use any other refrigerant in this system.
Puron (R-410A) refrigerant is provided in pink (rose) colored cylinders. These cylinders are available with and without dip tubes; cylinders with dip tubes will have a label indicating this feature. For a cylinder with a dip tube, place the cylinder in the upright position (access valve at the top) when removing liquid refrigerant for charging. For a cylinder without a dip tube, invert the cylinder (access valve on the bottom) when removing liquid refrigerant.
Because Puron (R-410A) refrigerant is a blend, it is strongly recommended that refrigerant always be removed from the cylinder as a liquid. Admit liquid refrigerant into the system in the discharge line. If adding refrigerant into the suction line, use a commercial metering/expansion device at the gauge manifold; remove liquid from the cylinder, pass it through the metering device at the gauge set and then pass it into the suction line as a vapor. Do not remove Puron (R-410A) refrigerant from the cylinder as a vapor.

20

Refrigerant Charge
Amount of refrigerant charge is listed on the unit’s nameplate. Refer to Bryant GTAC2-5 Charging, Recovery, Recycling and Reclamation training manual and the following procedures. Unit panels must be in place when unit is operating during the charging procedure.
NO CHARGE Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant.
LOW-CHARGE COOLING Using Cooling Charging Charts, Fig. 30-33, vary refrigerant until the conditions of the appropriate chart are met. NOTE: The charging charts are different from type normally used. Charts are based on charging the units to the correct sub-cooling for the various operating conditions. Accurate pressure gauge and temperature sensing device are required. Connect the pressure gauge to the service port on the liquid line. Mount the temperature sensing device on the liquid line and insulate it so that outdoor ambient temperature does not affect the reading. Indoor-air cfm must be within the normal operating range of the unit.
.
SEAT
1/2-20 UNF RH
0.596

547K SIZE DESIGNATION

NOMINAL TONS REFERENCE

08

7.5

09

8.5

12

10.0

14

12.5

EXAMPLE:

Model

547KM08

Outdoor Temperature

85°F (29°C)

Suction Pressure

140 psig (965 kPa)

Suction Temperature should be 65°F (16°C)

USING COOLING CHARGING CHARTS
Take the outdoor ambient temperature and read the liquid pressure gauge. Refer to chart to determine what liquid temperature should be. If liquid temperature is low, add refrigerant. If liquid temperature is high, carefully recover some of the charge. Recheck the liquid pressure as charge is adjusted.

CORE
(Part No. EC39EZ067)
45°

5/8″ HEX

30° 0.47

Washer O-Ring

1/2″ HEX

Depressor per AHRI 720 +.01/­.035 From Face of Body

This surface provides a metal to metal seal when torqued into the seat. Appropriate handling is required to not scratch or dent the surface.

7/16-20 UNF RH

Fig. 29 — CoreMaxTM 1 Access Port Assembly

1. Third-party trademarks and logos are the property of their respective owners.
21

Outdoor Coil Leaving Temperature (°C/°F)

COOLING CHARGING CHARTS
7.5 Ton 50FCQ / 547K / RHV R-410A Refrigerant Charging Chart
(Unit must run in cooling mode, have both compressors on and outdoor fans on high speed) 59.9 140

48.8 120

Add Charge if Above Curve

37.7 100

26.6 80

15.5 60

Remove Charge if Below the Curve

4.4 40

-6.7 20 150 200 250 300 350 400 450 500 550 600 1034 1379 1723 2068 2413 2758 3102 3447 3792 4136 Compressor Discharge Pressure (psig/kPa) 48TM007240 rev. –
Fig. 30 — Cooling Charging Chart – 7.5 Ton

22

Outdoor Coil Leaving Temperature (°C/°F)

COOLING CHARGING CHARTS

8.5 Ton 50FCQ / 547K / RHV R-410A Refrigerant Charging Chart
(Unit must run in cooling mode, have both compressors on and outdoor fans on high speed)
59.9 140

48.8 120

Add Charge if Above Curve

37.7 100

26.6 80

15.5 60

Remove Charge if Below the Curve

4.4 40

-6.7 20 150 200 250 300 350 400 450 500 550 600 1034 1379 1723 2068 2413 2758 3102 3447 3792 4136 Compressor Discharge Pressure (psig/kPa) 48TM007241 rev. –
Fig. 31 — Cooling Charging Chart – 8.5 Ton

23

Outdoor Coil Leaving Temperature (°C/°F)

COOLING CHARGING CHARTS

10 Ton 50FCQ / 547K / RHV R-410A Refrigerant Charging Chart
(Unit must run in cooling mode, have both compressors on and outdoor fans on high speed)
59.9 140

48.8 120

Add Charge if Above Curve

37.7 100

26.6 80

15.5 60

Remove Charge if Below the Curve

4.4 40

-6.7 20 150 200 250 300 350 400 450 500 550 600 1034 1379 1723 2068 2413 2758 3102 3447 3792 4136 Compressor Discharge Pressure (psig/kPa) 48TM007242 rev. –
Fig. 32 — Cooling Charging Chart – 10.0 Ton

24

Outdoor Coil Leaving Temperature (°C/°F)

COOLING CHARGING CHARTS

12.5 Ton 50FCQ / 547K / RHV R-410A Refrigerant Charging Chart
(Unit must run in cooling mode, have both compressors on and outdoor fans on high speed)
59.9 140

48.8 120

Add Charge if Above Curve

37.7 100

26.6 80

15.5 60

Remove Charge if Below the Curve

4.4 40

-6.7 20 150 200 250 300 350 400 450 500 550 600 1034 1379 1723 2068 2413 2758 3102 3447 3792 4136 Compressor Discharge Pressure (psig/kPa) 50TM002615 rev. –
Fig. 33 — Cooling Charging Chart – 12.5 Ton

25

COMPRESSOR
Lubrication
The compressor is charged with the correct amount of oil at the factory.
CAUTION
UNIT DAMAGE HAZARD Failure to follow this caution may result in damage to components. The compressor is in a R-410A refrigerant system and uses a polyolester (POE) oil. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Avoid exposure of the oil to the atmosphere.
WARNING
FIRE, EXPLOSION HAZARD Failure to follow this warning could result in death, serious personal injury and/or property damage. Never use air or gases containing oxygen for leak testing or for operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion.
WARNING
FIRE, EXPLOSION HAZARD Failure to follow this warning could result in death, serious personal injury and/or property damage. Never use non-certified refrigerants in this product. Noncertified refrigerants could contain contaminates that could lead to unsafe operating conditions. Use ONLY refrigerants that conform to AHRI Standard 700.
Replacing Compressor
NOTE: Only factory-trained service technicians should remove and replace compressor units.
CAUTION
INSTALLATION SITE DAMAGE Failure to follow this caution can result in damage to equipment location site. R-410A refrigerant contains polyolester (POE) oil that can damage the roof membrane. Caution should be taken to prevent POE oil from spilling onto the roof surface. The factory also recommends that the suction and discharge lines be cut with a tubing cutter instead of using a torch to remove brazed fittings.

Compressor Rotation
CAUTION
EQUIPMENT DAMAGE HAZARD Failure to follow this caution can result in premature wear and damage to equipment. Scroll compressors can only compress refrigerant if rotating in the right direction. Reverse rotation for extended times can result in internal damage to the compressor. Scroll compressors are sealed units and cannot be repaired on site location.
NOTE: When the compressor is rotating in the wrong direction, the unit makes an elevated level of noise and does not provide cooling. On 3-phase units with scroll compressors, it is important to be certain compressor is rotating in the proper direction. To determine whether or not compressor is rotating in the proper direction: 1. Connect service gauges to suction and discharge pressure fittings. 2. Energize the compressor. 3. The suction pressure should drop and the discharge pres-
sure should rise, as is normal on any start-up. NOTE: If the suction pressure does not drop and the discharge pressure does not rise to normal levels, the evaporator fan is probably also rotating in the wrong direction. 4. Turn off power to the unit. 5. Reverse any two of the three unit power leads. 6. Reapply electrical power to the compressor. The suction pressure should drop and the discharge pressure should rise which is normal for scroll compressors on start-up. 7. Replace compressor if suction/discharge pressures are not within specifications for the specific compressor. The suction and discharge pressure levels should now move to their normal start-up levels.
Filter Drier
Replace whenever refrigerant system is exposed to atmosphere. Only use factory specified liquid-line filter driers with working pressures no less than 650 psig (4482 kPa).
CAUTION
EQUIPMENT DAMAGE Failure to follow this caution can result in equipment damage. Do not install a suction-line filter drier in liquid line. A liquid- line filter drier designed for use with R-410A refrigerant is required on every unit.
Condenser-Fan Adjustment
1. Shut off unit power supply. Install lockout tag. 2. Remove condenser-fan assembly (grille, motor, and fan).
(See Fig. 34.) 3. Loosen fan hub setscrews. 4. Adjust fan height by pushing fan until it stops on the fan shaft. 5. Tighten set screw to 84 in.-lb (9.5 Nm) ± 12 in.-lb (1.5 Nm). 6. Replace condenser-fan assembly.

Fig. 34 — Condenser Fan Adjustment 26

Troubleshooting Cooling System
Refer to Table 11 for additional troubleshooting topics.
Table 11 — Troubleshooting

SYMPTOM

CAUSE

SOLUTION

Power failure.

Call power company.

Fuse blown or circuit breaker tripped.

Replace fuse or reset circuit breaker. Determine root cause.

Defective thermostat, contactor, transformer. control relay, or capacitor.

Replacement component.

Compressor and Outdoor Insufficient line voltage.

Fan Will Not Start

Incorrect or faulty wiring.

Determine cause and correct. Check wiring diagram and rewire correctly.

Thermostat setting too high.

Lower thermostat setting below room temperature.

High pressure switch tripped.

See problem “Excessive head pressure.”

Low pressure switch tripped.

Check system for leaks. Repair as necessary.

Freeze-up protection thermostat tripped.

See problem “Suction pressure too low.”

Faulty wiring or loose connections in compressor circuit.

Check wiring and repair or replace.

Compressor Will Not Start but Outdoor Fan Runs

Compressor motor burned out, seized, or internal Determine cause. Replace compressor or allow enough time for

overload open.

internal overload to cool and reset.

Defective run/start capacitor, overload, start relay.

Determine cause. Replace compressor or allow enough time for internal overload to cool and reset.

One leg of 3-phase power dead.

Replace fuse or reset circuit breaker. Determine cause.

Refrigerant overcharge or undercharge.

Recover refrigerant, evacuate system, and recharge to nameplate.

Defective compressor.

Replace and determine cause.

Insufficient line voltage.

Determine cause and correct.

Blocked outdoor coil or dirty air filter.

Determine cause and correct.

Compressor Cycles (Other Defective Run/Start capacitor, overload, start

Than Normally Satisfying relay.

Thermostat)

Defective thermostat.

Determine cause and correct. Replace thermostat.

Faulty outdoor-fan (cooling) or indoor-fan (heating) motor or capacitor.

Replace faulty part.

Restriction in refrigerant system.

Locate restriction and remove.

Defective loader plug.

Determine cause and replace.

Dirty air filter.

Replace filter.

Unit undersized for load.

Decrease load or increase unit size.

Compressor Operates Continuously

Thermostat set too low (cooling). Low refrigerant charge.

Reset thermostat. Locate leak; repair and recharge.

Air in system.

Recover refrigerant, evacuate system, and recharge.

Outdoor coil dirty or restricted.

Clean coil or remove restriction.

Compressor Makes Excessive Noise

Compressor rotating in the wrong direction.

Reverse the 3-phase power leads as described in Start-Up.

Dirty outside.

Replace filter.

Dirty outdoor coil (cooling).

Clean coil.

Excessive Head Pressure Refrigerant overcharged.

Recover excess refrigerant.

Air in system.

Recover refrigerant, evacuate system, and recharge.

Condensing air restricted or air short-cycling. Determine cause and correct.

Low refrigerant charge.

Check for leaks; repair and recharge

Head Pressure Too Low

Compressor scroll plates defective.

Replace compressor

Restriction in liquid tube.

Remove restriction.

High heat load.

Check for source and eliminate.

Excessive Suction Pressure Compressor scroll plates defective.

Replace compressor.

Refrigerant overcharge.

Recover excess refrigerant.

Dirty air filter (cooling).

Replace filter.

Dirt or heavily iced outdoor coil (heating).

Clean outdoor coil. Check defrost cycle operation.

Low refrigerant charge.

Check for leaks; repair and recharge.

Metering device or low side restricted

Remove source of restriction.

Suction Pressure Too Low Insufficient indoor airflow (cooling mode). Temperature too low in conditioned area.

Increase air quantity. Check filter and replace if necessary. Reset thermostat.

Field-installed filter drier restricted.

Replace.

Outdoor ambient temperature below 25°F (cooling).

Install low-ambient kit.

Outdoor fan motor(s) not operating (heating). Check fan motor operation.

27

CONVENIENCE OUTLETS

WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury or death.
Units with convenience outlet circuits may use multiple disconnects. Check convenience outlet for power status before opening unit for service. Locate its disconnect switch, if appropriate, and open it. Lock-out and tag-out this switch, if necessary.

Convenience Outlets
Two types of convenience outlets are offered on 547K models: non-powered and unit-powered. Both types provide a 125 vac ground-fault circuit-interrupt (GFCI) duplex receptacle rated at 15A behind a hinged waterproof access cover, located on the end panel of the unit. (See Fig. 35.)

Convenience Outlet GFCI

PWD-CO Fuse Switch

PWD-CO Transformer
Fig. 35 — Convenience Outlet Location
Installing Weatherproof Cover
A weatherproof while-in-use cover for the factory installed convenience outlets is now required by UL standards. This cover cannot be factory-mounted due to its depth. The cover must be installed at unit installation. For shipment, the convenience outlet is covered with a blank cover plate. The weatherproof cover kit is shipped in the unit’s control box. The kit includes the hinged cover, a backing plate and gasket.

NOTE: DISCONNECT ALL POWER TO UNIT AND CONVENIENCE OUTLET. Use approved lockout/tag-out procedures.

1. Remove the blank cover plate at the convenience outlet; discard the blank cover.
2. Loosen the two screws at the GFCI duplex outlet, until approximately 1/2-in. (13 mm) under screw heads is exposed.
3. Press the gasket over the screw heads. Slip the backing plate over the screw heads at the keyhole slots and align with the gasket; tighten the two screws until snug (do not over-tighten).
4. Mount the weatherproof cover to the backing plate as shown in Fig. 36.
5. Remove two slot fillers in the bottom of the cover to permit service tool cords to exit the cover.
6. Check cover installation for full closing and latching.

Cover — While-In-Use Weatherproof

GFCI Receptacle Not Included

TOP

TOP

TOP
WET LOCATIONS

WET LOCATIONS

Gasket

Baseplate For GFCI Receptacle
Fig. 36 — Weatherproof Cover Installation
Non-Powered Type
This type requires the field installation of a general-purpose 125-v 15-A circuit powered from a source elsewhere in the building. Observe national and local codes when selecting wire size, fuse or breaker requirements and disconnect switch size and location. Route 125-v power supply conductors into the bottom of the utility box containing the duplex receptacle.
Unit-Powered Type
A unit-mounted transformer is factory-installed to step-down the main power supply voltage to the unit to 115-v at the duplex receptacle. This option also includes a manual switch with fuse, located in a utility box and mounted on a bracket behind the convenience outlet; access is through the unit’s control box access panel. (See Fig. 35.)
The primary leads to the convenience outlet transformer are not factory- connected. Selection of primary power source is a customer option. If local codes permit, the transformer primary leads can be connected at the line-side terminals on a unit-mounted non-fused disconnect switch; this will provide service power to the unit when the unit disconnect switch is open. Other connection methods will result in the convenience outlet circuit being de- energized when the unit disconnect switch is open. (See Fig. 37.)

28

UNIT VOLTAGE 208, 230
460
575

CONNECT AS 240
480
600

PRIMARY CONNECTIONS
L1: RED +YEL L2: BLU + GRA
L1: RED Splice BLU + YEL L2: GRA
L1: RED L2: GRA

TRANSFORMER TERMINALS
H1 + H3 H2 + H4
H1 H2 + H3
H4
H1 H2

Fig. 37 — Powered Convenience Outlet Wiring

Duty Cycle
The unit-powered convenience outlet has a duty cycle limitation. The transformer is intended to provide power on an intermittent basis for service tools, lamps, etc; it is not intended to provide 15A loading for continuous duty loads (such as electric heaters for overnight use). Observe a 50% limit on circuit loading above 8A (i.e., limit loads exceeding 8A to 30 minutes of operation every hour).
Maintenance
Periodically test the GFCI receptacle by pressing the TEST button on the face of the receptacle. This should cause the internal circuit of the receptacle to trip and open the receptacle. Check for proper grounding wires and power line phasing if the GFCI receptacle does not trip as required. Press the RESET button to clear the tripped condition.
Fuse on Powered Type
The factory fuse is a Bussmann Fusetron1 T-15, non-renewable screw-in (Edison base) type plug fuse.

1. Third-party trademarks and logos are the property of their respective owners.

USING UNIT-MOUNTED CONVENIENCE OUTLETS Units with unit-mounted convenience outlet circuits will often require that two disconnects be opened to de- energize all power to the unit. Treat all units as electrically energized until the convenience outlet power is also checked and de-energization is confirmed. Observe National Electrical Code Article 210, Branch Circuits, for use of convenience outlets.
COMMERICAL DEFROST CONTROL
On 547K units equipped with electro-mechanical controls the Defrost Control Board (DFB) coordinates thermostat demands for supply fan control, 1 or 2 stage cooling, 2 stage heating, emergency heating and defrost control with unit operating sequences. The DFB also provides an indoor fan off delay feature (user selectable). See Fig. 38 for board arrangement. The DFB is located in the main control box of the 547K unit (see Fig. 39). All connections are factory-made through harnesses from the UCB (unit control board), OFR (outdoor fan relay), EHR (electric heat relay), reversing valve solenoids, and defrost thermostats. Refer to Table 12 for details of DFB Inputs and Outputs. NOTE: “IFO” terminal, “IFM” terminal and “SPPCOMPSTG2” terminal are not used on this unit and should remain open.
DIP Switches
Speed-Up Jumpers
Fig. 38 — Defrost Control Board Arrangement

29

NOTE: FUSES FOR 230V ARE LOCATED IN CONTROL BOX. FUSES FOR 460/575V ARE LOCATED BELOW THE CONTROL BOX.

Fig. 39 — Defrost Control Board Location – 547K*08-14 Electro-Mechanical Units

Table 12 — 547K Defrost Board I/O and Jumper Configurations

POINT NAME INPUTS
G Fan Y1 Cool 1 Y2 Cool 2 W1 Heat 1 W2 Heat 2 R Power C Common
DFT 1 DFT 2 OUTPUTS IFO Fan On OF OD Fan On RVSR RVSR COM COMP 1 COMP 2 HEAT 2 COM CONFIGURATION Select Jumper SPEED-UP CONFIGURATIONa,b Speed-Up Jumper Speed-Up Jumper

TYPE OF I/O
DI, 24 vac DI, 24 vac DI, 24 vac DI, 24 vac DI, 24 vac
24 vac 24 vac DI, 24 vac DI, 24 vac
DO, 24 vac DO, 24 vac DO, 24 vac DO, 24 vac DO, 24 vac DO, 24 vac DO, 24 vac
24 vac
24 vac
— —

CONNECTION PIN NUMBER
P2-3 P2-5 P2-4 P2-7 P2-6 P3-1 P3-2 DFT-1 to DFT-1 DFT-2 to DFT-2
P3-9 OF P3-7 and P3-6 P3-5 P3-10 P3-8 E-HEAT P3-3
P1-1 to P1-3
JMP17 JMP18

UNIT CONNECTION
UCB-REHEAT/HP-6 UCB-REHEAT/HP-1 UCB-REHEAT/HP-3
UCB-MAIN-3 UCB-MAIN-2 UCB-MAIN-6 UCB-MAIN-9
— —
UCB-MAIN-4 OFR — —
UCB-REHEAT/HP-2 UCB-REHEAT/HP-4
EHR EHR
—
— —

NOTE
Jumper from DFT2 Energize in COOL Energize in COOL

NOTE(S):
a. Jumper JMP17 to JMP18 for 1-3 seconds: Factory Test — The defrost interval timing is reduced by a factor of 0.1 seconds/minute based on the positions of DIP switches SW1 and SW2 (i.e., 90 minutes will be reduced to 9 seconds).
b. Jumper JMP17 to JMP18 for 5-20 seconds: Forced Defrost — Defrost runs for 30 seconds if DFT2 is open.

30

Reversing Valve Control
The DFB has two outputs for unit reversing valve control. Operation of the reversing valves is based on internal logic; this application does not use an “O” or “B” signal to determine reversing valve position. Reversing valves are energized during the cooling stages and the defrost cycle and de-energized during heating cycles. Once energized at the start of a cooling stage, the reversing valve will remain energized until the next heating cycle demand is received. Once de-energized at the start of a Heating cycle, the reversing valves will remain de-energized until the next cooling stage is initiated.

Compressor Control
The DFB receives inputs indicating Stage 1 Cooling, Stage 2 Cooling and Stage 1 Heating from the space thermostat or unit control system (RTU Open controller); it generates commands to start compressors with or without reversing valve operation to produce Stage 1 Cooling (one compressor runs), Stage 2 Cooling (both compressors run) or Stage 1 Heating (both compressors run).

Auxiliary (Electric) Heat Control
The 547K unit can be equipped with one or two auxiliary electric heaters, to provide a second stage of heating. The DFB will energize this Heating System for a Stage 2 Heating Command (heaters operate concurrently with compressor(s) in the Stage 1 Heating cycle), for an Emergency Heating sequence (compressors are off and only the electric heaters are energized) and also during the Defrost cycle (to eliminate a “cold blow” condition in the space).

Defrost
The defrost control mode is a time/temperature sequence. There are two time components: The continuous run period and the test/defrost cycle period. The temperature component is provided by Defrost Thermostat (DFT) mounted on the outdoor coil. The continuous run period is a fixed time period between the end of the last defrost cycle (or start of the current Heating cycle) during which no defrost will be permitted. This period can be set at 30, 60, 90 or 120 minutes by changing the positions of DIP switches SW1 and SW2 (see Fig. 40 and Table 13). The default run period is 30 minutes. Shorting the jumpers for a period of 5 to 20 seconds bypasses the remaining continuous run period and places the unit in a Forced Defrost mode. If the controlling DFT is closed when this mode is initiated, the unit will complete a normal defrost period that will terminate when the controlling DFT opens or the 10 minute defrost cycle limit is reached. If the controlling DFT is open when this mode is initiated, the Defrost cycle will run for 30 seconds. Both modes end at the end of the Defrost cycle.
Fig. 40 — DIP Switch Settings – Defrost Board

30 minutes (factory default)

Table 13 — DIP Switch Positions

1

2

1

2

·

1

1

·

0

·

·

0

60 minutes

90 minutes

1

2

·

·

120 minutes

3

1

·

On

0

Off

Fan Delay

31

ELECTRIC HEATERS (UNITS 547K*08-12)

IMPORTANT: The following instructions are for the 547K08-12 size units. Refer to your model number nomenclature to verify the correct size of your equipment. Instructions for size 14 start on page 34.
The 547K08-12 units can be equipped with field-installed accessory electric heaters. The heaters are modular in design, with heater frames holding open coil resistance wires strung through ceramic insulators and control contactor(s), using a combination of 24-v control side break/auto-reset or line-break/auto-reset limit switches and a pilot-circuit/manual reset limit switch to protect the unit against over-temperature situations. All 547K Model electric heaters are one module containing either one or two banks of electric heat coils.
Heater modules are installed in the compartment below the indoor (supply) fan outlet. Access is through the indoor access panel. Heater modules slide into the compartment on tracks along the bottom of the heater opening. (See Fig. 41-43.)

Heater Module
Fig. 43 — Typical Module Installation
Single Point Boxes and Supplementary Fuses
When the unit MOCP device value exceeds 60A, unit-mounted supplementary fuses are required for each heater circuit. These fuses are included in accessory single point boxes, with power distribution and fuse blocks. The single point box will be installed directly under the unit control box, just to the left of the partition separating the indoor section (with electric heaters) from the outdoor section. The single point box has a hinged access cover. (See Fig. 44.)
Control Wiring

Control Box Access Panel

Indoor Blower Access Panel

Fig. 41 — Typical Access Panel Location
Not all available heater modules can be used in every unit. Use only those heater modules that are UL listed for use in a specific size unit. Refer to the label on the unit cabinet regarding approved heaters.

Optional Factory-Installed Disconnect

Main Single

Control Point

Box

Box

Center Post

Vane Axial Indoor Fan System

Manual Reset Limit Switch

Control Wire Terminal Block

Heater Cover

Heater Mounting Bracket

Fig. 42 — Typical Component Location

Foam

Power Wiring

Heater Relay

Heater Mounting Screws

Fig. 44 — Typical Single Point Installation
On 547K units, all fuses are 60A. Single point boxes containing fuses for 208/230-v applications use UL Class RK5 250-v fuses (Bussmann FRNR 60 or Shawmut TR 60R). Single point boxes for 460-v and 575-v applications use UL Class T 600-v fuses (Bussmann JJS 60 or Shawmut A6T 60).
NOTE: All heaters are qualified for use with a 60A fuse, regardless of actual heater ampacity, so only 60A fuses are necessary.
Safety Devices
CRHEATER411A00 – CRHEATER428A00 electric heater applications use a combination of 24-v control side break/auto-reset, line-break/non-resettable “one shot” limit switches and a fan stator/manual reset limit switch to protect the unit against over-temperature situations.
Line-break/auto-reset limit switches, 24-v control side break/autoreset and line-break/non-resettable “one shot” limit switches are mounted on the base plate of each heater module. See Fig. 45. These are accessed through the indoor access panel. Remove the switch by removing two screws into the base plate and extracting the existing switch.
Fan stator/manual reset limit switch is located in the side plate of the indoor (supply) fan housing. (See Fig. 45.)

32

T
Stator Manual Reset Limit Switch

Control Side Automatic Reset Limit Switches

Line Break “One Shot” Limit Switches

Fig. 45 — Typical Location of Heater Limit Switches (3-phase heater shown)

Field Power Connections
Tap conductors must be installed between the base unit’s field power connection lugs and the single point box (with or without fuses). See Fig. 46. Refer to unit wiring schematic. Use copper wire only. For connection using the single point box without fuses, connect the field power supply conductors to the heater power leads and the field-supplied tap conductors inside the single point box. Use UL-approved pressure connectors (field-supplied) for these splice joints.

Low-Voltage Control Connections
Pull the low-voltage control leads from the heater module(s) — ORN, VIO and BRN — to the 4-pole terminal board TB4 located on the heater bulkhead to the left of heater 1. Connect the ORN lead to terminal TB4-1. Connect the VIO lead to terminal TB4-2. Connect the BRN lead to terminal TB4-3. (See Fig. 46.)

SEE NOTE 1
SEE NOTE 2 NOTE(S): 1. TB4 LOCATED IN HEAT SECTION. 2. TO CONVERT TO A SINGLE STAGE HEATER MOVE THE
VIOLET WIRE AT TB4 TO CONNECT WITH WHITE WIRE.
Fig. 46 — Accessory Electric Heater Control Connections
Control and Power Wiring Diagrams
To reference the wiring diagrams for the correct unit configuration, refer to the Wiring Diagram Table on page 87.

33

ELECTRIC HEATERS (UNIT 547K14)
IMPORTANT: The following instructions are for the 547K14 size units. Refer to your model number nomenclature to verify the correct size of your equipment. Instructions for sizes 8-12 start on page 32.

size unit. Refer to the label on the unit cabinet for the list of approved heaters.
Refer to the Small Roof Top Units Accessory Electric Heater and Single Point Box installation instructions for further details.

The 547K*14 units may be equipped with field-installed accessory electric heaters. The heaters are modular in design, with heater frames holding open coil resistance wires strung through ceramic insulators, line-break limit switches and a control contactor.
Heater modules are installed in the compartment below the indoor (supply) fan outlet. Access is through the electric heat access panel. (See Fig. 47-49.)
Not all available heater modules may be used in every unit. Use only those heater modules that are UL listed for use in a specific

Fig. 47 — Access Panel Location

Single Point Box

Center Post

Vane Axial Indoor Fan System

Control Box
Non-Fused Disconnect
Convenience Outlet

Manual Reset Limit Switch

• Factory-Installed Option.

Control Wire Terminal Block
Fig. 48 — Component Location

Heater (Cover Removed)

Heater Mounting Bracket

Heater Module
Fig. 49 — Heater Module Installation 34

Single Point Boxes and Supplementary Fuses
When the unit MOCP device value exceeds 60-A, unit-mounted supplementary fuses are required for each heater circuit. These fuses are included in accessory single point boxes, with power distribution and fuse blocks. The single point box will be installed directly under the unit control box, just to the left of the partition separating the indoor section (with electric heaters) from the outdoor section. The single point box has a hinged access cover. See Fig. 51. The single point box also includes a set of power taps and pigtails to complete the wiring between the single point box and the unit’s main control box terminals. Refer to the Small Roof Top Units Accessory Electric Heater and single point box installation instructions for details on tap connections.
All fuses on 547K units are 60-A. (Note that all heaters are qualified for use with a 60-A fuse, regardless of actual heater ampacity, so only 60-A fuses are necessary.)
Single Point Boxes without Fuses
Unit heater applications not requiring supplemental fuses require a special single point box without any fuses. The accessory single point boxes contain a set of power taps and pigtails to complete the wiring between the single point box and the unit’s main control box terminals. Refer to accessory heater and single point box installation instructions for details on tap connections.
Low-Voltage Control Connections
Pull the low-voltage control leads from the heater module — WHT, VIO and BRN to the 4-pole terminal board TB4 located on the heater bulkhead to the left of the Heater module. Connect the WHT lead from Heater circuit #1 to terminal TB4-1. For 2 stage heating, connect the VIO lead from Heater circuit #2 to terminal TB4-2. Connect the BRN lead(s) to terminal TB4-3. (See Fig. 50.)
Safety Devices
CRHEATER411A00 – CRHEATER428A00 electric heater applications use a combination of 24-v control side break/auto-reset, line-break/non-resettable “one shot” limit switches and a fan stator/manual reset limit switch to protect the unit against over-temperature situations.
Line-break/auto-reset limit switches, 24-v control side break/autoreset and line-break/non-resettable “one shot” limit switches are

mounted on the base plate of each heater module. See Fig. 48. These are accessed through the indoor access panel. Remove the switch by removing two screws into the base plate and extracting the existing switch. Fan stator/manual reset limit switch is located in the side plate of the indoor (supply) fan housing. (See Fig. 48.)
Fig. 50 — Accessory Electric Heater Control Connections
Control and Power Wiring Diagrams
To reference the wiring diagrams for the correct unit configuration, refer to the Wiring Diagram Table on page 87.

Fig. 51 — Typical Single Point Installation 35

SMOKE DETECTORS
Smoke detectors are available as factory-installed options on 547K models. Smoke detectors may be specified for supply air only, for return air without or with economizer, or in combination of supply air and return air. Return air smoke detectors are arranged for vertical return configurations only. All components necessary for operation are factory-provided and mounted. The unit is factory-configured for immediate smoke detector shutdown operation; additional wiring or modifications to unit terminal board may be necessary to complete the unit and smoke detector configuration to meet project requirements.
System
The smoke detector system consists of a four-wire controller and one or two sensors. Its primary function is to shut down the rooftop unit in order to prevent smoke from circulating throughout the building. It is not to be used as a life saving device.
Controller
The controller (see Fig. 52) includes a controller housing, a printed circuit board, and a clear plastic cover. The controller can be connected to one or two compatible duct smoke sensors. The clear plastic cover is secured to the housing with a single captive screw for easy access to the wiring terminals. The controller has three LEDs (for Power, Trouble and Alarm) and a manual test/reset button (on the cover face).
Duct Smoke Sensor Controller

Controller Housing and Electronics
Conduit Couplings (Supplied by Installer)
Fastener (x2)

Conduit Nuts (Supplied by Installer)
Conduit Support Plate Terminal Block Cover Cover Gasket (Ordering Option) Controller Cover

Alarm

Trouble Power

Test/Reset Switch

Fig. 52 — Controller Assembly
Smoke Detector Sensor
The smoke detector sensor (see Fig. 53) includes a plastic housing, a printed circuit board, a clear plastic cover, a sampling tube inlet and an exhaust tube. The sampling tube (when used) and exhaust tube are attached during installation. The sampling tube varies in length depending on the size of the rooftop unit. The clear plastic cover permits visual inspections without having to disassemble the sensor. The cover attaches to the sensor housing using four captive screws and forms an airtight chamber around the sensing electronics. Each sensor includes a harness with an RJ45 terminal for connecting to the controller. Each sensor has four LEDs (for Power, Trouble, Alarm and Dirty) and a manual test/reset button (on the left-side of the housing).

Duct Smoke Sensor

See Detail A

Exhaust Tube
Exhaust Gasket Sensor Housing and Electronics

Intake Gasket

TSD-CO2 (Ordering Option)
Plug

Sampling Tube

(Covered Separately)

Detail A

Coupling

Cover Gasket (Ordering Option)
Sensor Cover

Magnetic Test/Reset
Switch

Alarm Trouble

Power Dirty

Fig. 53 — Smoke Detector Sensor

Air is introduced to the duct smoke detector sensor’s sensing chamber through a sampling tube that extends into the HVAC duct and is directed back into the ventilation system through a (shorter) exhaust tube.
The difference in air pressure between the two tubes pulls the sampled air through the sensing chamber. When a sufficient amount of smoke is detected in the sensing chamber, the sensor signals an alarm state and the controller automatically takes the appropriate action to shut down fans and blowers, change over air handling systems, notify the fire alarm control panel, etc.
The sensor uses a process called differential sensing to prevent gradual environmental changes from triggering false alarms. A rapid change in environmental conditions, such as smoke from a fire, causes the sensor to signal an alarm state but dust and debris accumulated over time does not.
The difference in air pressure between the two tubes pulls the sampled air through the sensing chamber. When a sufficient amount of smoke is detected in the sensing chamber, the sensor signals an alarm state and the controller automatically takes the appropriate action to shut down fans and blowers, change over air handling systems, notify the fire alarm control panel, etc.
For installations using two sensors, the duct smoke detector does not differentiate which sensor signals an alarm or trouble condition.

Smoke Detector Locations

SUPPLY AIR
The supply air smoke detector sensor is located to the right of the unit’s indoor (supply) fan. See Fig. 54. Access is through the fan access panel. The sampling tube inlet extends through the fan deck (into a high pressure area). The controller is located on a bracket to the right of the return filter, accessed through the liftoff filter panel.

36

Supply Air Smoke Detector

RETURN AIR SMOKE DETECTOR SENSOR WITH
ECONOMIZER
The sampling tube is inserted through the side plates of the economizer housing, placing it across the return air opening on the unit basepan. See Fig. 56. The holes in the sampling tube face downward, into the return air stream. The sampling tube is connected using tubing to the return air sensor mounted on a bracket high on the partition between return filter and controller location. The sensor is shipped in a flat-mounting location. Installation requires the sensor be relocated to its operating location and the tubing to the sampling tube be connected. See installation steps below.

Fig. 54 — Typical Supply Air Smoke Detector Sensor Location
RETURN AIR SMOKE DETECTOR SENSOR WITHOUT ECONOMIZER The sampling tube is located across the return air opening on the unit basepan. See Fig. 55. The holes in the sampling tube face downward, into the return air stream. The sampling tube is connected through tubing to the return air sensor that is mounted on a bracket high on the partition between return filter and controller location. The sensor is shipped in a flat-mounting location. Installation requires that this sensor be relocated to its operating location and the tubing to the sampling tube be connected. See installation steps.
Return Air Smoke Detector (As Shipped)

Return Air Sampling Tube
Fig. 56 — Return Air Sampling Tube Location (View reoriented to show opposite side for clarity.)
Completing Installation of Return Air Smoke Detector
Use the following steps to complete the installation of the return air smoke detector. 1. Unscrew the two screws holding the return air sensor
detector plate. See Fig. 57. Save the screws.
Flexible Exhaust Tubes

Screws

Sample Tube

Fig. 55 — Typical Return Air Smoke Detector Location

Fig. 57 — Return Air Smoke Detector Shipping Position
2. Remove the return air smoke sensor module and its detector plate.
3. Rotate the detector plate so the sensor is facing outwards and the sampling tube connection is on the bottom. (See Fig. 58.)

37

Return Air Smoke Detector (Operating Position Shown)
Controller Module
Screws (2)
Sample Tube
Fig. 58 — Return Air Smoke Detector Operating Position
4. Screw the sensor and detector plate into its operating position using screws from Step 1. Ensure the sampling tube connection is on the bottom and the exhaust tube is on the top.

5. Connect the flexible tube on the sampling inlet to the sampling tube on the basepan.
6. For units with an economizer, the sampling tube is integrated into the economizer housing but connecting the flexible tubing to the sampling tube is the same.
FIOP Smoke Detector Wiring and Response
ALL UNITS
The FIOP smoke detector is configured to automatically shut down all unit operations when a smoke condition is detected. See Fig. 59, Smoke Detector Wiring.
HIGHLIGHT A
Smoke detector NC contact set will open on smoke alarm condition, de- energizing the ORN conductor.
HIGHLIGHT B
24-v power signal using the ORN lead is removed at the smoke detector input on UCB; all unit operations cease immediately.
ADDITIONAL APPLICATION DATA
Refer to the application data document “Factory Installed Smoke Detectors for Small and Medium Rooftop Units 2 to 25 Tons” for discussions on additional control features of these smoke detectors including multiple unit coordination.

NOTE: REMOVE DESIGNATED JUMPERS ON UCB WHEN ADDING SMOKE DETECTORS, OCCUPANCY AND REMOTE SHUTDOWN. Fig. 59 — Typical Smoke Detector System Wiring
38

SENSOR AND CONTROLLER TESTS
Sensor Alarm Test
The sensor alarm test checks a sensor’s ability to signal an alarm state. This test requires use of a field provided SD-MAG test magnet.
IMPORTANT: Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
This test places the duct detector into the alarm state. Unless part of the test, disconnect all auxiliary equipment from the controller before performing the test. If the duct detector is connected to a fire alarm system, notify the proper authorities before performing the test.
SENSOR ALARM TEST PROCEDURE
1. Hold the test magnet where indicated on the side of the sensor housing for seven seconds.
2. Verify that the sensor’s Alarm LED turns on. 3. Reset the sensor by holding the test magnet against the
sensor housing for two seconds. 4. Verify that the sensor’s Alarm LED turns off.
Controller Alarm Test
The controller alarm test checks the controller’s ability to initiate and indicate an alarm state.
CONTROLLER ALARM TEST PROCEDURE
1. Press the controller’s test/reset switch for seven seconds. 2. Verify that the controller’s Alarm LED turns on. 3. Reset the sensor by pressing the test/reset switch for two
seconds. 4. Verify that the controller’s Alarm LED turns off.
IMPORTANT: Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
This test places the duct detector into the alarm state. Unless part of the test, disconnect all auxiliary equipment from the controller before performing the test. If the duct detector is connected to a fire alarm system, notify the proper authorities before performing the test.
Dirty Controller Test
The dirty controller test checks the controller’s ability to initiate a dirty sensor test and indicate its results.
IMPORTANT: Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
Pressing the controller’s test/reset switch for longer than seven seconds will put the duct detector into the alarm state and activate all automatic alarm responses.

DIRTY CONTROLLER TEST PROCEDURE

1. Press the controller’s test/reset switch for two seconds. 2. Verify that the controller’s Trouble LED flashes.
Dirty Sensor Test
The dirty sensor test provides an indication of the sensor’s ability to compensate for gradual environmental changes. A sensor that can no longer compensate for environmental changes is considered 100% dirty and requires cleaning or replacing. A field provided SD-MAG test magnet must be used to initiate a sensor dirty test. The sensor’s Dirty LED indicates the results of the dirty test as shown in Table 14.

IMPORTANT: Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
Holding the test magnet against the sensor housing for more than seven seconds will put the duct detector into the alarm state and activate all automatic alarm responses.

Table 14 — Dirty LED Test

FLASHES 1 2 3 4

DESCRIPTION 0-25% dirty. (Typical of a newly installed detector)
25-50% dirty 51-75% dirty 76-99% dirty

DIRTY SENSOR TEST PROCEDURE
1. Hold the test magnet where indicated on the side of the sensor housing for two seconds.
2. Verify that the sensor’s Dirty LED flashes.

IMPORTANT: Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
Changing the dirty sensor test operation will put the detector into the alarm state and activate all automatic alarm responses. Before changing dirty sensor test operation, disconnect all auxiliary equipment from the controller and notify the proper authorities if connected to a fire alarm system.
Changing the Dirt Sensor Test
By default, sensor dirty test results are indicated by:
· The sensor’s Dirty LED flashing.
· The controller’s Trouble LED flashing.
· The controller’s supervision relay contacts toggle.
The operation of a sensor’s dirty test can be changed so that the controller’s supervision relay is not used to indicate test results. When two detectors are connected to a controller, sensor dirty test operation on both sensors must be configured to operate in the same manner.
TO CONFIGURE THE DIRTY SENSOR TEST OPERATION
1. Hold the test magnet where indicated on the side of the sensor housing until the sensor’s Alarm LED turns on and its Dirty LED flashes twice (approximately 60 seconds).
2. Reset the sensor by removing the test magnet then holding it against the sensor housing again until the sensor’s Alarm LED turns off (approximately 2 seconds).
Remote Station Test
The remote station alarm test checks a test/reset station’s ability to initiate and indicate an alarm state.

IMPORTANT: Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
This test places the duct detector into the alarm state. Unless part of the test, disconnect all auxiliary equipment from the controller before performing the test. If the duct detector is connected to a fire alarm system, notify the proper authorities before performing the test.
SD-TRM4 Remote Alarm Test Procedure
1. Hold the test magnet to the target area for seven seconds. 2. Verify that the test/reset station’s Alarm LED turns on. 3. Reset the sensor by holding the test magnet to the target
area for 2 seconds. 4. Verify that the test/reset station’s Alarm LED turns off.

39

Remote Test/Reset Station Dirty Sensor Test
The test/reset station dirty sensor test checks the test/reset station’s ability to initiate a sensor dirty test and indicate the results. It must be wired to the controller as shown in Fig. 60 and configured to operate the controller’s supervision relay. For more information, see “Dirty Sensor Test” on page 39.

12

Smoke Detector

1

Controller

TB3

1

– Auxiliary

2

+ Equipment

3

14

Supervision Relay Contacts [3]

13

19

Wire must be

added by installer

15

2

18 VDC (-)

SD-TRM4
Trouble 5
Power 4
Alarm 1
Reset/Test 3

18 VDC (-)

20

2

Fig. 60 — Remote Test/Reset Station Connections

IMPORTANT: Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
If the test/reset station’s key switch is left in the RESET/TEST position for longer than seven seconds, the detector will automatically go into the alarm state and activate all automatic alarm responses.

IMPORTANT: Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
Holding the test magnet to the target area for longer than seven seconds will put the detector into the alarm state and activate all automatic alarm responses.
Dirty Sensor Test Using an SD-TRM4
1. Hold the test magnet where indicated on the side of the sensor housing for two seconds.
2. Verify that the test/reset station’s Trouble LED flashes.
Detector Cleaning
CLEANING THE SMOKE DETECTOR
Clean the duct smoke sensor when the Dirty LED is flashing continuously or sooner, if conditions warrant.
IMPORTANT: OPERATIONAL TEST ALERT Failure to follow this ALERT can result in an unnecessary evacuation of the facility.
If the smoke detector is connected to a fire alarm system, first notify the proper authorities that the detector is undergoing maintenance then disable the relevant circuit to avoid generating a false alarm.

1. Disconnect power from the duct detector then remove the sensor’s cover. (See Fig. 61.)

Sampling Tube

HVAC Duct
Sensor Housing

Airflow

Optic Plate
Retainer Clip
Optic Housing

Fig. 61 — Sensor Cleaning Diagram
2. Using a vacuum cleaner, clean compressed air, or a soft bristle brush, remove loose dirt and debris from inside the sensor housing and cover. Use isopropyl alcohol and a lint-free cloth to remove dirt and other contaminants from the gasket on the sensor’s cover.
3. Squeeze the retainer clips on both sides of the optic housing. 4. Lift the housing away from the printed circuit board. 5. Gently remove dirt and debris from around the optic plate
and inside the optic housing. 6. Replace the optic housing and sensor cover. 7. Connect power to the duct detector then perform a sensor
alarm test.
Indicators
NORMAL STATE
The smoke detector operates in the normal state in the absence of any trouble conditions and when its sensing chamber is free of smoke. In the normal state, the Power LED on both the sensor and the controller are on and all other LEDs are off.
ALARM STATE
The smoke detector enters the alarm state when the amount of smoke particulate in the sensor’s sensing chamber exceeds the alarm threshold value. (See Table 15.) Upon entering the alarm state:
· The sensor’s Alarm LED and the controller’s Alarm LED turn on.
· The contacts on the controller’s two auxiliary relays switch positions.
· The contacts on the controller’s alarm initiation relay close.
· The controller’s remote alarm LED output is activated (turned on).
· The controller’s high impedance multiple fan shutdown control line is pulled to ground

Table 15 — Detector Indicators

CONTROL OR INDICATOR
Magnetic test/ reset switch Alarm LED Trouble LED
Dirty LED
Power LED

DESCRIPTION
Resets the sensor when it is in the alarm or trouble state. Activates or tests the sensor when it is in the normal state.
Indicates the sensor is in the alarm state.
Indicates the sensor is in the trouble state.
Indicates the amount of environmental compensation used by the sensor (flashing continuously = 100%)
Indicates the sensor is energized.

40

TROUBLE STATE
The SuperDuctTM duct smoke detector enters the trouble state under the following conditions:
· A sensor’s cover is removed and 20 minutes pass before it is properly secured.
· A sensor’s environmental compensation limit is reached (100% dirty).
· A wiring fault between a sensor and the controller is detected.
· An internal sensor fault is detected
Upon entering the trouble state:
· The contacts on the controller’s supervisory relay switch positions. (See Fig. 62.)
· If a sensor trouble, the sensor’s Trouble LED and the controller’s Trouble LED turn on.
· If 100% dirty, the sensor’s Dirty LED turns on and the controller’s Trouble LED flashes continuously.
· If a wiring fault between a sensor and the controller, the controller’s Trouble LED turns on but not the sensor’s.

Alarm

POWER TROUBLE ALARM RESET

Trouble Power

Test/Reset Switch

Fig. 62 — Controller Assembly
NOTE: All troubles are latched by the duct smoke detector. The trouble condition must be cleared and then the duct smoke detector must be reset in order to restore it to the normal state.
RESETTING ALARM AND TROUBLE CONDITION TRIPS
Manual reset is required to restore smoke detector systems to Normal operation. For installations using two sensors, the duct smoke detector does not differentiate which sensor signals an alarm or trouble condition. Check each sensor for Alarm or Trouble status (indicated by LED). Clear the condition that has generated the trip at this sensor. Then reset the sensor by pressing and holding the reset button (on the side) for 2 seconds. Verify that the sensor’s Alarm and Trouble LEDs are now off. At the controller, clear its Alarm or Trouble state by pressing and holding the manual reset button (on the front cover) for 2 seconds. Verify that the controller’s Alarm and Trouble LEDs are now off. Replace all panels.
Troubleshooting
CONTROLLER’S TROUBLE LED IS ON
1. Check the Trouble LED on each sensor connected to the controller. If a sensor’s Trouble LED is on, determine the cause and make the necessary repairs.
2. Check the wiring between the sensor and the controller. If wiring is loose or missing, repair or replace as required.

CONTROLLER’S TROUBLE LED IS FLASHING
1. One or both of the sensors is 100% dirty. 2. Determine which Dirty LED is flashing then clean that sensor
assembly as described in the detector cleaning section.
SENSOR’S TROUBLE LED IS ON
1. Check the sensor’s Dirty LED. If it is flashing, the sensor is dirty and must be cleaned.
2. Check the sensor’s cover. If it is loose or missing, secure the cover to the sensor housing.
3. Replace sensor assembly.
SENSOR’S POWER LED IS OFF
1. Check the controller’s Power LED. If it is off, determine why the controller does not have power and make the necessary repairs.
2. Check the wiring between the sensor and the controller. If wiring is loose or missing, repair or replace as required.
CONTROLLER’S POWER LED IS OFF
1. Make sure the circuit supplying power to the controller is operational. If not, make sure JP2 and JP3 are set correctly on the controller before applying power.
2. Verify that power is applied to the controller’s supply input terminals. If power is not present, replace or repair wiring as required.
REMOTE TEST/RESET STATION’S TROUBLE LED DOES NOT FLASH WHEN PERFORMING A DIRTY TEST, BUT THE CONTROLLER’S TROUBLE LED DOES
1. Verify that the remote test/station is wired as shown in Fig. 60. Repair or replace loose or missing wiring.
2. Configure the sensor dirty test to activate the controller’s supervision relay. See “Dirty Sensor Test” on page 39.
SENSOR’S TROUBLE LED IS ON, BUT THE CONTROLLER’S TROUBLE LED IS OFF
Remove JP1 on the controller.
PROTECTIVE DEVICES
Compressor Protection
OVERCURRENT
The compressor has internal line-break motor protection.
OVERTEMPERATURE
The compressor has an internal protector to protect it against excessively high discharge gas temperatures.
MIXED TEMPERATURE SENSOR
The Mixed Temperature Sensor (MTS) is installed on the return side of the unit filter bracket. See Fig. 63. The switch opens to prevent mechanical cooling operation at low return temperatures (below 60°F [±1.5°F]). When the switch is open, compressor operation is disabled but indoor fan and economizer operation may continue. The switch closes when return air warms to 65°F (±1.5°F) allowing compressor operation to resume.

41

Mixed Temperature Sensor (MTS)
Evaporator Filter Track
Fig. 63 — Mixed Temperature Sensor Location HIGH PRESSURE SWITCH The system is provided with a high pressure switch mounted on the discharge line. The switch is stem-mounted and brazed into the discharge tube. Trip setting is 630 psig ± 10 psig (4344 ± 69 kPa) when hot. Reset is automatic at 505 psig (3482 kPa).

LOW PRESSURE SWITCH
The system is protected against a loss of charge and low evaporator coil loading condition by a low pressure switch located on the suction line near the compressor. The switch is stem-mounted. Trip setting is 54 psig ± 5 psig (372 ± 34 kPa). Reset is automatic at 117 ± 5 psig (807 ± 34 kPa).
EVAPORATOR FREEZE PROTECTION
The system is protected against evaporator coil frosting and low temperature conditions by a temperature switch mounted on the evaporator coil hairpin. Trip setting is 30°F ± 5°F (­1°C ± 3°C). Reset is automatic at 45°F (7°C).
SUPPLY (INDOOR) FAN MOTOR PROTECTION
Disconnect and lockout power when servicing fan motor.
Supply fan motors contain a safety relay that opens in the event of a fault. This relay protects the motor against certain supply power conditions as well as over-temperature and over-current protection. If the relay is open it will remove 24V to R on the UCB and will also prevent cooling/heating operation to protect the unit until the fault condition clears. Do not bypass this switch to correct trouble. Determine the cause and correct it. (See Table 16.)
CONDENSER FAN MOTOR PROTECTION
The condenser fan motor is internally protected against over-temperature.
Relief Device
A soft solder joint at the suction service access port provides pressure relief under abnormal temperature and pressure conditions (i.e., fire in building). Protect this joint during brazing operations near this joint.
Control Circuit, 24-V
The control circuit is protected against over-current conditions by a circuit breaker mounted on control transformer TRAN. Reset is manual.

DESCRIPTION No Error NTC Over-Temperature Protection Phase Fault
Over Current Protection
Locked Rotor Protection, Start-up Locked Rotor Protection, Running Over/Under Voltage Current Sampling Error Microelectronic (MCU) Fault Microelectronic (MCU) Fault

Table 16 — Supply Fan Motor Logic and Safety Relays
START DELAY —
Automatic Reset ­ Motor starts 12 seconds after the temperature falls below reset limit. Automatic Reset ­ Motor to start after 3 phases present. Automatic Reset ­ If motor over-current protection trips, motor restarts after 20 seconds off time. If over-current is detected 3 times consecutively, the motor is off for 3 minutes and restarts. Cycle starts again after 20 seconds. Automatic Reset ­ If motor detects locked rotor, it attempts to restart after 5 seconds. If motor detects 3 consecutive faults, the motor waits 3 minutes and restarts. Cycle starts again after 20 seconds. Automatic Reset ­ Motor restarts as soon as input voltage is back within ±10%. Manual Reset ­ Power off and wait 2 minutes and restart motor. Automatic Reset ­ Motor restarts 3 minutes after fault clears. Manual Reset ­ Power off and wait 2 minutes and restart motor.

42

ECONOMIZER SYSTEMS
The unit may be equipped with a factory-installed or accessory (field- installed) economizer system. Three types are available: two with logic control systems (EconoMi$er®X and EconoMi$er IV) and one without a control system (EconoMi$er2). See Fig. 64-66 for component locations on each type.
Economizers use direct-drive damper actuators.

IMPORTANT: Any economizer that meets the economizer requirements as laid out in California’s Title 24 mandatory section 120.2 (fault detection and diagnostics) and/or prescriptive section 140.4 (life-cycle tests, damper leakage, 5 year warranty, sensor accuracy, etc), will have a label on the economizer. Any economizer without this label does not meet California’s Title 24. The five year limited parts warranty referred to in section 140.4 only applies to factory installed economizers. Please refer to your economizer on your unit.

Outside Air Temperature Sensor

EconoMi$er X Harness

Outside Air Temperature Sensor
Low Ambient Sensor

EconoMi$er IV Controller (W7212)

Fig. 65 — EconoMi$er IV Component Locations

Outside Air Temperature Sensor

EconoMi$er2 Plug

HH79AH001

Honeywell

Fig. 64 — EconoMi$er X Component Locations

Fig. 66 — EconoMi$er2 Component Locations
EconoMi$er2

IMPORTANT: The optional EconoMi$er®2 does not include a controller. The EconoMi$er2 is operated by a 4 mA to 20 mA signal from an existing field- supplied controller. See Fig. 67 for wiring information.

Run Direct Drive
Actuator

BLACK 4 Transformer Ground
3

500 OHM Resistor
ORANGE

OAT Sensor

VIOLET PINK

5 BLUE
2
8 6 7 RED 1 10

Actuator Feedback (2-10VDC)

YELLOW

11

4-20mA Signal

9 WHITE
12

Actuator Control (4-20mA)

EconoMi$er 2 Plug

Fig. 67 — EconoMi$er2 with 4 mA to 20 mA Control Wiring

43

EconoMi$er IV (Field-Installed Accessory)
IMPORTANT: EconoMi$er IV is only available as a fieldinstalled option for 547K*08-14 rooftop units. ECONOMI$ER IV STANDARD SENSORS Troubleshooting instructions are enclosed. A functional view of the EconoMi$er® IV accessory is shown in Fig. 68. Typical settings, sensor ranges, and jumper positions are also shown. An EconoMi$er IV simulator program is available to help with EconoMi$er IV training and troubleshooting. See Fig. 69 and Table 17 for further details.
Fig. 68 — EconoMi$er IV Functional View

LEGEND

DCV IAQ LA OAT POT RAT

— Demand Controlled Ventilation — Indoor Air Quality — Low Ambient Lockout Device — Outdoor-Air Temperature — Potentiometer — Return-Air Temperature

Fig. 69 — Typical EconoMi$er IV (W7212 Controller) Wiring

44

Demand Controlled Ventilation
(DCV)
Below set (DCV LED
Off)
Above set (DCV LED
On)

Table 17 — EconoMi$er IV Input/Output Logic

INPUTS

OUTPUTS

Enthalpya

Compressor

N Terminalb

Outdoor

Y1 Y2

Return

Stage 1 Stage 2

Occupied

Unoccupied

High

On On

On

(Free Cooling

Low On Off

On

LED Off)

Off Off

Off

Low

On On

On

(Free Cooling

High On Off

Off

LED On)

Off Off

Off

High

On On

On

(Free Cooling

Low On Off

On

LED Off)

Off Off

Off

Low

On On

On

(Free Cooling

High On Off

Off

LED On)

Off Off

Off

On

Off

Minimum position

Closed

Off

Off

Modulatingc (between

Modulatingc (between

Off

min. position and full-open)

closed and full-open)

Off

Minimum position

Closed

On

Off

Modulatingd (between min.

Modulatingd (between

position and DCV maximum) closed and DCV maximum)

Off

Off

Off

Modulatinge

Modulatingf

Off

NOTE(S):
a. For single enthalpy control, the module compares outdoor enthalpy to the ABCD set point. b. Power at N terminal determines Occupied/Unoccupied setting: 24 vac (Occupied), no power (Unoccupied). c. Modulation is based on the supply-air sensor signal. d. Modulation is based on the DCV signal. e. Modulation is based on the greater of DCV and supply-air sensor signals, between minimum position and either maximum position (DCV) or fully open (supply-air signal). f. Modulation is based on the greater of DCV and supply- air sensor signals, between closed and either maximum position (DCV) or fully open (supply-air signal).

Outdoor Air Temperature (OAT) Sensor
The outdoor air temperature sensor (HH57AC074) is a 10 to 20 mA device used to measure the outdoor-air temperature. The outdoor-air temperature is used to determine when the EconoMi$er IV can be used for free cooling. The sensor has 8 selectable temperature changeover setpoints, ranging from 48°F to 78°F. The temperature changeover is set using the 3 dip switches on the sensor. (See Fig. 70.)

Supply Air Temperature (SAT) Sensor
The supply air temperature sensor is a field-installed 3 K thermistor located on the fan deck. See Fig. 71. This sensor is factory installed. The operating range of temperature measurement is 0°F to 158°F (­18°C to 70°C). See Table 18 on page 46 for sensor temperature/resistance values.

Fig. 70 — C7660 Temperature Sensor

Supply Air Temperature (SAT) Sensor
Fig. 71 — Supply Air Temperature Sensor Location The temperature sensor looks like an eyelet terminal with wires running to it. The sensor is located in the “crimp end” and is sealed from moisture.

45

Outdoor Air Lockout Sensor
The EconoMi$er IV is equipped with an ambient temperature lockout switch located in the outdoor airstream which is used to lock out the compressors below a 42°F (6°C) ambient temperature. (See Fig. 65 on page 43.)

Table 18 — Supply Air Sensor Temperature/Resistance Values

TEMPERATURE (F) ­58

RESISTANCE (ohms) 220,250

­40

100,000

­22

53,010

­4

29,091

14

16,500

32

9,795

50

5,970

68

3,747

77

3,000

86

2,416

104

1,597

122

1,080

140

746

158

525

176

376

185

321

194

274

212

203

230

153

248

116

257

102

266

89

284

70

302

55

ECONOMI$ER IV CONTROL MODES

Determine the EconoMi$er IV control mode before set up of the control. Some modes of operation may require different sensors. The EconoMi$er IV accessory is supplied from the factory with a supply-air temperature sensor and an outdoor-air temperature sensor. This allows for operation of the EconoMi$er IV with outdoor air dry bulb changeover control. Additional accessories can be added to allow for different types of changeover control and operation of the EconoMi$er IV and unit.

Outdoor Dry Bulb Changeover

The standard controller is shipped from the factory configured for outdoor dry bulb changeover control. For this control mode, the outdoor temperature is compared to a selectable set point on the OAT sensor. If the outdoor air temperature is above the set point, the EconoMi$er IV will adjust the outdoor air dampers to minimum position. If the outdoor air temperature is below the set point, the position of the outdoor air dampers will be controlled to provide free cooling using outdoor air. When in this mode, the Free Cool LED next to the outdoor enthalpy set point (ABCD) potentiometer will be on. The changeover temperature set point is controlled by the dip switches on the sensor. See Fig. 72 for the switch positions corresponding to the temperature changeover values. The ABCD potentiometer on the controller should be turned fully clockwise (CW) to the “D” position. See Fig. 73-75 for damper leakage.

Outdoor Enthalpy Changeover
For enthalpy control, accessory enthalpy sensor (P/N: HH57AC078) is required. Replace the standard outdoor dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. See Fig. 76. When the outdoor air enthalpy rises above the outdoor enthalpy changeover set point, the outdoor-air damper moves to its minimum position. The outdoor enthalpy changeover set point is set with the outdoor enthalpy set point potentiometer on the EconoMi$er® IV controller. The set points are A, B, C, and D. See Fig. 77 and 78. The factoryinstalled 620-ohm jumper must be in place across terminals SR and SR+ on the EconoMi$er IV controller.

DIP Switch Position
ON OFF
123 ON OFF
123 ON OFF
123 ON OFF
123 ON OFF
123 ON OFF
123 ON OFF
123 ON OFF
123

Changeover Temperature
48°F 53°F 55°F 58°F 63°F 68°F 73°F 78°F

Fig. 72 — Outdoor Air Temperature Changeover Set Points
Differential Enthalpy Control
For differential enthalpy control, the EconoMi$er IV controller uses two enthalpy sensors (P/N: HH57AC078 and CRENTDIF004A00), one in the outside air and one in the return air duct. The EconoMi$er IV controller compares the outdoor air enthalpy to the return air enthalpy to determine EconoMi$er IV use. The controller selects the lower enthalpy air (return or outdoor) for cooling. For example, when the outdoor air has a lower enthalpy than the return air, the EconoMi$er IV opens to bring in outdoor air for free cooling.
Replace the standard outside air dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location. See Fig. 65 on page 43. Mount the return air enthalpy sensor in the return air duct. See Fig. 76. Wiring is provided in the EconoMi$er IV wiring harness. See Fig. 69 on page 44. The outdoor enthalpy changeover set point is set with the outdoor enthalpy set point potentiometer on the EconoMi$er IV controller. When using this mode of changeover control, turn the enthalpy set point potentiometer fully clockwise to the “D” setting. (See Fig. 77 and 78.)

46

Relief Flow (cfm)

Horizontal Economizer Barometric Relief

2500

Horizontal Economizer Barometric Relief Flow

2000

1500

1000

500

0

0.00

0.05

0.10

0.15

0.20

0.25

0.30

Return Duct Static Pressure (in. wg)

Relief Flow (cfm)

Vertical Economizer Barometric Relief

2500

Vertical Economizer Barometric Relief Flow

2000

1500

1000

500

0

0.00

0.05

0.10

0.15

0.20

0.25

0.30

Return Duct Static Pressure (in. wg)

Horizontal Economizer Damper Leakage

Horizontal Damper Leakage 30

25

20

15

10

5

0

0.00

0.10

0.20

0.30

0.40

0.50

0.60

Static Pressure Delta (in. wg)

Leakage Across Damper (cfm)

Vertical Economizer Damper Leakage

Vertical Damper Leakage

30

25

20

15

10

5

0

0.00

0.10

0.20

0.30

0.40

0.50

0.60

Static Pressure Delta (in. wg)

Fig. 73 — Economizer Barometric Relief and Damper Leakage — 7.5 to 10 Ton Units

Leakage Across Damper (cfm)

47

Relief Flow (cfm)

Leakage Across Damper (cfm)

Horizontal Economizer Barometric Relief

2500

Horizontal Economizer Barometric Relief Flow

2000

1500

1000

500

0

0.00

0.05

0.10

0.15

0.20

0.25

0.30

Return Duct Static Pressure (in. wg)

Relief Flow (cfm)

Vertical Economizer Barometric Relief

2500

Vertical Economizer Barometric Relief Flow

2000

1500

1000

500

0

0.00

0.05

0.10

0.15

0.20

0.25

0.30

Return Duct Static Pressure (in. wg)

Horizontal Economizer Damper Leakage

Vertical Economizer Damper Leakage

Horizontal Damper Leakage 250

200

150

100

50

0

0.00

0.10

0.20

0.30

0.40

0.50

0.60

Static Pressure Delta (in. wg)

Leakage Across Damper (cfm)

Vertical Damper Leakage

350

300

250

200

150

100

50

0

0.00

0.10

0.20

0.30

0.40

0.50

0.60

Static Pressure Delta (in. wg)

Fig. 74 — Economizer Barometric Relief and Damper Leakage — 12.5 Ton Units

7.5 to 10 Ton Units

0.45 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00
0

Economizer Pressure Drop, 7.5 to 10 Ton Units

1000

2000

3000

4000

Return Duct Air Flow (cfm)

5000

6000

Vertical Economizer

Horizontal Economizer

Static Pressure Drop (in. wg)

12.5 Ton Units

0.20 0.18 0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00
0

Economizer Pressure Drop, 12.5 Ton Units

1000 2000 3000 4000 Return Duct Air Flow (cfm)

5000

6000

7000

Vertical Economizer

Horizontal Economizer

Fig. 75 — Economizer Pressure Drop

Static Pressure Drop (in. wg)

48

EconoMi$er IV

EconoMi$er IV Controller

Grommet

Return Air Sensor
Return Duct (Field-Provided)
Fig. 76 — Return Air Temperature or Enthalpy Sensor Mounting Location

N1 N
P1 P
T1 T
AQ1 AQ
SO+ SO
SR+ SR

2V EXH

EXH Set
10V

Min Pos
Open

DCV Max
2V 10V

DCV
2V Free Cool
B

DCV Set
10V
C

AD

TR TR1

24 Va c HOT

24 Vac COM
_

1

2

5

3

4

EF

EF1

Fig. 77 — EconoMi$er IV W7212 Control

CONTROL CONTROL POINT CURVE APPROX. °F (°C) AT 50% RH

A

73 (23)

B

70 (21)

C

67 (19)

D

63 (17)

P 3O6UND38DRY

AIR

4 0

4 2 4 4 46

85 90 95 100 105 110 (29) (32) (35) (38) (41) (43)
80 (27)
75 (24)

RELATIVE HUMIDITY (%)

PER 3 4

BTU 3 2

E 2N8THALPY 3 0

2 2

2 0

2 4

2 6

70 (21)
65 (18)
60 (16)
A 55 (13) B 50 (10) C
45 D (7) 40 (4) 35 (2)

100 90 80 70 60

50

40

30

20 10

1 8

1 6

1 4

1 2

DC B A

HIGH LIMIT CURVE

35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 (2) (4) (7) (10) (13) (16) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43)
APPROXIMATE DRY BULB TEMPERATURE °F (°C)

Fig. 78 — Enthalpy Changeover Set Points
Indoor Air Quality (IAQ) Sensor Input
The IAQ input can be used for demand controlled ventilation control based on the level of CO2 measured in the space or return air duct.
Mount the accessory IAQ sensor according to manufacturer specifications. The IAQ sensor should be wired to the AQ and AQ1 terminals of the controller. Adjust the DCV potentiometers to correspond to the DCV voltage output of the indoor air quality sensor at the user-determined set point. (See Fig. 79.)
If a separate field-supplied transformer is used to power the IAQ sensor, the sensor must not be grounded or the EconoMi$er® IV control board will be damaged.
When using demand controlled ventilation, the minimum damper position represents the minimum ventilation position for VOC (volatile organic compounds) ventilation requirements. The maximum demand ventilation position is used for fully occupied ventilation.
When demand controlled ventilation is not being used, the minimum position potentiometer should be used to set the occupied ventilation position. The maximum demand ventilation position should be turned fully clockwise.
CO Sensor Max Range Setting
6000

Range Configuration (ppm)

5000

4000 3000 2000

800 ppm 900 ppm 1000 ppm 1100 ppm

1000

0

2

3

4

5

6

7

8

Damper Voltage for Maximum Ventilation Rate

Fig. 79 — CO2 Sensor Maximum Range Settings

49

Exhaust Set Point Adjustment
The exhaust set point will determine when the exhaust fan runs based on damper position (if accessory power exhaust is installed). The set point is modified with the Exhaust Fan set point (EXH SET) potentiometer. See Fig. 77. The set point represents the damper position above which the exhaust fans will be turned on. When there is a call for exhaust, the EconoMi$er IV controller provides a 45 ± 15 second delay before exhaust fan activation to allow the dampers to open. This delay allows the damper to reach the appropriate position to avoid unnecessary fan overload.

Minimum Position Control
There is a minimum damper position potentiometer on the EconoMi$er IV controller. See Fig. 77. The minimum damper position maintains the minimum airflow into the building during the occupied period.
When using demand controlled ventilation, the minimum damper position represents the minimum ventilation position for Volatile Organic Compound (VOC) ventilation requirements. The maximum demand ventilation position is used for fully occupied ventilation.
When demand controlled ventilation is not being used, the minimum position potentiometer should be used to set the occupied ventilation position. The maximum demand ventilation position should be turned fully clockwise.
Adjust the minimum position potentiometer to allow the minimum amount of outdoor air, as required by local codes, to enter the building. Make minimum position adjustments with at least 10°F temperature difference between the outdoor and return-air temperatures.
To determine the minimum position setting, perform the following procedure:
1. Calculate the appropriate mixed air temperature using the following formula:

OA

RA

(TO x

100

)

(T
R

x

100

) = TM

TO = Outdoor-Air Temperature

OA = Percent of Outdoor Air

TR = Return-Air Temperature

RA = Percent of Return Air

TM = Mixed-Air Temperature

As an example, if local codes require 10% outdoor air during occupied conditions, outdoor-air temperature is 60°F, and return-air temperature is 75°F.

(60 x 0.10) + (75 x 0.90) = 73.5°F

2. Disconnect the supply air sensor from terminals T and T1. 3. Ensure that the factory-installed jumper is in place across
terminals P and P1. If remote damper positioning is being used, make sure that the terminals are wired according to Fig. 70 and that the minimum position potentiometer is turned fully clockwise. 4. Connect 24 vac across terminals TR and TR1. 5. Carefully adjust the minimum position potentiometer until the measured mixed air temperature matches the calculated value. 6. Reconnect the supply air sensor to terminals T and T1.
Remote control of the EconoMi$er IV damper is desirable when requiring additional temporary ventilation. If a field-supplied remote potentiometer (Honeywell P/N: S963B1128) is wired to the EconoMi$er IV controller, the minimum position of the damper can be controlled from a remote location.
To control the minimum damper position remotely, remove the factory-installed jumper on the P and P1 terminals on the EconoMi$er IV controller. Wire the field-supplied potentiometer to the P and P1 terminals on the EconoMi$er® IV controller. (See Fig. 77.)

Damper Movement
Damper movement from full open to full closed (or vice versa) takes 2-1/2 minutes.
Thermostats
The EconoMi$er IV control works with conventional thermostats that have a Y1 (cool stage 1), Y2 (cool stage 2), W1 (heat stage 1), W2 (heat stage 2), and G (fan). The EconoMi$er IV control does not support space temperature sensors. Connections are made at the thermostat terminal connection board located in the main control box.
Occupancy Control
The factory default configuration for the EconoMi$er IV control is occupied mode. Occupied status is provided by the black jumper from terminal TR to terminal N. When unoccupied mode is desired, install a field-supplied timeclock function in place of the jumper between TR and N. When the timeclock contacts are closed, the EconoMi$er IV control will be in occupied mode. When the timeclock contacts are open (removing the 24-v signal from terminal N), the EconoMi$er IV will be in unoccupied mode.
Demand Controlled Ventilation (DCV)
When using the EconoMi$er IV for demand controlled ventilation, there are some equipment selection criteria which should be considered. When selecting the heat capacity and cool capacity of the equipment, the maximum ventilation rate must be evaluated for design conditions. The maximum damper position must be calculated to provide the desired fresh air.
Typically the maximum ventilation rate will be about 5 to 10% more than the typical cfm required per person, using normal outside air design criteria.
A proportional anticipatory strategy should be taken with the following conditions: a zone with a large area, varied occupancy, and equipment that cannot exceed the required ventilation rate at design conditions. Exceeding the required ventilation rate means the equipment can condition air at a maximum ventilation rate that is greater than the required ventilation rate for maximum occupancy. A proportional-anticipatory strategy will cause the fresh air supplied to increase as the room CO2 level increases even though the CO2 set point has not been reached. By the time the CO2 level reaches the set point, the damper will be at maximum ventilation and should maintain the set point.
In order to have the CO2 sensor control the economizer damper in this manner, first determine the damper voltage output for minimum or base ventilation. Base ventilation is the ventilation required to remove contaminants during unoccupied periods. The following equation may be used to determine the percent of outside air entering the building for a given damper position. For best results, there should be at least a 10 degree difference in outside and return-air temperatures.

OA

RA

(TO x

100

)

(T
R

x

100

) = TM

TO = Outdoor-Air Temperature

OA = Percent of Outdoor Air

TR = Return-Air Temperature

RA = Percent of Return Air

TM = Mixed-Air Temperature

Once base ventilation has been determined, set the minimum damper position potentiometer to the correct position.

The same equation can be used to determine the occupied or maximum ventilation rate to the building. For example, an output of 3.6 volts to the actuator provides a base ventilation rate of 5% and an output of 6.7 volts provides the maximum ventilation rate of 20% (or base plus 15 cfm per person). Use Fig. 79 to determine the maximum setting of the CO2 sensor. For example, an 1100 ppm set point relates to a 15 cfm per person design. Use the 1100 ppm curve on Fig. 79 to find the point when the CO2 sensor

50

output will be 6.7 volts. Line up the point on the graph with the left side of the chart to determine that the range configuration for the CO2 sensor should be 1800 ppm. The EconoMi$er IV controller will output the 6.7 volts from the CO2 sensor to the actuator when the CO2 concentration in the space is at 1100 ppm. The DCV set point may be left at 2 volts since the CO2 sensor voltage will be ignored by the EconoMi$er IV controller until it rises above the 3.6 volt setting of the minimum position potentiometer.
Once the fully occupied damper position has been determined, set the maximum damper demand controlled ventilation potentiometer to this position. Do not set to the maximum position as this can result in over-ventilation to the space and potential high humidity levels.
CO2 Sensor Configuration
The CO2 sensor has preset standard voltage settings that can be selected anytime after the sensor is powered up.
Use setting 1 or 2 for Bryant equipment.
1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.
2. Press Mode twice. The STDSET Menu will appear. 3. Use the Up/Down button to select the preset number. 4. Press Enter to lock in the selection. 5. Press Mode to exit and resume normal operation.
The custom settings of the CO2 sensor can be changed anytime after the sensor is energized. Follow the steps below to change the non-standard settings:
1. Press Clear and Mode buttons. Hold at least 5 seconds until the sensor enters the Edit mode.
2. Press Mode twice. The STDSET Menu will appear. 3. Use the Up/Down button to toggle to the NONSTD menu
and press Enter. 4. Use the Up/Down button to toggle through each of the
nine variables, starting with Altitude, until the desired setting is reached. 5. Press Mode to move through the variables. 6. Press Enter to lock in the selection, then press Mode to continue to the next variable.
Dehumidification of Fresh Air with DCV (Demand Controlled Ventilation) Control
If normal rooftop heating and cooling operation is not adequate for the outdoor humidity level, an energy recovery unit and/or a dehumidification option should be considered.
ECONOMI$ER IV PREPARATION
This procedure is used to prepare the EconoMi$er® IV for troubleshooting. No troubleshooting or testing is done by performing the following procedure.
NOTE: This procedure requires a 9-v battery, 1.2 kilo-ohm resistor, and a 5.6 kilo-ohm resistor which are not supplied with the EconoMi$er IV.
IMPORTANT: Be sure to record the positions of all potentiometers before starting troubleshooting.
1. Disconnect power at TR and TR1. All LEDs should be off. Exhaust fan contacts should be open.
2. Disconnect device at P and P1. 3. Jumper P to P1. 4. Disconnect wires at T and T1. Place 5.6 kilo-ohm resistor
across T and T1.

5. Jumper TR to 1. 6. Jumper TR to N. 7. If connected, remove sensor from terminals SO and +.
Connect 1.2 kilo-ohm 4074EJM checkout resistor across terminals SO and +. 8. Put 620-ohm resistor across terminals SR and +. 9. Set minimum position, DCV set point, and exhaust potentiometers fully CCW (counterclockwise). 10. Set DCV maximum position potentiometer fully CW (clockwise). 11. Set enthalpy potentiometer to D. 12. Apply power (24 vac) to terminals TR and TR1.
DIFFERENTIAL ENTHALPY
To check differential enthalpy:
1. Make sure EconoMi$er® IV preparation procedure has been performed.
2. Place 620-ohm resistor across SO and +. 3. Place 1.2 kilo-ohm resistor across SR and +. The Free
Cool LED should be lit. 4. Remove 620-ohm resistor across SO and +. The Free Cool
LED should turn off. 5. Return EconoMi$er IV settings and wiring to normal after
completing troubleshooting.
SINGLE ENTHALPY
To check single enthalpy:
1. Make sure EconoMi$er IV preparation procedure has been performed.
2. Set the enthalpy potentiometer to A (fully CCW). The Free Cool LED should be lit.
3. Set the enthalpy potentiometer to D (fully CW). The Free Cool LED should turn off.
4. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.
DCV (DEMAND CONTROLLED VENTILATION) AND POWER EXHAUST
To check DCV and Power Exhaust:
1. Make sure EconoMi$er IV preparation procedure has been performed.
2. Ensure terminals AQ and AQ1 are open. The LED for both DCV and Exhaust should be off. The actuator should be fully closed.
3. Connect a 9-v battery to AQ (positive node) and AQ1 (negative node). The LED for both DCV and Exhaust should turn on. The actuator should drive to between 90 and 95% open.
4. Turn the Exhaust potentiometer CW until the Exhaust LED turns off. The LED should turn off when the potentiometer is approximately 90%. The actuator should remain in position.
5. Turn the DCV set point potentiometer CW until the DCV LED turns off. The DCV LED should turn off when the potentiometer is approximately 9-v. The actuator should drive fully closed.
6. Turn the DCV and Exhaust potentiometers CCW until the Exhaust LED turns on. The exhaust contacts will close 30 to 120 seconds after the Exhaust LED turns on.
7. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.

51

DCV MINIMUM AND MAXIMUM POSITION
To check the DCV minimum and maximum position:
1. Make sure EconoMi$er IV preparation procedure has been performed.
2. Connect a 9-v battery to AQ (positive node) and AQ1 (negative node). The DCV LED should turn on. The actuator should drive to between 90 and 95% open.
3. Turn the DCV Maximum Position potentiometer to midpoint. The actuator should drive to between 20 and 80% open.
4. Turn the DCV Maximum Position potentiometer to fully CCW. The actuator should drive fully closed.
5. Turn the Minimum Position potentiometer to mid-point. The actuator should drive to between 20 and 80% open.
6. Turn the Minimum Position Potentiometer fully CW. The actuator should drive fully open.
7. Remove the jumper from TR and N. The actuator should drive fully closed.
8. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.
SUPPLY-AIR SENSOR INPUT
To check supply-air sensor input:
1. Make sure EconoMi$er IV preparation procedure has been performed.
2. Set the Enthalpy potentiometer to A. The Free Cool LED turns on. The actuator should drive to between 20 and 80% open.
3. Remove the 5.6 kilo-ohm resistor and jumper T to T1. The actuator should drive fully open.
4. Remove the jumper across T and T1. The actuator should drive fully closed.
5. Return EconoMi$er IV settings and wiring to normal after completing troubleshooting.

ECONOMI$ER IV TROUBLESHOOTING COMPLETION
This procedure is used to return the EconoMi$er IV to operation. No troubleshooting or testing is done by performing the following procedure.

1. Disconnect power at TR and TR1. 2. Set enthalpy potentiometer to previous setting. 3. Set DCV maximum position potentiometer to previous
setting. 4. Set minimum position, DCV set point, and exhaust poten-
tiometers to previous settings. 5. Remove 620-ohm resistor from terminals SR and +. 6. Remove 1.2 kilo-ohm checkout resistor from terminals SO
and +. If used, reconnect sensor from terminals SO and +. 7. Remove jumper from TR to N. 8. Remove jumper from TR to 1. 9. Remove 5.6 kilo-ohm resistor from T and T1. Reconnect
wires at T and T1. 10. Remove jumper from P to P1. Reconnect device at P and P1. 11. Apply power (24 vac) to terminals TR and TR1.
EconoMi$er X (Factory Option)
The EconoMi$er® X system is an expandable economizer control system, which includes a W7220 economizer module (controller) with an LCD and keypad (see Fig. 80). The W7220 can be configured with optional sensors. See Fig. 81 for wiring.
Fig. 80 — W7220 Economizer Module

Fig. 81 — Typical EconoMi$er X (W7220 Controller) Wiring 52

The W7220 economizer module can be used as a stand-alone economizer module wired directly to a commercial set-back space thermostat and sensors to provide outside air dry-bulb economizer control.
The W7220 economizer module can be connected to optional sensors for single or differential enthalpy control. The W7220 economizer module provides power and communications for the sensors.
The W7220 economizer module automatically detects sensors by polling to determine which sensors are present. If a sensor loses communications after it has been detected, the W7220 economizer controller indicates a device fail error on its LCD.

SYSTEM COMPONENTS
The EconoMi$er X system includes an economizer module, 20k mixed air sensor, damper actuator, and either a 20k outdoor air temperature sensor or S-Bus enthalpy sensors.
Economizer Module
The module is the core of the EconoMi$er X system. The module is mounted in the unit’s control box, and includes the user interface for the system. The W7220 economizer module provides the basic inputs and outputs to provide simple economizer control. When used with the optional sensors, the economizer module provides more advanced economizer functionality.
S-Bus Enthalpy Control Sensors
The sensor is a combination temperature and humidity sensor which is powered by and communicates on the S-Bus. Up to three sensors may be configured with the W7220 economizer module.
CO2 Sensor (optional)
The sensor can be added for Demand Controlled Ventilation (DCV).

SPECIFICATIONS
W7220 Economizer Module
The module is designed for use with 2 to 10 vdc or bus communicating actuator. The module

References

• Home Page-California Energy Commission

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