Bryant LEGACY 604D-A Installation Instructions Manual Download Page 21

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COMPRESSOR

ACCUMULATOR

OUTDOOR COIL

INDOOR COIL

LCS

LEGEND

HPS – High Pressure Switch

LCS – Loss of Charge Switch

Accurater

Metering De vice

Arrow indicates direction of flo

TXV in Metering

Position

Bypass

Position

HP S

C03011

Fig. 14 -- Typical Heat Pump Operation, Cooling Mode

HIGH

LOW

COM

QC5

QC4

QC3

0L0

ALO

R13 C8

R11

AL2

DCR

QCR

QC1

AB A15

QIL

RL4

JWZ

R3 R5

JW5

QCB

W2 Y

W3 W3 W2 W2 C

JW4

JW3

SSTZ-8

SDL

24V

AC/R

3AMP

CDM/C

STD

DEHUM

A09059

Fig. 15 -- Interface Fan Board (IFB)

COMPRESSOR

ACCUMULATOR

OUTDOOR COIL

INDOOR COIL

LCS

LEGEND

HPS – High Pressure Switch

LCS – Loss of Charge Switch

Accurater

Metering De vice

Arrow indicates direction of flo

Position

HP S

TXV in Bypass

Metering
Position

C03012

Fig. 16 -- Typical Heat Pump Operation, Heating Mode

604D

Summary of Contents for LEGACY 604D-A

Page 1: ...n 23 Electrical Controls and Wiring 26 Refrigerant Circuit 26 Indoor Airflow 27 Metering Devices TXV Piston 27 Pressure Switches 27 Loss of Charge Switch 27 High Pressure Switch 27 Copeland Scroll compressor Puron Refrigerant 27 Refrigerant System 27 A09034 Fig 1 Unit 604D A Refrigerant 27 Compressor Oil 27 Servicing Systems on Roofs with Synthetic Materials 27 Liquid Line Filter Drier 28 PuronR R...

Page 2: ... is to be used to remove the downflow panels before rigging and lifting into place The panel removal process may require the unit to be on the ground IMPORTANT The unit must be secured to the curb by installing screws through the bottom of the curb flange and into the unit base rails When installing large base units onto the common curb the screws must be installed before allowing the full weight ...

Page 3: ...t and any other safety precautions that might apply Trainingforoperators ofthe liftingequipment shouldinclude butnot be limited to the following 1 Application of the lifter to the load and adjustment of the lifts to adapt to various sizes or kinds of loads 2 Instruction in any special operation or precaution 3 Condition of the load as it relates to operation of the lifting kit such as balance temp...

Page 4: ...4 A09471 Fig 2 604D A24 36 Unit Dimensions 604D A ...

Page 5: ...5 A09472 Fig 3 604D A42 60 Unit Dimensions 604D A ...

Page 6: ...m B large base IN mm C IN mm D IN mm E IN mm F IN mm G IN mm H IN mm Small or Large CPRFCURB010A00 11 279 10 254 14 356 16 406 47 8 1214 32 4 822 2 7 69 30 6 778 46 1 1170 CPRFCURB011A00 14 356 Large CPRFCURB012A00 11 279 14 356 43 9 1116 42 2 1072 CPRFCURB013A00 14 356 Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small and large basepan units The cross supports must be located...

Page 7: ...ane is still supporting unit WARNING Lifting holes are provided in base rails as shown in Fig 2 and 3 1 Leave top shipping skid on the unit for use as a spreader bar to prevent the rigging straps from damaging the unit If the skid is not available use a spreader bar of sufficient length to protect the unit from damage 2 Attach shackles clevis pins and straps to the base rails of the unit Be sure m...

Page 8: ...r Conditioning Contractors Association ACCA minimum installation standards for residential heating and air conditioning systems 5 Secure all ducts to building structure Flash weatherproof and vibration isolate duct openings in wall or roof according to good construction practices Converting Horizontal Discharge Units to Downflow Vertical Discharge Units ELECTRICAL SHOCK HAZARD Failure to follow th...

Page 9: ...oper voltage and or phase imbalance 4 Do not damage internal components when drilling through any panel to mount electrical hardware conduit etc CAUTION ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death The unit cabinet must have an uninterrupted unbroken electrical ground This ground may consist of an electrical wire connected to the unit ground screw...

Page 10: ...p loop before running wires through panel Secure and strain relief all wires so that they do not interfere with operation of unit A gray wire is standard on 3 phase units for connection to an economizer If an accessory electric heater is installed low voltage leads from heater must be connected to factory supplied control leads from Indoor Fan Board P4 connector Factory wires are provided for elec...

Page 11: ...low CFM Size in mm Motor HP 800 10x10 254x254 1 2 1000 10x10 254x254 1 2 1200 11x10 279x254 3 4 1400 11x10 279x254 3 4 1600 11x10 279x254 1 0 1800 11x10 279x254 1 0 HIGH PRESSURE SWITCH psig Cutout Reset Auto 650 15 420 25 LOSS OF CHARGE LOW PRESSURE SWITCH Liquid Line psig Cutout Reset Auto 20 5 45 10 20 5 45 10 RETURN AIR FILTERS throwaway in mm 20x20x1 508x508x25 20x24x1 508x610x25 24x30x1 610x...

Page 12: ...12 A10197 Fig 11 Connection Wiring Schematics 208 230 1 60 604D A ...

Page 13: ...13 A10197 Fig 11 Cont Ladder Wiring Schematics 208 230 1 60 604D A ...

Page 14: ...14 A10194 Fig 12 Connection Wiring Schematics 208 230 3 60 604D A ...

Page 15: ...15 A10194 Fig 12 Cont Ladder Wiring Schematics 208 230 3 60 604D A ...

Page 16: ...16 A10195 Fig 13 Connection Wiring Diagram 460 3 60 604D A ...

Page 17: ...17 A10195 Fig 13 Cont Ladder Wiring Diagram 460 3 60 604D A ...

Page 18: ...check the unit for proper control operation as follows 1 Place room thermostat SYSTEM switch or MODE control in OFF position Observe that blower motor starts when FAN mode is placed in FAN ON position and shuts down when FAN MODE switch is placed in AUTO position 2 Thermostat When the room temperature rises to a point that is slightly above the cooling control setting of the thermostat the thermos...

Page 19: ...5 Using Cooling Charging Charts compare outdoor air temperature F C db with the discharge line pressure psig to determine desired system operating liquid line temperature See Fig 17 6 Compare actual liquid line temperature with desired liquid line temperature Using a tolerance of 2 F 1 1 C add refrigerant if actual temperature is more than 2 F 1 1 C higher than proper liquid line temperature or re...

Page 20: ...the dehumidification cooling fan speed and place desired speed tap wire on the LOW connection on the interface board IFB Verify that static pressure is in the acceptable range for the speed tap to be used for dehumidification cooling 7 Use any spare vinyl plugs to cap any unused speed tap wires Table 3 Color Coding for Indoor Fan Motor Leads Black High Speed Orange Med High Speed Red Med Speed Pin...

Page 21: ...2 AL2 DCR QCR QC1 C RL 01 G1 G2 Z1 A7 R9 AB A15 C4 C9 C0 QIL Z2 06 04 U1 C3 R4 RL4 JWZ C7 D5 D3 R3 R5 R6 R2 JW5 QCB Y R W2 Y C W3 W3 W2 W2 C JW4 P2 JW3 P4 P1 W2 W3 Y2 Y1 Y DH G C R SSTZ 8 P3 SDL 24VAC R 3AMP CDM C F1 STD DEHUM A09059 Fig 15 Interface Fan Board IFB COMPRESSOR ACCUMULATOR OUTDOOR COIL INDOOR COIL LCS LEGEND HPS High Pressure Switch LCS Loss of Charge Switch Accurater Metering Device...

Page 22: ...TO EQUIPMENT OWNER Consult your local dealer about the availability of a maintenance contract PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and unit component damage The ability to properly perform maintenance on this equipment requires certain expertise mechanical skills tools and equipment If you do not possess these do not attempt...

Page 23: ...ing cooling cycles Step 2 Outdoor Coil Indoor Coil and Condensate Drain Pan Inspect the condenser coil evaporator coil and condensate drain pan at least once each year The coils are easily cleaned when dry therefore inspect and clean the coils either before or after each cooling season Remove all obstructions including weeds and shrubs that interfere with the airflow through the condenser coil Str...

Page 24: ...e drop and wet coil pressure drop to obtain external static pressure available for ducting Shaded areas indicate speed static combinations that are not permitted for dehumidification speed Table 5 604D A Wet Coil Pressure Drop IN W C UNIT SIZE STANDARD CFM S C F M 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 24 0 06 0 07 0 08 0 09 0 1 30 0 12 0 15 0 19 0 23 0 27 36 0 ...

Page 25: ...25 A09070 Fig 17 Cooling Charging Table Subcooling 604D A ...

Page 26: ...ntrols and wiring replace all the panels Start the unit and observe at least one complete cooling cycle to ensure proper operation If discrepancies are observed in operating cycle or if a suspected malfunction has occurred check each electrical component with the proper electrical instrumentation Refer to the unit wiring label when making these checkouts Step 5 Refrigerant Circuit Inspect all refr...

Page 27: ...ch Step 11 Copeland Scroll Compressor Puron Refrigerant The compressor used in this product is specifically designed to operate with Puron R 410A refrigerant and cannot be interchanged EXPLOSION HAZARD Failure to follow this warning could result in personal injury death or property damage Wear safety glasses and gloves when handling refrigerants Keep torches and other ignition sources away from re...

Page 28: ...in a dip tube to allow liquid refrigerant to flow from cylinder in upright position For cylinders equipped with a dip tube charge Puron units with cylinder in upright position and a commercial metering device in manifold hose Charge refrigerant into suction line Step 13 System Information Loss of Charge Switch The loss of charge switch is a protective device wired into control circuit low voltage ...

Page 29: ...ils S Vacuum pumps will not remove moisture from oil S Do not use liquid line filter driers with rated working pressures less than 600 psig S Do not leave Puron suction line filter driers in line longer than 72 hours S Do not install a suction line filter drier in liquid line S POE oils absorb moisture rapidly Do not expose oil to atmosphere S POE oils may cause damage to certain plastics and roof...

Page 30: ...Defective run start capacitor overload or start relay Determine cause and replace Defective thermostat Replace thermostat Faulty condenser fan motor or capacitor Replace Restriction in refrigerant system Locate restriction and remove Compressor operates continuously Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low Reset thermostat ...

Page 31: ...AND IN PLACE VERIFY THAT UNIT INSTALLATION IS LEVEL CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS III START UP ELECTRICAL SUPPLY VOLTAGE COMPRESSOR AMPS INDOOR EVAPORATOR FAN AMPS TEMPERATURES OUTDOOR CONDENSER AIR TEMPERATURE DB RETURN AIR TEMPERATURE DB WB COOLING SUPPLY AIR DB WB HEAT PUMP SUPPLY AIR __________________ ELECTRIC HEAT SUPPLY AIR_____________...

Page 32: ...CV Control Using a Duct Mounted CO2 Sensor 33ZCSENC02 or CGCDXSEN004A00 and 33ZCASPCO2 or CGCDXASP00100 or CRCBDIOX005A00 CRENTDIF004A00 accessory is used on many different base units As such these kits may contain parts that will not be needed for installation 33ZCSENCO2 and CGCDXSEN004A00 are accessory CO2 sensors 33ZCASPC02 AND CGCDXASP00100 are accessory aspirator boxes required for duct mount...

Page 33: ...mber Table 13 Filter Part Number DESCRIPTION PART NUMBER Indoor Coil Air Filter 12 x 20 x 1 304 8 x 508 x 25 4 mm KH01AA312 NOTE The economizer control settings and the filters are accessible through the filter access door 13 Economizer controls are set to a standard factory setting Nevertheless you can adjust these settings through the filter access door Review the settings in the Operation secti...

Page 34: ... Duct Cover Panel Hood Divider Removed A09691 Fig 24 Horizontal Return Duct Cover Panel Removal Filter Angle Bracket Right Hood Side Panel Left Hood Side Panel Filter Angle Bracket A09692 Fig 25 Filter Angle Bracket Installation 604D A ...

Page 35: ...anel Hood Top Panel Left Hood Side Panel Hood Divider A09693 Fig 26 Economizer Hood Assembly A09694 Fig 27 Economizer Hood Installation Filter Clips Aluminum Filter A09695 Fig 28 Filter Installation See Through View 604D A ...

Page 36: ...return duct cover panel Screw in place ensuring all seams are air and watertight 6 Open economizer hood package found on the top skid Mount OAT sensor to its assigned bracket by screwing together with provided two 8 fasteners Afterwards install OAT sensor to the right side hood panel with the provided 10 screws See Fig 31 7 Install the 2 angle filter brackets to the right and left hood side panels...

Page 37: ...9698 Fig 31 OAT Bracket Installation Filter Angle Bracket Right Hood Side Panel Filter Angle Bracket Left Hood Side Panel Right Hood Side Left Hood Side A09699 Fig 32 Filter Angle Bracket Installation 604D A ...

Page 38: ... mm KH01AA316 18 x 24 x 1 457 2 x 609 5 x 25 4 mm KH01AA318 13 Economizer controls are set to a standard factory setting Nevertheless you can adjust these settings through the filter access door Review the settings in the Operation section 1 The standard economizer controller has a factory setting of C for the outdoor air temperature changeover and 63_F 17_C for the supply air mixed air temperatur...

Page 39: ...tpoints The temperature changeover is set using 3 dip switches on the sensor The ABCD potentiometer on the controller should be set to the D position See Fig 39 SUPPLY AIR TEMPERATURE SAT SENSOR The supply air temperature sensor is a 3 KΩ thermistor located at the inlet of the indoor fan See Fig 37 The operating range of temperature measurement is 0_ to 158_F 17 8_ to 70_C See Table 15 for sensor ...

Page 40: ... 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 LED next to the free cooling set point potentiometer will be on The changeover temperature set point is set using the switches on the sensor See Fig 39 for the correspondi...

Page 41: ...hen the outdoor air has a lower enthalpy than the return air and is below the set point the Economizeropenstobringinoutdoorairfor freecooling Replacethe standard outside air dry bulb temperature sensor with the accessory enthalpy sensor in the same mounting location Mount the return air enthalpy sensor in the return air duct See Fig 40 When using this mode of changeover control turn the enthalpy s...

Page 42: ...re is 75_F 23 9_C 60 x 10 75 x 90 73 5_F 23 1_C 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 44 and that the minimum position potentiometer is turned fully clockwise 4 Connect 24 vac across terminals TR and...

Page 43: ...43 A10059 Fig 44 Economizer Wiring Diagram 604D A ...

Page 44: ...ILS OF RELAY R AND RELAY R1 9 DEHUM FEATURE CANNOT BE USED WHEN ECONOMIZER IS INSTALLED UNIT FACTORY SHIPPED IN STD MODE COMP COMPRESSOR MOTOR EQUIP EQUIPMENT GND GROUND IFM INDOOR FAN MOTOR OFM OUTDOOR FAN MOTOR TRAN TRANSFORMER IFB INDOOR FAN BOARD LPS LOW PRESSURE SWITCH HPS HIGH PRESSURE SWITCH T STAT THERMOSTAT DB DEFROST BOARD DFT DEFROST TEMPERATURE SWITCH DR DEFROST RELAY HR HEATER RELAY R...

Page 45: ...45 A10200 Fig 45 Cont Ladder Wiring Diagram 230 3 604D A ...

Page 46: ...46 A10199 Fig 46 Connection Wiring Diagram 460 3 604D A ...

Page 47: ...47 A10199 Fig 46 Cont Ladder Wiring Diagram 460 3 604D A ...

Page 48: ...ometer 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 42 to determine the maximum setting of the CO2 sensor For example a 11...

Page 49: ...free cooling is not available the compressor will be controlled by the thermostat When free cooling is available the outdoor air damper is modulated by the Economizer control to provide a 50_ to 55_F 10_ to 12 8_C supply air temperature into the zone As the supply air temperature fluctuates above 55_ 12 8_C or below 50_F 10_C the dampers will be modulated open or close to bring the supply air temp...

Page 50: ...d 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 Economizer settings and wiring ...

Page 51: ...51 REQUIRED CLEARANCES TO COMBUSTIBLE MATL NEC REQUIRED CLEARANCES REQUIRED CLEARANCE FOR OPERATION AND SERVICING A10226 Fig 47 604D A 30 36 3 Phase with Economizer 604D A ...

Page 52: ...8 604D A 42 60 3 Phase with Economizer Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations E2010 Bryant Heating Cooling Systems D 7310 W Morris St D Indianapolis IN 46231 Edition Date 04 10 Replaces II604D 06 Catalog No II604D 07 604D A ...

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